Provide the essential do design a pwps, wps according to ASME IX: Qualification Standard For Welding And Brazing Procedures, Welders, Brazers, And Welding And Brazing Operators ?
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Designing a PWP and WPS according to ASME IX: A Detailed Question

Context:

You are a welding engineer tasked with designing a Procedure Qualification Record (PQR) and Welding Procedure Specification (WPS) for a critical structural component in a power plant. The component is made of ASTM A533 Grade B Class 1 steel and will be welded using the Gas Metal Arc Welding (GMAW) process with ER70S-6 wire and a CO2 shielding gas. The weld joint will be a single V-groove butt joint with a root opening of 1/8".

The Question:

Based on the provided information, how would you design a PQR and WPS for this weld, ensuring compliance with ASME IX?

Specifically, address the following in your response:

  1. PQR Design:
    • Essential variables to be included in the PQR based on ASME IX requirements for the chosen welding process, base metal, filler metal, and weld joint design.
    • Non-essential variables that can be varied within the WPS without requiring further PQR qualification.
    • Testing requirements for the PQR based on ASME IX, including mechanical testing, macro-examination, and radiographic testing.
    • Acceptance criteria for each test based on ASME IX.
  2. WPS Design:
    • Essential variables to be included in the WPS, aligning with the PQR.
    • Non-essential variables that can be adjusted within the WPS based on site conditions.
    • Detailed weld procedure outlining specific welding parameters like travel speed, voltage, wire feed rate, and gas flow rate.
    • Inspection and quality control requirements for the WPS, including visual inspection and dimensional verification.
  3. Additional Considerations:
    • Pre-heating and interpass temperature control: How would you determine the necessary pre-heat and interpass temperatures based on ASME IX and the material specifications?
    • Heat treatment: Would heat treatment be required for this weld based on ASME IX and the specific application? Explain your reasoning.
    • Impact testing: Would impact testing be required for this specific application based on ASME IX? Justify your decision.

Note: Provide detailed explanations for each aspect of the PQR, WPS, and additional considerations, referring to specific sections and paragraphs in ASME IX where applicable.

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asked July 28, 2024, 1:05 p.m.
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alibat27
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Designing a PWP and WPS according to ASME IX

Designing a PWP (Procedure Qualification Record) and WPS (Welding Procedure Specification) according to ASME IX requires a systematic approach and meticulous attention to detail. Here's a breakdown of the essential steps involved:

1. Define the Welding Application:

  • Material: Specify the base metals, filler metals, and their respective grades and specifications.
  • Joint Type: Identify the specific joint configuration (e.g., butt joint, fillet weld, corner joint).
  • Position: Define the welding position (e.g., flat, horizontal, vertical, overhead).
  • Thickness: Specify the thickness of the base material.
  • Design Requirements: Outline any specific strength, fatigue, or other design considerations.

2. Determine the Welding Process:

  • Choose the Welding Process: Select the appropriate welding process based on material, joint type, and desired characteristics. Common processes include:
    • Shielded Metal Arc Welding (SMAW)
    • Gas Metal Arc Welding (GMAW)
    • Gas Tungsten Arc Welding (GTAW)
    • Submerged Arc Welding (SAW)
    • Flux Cored Arc Welding (FCAW)
  • Select the Filler Metal: Choose a filler metal that is compatible with the base material and welding process, ensuring appropriate strength, ductility, and corrosion resistance.

3. Define Welding Parameters:

  • Current: Specify the current range for the chosen welding process.
  • Voltage: Define the voltage range for the chosen welding process.
  • Travel Speed: Determine the appropriate travel speed based on the material, thickness, and process.
  • Interpass Temperature: Set the interpass temperature for multi-pass welds to prevent cracking and ensure proper fusion.
  • Preheating and Post-heating: Specify any required preheating or post-heating temperatures and procedures.

4. Establish Quality Control:

  • Inspection Method: Define the inspection methods to be used (e.g., visual inspection, radiographic inspection, ultrasonic inspection).
  • Acceptance Criteria: Establish clear acceptance criteria for the welds based on the ASME IX requirements and specific application needs.
  • Documentation: Establish a system for documenting welding procedures, qualifications, and inspection results.

5. Develop the PWP:

  • Qualification Tests: Perform qualification tests on the specific welding procedure, using test coupons that represent the actual welding application.
  • Mechanical Testing: Conduct mechanical tests on the qualified test coupons, including tensile strength, yield strength, ductility, and impact testing, as per ASME IX requirements.
  • Documentation: Record the results of the qualification tests and mechanical testing in the PWP.

6. Develop the WPS:

  • Detailed Instructions: Compile a comprehensive document that outlines the specific welding procedure in detail. This includes:
    • Welding Process and Equipment
    • Filler Metal
    • Welding Parameters
    • Joint Preparation
    • Preheating and Post-heating
    • Inspection and Acceptance Criteria
  • Quality Control: Include a section on quality control measures to be implemented during production welding.

Formula for Calculating the Required WPS Qualification Number (QW Number):

The QW number is determined by the type of weld, the thickness of the material, and the welding process used. It is a unique identifier for each WPS and is used to track the qualification of the procedure.

QW Number = [Weld Type] + [Thickness] + [Welding Process]

Example:

  • Weld Type: Butt joint
  • Thickness: 1/2 inch
  • Welding Process: GMAW

QW Number: BW-1/2-GMAW

Note: The specific formulas and requirements for calculating the QW number may vary depending on the specific ASME IX code section and the year of publication.

Important Considerations:

  • ASME IX updates: Regularly review and update your PWP and WPS documents to comply with the latest revisions of ASME IX.
  • Material compatibility: Ensure the materials selected for the welding procedure are compatible and meet the ASME IX requirements.
  • Training and certification: Welders must be trained and certified according to ASME IX requirements to perform welding procedures.

In conclusion, designing a PWP and WPS according to ASME IX requires a comprehensive understanding of the code requirements, meticulous attention to detail, and adherence to established procedures. This ensures the safety, integrity, and reliability of the welding processes used in various industries.

answer July 28, 2024, 1:05 p.m.
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dellisali
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