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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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.

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