Welder Qualification Procedure - Visakh Refinery

I~I
1.0
VISAKH REFINERY
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
INSPECTION DIVISION
Doc no. : TSD/INSP/GEN/26
Rev. 0
TECHNICAL DEPARTMENT
Dale of issue: 16.03.2012
Date offirsl issue: 16.03.2012
SCOPE
This procedure outlines the method for qualification of welders for carrying out welding jobs
on refinery equipments and piping.
2.0
PURPOSE
The purpose of this procedure is to have a unified testing practice for qualitying the welders of
both the company and contractor as only qualified welders are permitted to do all welding jobs
in the refinery.
3.0
INTRODUCTION
3.1
This procedure describes the essential variables, classifications and limits of qualification, test
required, testing procedures, identification and certification of welder, retest and renewals. The
procedure is based on the requirements of ASME Sec IX (Welding & Brazing Qualifications).
4.0
DETAILS OF THE ADVISORY
4.1
General
The use of the word "Welder" within this procedure shall denote both company and
contractor personneL
A Welder will be required to re-qualify if he has not consistently welded for a period of three
months or if the quality of his production work falls below the standards of the qualified
procedure.
A welder shall be re-qualified if change is made in one or more of the essential variables
listed for each welding process as per ASME Sec. IX.
TIle grouping ofP-Nos. and F-Nos. (with ASME SFA Nos.) which are to be considered while
deciding on re-qualification of welders is given in QW-422 and QW-432 (See Attachment A1 for the F-Nos. for the most commonly used welding electrodes & filler wires and
Attachment - A2 for the P-Nos. for the most commonly used base materials in the refinery).
The diameter and thickness limits qualified for are mentioned in QW-452.3 and QW-452.1
(b) respectively of ASME Sec IX.
The various groove welds in plate and pipe and fillet welds in plate & pipe are shown in QW461.3,461.4,461.5 & 461.6 respectively of ASME Sec IX.
The positions of welding qualified for are given in QW-461.9 of ASME Sec IX.
Page10fB
VISAKH REFINERY
[i$[
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
INSPECTION DIVISION
Doc no. : TSD/INSP/GEN/26
Rev. 0
TECHNICAL DEPARTMENT
Date of issue: 16.03.2012
Dale offirsl issue: 16.03.2012
If a welder fails to qualify in the first attempt, he will not be allowed a second attempt until
he undergoes a minimum of one month practice.
All certified welders will be issued certificates which shall be available with them and should
be displayed when onjoh. A copy of the blank certificate fannat is shown in AttachmentA3.
Certification will be issued for six months duration and renewable every six months on the
basis of satisfactory performance of the welder. In case of welders being qualified for T&I,
they will be issued certificates covering the T&I period only.
Any welder certified by other organizations shall be required to fe-qualify by HPCL as per
the requirement of this procedure. In case ofT&I, welders qualified by HPCL approved TPI
may be considered valid & recertified without any qualification test at the sole discretion of
Inspection Div. The certification will be valid for the T&I period only.
4.1.0
Tests Requirements
All test pieces, plates or pipes, shall be flame cut I machined and beveled generally in
accordance with ASME Section IX, as shown in QW-469.2. The minimum length of test
coupons in case of plates shall be 6 inches.
Welding shall be generally in the 2G and 3G for plate (single or any combination) and in 6G
for pipe.
For weld tests conducted on pipe in the 6G position, the pipe bottom shall be fixed rigidly at
450 mm maximum (18") above ground level, at an angle of 45 deg ± 5 deg.
Grinding of the root pass is only allowed. No inter pass grinding is allowed. The top position
of the test piece shall be marked before removal of the same for grinding after root run.
While putting back after grinding, it shall be installed so as to ensure that the section marked
as top is at top only.
The test plates or pipes must not be moved from their position once installed after root
grinding until welding is complete.
No backing strips or rings are allowed.
The completed weld shall be thoroughly brushed and cleaned and offered for visual
inspection for checking for any presence of surface defects.
The test weld can be evaluated by radiography or mechanical testing as per requirements of
ASME Section IX. If evaluated by radiography, the acceptance criteria shall be in accordance
with QW-191.
Page 2 of8
VISAKH REFINERY
liil
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
INSPECTION DIVISION
Doc no. : TSD/INSP/GEN/26
Rev. 0
TECHNICAL DEPARTMENT
Date of issue: 16.03.2012
Date of first issue: 16.03.2012
During perfonnance qualification test welder will not allowed to take the help of any support
during welding.
Performance qualifications which are not included in this procedure shall be conducted as per
ASME Sec. IX (latest edition).
4.1.1
Welders Classifications
Test
Welding
Coupon
pOSItion
..
Welding
direction
Carbon Steel Welder Plate)
"T" thick 2G&3G Horizontal
CS plates
and Vertical
Welding
Electrodes
Examin
alian
E6010 root /
#
process
SMAW
E7018 Filler
uphill
Qualifications
1G, 20 & 30 positions
up to "2T" max. thk in
plates and over 24" dia
pipes.
Carbon Steel Welder Pinel
2" dia.
6G
Vertical
sch 40 1
uphill
80 CS
pipes
Carbon Steel Welder PiDe)
6" dia. 1
6G
Vertical
8"
dia
uphill
sch
40
CS pipe
.SMAW
E6010 root I
E7018 Filler
#
All position CS pipe over
I" dia & up to 7.8 mm
thk. for sch 40 and max.
12.7 mm thk. for sch 80.
SMAW
E6010 root I
E7018 Filler
#
All position CS pipe for
>='=2 7/8" dia. & up to
14.22 mm max. thk for
6" dia sch. 40 test coupon
& 16.36 mm max. thk for
8" dia. sch. 40 test
coupon
GTAW 1 ER 308 root
SMAW
1 E 308
Filler
100%
radiogra
phy
Vertical
uphill
GTAW 1 ER 308 root
SMAW
1 E 308
Filler
#
All position austenitic SS
welding. Max. thk7.8
mm and 12.7 mm for sch
40
and
sch
80
respectively.
Over 1"
dia. pipes
All position austenitic SS
welding. Max. thk 14.22
mm & pipe dia >~2 7/8"
Vertical
uphill
100%
GTAW 1 ER-80S
SMAW
B2/B3/B6/B radiogra
8 for root phy
and E-8018
Austenitic Stainless Steel Welder
2"
dia.
60
Horizontal
sch 40 /
and vertical
80
SS
uphill
304 pipes
6" dia.
sch
40
SS 304
pipes
6G
Allov Steel Welder
2"
dia.
6G
sch 40 /
80 Alloy
steel
All position in Ferritic
alloy welding. Max. thk
7.8 112.7 mm for Sch
40/80 & > I" dia. pipes
Page 3 ofS
[iJ
·
VISAKH REFINERY
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
INSPECTION DIVISION
Doc no. : TSD/INSP/GEN/26
Rev. 0
TECHNICAL DEPARTMENT
Date of issue: 16.03.2012
Date offirsl issue: 16.03.2012
pipes
(PIIIP22
IP5/P9)
6" dia.
sch 40
Alloy
6G
Vertical
uphill
GTAWI
SMAW
B21
9018
B31
8018
B6/8018 B8
for filler for
P II/P22/P61
matI.
P9
Respectively
- do-
#
steel
All position in Ferritic
alloy welding. Max. thk
14.22 mm & pipe dia >=
27/8"
pipes
(PII/P22
1P5/P9)
# Mechanical tests or 100% radiography of test butt as per ASME Sec. IX
For Alloy steel qualification, separate qualification is required for PH and P22 welding
as P Nos. are 4 and SA respectively. However, Qualification in either of PS or P9 will
qualify for both base materials as they have same P No. SR.
For welders requiring qualification other than carbon steel plate, viz., austenitic
stainless steel &/or alloy steel plates, qualification procedure adopted for carbon steel
plates shall be used with relevant plate material & electrodes. If a welder is qualified for
pipe welding he is also qualified for welding plates.
For qualifying welding on 1" and below size small bore piping, the test coupon shall be
of the same dia. on which the actual welding will be done.
For special materials like Cn and Cn-base alloys, Nickel and Ni-base alloys, Aluminium,
etc., Welder performance qualification test shall be carried out separately as per ASME
Sec IX.
4.1.4
Assessment of Weld Quality and Test Results
Inspection Engineer may stop the test and fail the welder at any time during the test if the
welder shows he has insufficient skill resulting in burn through or rod getting stuck to test
piece or inadequate welding knowledge.
Test welds shall be examined visually before the test pieces are radiographed or mechanically
tested and may be accepted I rejected on the basis of lack of penetration, under cut or other
gross defect as per Radiographic Acceptance criteria QW -191.2.
When specified, radiography shall be in accordance with ASME Section IX, QW-191.
Page 4 of 8
VISAKH REFINERY
[ii
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
INSPECTION DIVISION
Doc no. : TSD/INSP/GEN126
Rev. 0
TECHNICAL DEPARTMENT
Date of issue: 16.03.2012
Date of first issue : 16.03.2012
A change from onc F-number to any other F-number or to any other filler metal will require
separate qualification test, except, qualification under any F-number up to and includi ng Fnumber 4 sha ll qualify a welder for a ll lower F-numbers for we lding. Reference ASME
Section IX, QW404: 15 and QW433.
Change in p. number is an essential variable. Base metal used for procedure qualification and
base metal qualified as a result ortha! is given in QW-423.
5.0
RESPONSIBILITY
5.1
All concerned departments I divisions sha ll make a written request to Div. Head - Inspection
for conducting welder qualification test. All the request s hall be forwarded along w ith the
welder's " Resume" and s upporting documents I certificates fo r evaluation. No inexperienced
welders will be tested by the Inspect ion Div and he will be tested for same P-No. , F-No. &
position for which he possesses certificates.
5.2
The Inspection Div. shall control all welder qualification tests. This control includes
exam ination of prepared test pieces, witnessing the welding when the welder performs,
exam ination of the weld done, interpretation ortest results and acceptance of welders.
5.3
The preparation of test pieces, equ ipment, test set-up, mechanical test, radiography and all
other requirements are to be carried out by the Maintenance Dept. / concerned department.
Inspection Division w ill inform the test date after review/acceptance of the welder's
documents.
5.4
The Inspection Div. s ha ll keep a record of all qualification test data including the welder
identification, test date and results. Inspection Div. sha ll also issue we lder cert ificates
identi fying each approved we lder show ing his qualifications.
6.0
REFERENCES
1.
r
ASME Boiler and Pressure Vessel Code - Welding and
Brazing Q ualification - Section IX - 2002.
(II)
Specifications for We lding rods, electrodes and filler
metal- Section II - Part C - 2002.
pared by:
~,
-
(I)
--
Reviewed by:
'b
~-
Sr. Manager-SN
R. P. BHAN
Head- Inspection
Page 5 of8
VISAKH REFINERY
liil
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
Doc no. : TSD/INSP/GEN/26
INSPECTION DIVISION
Rev. 0
TECHNICAL DEPARTMENT
Date of issue: 16.03.2012
Date of first issue: 16.03.2012
ATTACHMENT -AI
F -NOS. FOR COMMONLY USED ELECTRODES AND FILLER WIRES
FNO.
F-2
ASME SPEC. NO.
SFA-S.I
AWS CLASSIFICATION
E6013
F-l
SFA-S.I
E6010
F-4
SFA-S.I
E70lB
F·4
SFA-S.4 (OTHER
AUSTENITIC)
F·4
SFA-S.S
E70IBAI.
EBOIBBB
F·S
SFA·S.4 (AUSTENITIC)
E10B, E10BL, E10BH, E109, E109Mo, E110,
E110H,ElI6, E316L, ElI6H, E147
F·6
SFA-S.9
ER30B, ER10BL, ER10BH, ER109, ER109Mo,
ER310, ERlI6, ERlI6L, ERlI6H, ER 121,
ER347, ER410
F·6
SFA-S.IB
ER 70S-2
F·6
SFA-S.2B
ERBOS-B2, ER90S-Bl, ERBOS-B6, ERBOS·BB
F·14
SFA·S.6
ECuNi
F·14
SFA·S.7
ERCuNi
F·41
SFA·S.II
ENil
SFA·S.14
ERNil
SFA·S.II
ENiCu7
SFA-S.14
ERNieu7
SFA-S.II
ENiCrFe-l, ENiCrFe-2, ENiCrFe-3, ENiCrFe-4
SFA-S.14
ERNiCr-3, ERNiCr-4, ERNiCrFe-5, ENiCrfe-6
THAN
E410
---~--
I-jo:;[i
F·42
F-41
EBOIBB2,
E901BB1,
EBOIBB6,
- , - - _ ...
----- ---
Page 6 of8
I~I
VISAKH REFINERY
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
INSPECTION DIVISION
Doc no. : TSD/INSP/GEN/26
Rev. 0
TECHNICAL DEPARTMENT
Date of issue: 16,03,2012
Date of first issue: 16.03.2012
ATTACHMENT-A2
P -NOS. FOR COMMONLY USED MATERIALS
P-NO.
TYPE
I
C,C-Mo
3
C-1/2 Mo
4
1-1/4 Cr-1I2Mo
5A
2-1/4 Cr-IMo
58
5Cr-tl2Mo, 9Cr-l Mo
6
13Cr
7
SS 404, S84108
8
-------
Austenitic Cr-Ni Stainless steel
34
70/30 Cu-Ni, 90/10 Cu-Ni
42
Monel
45
Inconei,localoy
-- -- -- -
Page 7 ofB
VISAKH REFINERY
~
PROCEDURE FOR WELDER QUALIFICATION EXAMINATION
Doc no. : TSD/INSP/GEN/26
INSPECTION DIVISION
Rev. 0
TECHNICAL DEPARTMENT
Date oftssue: 16,03.2012
Date of first issue: 16.03.2012
ATTACHMENT_A3
~
HlNDUSTAN PETROLEUM COlU'ORATlON LIMITED
(A GOVERNMnNTOf INDlA ENTERPRISE)
VISAKH REFINERY, P,O BOX No. IS, VISAKHAPTNAM - 530 011, INOLA
PHOr:!E:2578G2I!518200 • 29 Extn. : 4809 TELEFAX: (6091) - 891-1159861/2511168
QW ~1l.oI: WELOER QUALlflCII.TION TEST RESULTS
SECllON IX • JlSMe BOILER AND PRESSURE VESSEL ~OOE
Em 10 H Hoi Wold"
ELDER NAME;
,
Qu.lln~d
feS1M IQI
lor.
p/o,.."
P,o'.'sTl'l"':
1I.,~1"9:
I
M.l ..... ' Spoc:
Thl~fi ...:
,
I
I
G,,,...:
-
___i'
"III.~
OI.mol."
Filler h\eIaI:
Spec No;
Po.lll,":
weld P,~.lo":
G•• Typo:
EIKIrI..1CMMtristl~:
Cu,unt
PoT." .....
GU'~Q<) Bead utRuu!Js
, •• ,-
-
fI •• ull
, -
Bt,oIQo;;.!!.!.f!:ll!t u;!r BEli!.!LU
'. diogrophl, Ruults:
flllETWELR IESTBfSUL T5
fradu~ lool:
Leng!h .,., Ptrc.nl of Del.cls;
FllielSI ..,
lip!","""'" :
Teol Condvcted By;
Conc •• lly:
T~~.~
Concovlty:
Lab T.. tNo:
Ccr1lned 111>1 the .t.temtn\.o In lhl. ,.co,d ... co"o<t .nd that thO 1.,1 weld. were p,ep."d. w.l<liXI and tHUd In acco,d'nce with
Iho "qoi"men(O 01 Section IX 01 ASME code.
0,1.;
Valid for a period of ,ix ruolllh, from Ihe dale of th. issue of Ihi, certificale
"
Authorized In'g"elo,