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IntroductionsThe Secrets to UsingASME Section IXAn Educational SeminarWalter J. Sperko, PESperko EngineeringGreensboro, NC 27406www.sperkoengineering.comSperko@asme.org Sperko Engineering Services, Inc. Welding EngineersMetallurgistsOther EngineersNDE specialistsQA/QC specialistsWeldersTechnical Committee MembersPrevious exposure to Section IXRingers. . .Notice Please turn cell phones, iPods, PDAs,and any other ringing things to “silent.”All statements by the speaker represent hisopinion alone and do not necessarily representthe position of the ASME Boiler and PressureVessel Code Committee. All requests forinterpretations or other inquiries relative toASME Code and Standards should beaddressed to the Secretary, ASME Boiler andPressure Vessel Code Committee, ASMEInternational, Three Park Avenue, New York, NY10016-5990.The Secrets to Using ASME Section IX1

Secrets to be revealed. . . What does Section IX cover? When do you have to use Section IX? The purpose and function of Section IX Relationship of Section IX to other Code Sections How to read Section IX – Organization and Structure How to read Section IX – reading variables Commonly misread procedure qualification variables The biggest lie in the wonderful world of welding Commonly misread performance qualification variables This seminar will not make you a welding engineer.Historical Background Boiler Code Committee was formed in 1911 toprepare a uniform code that could be adopted bylocal jurisdictions for safe design, manufacture andtesting of steam boilers. The first edition of this safety code was published in1914 (Boiler Code). 5 X 8 format, 119 pages The Boiler Code was expanded to include pressurevessels in 1928 (P&PV Code). Section IX (Welding) was added in 1941 toconsolidate welding requirements in theconstruction codes.ASME Construction 31.9B31.11B31.12Rules for Construction of Power BoilersMaterialsNuclear ComponentsHeating BoilersPressure VesselsRules for Inservice Inspection of Nuclear Power PlantsTransport TanksPower PipingProcess PipingLiquid Transportation SystemsRefrigeration PipingGas Transmission and Distribution Piping SystemsBuilding Services PipingSlurry Transportation Piping SystemsHydrogen PipingASME Section I PW-1.2 Responsibility. Each Manufacturer isresponsible for the welding done by hisorganization and shall establish theprocedures and conduct the tests required inSection IX to qualify the welding procedures heuses in the construction of the weldments builtunder Section I and the performance tests ofwelders who apply these procedures.Secret: The Codes listed all refer to Section IX forwelding and brazingThe Secrets to Using ASME Section IX2

Scope of Section IX QW-100 GENERAL “Section IX of the ASME Boiler and PressureVessel Code relates to the qualification of welders,welding operators, brazers, and brazing operators,and the procedures that they employ in weldingand brazing. . . “ Section IX does not deal with fabrication orinspection except that it specifies the minimumcontent of welding procedures that are used forfabrication.Scope of Section IX QW-100 GENERAL “. . . . according to the ASME Boiler and PressureVessel Code and the ASME B31 Code forPressure Piping.” It is compatible with the B&PV code and B31codes; if invoked by other standards (API, NFPA,AWWA, etc.) or directly in a contract, there may bedisconnects (materials, joint configurations, etc).The Secrets to Using ASME Section IXSection IX is different from otherStandards Where Qualificationand Construction Are IntegratedAWS D1.1AWS D1.2AWS D1.3AWS D1.4AWS D1.5AWS D1.6AWS D1.7AWS D1.8AWS D1.9AWS D14.XStructural Welding Code - SteelStructural Welding Code - AluminumStructural Welding Code - Sheet SteelStructural Welding Code - Reinforcing SteelStructural Welding Code - Bridge Welding CodeStructural Welding Code - Stainless SteelGuide for Strengthening/Repairing Existing StructuresStructural Welding Code - Seismic SupplementStructural Welding Code – TitaniumCranes, earthmoving, etc. Equipment weldingAPI 1104.Welding of Pipelines and Related FacilitiesQW-100 QW-100. . . . “Other Sections of the Codemay specify different requirements thanthose specified by this Section. Suchrequirements take precedence over those ofthis Section, and the manufacturer orcontractor shall comply with them.”3

When other Sections refer toSection IX. . . Some have additional requirements (e.g.,Section III) some reduce requirements (e.g., B31Sections) Some have downstream requirements,e.g. B31 code sections have specificrequirements regarding filler metals thatmay be used in production.Section IX vs. Other Sections Secret: Read the applicable constructioncode; it may contain requirements thataffect qualification. This is especiallytrue when impact testing is required.ASME Code Editions and AddendaASME Code Editions and AddendaASME B&PV Codes will be published two-yearannual addenda beginning in 2013. The latestaddenda was published July 1, 2011 andbecome mandatory for use for new constructionJanuary 1, 2012.Secret: Once work starts on a boiler or vessel,the designer works to a specific edition andaddenda, that edition and addenda applies to allthe work done on that boiler or pressure vesselregardless of how long it takes to build it.Applicable edition that applies to a boiler, vesselor piping is based on:1)contract date, unless there is an2)edition and addenda specified in the purchaseorder.Secret: This includes Section IX. But Section IXhas always said the following. . . .The Secrets to Using ASME Section IX4

Life expectancy of a WPS/PQRLife expectancy of a WPS/PQR QW-100.3 “Welding ProcedureSpecifications, Procedure QualificationRecords, and Welder/Welding OperatorPerformance Qualification made inaccordance with the requirements of the1962 Edition or any later Edition ofSection IX may be used in anyconstruction built to the ASME Boiler andPressure Vessel Code or the ASME B31Code for Pressure Piping.” QW-100.3 “Welding ProcedureSpecifications and Welder/WeldingOperator Performance Qualificationrecords meeting the above requirementsdo not need to be amended to includeany variables required by later Editionsand Addenda except as specified in QW-420.1.”Life expectancy of a WPS/PQRLife expectancy of a WPS/PQR Secret: Once WPSs and PQRs arequalified, they are good for pretty muchforever except when impacts are required They may be updated to later editions ofthe code at the manufacturer orcontractor’s option assuming data wasrecorded that supports the revisions (e.g.,GMAW-S) How about except as specified in QW420.1? QW-420.1. When base metals are reassigned toanother P-number by in QW-422 (e.g, P5 became P-5A, P-5B and P-5C around2001 AD), all PQRs listing thereassigned base metals as the testcoupon need to be examined and theWPS they support need to be revised toshow the new P-number -- for new work.The Secrets to Using ASME Section IX5

Life expectancy of a WPS/PQRLife expectancy of a WPS/PQR QW-100.3 “Qualification of new WeldingProcedure Specifications orWelders/Welding Operators andrequalification of existing WeldingProcedure Specifications orWelders/Welding Operators shall be inaccordance with the current Edition (seeForeword) and Addenda of Section IX.” This has been in Section IX since themid-1960s. Secret: All new qualifications are done tocurrent edition and addenda. WPS with multiple PQRs dated over adecade. How about a Vessel designed in 2002that is still being built?ASME CODESINTERPRETATIONSASME issues written replies to inquiriesconcerning interpretation of technical aspects ofthe Code.Secret: Interpretations may not apply to latereditions/addendaThe Secrets to Using ASME Section IXOrganization and Structure QW-100: “It is divided into two parts:Part QW gives requirements for weldingand Part QB contains requirements forbrazing.” QW-XXX Welding Sections QB-XXX Brazing Sections Prior to 1974 rewrite, all Section IXparagraphs began with “Q” (e.g. Q-27)6

Organization and Structure WELDINGQW-1XX General RequirementsQW-2XX Procedure QualificationQW-3XX Welder and Welding OperatorQualificationQW-4XX VariablesQW-5XX Standard Welding Procedures(SWPSs)The Secret to Using Section IXOrganization and Structure BRAZINGQB-1XX General RequirementsQB-2XX Procedure QualificationQB-3XX Welder and Welding OperatorQualificationQB-4XX VariablesThe Secret to Using Section IXAm I concerned about theLet’s say that the objective it to writeand qualify theWELDERWELDING PROCEDURE. . . .or about theYou have a CHOICE. . . .WELDING PROCEDURE?The Secrets to Using ASME Section IX7

The WPS QW-100.1 “Any WPSs used by a manufacturer orcontractor that will have responsible operationalcontrol of production welding shall be– a WPS that has been qualified by thatmanufacturer or contractor in accordance withArticle II (QW-200), or. . . .– it shall be an AWS Standard WeldingProcedure Specification (SWPS) listed inAppendix E and adopted by that manufactureror contractor in accordance with Article V (QW500).”The Secret to Using Section IXQW-5XX Standard WeldingProcedures (SWPSs) SWPSs cover base metals from 1/8 to 1-1/2inches in thickness, GTAW, SMAW andFCAW, P-1 in the as-welded and heat treatedcondition and P-8 to P-8 and P-1 to P-8, aswelded only This section stands alone. Read it, buy theappropriate SWPS(s), perform theDemonstration weld(s). Secret: SWPSs can be purchased at AWS.orgThe Secrets to Using ASME Section IXThe Secret to Using Section IX QW-1XX General Requirements QW-2XX Procedure Qualification QW-3XX Welder and Welding OperatorQualification QW-4XX Variables QW-5XX Standard WeldingProcedures (SWPSs)The Secret to Using Section IX QW-1XX General Requirements QW-2XX Procedure Qualification QW-3XX Welder and Welding OperatorQualification QW-4XX Variables QW-5XX Standard Welding Procedures(SWPSs)8

The Secret to Using Section IX QW-1XX General Requirements QW-2XX Procedure Qualification QW-3XX Welder and Welding OperatorQualification QW-4XX Variables QW-5XX Standard Welding Procedures(SWPSs)The Secret to Using Section IXLet’s say that the objective it to writeand qualify theWELDER OR WELDING OPERATORThe Secrets to Using ASME Section IXThe Secret to Using Section IX QW-1XX General Requirements QW-2XX Procedure Qualification QW-3XX Welder and Welding OperatorQualification QW-4XX Variables QW-5XX Standard Welding Procedures(SWPSs)9

The Secret to Using Section IX QW-1XX General Requirements QW-2XX Procedure Qualification QW-3XX Welder and Welding OperatorQualification QW-4XX Variables QW-5XX Standard Welding Procedures(SWPSs) QW-1XX General Requirements QW-2XX Procedure Qualification QW-3XX Welder and Welding OperatorQualification QW-4XX Variables QW-5XX Standard Welding Procedures(SWPSs)The Secret to Using Section IXThe Procedure or the iedWPSThe Secrets to Using ASME Section IXSWPSReadQW-500WelderInvisible WallThe Secret to Using Section 10

The WPSContents of the WPS QW-100.1 “QW-100.1 A Welding ProcedureSpecification (WPS) is a writtendocument that provides direction to thewelder or welding operator for makingproduction welds in accordance withCode requirements.” Secret: when writing a WPS, remember,you are giving the welder direction “When a WPS is to be prepared by themanufacturer or contractor, it must address, asa minimum, the specific variables, bothessential and nonessential, as provided inArticle II for each process to be used inproduction welding. In addition, when other Sections of the Coderequire notch toughness qualification of theWPS, the applicable supplementary essentialvariables must be addressed in the WPS.”Changes to the WPS QW-200.1 (c) “Changes may be made in the nonessentialvariables of a WPS to suit productionrequirements without requalification providedsuch changes are documented . . . . . This maybe by amendment to the WPS or by use of anew WPS.” Revisions, supplemental cover sheets, notes ondrawings can be considered amendments.The Secrets to Using ASME Section IX11

Changes to the WPS QW-200.1 (c) “Changes in essential or supplementaryessential (when required) variables requirerequalification of the WPS (new or additionalPQRs to support the change in essential orsupplementary essential variables).”Changes to the WPS QW-200.1 When an essential or supplementary essentialvariables is changed, additional PQR(s) arerequired to support the change and the WPSmust also be revised by amendment to the WPSor by use of a new WPS. Example: addition of PWHTThe Secrets to Using ASME Section IX12

Format of the WPS QW-200.1 (d) “The information required to be in the WPSmay be in any format, written or tabular, to fitthe needs of each manufacturer or contractor,as long as every essential, nonessential, and,when required, supplementary essentialvariables outlined in QW-250 through QW-280is included (on the WPS) or referenced (to someother document by the WPS).”Intrinsically Addressed matters. . .Indicate Gender Male Female What was the date of your lastpregnancy If “Male” is checked, the date ofpregnancy is intrinsically addressed .The Secrets to Using ASME Section IXThe contents of the WPS Every essential and nonessential variable has tobe addressed on the WPS – always! Supplementary essential variables have to beaddressed ONLY when the construction coderequires the WPS to be qualified with impacttesting. Some variables are addressed intrinsically byaddressing other variables, e.g., QW-410.64addresses use of torch cutting for P-11A and P11B materials; if the base metals that the WPSspecifies are P-1, there is no need to specificallyaddress QW-410.64 in the WPSQW-100.1, The PQR “The purpose for qualification of a WPSis to determine that the weldmentproposed for construction is capable ofproviding the required properties for itsintended application. Welding procedurequalification establishes the propertiesof the weldment, not the skill of thewelder or welding operator.” Secret: this is the basis the committeeuses to identify essential variables.13

QW-100.1, The PQR“The Procedure Qualification Record (PQR)documents what occurred during welding thetest coupon and the results of testing of thecoupon. As a minimum, the PQR shalldocument the essential variables and other specificinformation identified in Article II for eachprocess used during welding the test couponand the results of the required testing.”QW-100.1, The PQR continued. . . . . and other specific information identified inArticle II. . . See QW-200.2(b) “One or more combinations of weldingprocesses, filler metal, and other variablesmay be used when welding a test coupon.The approximate thickness of weld metaldeposited shall be recorded for each processand for each set of essential and, whenrequired, supplementary essential variables.”The Secrets to Using ASME Section IXQW-100.1, The PQR “In addition, when notch toughnesstesting is required for procedurequalification, the applicablesupplementary essential variables foreach process shall be recorded.”14

Notch-Toughness Tests “QW-171.1 General. Charpy V-notch impacttests shall be made when required by otherSections. Test procedures and apparatusshall conform to the requirements of SA-370. QW-171.2 Acceptance. The acceptancecriteria shall be in accordance with thatSection specifying impact requirements.” Test temperature, acceptance criteria mustbe provided by that SectionNotch-Toughness Tests “QW-171.3 Location and Orientation of TestSpecimen. The impact test specimen andnotch location and orientation shall be as givenin the Section requiring such tests.” Secret: The Section tells you what to test: weldmetal, HAZ, the base metal, where to removedspecimens relative to depth of the coupon,how many specimens, Temperature,acceptance criteria, etc.The Secrets to Using ASME Section IXQW-200.2 The PQR “The PQR is a record of variablesrecorded during the welding of the testcoupons. It also contains the test resultsof the tested specimens.15

QW-200.2 The PQR “(b) Contents of the PQR. Thecompleted PQR shall document allessential and, when required,supplementary essential variables ofQW-250 through QW-280 for eachwelding process used during the weldingof the test coupon.”QW-200.2 The PQRQW-200.2 The PQR “Nonessential or other variables usedduring the welding of the test couponmay be recorded at the manufacturer’sor contractor’s option.” Recording some nonessential variablesfills out the PQR. Recording them does not affect what youcan put on the WPS regardingnonessential variables. Secret: Complete PQRs in the past tense “All variables, if recorded, shall be theactual variables (including ranges) usedduring the welding of the test coupon.The Secrets to Using ASME Section IX If variables are not monitored duringwelding, they shall not be recorded.” Implication?16

QW-200.2 The PQRQW-200.2 The PQR “(c) Changes to the PQR. Changes tothe PQR are not permitted.” Historical Record Typos Code changes P-number is reassigned Annotate Certify “(d) Format of the PQR. The informationrequired to be in the PQR may be in anyformat . . . as long as every essentialand, when required, supplementaryessential variable required by QW-250through QW-280, is included. Also the type of tests, number of tests,and test results shall be listed in thePQR.QW-200.2 The PQRQW-201 Manufacturer’s orContractor’s Responsibility “(e) Availability of the PQR. PQRs usedto support WPSs shall be available, uponrequest, for review by the AuthorizedInspector (AI). The PQR need not be available to thewelder or welding operator. The welders or welding operators usedto produce weldments to be tested forqualification of procedures shall be underthe full supervision and control of themanufacturer or contractor during theproduction of these test weldments. How about the WPS?The Secrets to Using ASME Section IX17

QW-201 Manufacturer’s orContractor’s ResponsibilityQW-201 Manufacturer’s orContractor’s ResponsibilityThe weldments to be tested for qualificationof procedures shall be welded either byIt is not permissible for the manufacturer orcontractor to have the supervision andcontrol of welding of the test weldmentsperformed by another organization.–direct employees or–by individuals engaged by contract for theirservices as welders or welding operators–under the full supervision and control of themanufacturer or contractor.QW-201 Manufacturer’s orContractor’s ResponsibilityWho has to qualify the WPSs?The manufacturer or contractor that has first-lineresponsibility for supervising the welders who doproduction welding is the organization that has toqualify the WPS.How about Welders?Same provisions apply to welder qualification –the organization that supervises the welders isthe organization that has to qualify the welders.The Secrets to Using ASME Section IXQW-250 WELDING VARIABLES “QW-251.1 Types of Variables forWelding Procedure Specifications.These variables listed for each weldingprocess are subdivided into essential,supplementary essential andnonessential variables.18

QW-250 WELDING VARIABLESQW-250 WELDING VARIABLESQW-250 WELDING VARIABLESQW-250 WELDING VARIABLESSECRET:The Secrets to Using ASME Section IX19

QW-250 WELDING VARIABLESQW-250 WELDING VARIABLES “QW-251.1 Types of Variables forWelding Procedure Specifications. The “Brief of Variables” listed in thetables are for reference only. See thecomplete variable in Welding Data ofArticle IV.(QW-400)” Secret: the “brief of variables” is not thevariable!QW-250 WELDING VARIABLESHow do you read variables? “QW-251.4 Special Processes (a) The special process essentialvariables for corrosion resistant andhard-surfacing weld metal overlays areas indicated in the following tables for thespecified process. Only the variablesspecified for special pr

Jul 01, 2011 · ASME Code Editions and Addenda ASME B&PV Codes will be published two-year annual addenda beginning in 2013. The latest addenda was published July 1, 2011 and become mandatory for use for new construction January 1, 2012. Applicable edition that applies to a boiler, vessel or piping is based

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