welder qualification manual revision 5

8/17/2019 Welder Qualification Manual Revision 5

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WELDER QUALIFICATIONMANUAL


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Welder Qualification Manual

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Prepared by: Dennis Johnson Effective Date: July 16, 2012

UNCONTROLLEDWHEN PRINTED

Revision Number: 5


Table of Contents

Subject Work Instruct ion Page

Revision History 3Welder Qualification Procedure PR-4003 4

Welder Qualification Tests

WQT 1 5WQT 2 6WQT 3 7WQT 4 8WQT 5 9WQT 6 10WQT 7 11WQT 8 12WQT 11P 13WQT 11G 14

WQT 12P 15WQT 12G 16WQT 13P-16 17WQT 13G-16 18WQT 13P-12 19WQT 13G-12 20


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Revision Number: 5

Revision HistoryRevisionNumber

Effective Date Revis ion Summary

1 Apri l 14, 2010 General Revision to for typographical clarif ications

2 May 28, 2010 Add revision history Add vert ical tack weld tes t procedure WQT4

3 December 16, 2010 Removed WQT 7 and WQT 8

4 November 11, 2011 Revised welding procedure WQT5

5 July 16, 2012 Add Gas Flow Rate to WQT1


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Revision Number: 5

Welder Qualification Procedure

PR-4003 (IAS AC472, 5.1.3.1)

All welders and welder operators will be qualified for the type of weld, process and position that they areexpected to perform.The weld test as indicated in Table 1 shall be administered by the ACI In-House CWI. Welder Tests shallbe administered according to the procedures indicated in the Welding Operations Manual, WelderQualification Procedure PR-4000.

TABLE 1 WELDER, WELDER OPERATOR AND TACK WELDER TEST PROCEDURESWelder TestWQT Number

Process ThicknessRangeQualified

DiameterQualified

Coating Position Qualified

AWS D1.1 Hot Rolled and Built-Up Members

WQT 1 GMAW 1/8-

Unlimited

N/A None 2G (Flat and Horizontal Groove)

2F (Horizontal Fillet)WQT 2 GMAW 1/8 – 3/4 > 4” Nominal

Pipe SizeNone 1G (Flat Groove Rotated)

WQT 3 SAW 1/8-Unlimited

N/A None 2F (Horizontal Fillet)

WQT4 GMAW 1/8 -Unlimited

N/A None 3F Tack (Vertical Down Only) TackWeld Only

WQT 5 SAW 1/8-Unlimited

N/A None 1G (Flat Groove)

WQT 6 GMAW 1/8-Unlimited

N/A None 2F (Flat and Horizontal Only) TackWeld Only

AWS D1.3 Cold-Formed Members

11P GMAW 16 gage to12 gage

N/A Painted 2F (Flat and Horizontal Fillet)

11G GMAW 16 gage to12 gage

N/A Galvanized 2F (Flat and Horizontal Fillet)

12P GMAW 16 gage to12 gage

N/A Painted 2G (Flair V-Groove and Flair BevelGroove Flat)

12G GMAW 16 gage to12 gage

N/A Galvanized 2G (Flair V-Groove and Flair BevelGroove Flat)

Special Note: Qualify Welders for Arc Plug Welds for the full production range of the Welding Procedure by weldingtwo samples of each Welder Qualification Test WQT 13P-16, 13G-16, 13P-12 and 13G-12

13P-16 GMAW 16 gage N/A Painted 1G (Plug Weld)

13G-16 GMAW 16 gage N/A Galvanized 1G (Plug Weld)

13P-12 GMAW 12 gage N/A Painted 1G (Plug Weld)

13G-12 GMAW 12 gage N/A Galvanized 1G (Plug Weld)


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Revision Number: 5

WQT Number: 1

Revision: 3

Use Figure 4.30 of AWS D1.1 2008 for Assembly Preparation

Process: GMAW

Position: 2G(Horizontal)

Material Type ASTM A572Grade 55

Material Thickness: 1”

Diameter: N/A

Backing: Yes

Backing Type: ASTM A572Grade 55

Welding Procedure: See Electrical Parameters Below

Gas Flow Rate: 40 CFH

Coating: None

Acceptance Criteria: Visual AcceptanceSide Bends (2) or Radiograph

Thickness Layers Side Numberof

Passes

FillerMetal

Size

Amps Volts WireSpeed

(IPM)

TravelSpeed

(IPM)

Position

1” 1234567

1111111

1-22-33-44-55-66-77-8

0.0450.0450.0450.0450.0450.0450.045

243-297243-297243-297243-297243-297243-297243-297

26-3026-3026-3026-3026-3026-3026-30

374-458374-458374-458374-458374-458374-458374-458

12-2012-2012-2012-2012-2012-2012-20

2G2G2G2G2G2G2G

14"

6 "

14"

1"

4 5 °


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Revision Number: 5

WQT Number: 2Revision: 6

Use Figure 4.24 of AWS D1.1 2008 for Assembly Preparation

Process: GMAW

Position: 1G (Flat Rotated)

Material Type ASTM A500 B

Material Thickness: 0.280”

Diameter: 6” Nominal (6-5/8” actual)

Backing: Yes

Backing Type: ASTM A109

Welding Procedure: WPS B-L1b-G (For Electrical Parameters Only)(Use Fit-Up Configuration as shown above)

Coating: None

Acceptance Criteria: Visual AcceptanceRoot Bend (1)Face Bend (1)Radiograph may be substituted for Root and Face Bends


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Revision Number: 5

WQT Number: 3

Revision: 4

Use Figure 4.37 of AWS D1.12008 for Assembly Preparation

Process: SAW

Position: 2F (Horizontal)

Material Type ASTM A572 Grade 55

Material Thickness: 1/2”

Diameter: N/A

Backing: N/A

Backing Type: N/A

Welding Procedure: WPS Fillet-S

Coating: None

Acceptance Criteria: Visual AcceptanceFillet Weld Break (1)Macroetch (1)


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Revision Number: 5

WQT Number: 4

Revision: 0


Process: GMAW

Position: 3F (Vertical Down)



Diameter: N/A

Backing: N/A

Backing Type: N/A

Welding Procedure: WPS Fillet-G

Coating: None

Acceptance Criteria: Reasonably Uniform AppearanceFree of overlap, cracks and undercut exceeding 1/32”Free of visible porosityTack Weld Break Test per Figure 4.35 AWS D1.1 2008


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Revision Number: 5

WQT Number: 5

Revision: 3


Process: SAW

Position: 1G(Flat)


Material Thickness: 1”

Diameter: N/A

Backing: Yes

Backing Type: Flux

Welding Procedure: WPS B-U2-S

Coating: None

Acceptance Criteria: Visual AcceptanceSide Bends (2) or Radiograph


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Revision Number: 5

WQT Number: 6

Revision: 2


Process: GMAW




Diameter: N/A

Backing: N/A

Backing Type: N/A

Welding Procedure: WPS Fillet-G

Coating: None

Acceptance Criteria: Reasonably Uniform AppearanceFree of overlap, cracks and undercut exceeding 1/32”Free of visible porosityTack Weld Break Test per Figure 4.35 AWS D1.1 2008


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Revision Number: 5

WQT Number: 11P

Revision: 5

Process: GMAW



Material Thickness: 16 gage

Root Opening: 0”

Welding Procedure: WPS 11P-G

Coating: Painted

Coating Thickness: 0.5 mils per side

Acceptance Criteria: Visual AcceptanceTwo Assemblies Shall be Tested per

Bend Test indicated in Figure 4.2A of AWS D1.3 2008


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Revision Number: 5

WQT Number: 11GRevision: 4

Process: GMAW




Root Opening: 0”

Welding Procedure: WPS 11G-G

Coating: Galvanized

Coating Thickness: G90

Acceptance Criteria: Visual Acceptance

Two Assemblies Shall be Tested perBend Test indicated in Figure 4.2A of AWS D1.3 2008


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Revision Number: 5

WQT Number: 12P

Revision: 3

Process: GMAW

Position: 1G (Flat)


Material Thickness: 16 gage (both pieces)

Root Opening: 0”


Coating: Painted


Acceptance Criteria: Visual AcceptanceTwo Assemblies Shall be Tested perTest indicated in Figure 4.3C of AWS D1.3 2008


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Revision Number: 5

WQT Number: 12G

Revision: 2

Process: GMAW

Position: 1G (Flat)


Material Thickness: 16 gage (both pieces)

Root Opening: 0”


Coating: Galvanized


Acceptance Criteria: Visual AcceptanceTwo Assemblies Shall be Tested perTest indicated in Figure 4.3C of AWS D1.3 2008


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Revision Number: 5

WQT Number: 13P-16

Revision: 1

Special Note: Arc Plug Welders must beQualified by using WQT13P-16 and 13P-12. ThisQualifies Welders for theFull thickness range of

The production WPS 13P

Process: GMAW

Position: 1G (Flat)



Root Opening: 0”


Coating: Painted


Acceptance Criteria: Visual AcceptanceTwo Assemblies Shall be Tested perTest indicated in Figure 4.6 of AWS D1.3 2008

9/16" HoleFirst Plug

Weld

1 0 " t o 1 2 " m i n . 2 1 / 2 "

m i n

.

1 " m i n .


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Revision Number: 5

WQT Number: 13G-16

Revision: 1

Special Note: Arc Plug Welders must beQualified by using WQT13G-16 and 13G-16. ThisQualifies Welders for theFull thickness range ofThe production WPS 13G

Process: GMAW

Position: 1G (Flat)



Root Opening: 0”


Coating: Galvanized



9/16" Hole

First PlugWeld

1 0 " t o 1 2 " m i n . 2 1 / 2 "

m i n

.

1 " m i n .


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Revision Number: 5

WQT Number: 13P-12

Revision: 1

Special Note: Arc Plug Welders must beQualified by using WQT13P-16 and 13P-12. ThisQualifies Welders for theFull thickness range ofThe production WPS 13P

Process: GMAW

Position: 1G (Flat)



Root Opening: 0”


Coating: Painted



9/16" HoleFirst Plug

Weld

1 0 " t o 1 2 " m i n . 2 1 / 2 "

m i n

.

1 " m i n .


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Revision Number: 5

WQT Number: 13G-12

Revision: 1

Special Note: Arc Plug Welders must beQualified by using WQT13G-16 and 13G-16. ThisQualifies Welders for theFull thickness range ofThe production WPS 13G

Process: GMAW

Position: 1G (Flat)



Root Opening: 0”


Coating: Galvanized



9/16" Hole

First PlugWeld

1 0 " t o 1 2 " m i n . 2 1 / 2 "

m i n

.

1 " m i n .

welder qualification manual revision 5

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