ASME Section IX Welding Codes and Metallurgy for Carbon/Alloy Steel

Introduction

This is an introductory course to provide a basic understanding of the proper use and interpretation of ASME Section IX - Welding Qualifications Code and its related ASME construction codes. To accomplish this objective, the course starts with a review of the ASME Sec. IX, followed by one day of studying the base metal metallurgy and welding metallurgy that ASME IX is based on. The fourth day covers the welding portions of related ASME construction codes (Section VIII-1, B31.1, and B31.3) and how ASME Sec. IX interacts with each, including the metallurgy previously covered through a series of workshops. It is also intended to prepare exam candidates for the ABSA Welding Examiner on Regulations and Codes and most parts covering properties and structures of metals, welding metallurgy and material specifications (i.e., steel manufacturing will not be covered).

Objectives

Upon the successful completion of this course, the participants should be able to:

• To introduce participants to the purpose and methodology of Welding Qualifications
• Learn how to understand, interpret, and comply with ASME Section IX requirements
• How to conduct Procedure and Welder Tests, and certification of welders
• To provide a step-by-step approach in the preparation of WPS, PQR, and WPQ records
• To know Essential, Non-essential and Supplementary Essential Variables, and their use
• Review welding processes/variables and basic welding metallurgy
• Review, scrutinize and accept or reject sub-contractor’s Welding procedures and Welders

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

Inspectors, welders, welding supervisors, quality control personnel, technologists, and engineers involved with new welding procedures and welder qualifications for new fabrication, repairs, maintenance, and inspection for pressure vessel or piping. This course is also designed to assist ABSA Welding Examiner, Pressure Equipment Inspector, and CSA W178.2 exam candidates.

Course Outline

Safety Codes Acts

• Overview of Pressure Equipment Safety Regulations
• Pressure Welders Regulation

General Review to ASME IX

• General requirements
• Procedure qualifications
• Performance qualifications
• Welding data
• Development of ASME Section IX
• Overview of ASME Section IX
• Relationship of Section IX to Other Codes
• A brief review of Welding processes SMAW, SAW, GTAW, GMAW,
• A brief review of Welding consumables, AWS and ASME classification
• Requirements for Procedure Qualification
• The requirement of performance qualification
• Welding variables- Essential, non-essential, Supplementary
• Documentation of PQR tests

ASME Section IX - WPS, PQR, WPQ Reviews

• Several workshops will be conducted to allow each participant to develop the required skills to review WPS, PQR, and WPQ documents

Base Metal Metallurgy of Carbon and Alloy Steels

• Basic carbon steel metallurgy (crystalline structures, grains, microstructures: ferrite, pearlite, banite, martensite)
• Using the Fe-Fe3C phase diagram in practical terms
• Common heat treatments for carbon steel and effect on mechanical properties (annealing, normalizing, quench and tempering)
• Ductile to brittle behavior of steels - grain size (ASTM No.), microstructures, low-temperature notch toughness, and anisotropy
• Alloying steels and their effects on hardenability and weldability
• Material test reports and what they really mean

Welding Metallurgy of Carbon and Alloy Steels

• The various weld zones and metallurgical heat-affected zones using fundamental principles of welding metallurgy
• Use of carbon equivalence to predict weldability
• Hydrogen assisted cracking related to welding (toe cracking, cold cracking, delayed cracking, HAZ cracking, and under bead cracking)
• Preheating and postweld heat treat in practical terms to avoid cracking and improve weldability

Base Metal and Filler Metal Specifications (ASME Section II Parts A and C)

• Classification of steels - UNS, SAE, ASTM, ASME
• ASME SA-106, SA-516, SA-333, SA-387, and SA-312
• AWS classification of filler metals, SFA No., F No., and A No.
• ASME SFA-5.1 and SFA-5.5

Developing a WPS/PQR for ASME Sec. VIII-1, B31.1, B31.3

• Each attendee will participate to write new construction and maintenance welding procedures in accordance with ASME Section VIII - Pressure Vessels, ASME B31.1 - Power Boilers and ASME B31.3 - Process Piping
• These welding procedures will be reviewed and discussed in detail during the class