CSA W47.1:19 PDF - Procedure Qualification Record (PQR)

CSA W47.1:19 Certification of companies for fusion welding of steel 11.3 Procedure qualification record (PQR) 11.3.1 A procedure qualification record (PQR) is a document that shall list all essential variable information recorded during the welding of the test assembly. It may also contain any ad...

CSA W47.1:19 Certification of companies for fusion welding of steel 11.3 Procedure qualification record (PQR) 11.3.1 A procedure qualification record (PQR) is a document that shall list all essential variable information recorded during the welding of the test assembly. It may also contain any additional information as appropriate and shall list the test results of the tested specimen(s). 11.3.2 Where a PQR has been conducted in accordance with another recognized specification or standard, it shall be limited by the range of validity (i.e., essential variables) specified in that specification or standard. However, to qualify to this Standard, the essential variables listed in this Standard for the given welding process shall be satisfied. 1133 Welding of the test assemblies, as specified in Tables 9 and 10, shall be carried out in the presence of the CWB'’s representative. Mechanical testing and evaluation of the specimens shall be performed by an ATO, a welding inspection organization certified to CSA W178.1 for mechanical testing, or other organizations or laboratories acceptable to the CWB; alternatively, the testing shall be witnessed by a CWB representative. Bending of the test specimens may be performed by the company; however, the evaluation of the specimens shall be performed by the CWB. 1134 When permitted'by the filler metal specification or standard, a procedure qualification test assembly welded with a non-controlled hydrogen welding consumable may be aged at 100 + 5 °C (212 + 41 °F) for a maximum of 48 h, prior to testing. 11.3.5 All welding of procedure qualification test assemblies shall be performed by the company in their plant or site using their welding equipment and welding personnel. However, at the discretion of the company, and with the approval of the CWB, the welding of a procedure qualification assembly may be performed at other locations. In such cases, the company shall be responsible for ensuring that the welding conditions and parameters of the test can be reproduced to make satisfactory welds using the welding equipment available to the company in their plant or site. If the welding conditions and parameters, regardless of where the welding of a procedure qualification assembly was performed, cannot be reproduced in production, a new welding procedure qualification test shall be performed. 11.4 Types of test groupings of welds 114.1 Soundness and mechanical testing required by this Standard shall be as specified in Tables 9 and 10. Such tests shall include the following: a) soundness tests: i) mandatory tests: 1) visual examination; 2) root- and face- (transverse or longitudinal) bend test; 3) side- (transverse) bend test; and 4) macro-etch test; and October 2019 Licensed to/autorisé A CSWind Vietnam, nnhaigmécswin ., Csitiad vietaam Co Sold by/vendu par CSA Group/Groupe CSA on, 9-21 netuork pronibiied. Le siockage, reproduction, la diseribution. o utilisation sur le réseau est lncerdit Certification of companies for fusion welding of steel CSA W47.1:19 ii) b) optional tests: 1) radiography examination; 2) ultrasonic examination; or 3) other tests as specified in the contract or applicable governing application standard; and mechanical tests: i) mandatory test — a reduced section tension test; and ii) optional tests: 1) Charpy V notch (CVN) impact test; 2) hardness test; and 3) other tests as specified in the contract or applicable governing application standard. Details on CharpyV notch (CVN) impact testing and hardness testing are included in Annexes E and G for guidance. Alternatively, such details shall be as specified in the contract documents or applicable governing standards. 114.2 Essential variables for soundness and mechanical testing shall be as specified in Tables 11 and 12 and Clause 11.4.3. 11.4.3 The PQR mechanical test essential variable changes requiring a requalification for the SMAW, FCAW, MCAW, GMAW, SAW, GTAW, ESW, and EGW processes shall be as follows: a) achange in the'base metal steel group (number) as defined in Table 17; b) achange in welding process; c) anincrease in filler metal classification strength level*; and d) achange of thickness outside the range allowed by Table 13. * For the SMAW process, a strength level greater than E49XX requires requalification. 1144 When soundness and/or mechanical tests are required by Table 9 or Clause 11.4.3, they shall follow the specific test requirements in Table 10. 114.5 The range of thickness and/or diameter and/or fillet weld sizes required to qualify a WPDS shall conform to Note 5 of Table 11 and to Tables 13, 14, or 15. 11.4.6 In addition to the essential variables listed in Clauses 11.4.2 to 11.4.5, the PQR mechanical test essential variable requiring a requalification for the robotic arc welding shall be as follows: a) the brand name of the robot when applicable; b) the program identification number or name; and c) the type of sensor (e.g., seam find, seam tracker, adaptive welding, etc.). Note: If the program can be replicated on a different robot brand name or if the identification number or the name of the program changes, but it replicates the same frame work of essential variables, a new qualification is not required. Modifications to the program that do not affect the framework of essential variables do not require a new qualification. October 2019 Licensed to/autorisé 2 CSWind Vietnam, nnhaigmécswind.c Sold by/vendu par CSA Group/Groupe CSA on/Le 2023-0: s network prohibited. Le stockage, reproducti 48 CSHind Vietnam Co., LTD. Tax code: 3500785873 ense only. Storage, copying, istribution or use on . “ou L'utilisation sur le réseau est incerdic CSA W47.1:19 Certification of companies for fusion welding of steel 11.4.7 A procedure qualified by semi-automatic process shall be considered valid for robotic welding operations but not vice versa. 11.5 Test assembly, positions, and specimens 11.5.1 All welds shall be classified as flat, horizontal, vertical, or overhead in accordance with Figure 4. 11.5.2 Test a) b) c) d) assembly positions shall be as shown in the following: Figure 1 (plate test assemblies for fillet welds); Figure 2 (plate test assemblies for groove welds); Figure 3 (pipe or tubing test assemblies for groove welds); and Figure 20 (pipe or tubing test assemblies for fillet welds). 11.5.3 When soundness tests are required, the minimum length of a test plate assembly shall be 300 mm (12 in) to ensure a suitable length for visual examination (see Figure 21). For plug and slot welds, the minimum sizes of the test plate assembly shall be as described in Figure 5. The minimum length of a plate test assembly for mechanical testing shall be as required to extract the necessary test specimens (see Figure 22). Test assemblies larger than the minimum can be required to allow for sufficient weld length to extract test specimens or to allow for retesting where permitted. 1154 The number and location of test specimens for both soundness and mechanical tests shall be as shown in Figure 5, Figures 21 to 32 and 35, and Table 10. The test specimens shall be prepared for testing in conformance with Figures 5, 15, 16, 31, 32, and 33 as applicable. 11.5.5 When both soundness and mechanical tests are required, they may be completed on separate welded test assemblies welded with similar welding parameters or on a combined single test assembly. In either case, due consideration shall be given to the essential variables for the type of test (soundness or mechanical) being employed. When a combined test assembly is used, each type of test (soundness or mechanical) shall be regarded as an independent qualification. 11.5.6 Welding procedure qualification tests whose only acceptance criterion is a macro-etch may be performed on any steel within its own group for soundness tests. See Tables 17 and F.1. 11.5.7 Alternative production test assemblies can be used for PQR in lieu of the test assemblies shown in Figures 5, 21 to 32, and 35. The number of test specimens for both soundness and mechanical tests shall be the same as required to be extracted from the test assemblies shown in Figures 5, 21 to 32, and 35. October 2019 Licensed to/auz 3 cswind vietnan, nmnaigmecswind.com Sold by/vendu par CSA Group/Grouse CSA on, 3-0 st network pronibited. Le stockage, produ 49 ucion, . Tax code: 3500785873 Storage, copying, discribucion or use on ou L'ucilisacion sur le réseau est interdit CSA W47.1:19 Certification of companies for fusion welding of steel 11.6 Test methods and acceptance criteria — Soundness tests 11.6.1 Visual examination 11.6.1.1 The complete welded test assembly (excluding any extensions or run-off tabs as noted in Figure 21) shall be 100% visually examined without the aid of magnification. The acceptance criteria shall be as follows: a) b) c) d) e) f) g) the weld shall be free of surface cracks; all craters shall be filled to the full cross-section of the weld; there shall be no visible lack of fusion between welds and base metal; weld profiles shall be in accordance with Figure 14; the sum of diameters of visible porosity shall not exceed 10 mm (3/8 in) in any 25 mm (1 in) linear length of weld and shall not exceed 20 mm (3/4 in) in any 300 mm (12 in) length of weld. Any individual pore shall have a dimension not exceeding 2.5 mm (3/32 in); depth of undercut shall not exceed 1 mm (1/32 in); and for complete joint penetration groove welds made from one side, the root of the weld shall be inspected and there shall be no evidence of cracks, incomplete fusion, or inadequate joint penetration. A concave root surface shall be permitted within the limits stated below, provided the total weld thickness is equal to or greater than that of the base metal: i) the maximum root surface concavity shall be 2 mm (1/16 in) deep; and i) the maximum melt-through shall be 3 mm (1/8 in). 11.6.1.2 Visual inspection of a complete welded test assembly may be performed immediately after the test assembly has cooled to ambient temperature. However, for quenched and tempered steels and alloys known to be susceptible to delayed cold cracking, an additional visual inspection shall be performed not less than 48 h after the completion of the test assembly. 11.6.1.3 Visual examination of a welded test assembly shall be performed after postweld heat treatment when postweld heat treatment is specified. Visual examination may also be performed prior to heat treatment. 11.6.2 Radiographic/ultrasonic examination When radiographic or ultrasonic examination is to be used, the procedure and technique shall be in accordance with CSA W59. Acceptance criteria shall be in accordance with Clause 11 of CSA W59, unless otherwise specified. 11.6.3 Root-, face-, and side-bend test specimens 11.6.3.1 Bend test specimens shall be prepared in accordance with Figures 15 and 16. 11.6.3.2 Each test specimen shall be bent in a jig substantially in accordance with one of the jigs as shown in Figure 18. Any convenient means may be used for moving the plunger member in relation to the die member with the weld at midspan for jigs as shown in Figure 18. October 2019 Licensed to/autorisé A CSWind Vietaam, nmhaigmocswind.com, CSWind Vietnam Co., LTD. Tax code: 3500783873 S01d by/vendu par CSA Group/Groupe CSA on/le 2023-09-21. -Single user license only. Storage, copying, distribucion or use on network prohibited. Le stockage, reproduction, ia distribucion, ou l'ucilisation sur le réseau est interdit 50 CSA W47.1:19 Certification of companies for fusion welding of steel Root-bend specimens shall be placed with the root of the weld directed toward the gap for jigs as shown in Figures 18 a) and b) or shall have the root side of the specimen contacting the roller for the jig as shown in Figure 18 c). Face-bend specimens shall be placed with the face of the weld directed toward the gap for jigs as shown in Figures 18 a) and b) or shall have the face side of the specimen contacting the roller for the jig as shown in Figure 18 c). Side-bend specimens shall be placed with the side showing the greater defects, if any, directed toward the gap for jigs as shown in Figures 18 a) and b) or with the other side enclosing the inside mandrel for the jig as shown in Figure 18 c). The two members of the jig shall be forced together or moved in relation to one another until the specimen is bent through an angle of 180°. 11.6.3.3 Bend test specimens shall be bent about the centre of the weld. 11.6.3.4 When material combinations differ in mechanical properties (e.g., between two base materials or between the weld metal and the base metal), longitudinal bend tests (face and root) may be used in lieu of transverse face- and root- or side-bend tests. In these cases, the test assemblies shall be prepared in accordance with Figure 15. 11.6.3.5 The convex surface bend test specimen shall be visually examined for surface discontinuities. For acceptance, the surface shall contain no discontinuities exceeding the following dimensions: a) 3 mm (1/8 in) measured in any direction on the surface; b) 10 mm (3/8 in) — the sum of the greatest dimensions of all discontinuities exceeding 1 mm (1/32in) but less than or equal to 3 mm (1/8 in); and c) 6mm (1/4in) — the maximum corner crack, except when such a corner crack resulted from visible slag inclusion or other fusion-type discontinuities, in which case Item 2) shall apply. Specimens with corner cracks exceeding 6 mm (1/4 in) with no evidence of slag inclusions or other fusion-type discontinuities shall be disregarded and a replacement test specimen from the original test assembly shall be tested. 11.6.4 Macro-etch test specimens 11.6.4.1 For partial joint penetration and fillet weld test assemblies, two transverse sections of the weld shall be cut, polished, and etched with a suitable etchant to clearly reveal the weld fusion boundary as shown in Figures 23, 24, and 25. 11.6.4.2 Both macro-etched test specimens, when inspected visually with a maximum magnification up to 5 power, shall conform to the following requirements: a) fillet welds shall have fusion to the root of the joint but not necessarily beyond it unless required; b) minimum leg size shall meet the specified fillet weld size and no leg size more than 3 mm (1/8 in) larger than the minimum size specified shall be allowed; October 2019 Licensed 51 to/autorisé A CSWind Vietaam, halgmécswind.com, CSWind Vietnam Co., LTD o Tax code: 3500785873, CSA W47.1:19 c) d) Certification of companies for fusion welding of steel partial joint penetration groove welds shall have the actual effective throat thickness, E, equal to or greater than the specified effective throat thickness; and the partial joint penetration groove welds and fillet welds shall have the following: i) no cracks; ii) fusion between adjacent layers of weld metal and between weld metal and base metal; iii) weld profiles conforming to Figure 14; and iv) no undercut exceeding 1 mm (1/32 in). 11.6.4.3 For plug and slot test assemblies, four transverse sections of the weld shall be cut, polished, and etched with a suitable etchant to clearly reveal the weld fusion boundary as shown in Figure 5. All four macroetched test specimens, when inspected visually with maximum magnification up to 5 power, shall conform to the following requirements: a) no cracks; b) thorough fusion between the adjacent layers of weld metal and at the fusion of the plug or slot with the backing; c) no visible slag; and d) no undercut. 11.6.5 Retests for soundness tests 11.6.5.1 ' If the visual examination fails to meet the acceptance level, a further welded test assembly shall be prepared and subjected to the same visual examination. If this fails to meet the requirements, the qualification has failed and the procedure shall require modification before further testing. 11.6.5.2 If any one specimen (used in the bend or macro-etch test) of all those tested fails to meet the test requirements, two retests for that particular type of test specimen may be performed with specimens extracted from the original welded test assembly. The results of both test specimens shall meet the test requirements. For material over 38 mm (1-1/2 in) thick, failure of a specimen shall require testing of all specimens of the same type from two additional locations in the original welded test assembly. 11.6.5.3 For plug and slot welds, if any one of the specimens used in macro-etch test fails to meet the test requirements, the qualification has failed and the procedure shall require modification before further testing. 11.7 Test methods and acceptance criteria — Mechanical tests 11.7.1 Reduced section tension test specimens 11.7.1.1 When required, each reduced section tension test specimen shall be prepared in accordance with Figure 33. October 2019 Licensed to/autorisé A CSWind Vietnam, nnhaigmecswind.com, CSWind Vietnam Co., LTD Tax code: 3500785373, Sold by/vendu par CSA Group/Groupe CSA on/le 2023-09-21. -Single user license only. Storage, copying, distribution or use on Getwork prohibited. Le stockage, reproduction, la distribution, ou llutilisation sur le réseau ssc interdic 52 o CSA W47.1:19 Certification of companies for fusion welding of steel 11.7.1.2 The tensile strength (averaged at each location in the case of multiple-test specimens) shall not be less than the specified minimum ultimate tensile strength of the weaker base material used in the test assembly. For thicknesses over 38 mm (1-1/2 in), where there are limitations of the testing equipment to accommodate the full size specimens or due to equipment load capacity, individual reduced section tension test specimens may be cut into multiple specimens of approximately equal strips as specified in Figure 33. In the case of multiple-test specimens, the tensile strength results of the set of multiple specimens shall be averaged, and no individual result at each location shall be lower than 95% of the specified minimum ultimate strength of the weaker base material if the specimen breaks in the base material outside the weld and heat-affected zone (HAZ). 11.7.1.3 If filler metal of classification strength lower than the base metal strength is used, the tensile strength of the test specimen shall not be less than the specified minimum ultimate strength of the lower strength filler material. 11.7.2 Retests for mechanical tests If either or both of the two reduced section (transverse) tension test specimens fail to meet the test requirements, two retests for each specimen that failed may be performed with specimens extracted from the original welded test assembly. The results of both test specimens shall meet the test requirements. For material over 38 mm (1-1/2 in) thick, failure of a specimen shall require testing of all specimens of the same type from two additional locations on the original welded test assembly. 11.8 Welding consumables 11.8.1 Companies shall use welding consumables that are certified by the CWB to the requirements of CSA W48, or in the absence of a CSA Standard, to the requirements of the applicable AWS A5 Specification. 11.8.2 The following provisions shall apply when non-certified electrodes or non-certified combinations of electrodes/fluxes or electrodes/shielding gases are used: a) The company may conditionally qualify such electrodes or combinations of electrodes/fluxes or electrodes/shielding gases under the appropriate CSA or AWS electrode standard (with a two-year check test period). Such conditional electrode qualifications shall i) be witnessed by the CWB; i) be subject to all of the requirements of the appropriate CSA or AWS electrode standard; iii) be valid only for the company performing the qualification; iv) require the electrode manufacturer’s quality system at the point of manufacture to be periodically audited by the CWB. If the quality system has not been audited or is no longer being audited by the CWB, the conditional approval of the electrodes or combinations of electrodes/fluxes or electrodes/shielding gases shall only be valid for the particular heat/lot number of the filler metal tested. Additional heat/lot numbers to be used by the company shall be subjected to full testing. October 2019 Licensed to/autorisé A CSWind Vistnam, aahaigmécswind.com, CSWind Co., LTD Tax code: 3500783873 Sold by/vendu par CSA Group/Groupe CSA on/le 2023-09-21. -Single user Vietasm se only. Storage, copying, distrib of use on necwork pronibited. Le stockage, reproduction, la distribution, ou l'ucilisacion sur le résesu est incerdit. 53 CSA W47.1:19 b) Certification of companies for fusion welding ofsteel Where qualification under Item a) is not considered by the company, the company may have the electrodes or combinations of electrodes/fluxes or electrodes/shielding gases approved as part of the PQR, provided the mandatory soundness and mechanical tests specified in Table 10 for the applicable joint type are successfully completed. Such approval shall be valid only for the type and geometry of the joint and base metal specification grade used in the PQR assembly. 11.8.3 The following are representative examples of situations where Clause 11.8.2 b) applies: a) where the electrode or electrode/flux or electrode/shielding gas combinations have not been submitted by the manufacturer to the CWB for approval; b) where the electrode or electrode/flux or electrode/shielding gas combination approvals are underway but not complete; and c) where the weld metal is produced from a composite wire and flux obtained from different manufacturers. Note: If an all-weld-metal tension specimen can be removed from the original joint geometry of the PQR test assembly, the length of the PQR test assembly should be extended beyond that shown in Figure 22. Otherwise, a separate test assembly applies. 11.84 If an all-weld-metal tension specimen is required, see Figure 34. 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