SECTION 4. QUALIFICATION whether the qualification is conducted by the manofac- turer, Contractor, or an independent testing azency, 4.1.3 Period of Effectiveness 41.3.1 Welders and Welding Operators. ‘The \welder's or welding operator's qualification as specified in this code shall be considered as remaining in effect indefinitely unless (1) the welder is not engaged in a given process of welding for which the welder or welding ‘operator is qualified for a period exceeding six months oF unless (2) there is some specific reason to question a Wwelder’s or welding operator's ability (see 4.32.1) 44.3.2 Tack Welders. A tack welder who passes the test described in Part C or those tests required for welder ‘qualification shall be considered eligible to perform tack welding indefinitely in the positions end with the process for which the tack welder is qualified unless there is sotme specific reason to question the tack welder's ability (ee 4.32.2), 4.2. Common Requirements for WPS and Welding Personnel Performance Qualification 42.1 Qualification to Earlier Editions, Qualifications which were performed to and met the requirements of earlier editions of AWS D1.1 or AWS D1.0 or AWS 12.0 while those editions were in effect are valid and ‘may be used. The use of earlier editions shall be prohib ited for new qualifications in lieu ofthe current editions, unless the specific early edition is specified in the con- tract documents 42.2 Aging. When allowed by the filler metal specifica tion applicable to weld metal being tested, fully welded qualification test specimens may be aged at 200°F to 20°F [95°C to 105°C} for 48 + 2 hours. 42.3 Records. Records of the test results shall be kept by the manufacturer or Contractor and shall be made available to those authorized to examine them. 4.2.4 Positions of Welds, All welds shall be classified as flat (F), horizontal (H), vertical (V), and overhead (OM), in conformance with the definitions shown in Fig. ures 4.1 and 4:2 ‘Test assembly postions are shown in: (1) Figure 4.3 (groove welds in plate) (2) Figure 4.4 (groove welds in pipe or bing) G) Figure 45 fillet welds in plate) 4) Figure 46 (fillet welds in pipe or tubing) PARTS AaB 12 ws D111 M2008, Part B Welding Procedure Specification (WPS) 4.3 Production Welding Positions Qualified "The production welding positions qualified by a WPS. shall conform to the requirements of Table 4.1 4.4 Type of Qualification Tests The type and number of qualification tests requited to qualify « WPS for a given thickness, diameter, ot both, shall conform to Table 42 (CIP), Table 4.3 (PIP) or ‘Table 44 (fillet). Details on the individual NDT and me. chanical test requirements are found in the following subsections: (1) Visual Inspection (see 4.8.1) @) NDT (ee 4.8.2) (G) Face, root and side bend (see 4.8.3.1) (4) Reduced Section Tension (see 4.8.3.4) (5) All-Weld-Metal Tension (se 4.8.3.6) (6) Macroetch (see 4.8.4) 4.5 Weld Types for WPS Qualification For the purpose of WPS qualification, weld types shall be classified as follows: (1) CIP groove welds for Nontubuilar Connections (see 4.9) (2) PIP groove welds for Nontubular Connections (02 4.10) (@) Fillet Welds for Tubular and Nontubular Connec- tions (see 4.11) (4) CIP groove welds for Tubular Connections (see 4.12) (5) PIP groove welds for Tubular T-, Y-, and K- ‘connections and Butt Joints (see 4.13) (6) Plug and Slot welds for Tubular and Nontubular ‘Connections (see 4.14) 4.6 Preparation of WPS ‘The manufueturer or Contractor shall prepare a writ- ten WPS that specifies all ofthe applicable essential vari ables referenced in 4.7, The specific values for these WPS variables shall be obtained from the procedure qualification record (PQR), wich shall serve as waitten, ‘confirmation of a successful WPS qualification,‘AWS 01.1/01.1N:2006 4.7 Essential Variables 47.1 SMAW, SAW, GMAW, GTAW, and FCAW. Changes beyond the Timitations of PQR essential vari- ables for de SMAW, SAW, GMAW, GTAW, and FCAW processes shown in Table 4,5 and Table 4.6, ‘when CVN testing is specified, shall require requalifica- tion of the WPS (see 4.1.1.3). 4.72 BSW and EGW. See Table 4.7 for the POR ‘essential variable changes requiring WPS requalification for the EGW and BSW processes. 473 Base-Metal Qualification. WPSs requiring quai fication that use base metals listed in Table 3.1 shall qualify other base metal groups in conformance with ‘Table 4.8. WPSs for base metals not listed in Table 3.1 or Table 4.9 shall be qualified in conformance with Section 4 The use of unlisted base metals shall be approved by the Engineer. ‘WPSs with stels listed in Table 4.9 shall also qualify Table 3.1 or Table 4.9 steels in conformance with Table. 48, Table 49 contains recommendations for matching. strength filler metal and minimum preheat and interpass temperatures for ASTM A 514, A 517, A 709 Grades 100 and 100W, ASTM A 710 Grade A (Class 1 and 3) steels, and ASTM A 871 Grades 60 and 65. 4.74 Preheat and Interpass Temperature. The mini mum preheat and interpass temperature should be estab lished on the basis of steel composition as shown in ‘Table 3.1. Altematively, recognized methods of predic- tion of guidelines such as those provided in Annex I, or other methods may be used. Preheat and interpass tem- peratures lower than required per Table 3.2 or calculated per Annex I may be used provided they are approved by ‘the Engineer and qualified by WPS testing. ‘The methods of Annex I are based on laboratory ‘racking tests and may predict preheat temperatures, higher than the minirrum temperature shown in Table 32, Annex 1 may be of value in identifying situations ‘here the risk of cracking is increased due to composi tion, restraint, hydrogen level or lower welding heat input where higher preheat may be warranted. Alterna tively, Annex I may assist in defining conditions under which hydrogen cracking is unlikely and where the mini- ‘mum requirements of Table 3.2 may be safely elaxed. 4.8 Methods of Testing and ‘Acceptance Criteria for WPS Qualification The welded test assemblies conforming to 4.8.2 shall have test specimens prepared by cutting the test plate, pipe, or tubing as shown in Figures 4.7 through 4.11, pane 123 SECTION 4, QUALIFICATION Whichever is applicable. The test specimens shall be pre ‘pared for testing in conformance with Figures 4.12, 4.13, 4.14, and 4.18, as applicable, 481 Visual Inspection of Welds. The visu] acceptable ‘qualification for qualification of groove and filet welds (excluding tui-of abs) shall conform to the following requirements, a applicable: 4.8.1.1 Visual Inspection of Groove Welds. Groove ids shall meet the following requiremen (2)Any crack shall be unacceptable, regardles ©) All era of the weld 5 mm], The weld profile shall conform to Figure 5.4 and shall have complete fusion. (G@) Undereut shall not exceed 1/32 in, [1 mm] for CIP grooves shall be inspected, and shall not have any cracks, incomplete fusion, or in- adequate joint penetration 6) For CIP grooves welded from one side without backing, root concavity or melt through shall conform to the following: (2) Tae maximum root concavity shall be 1/16 in {2.:mm|, provided the (olal weld thickness is equal to or seas than that ofthe base mu (b) The maximum melt-through shall be_1/8 in. [3.mm| except for tubular T-, ¥-, and K-eonnections ‘where melt dhrough is not Hinited, 48.1.2 Visual Inspection of Fillet Wel welds shall meet the following requirements {Any erack shall be unacceptable, regardless of 2) Al craters shall be filled to the full eross section of the weld 3) The fillet weld leg sizes shall not be less than the required leg si (@) The weld profile shall mest the requirements of Figure 5.4 5) Base metal undercut shall not exceed 1/32 in fmm). 4.8.2 NDT. Before preparing mechanical test speci- mens, the qualification test plate, pipe, or tubing shall be nondestructively tested for soundness as follows: Eilles 48.2.1 RT or UT. Either RT or UT shall be used, ‘The entire length of the weld in test plates, except the discard lengths at each end, shall be examined in con- formance with Section 6, Part E or F. For tubulas, the full circumference of the completed weld shall be exam ined in conformance with Section 6, Part C.[SECTION 4, QUALIFICATION 48.2.2 RT or UT Acceptance Criteria. For accept able qualification, the weld, as revealed by RT of UT, shall conform (othe requirements of Section 6, Patt C. 483 Mechanical Testing. Mechanical testing shall be as follows: 4.8.3.1 Root, Face, and Side Bend Specimens (see Figure 4.12 for root and face bends, Figure 4.13 for side bends). Each specimen shall be bent in a bend test jig that meets the requirements shown in Figures 415, through 4.17 or is substantially in conformance with those figures, provided the maximum bend radius is not exceeded. Any convenient means may be used to move the plunger member with relation to the die member. ‘The specimen shall be placed on the die member of the jig with the weld st midspan, Face bend specimens shail be placed with the face of the weld directed toward the gap. Root bend and fillet weld soundness specimens shall be placed with the root of the weld directed toward the gap. Side bend specimens shall be placed with that side showing the greater discontinuity, if any, directed toward the gap ‘The plunger shall force the specimen into the die until the specimen becomes U-shaped. The weld and HAZs shall be centered and completely within the bent portion of the specimen after testing. When using the wrap- around jig, the specimen shall be firmly clamped on one end so that there is no sliding of the specimen during the bending operation. The weld and HAZs shall be com- pletely in the bent portion of the specimen after testing ‘Test specimens shall be removed from the jig when the ‘outer roll has been moved 180° from the starting point 4832 Longitudinal Bend Specimens. When mate- rial combinations differ markedly in mechanical bending properties, as between two base materials or between the ‘weld metal and the base metal, longitudinal hend tests (ace and root) may be used in lieu of the transverse face and root bend tess, The welded test assemblies conform ing to 4.8.2 shall have test specimens prepared by cutting the test plate as shown in Figure 4.10 or 4.11, whichever is applicable. The test specimens forthe longitudinal bend test shall be prepared for testing as shown in Figure 4.12, 4833 Acceptance Criteria for Bend Tests. The convex. surface of the bend test specimen shall be visually examined for surface discontinuities. Fer aecep- tance, the surface shall contain no discontinuities ex- ‘ceeding the following dimensions: (1) V8 in. (3 mm] measured in any direction on the surface (2) 3/8 in. [10 mm} —the sum of the greatest dimen- sions of all discontinuities exceeding 1/32 in. (1 mm), Dat less than or equal to 1/8 in. [3 mm] 124 AWS D1.1/01.14-2006 Q) V4 in. [6 mm]—the maximum comer crack, ‘except when that comer crack results from visible lag inclusion or other fusion type discontinuity, then the 18 in, [3 mm] maximum shall apply ‘Specimens with comer eracks exceeding 1/4 i, (6 mm} With no evidence of slag inclusions or other fusion type discontinuity shall be disregarded, and a replacement test specimen from the original weldment shall be tested. 48.34 Reduced-Section Tension Specimens (see Figure 4.14). Before testing, the least width and corre- sponding thickness of the reduced section shall be mes sured. The specimen shall be ruptured under tensile load, and the maximum load shall be determined. The cross soctional area shall be obtained by multiplying the width by the thickness, The tensile strength shall be obtained by dividing the maximom fond by the cross-sectional arca 4835 Acceptance Criteria for Reduced-Seetion ‘Tension Test. The tensile strength shall be no less than the minimum of the specified tensile range of the hase ‘metal used. 48.36 AN-Weld-Metal ‘Tension Specimen (see Figure 4.18). The test specimen shall be tested in con- formance with ASTM A370, Mechanical Testing of Stoel Products 4.8.4 Macroetch Test. The weld test specimens shall be prepared with a finish suitable for macroetch examina- tion. A suitable solution shall be used for etching to give a clear definition ofthe weld 48.4.1 Acceptance Criteria for Macroetch Test. For acceptable qualification, the test specimen, when inspected visually, shall conform to the following requirements: (1) PIP groove welds; the actual weld size shall be equal to or greater than the specified weld size, (P). (@) Fillet welds shall have fusion to the root of the Joint, but not necessarily beyond. G) Minimam leg, size shall meet the specified fillet weld size (A) The PIP groove welds and fillet welds shall have the following: (a) no cracks (b) thorough fusion between adjacent layers of ‘weld metal and between weld metal and base metal (6) wold profiles conforming to specified detail, ‘bat with none of the variations prohibited in 5:24 (@) no undercut exceeding 1/32 in. [1 mm) 48.5 Retest. If any one specimen of all those tested fails to meet the test requirements, co retests for that particular type of test specimen may be performed with specimens cut from the same WPS qualification material. The results of both test specimens shall meet the test requirements,‘AWS D1.40D1.1612006 For material over 1-1/2 in, (38 mu) thick, failure of specimen shall require testing ofall specimens ofthe samme {ype from two additional locations inthe test material. 4.9 CJP Groove Welds for Nontubular Connections See Tuble 4.2(1) for the requirements for qualifying & WPS of a CIP weld on nontubular connections. See Fi tures 4.94.11 for the appropriate tes plate. 491.1 Corner or T-Foints. Test specimens for sroove welds in comer or T-joints shall be but joints having the same groove configuration as the comer or joint to be used on construction, except the depth of ‘groove need not exceed 1 in. [25 min. 4.10 PJP Groove Welds for Nontubular Connections 4.10.1 Type and Number of Specimens to be Tested. ‘The type and number of speeimens that shall be tested to qualify a WPS are shown in Table 4.3. A sample weld shall be made using the type of groove design and WPS to be used in construction, except the depth of groove need not exceed I in. {25 mm]. For the macroetch test required below, any steel of Groups I, I, and Il of Table 3.1 may ‘be used to qualify the weld size on any steels or combina- tion of steels in those groups. Ifthe PIP groove weld is to be used for corner or T-joints, the butt joint shall have 2 temporary restrictive plate inthe plane of the square face to simulate the T-joint configuration. The sample welds shall be tested as follows: 4.10.2 Weld Size Verification by Macroetch. For WPSs which conform in all respects to Section 4, three macroetch cross-section specimens shall be prepared to demonstrate that the designated weld size (obiained from the requirements of the WPS) are met. 4.103 Verification of CJP Groove WPS by Macro- etch. When 2 WPS has been qualified for a CIP groove ‘weld and is applied to the welding conditions of a PIP ‘groove weld, three macroetch cross-section tests speci- mens shall be requized to demonstrate that the specified weld size shall be equalled or exceeded. 4.10.4 Other WPS Verifications by Macroeteh. If 2 “WPS is not covered by either 4.10.2 oF 4.10.3, or i the ‘welding conditions do not meet a prequalified status, ot if these have not been used and tested for a CIP weld in a butt joint, then a sample joint shall be prepared and the first operation shall be to make a macroeich test speci ‘men to determine the weld size of the joint, Then, the ex parr 25 SECTION 4. QUALIFICATION ‘cess material shall be machined off on the bottom side of the joint to the thickness of the weld size, Tension and bend test specimens shall be prepared and tests per- formed, as required for CIP groove welds (see 4.9) 4.10.5 Flare-Groove Welds. The effective weld sizes for qualified flare-groove welds shall be determined by the following: (1) Test sections shall be used to verify that the effec tive weld size is consistently obtained. (Q) Fora given set of WPS conditions, ifthe Contrac- tor has demonstrated consistent production of larger effective weld sizes than those shown in Table 2.1, the Contractor may establish such larger effective weld sizes by qualification, {G) Qualification required by (2) shall consist of see- sioning the radiused member, normal to its axis, at ‘midlength and ends of the weld. Such sectioning shall be made on a number of combinations of material sizes representative of the range used by the Contractor in 4.11 Fillet Welds for Tubular and Nontubular Connections 4.11.1 Type und Number of Specimens. ‘The type and ‘number of specimens that shall be tested to qualify @ fillet weld WPS are shown in Table 4.4 4.11.2 Fillet Weld Test. A fillet welded ‘T-joint, as shown in Figure 4.19 for plate or Figure 4.20 for pipe (Detail A or Detail B), shall be made for each WPS and position to be used in construction. One test weld shall be the raximuun size single-pass fillet weld and one test ‘weld shall be the minimum size multiple-pass fillet weld used in construction. These two fillet weld tests may be ‘combined in a single test weldment or assembly, The weldment shall be cut perpendicular to the direction of ‘welding at locations shown in Figure 4.19 or Figure 4.20 as applicable, Specimens representing one face of each cut shall constitute a macroetch test specimen and shall ‘be tested in conformance with 4.84. 4.11.3 Consumables Verification Test. If both the pro- posed welding consumable and the proposed WPS for ‘welding the fillet weld test plate or test pipe described in 4.11.2 are neither prequalified nor otherwise qualified by Section 4, that is (1) If the welding consumables used do not conform to the prequalified provisions of Section 3, and also (@) If the WPS using the proposed consumable has not been established by the Contractor in conformance ‘with either 4.9 or 4.10, den a CIP groove weld test plate shall be welded to qualify the proposed combination.SEGTION 4. QUALIFICATION ‘The test plate shall be welded as follows: (1) The test plate shall have the groove configuration shown in Figure 4.21 (Figure 4.22 for SAW), with stee! backing. (@) The plate shall be welded in the £G (fat) position. G) The plate length shall be adequate to provide the test specimens required and oriented as shown in Figure 423, (4) The welding test conditions of current, voltage, travel speed, and gas flow shall approximate those to be used in making production fillet welds as closely as practical ‘These conditions establish the WPS from which, ‘when production fillet welds are made, changes in es tial variables will be measured in conformance with 4.7, ‘The test plate shall be tested as follows: (1) Two side bend (Figure 4.13) specimens and one all-weld-metal tension (Figure 4.18) test specimen shall be removed from the test plate, as shown in Figure 4,23, (2) The bend test specimens shall be tested in con- formance with 4.8.3.1. Those test results shall conform to the requirements of 4.8.3.3 (3) The tension test specimen shall be tested in con- formance with 4.8.3.6. The test result shall determine the strength level for the welding consumable, which shall conform to the requirements of Table 2.3 or the base ‘metal strength level being welded. 4.12 CJP Groove Welds for Tubular Connections CIP groove welds shall be classified as follows: (1) CHP bute joints with backing or backgouging (see 412.1) (2) CIP butt joints without backing welded from one side omly (see 4.12.2). (3) T-, Y-, K-connections with backing or backgoug. ing (see 4.12.3), (HT, Y-, K-connections without backing welded from one side only (see 4.12.4). 4.12: CIP Butt Joints with Backing or Backgouging. ‘A WPS with backing or backgouging shall be qualified ‘sing the detail shown in Figure 425(A) (with back ‘gouging or Figure 425(B) (with backing) 4.12.2. CIP Butt Joints without Backing Welded from ‘One Side Only. A WPS without backing welded from one side only shall be qualified using the joint detail shown in Figure 4.25(A) 4.12.3 T>, Y-, or K-Connections with Backing or Backgouging. A WPS for tubular T-,¥-, o K-connections ‘with backing or backgouging shall be qualified using: Q) the appropriate nominal pipe OD selected from Table 4.2(2), and paar 126 AWS D1.1/01.1882008 (2) the joint detail of Figure 4.25(B), 0 8) for nominal pipe ODs equal to or greater than 24 in. (600 mm}, plate qualification in conformance ‘with 4.9 sing te joint detail of Figure 4.25(B). 4.124 T-, Yo, or K-Connections without Backing ‘Welded from One Side Only. When qualification is re~ quired, a WPS for'T-. Y-, or K-connections without back: ing welded from one side only shall require the following: 4,124.1 WPSs without Prequalified Status. For a WPS whose essential variables ere outside the prequali- fied range, qualification for CIP tubular groove welds shall require the following: (1) Qualification in conformance with Figure 4.27 for pipes with ouside diameters preater chan or equal t04 in, 10 mm or Figure 4.27 and Figure 4.29 for box tubes. Qualification in conformance with Figure 4.28 for pipes ‘with outside diameters Jess than 4 in. [100 mm] or Figure ‘ zure 4.29 for box tubes. (2) A Sample Joint or Tubular Mock-up. The sample joint or tubular mock-up shall provide atleast one macro- ctch test section for each of the following conditions: (@) The groove combining the greatest groove depth withthe smallest groove angle, oF combination of ‘grooves to be used: test with welding position vertical (b) The narrowest root opening to be used with 37.5° groove angle: one test welded in the flat position and one test welded in the overhead position. (©) The widest root opening to be used with a 37.5 groove angle: one test to be welded in the fat post tion and one test to be welded in the overhead position, (@) for matched box connections only, the mini- ‘mum groove angle, corner dimension and comer radius tbe used in combination: one test in horizontal position, {G) The macroetc test specimens required in(1) and (2) above shall be examined for discontinuities and shall have: (a) No cracks (b) Thorough fusion between adjacent layers of ‘weld metal and between weld metal and base metal (©) Weld details conforming to the specified de- tail but with none ofthe variations prohibited in 5.24 (@ No undercut exceeding the values allowed in 6.9. (© For porosity 1/32 in. [1 mm} or larger, accu- ‘ulated porosity shall not exceed 1/4 in, (6 mum} (®) No accumulated slag, the sum of the greatest dimension of which shall not exceed 1/4 in. (6 mm] ‘Those specimens not conforming to (a) through (9) shall be considered unacceptable; (b) through (f) not ap- plicable to backup weld 4.12.42 CIP Groove Welds in a T-, Y-, or Ke Connection WPS with Dihedral Angles Less than 30°, ‘The sample joint described in 4.12.4.1(2)(a) shall be re quired. Three macroetch test sections shall be cut from the test specimens, shall conform to the requirements of