Boretech WPS and WOPQ 2

[m3brunof]

Hey guys, I will be qualifying a new WPS and WOPQ using a Boretech welder. So far I've done only plate WPS, and am a little unfamiliar with pipe and automated equipment.
What is the best size diameter and thickness combo to qualify a WPS and WOPQ simultaneously with a Boretech?
This will be done per ASME.

 

[Mr168]

Good place to start would be to tell us what it is you're planning on welding with it. Lots of processes, applications, thicknesses, and diameters you can weld with Bortech equipment.

 

[m3brunof]

I will be using the GMAW process, the thickness will range from 1/8" to 2". The welding will be performed on pump impellers mostly. I hope this info helps.

 

[Mr168]

For our machine applications (groove weld), we run 10" diameter, as it's large enough for us to mount our equipment, but small enough to be economically feasible on a routine basis. Your conditions may vary depending on equipment type and availability.

For overlay apps, you would be restricted to a 1/8" minimum wall thickness per QW-453. For groove weld applications, you will need two coupons at a minimum for your specified thickness ranges per QW-451. I will say that for the upper end of your thickness limits on groove applications, going from a 1" coupon to a 1.5" coupon is usually a smart move investment-wise to qualify you to 8" from the get-go.

 

[m3brunof]

In my situation, the Boretech will be used for weld repair and weld build up only. The welding performed will be like an overlay weld. How should I set up the weld test, if the welding performed will be like an overlay?

 

[Mr168]

See the applicable notes for QW-453.

Personally, I would set it up as an in-situ type scenario, especially on the thinner material. I'd also invest in a heavier coupon/mock-up to get your actual weld parameters under control.

We had major issues on multiple projects with faulty overlays in our boiler feed pumps that surfaced before they were even put into service. The manufacturer is hemorrhaging money now due to repair costs and warranty claims.

 

[m3brunof]

I know the welder operator needs to be qualified per QW-484B, but can I take a WPS that was qualified manually and use it with the Boretech welder? Or does it need its own WPS?

 

[Mr168]

See QW-410.25. Manual vs. automatic is a nonessential variable. Manual qualifications may be used with machine equipment and vice versa.

 

[m3brunof]

I will be qualifying new WPS for P1, P8 and P6gr4. I will be using GMAW with short circuit transfer. Since these WPS will be used for weld build up only, should I follow QW-453 corrosion-resistant overlay or QW-453 hard-facing overlay?

 

[Duwe6]

Neither 'corrosion-resistant' nor 'hard-face' fit a basic buildup well. I would just do a PQR on a medium size pipe with a groove and backing ring for the P1, P8, and P6gr4. If there is any excavation or grinding that takes the old weld below the thickness of the thinner basemetals, you are now classified as "Weld Repair" by overlay. Best to have your WPS rated for welding, not just overlay.

If the P8 will be overlaid on a different P#, then it would be a Corrosion-Resistant overlay.

If the P6gr4 will be overlaid on P1 I would call it a Hard-Facing.