Partial welding of pipe test piece for ASME IX procedure qual 1

[afocuf]

Hello All,

I work for a consultancy firm. A client has requested that we prepare a WPS for girth welds in API 5L X65 pipe (25mm thick), to be qualified according to ASME IX. The client also requested that we source the material to be used for the test pieces. These will then be welded and tested by our client.

I am trying to source to source short lengths of X65 pipe, but I can only get quotes for entire pipe lengths (11m). Th eclien tdoes not have material in stock as the WPS is not requsted for specific project, but it is being qualified to 'fill some voids' in their current WPS/PQR collection. We have a suitable pipe end left from a previous project, but this is 30" OD and manual welding is required (GTAW+SMAW); it would be impractical and in my opinion unnecessary to weld the entire weld circumference.

My intention is to use the 30" OD pipe, but only weld one half from 6 to 12 o'clock (5G test position, vertical-up progression), the remove specimens as follows:
- Tension test: as per QW-463.1(e)
- Bend test: two specimens from two of the four locations shown in QW-463.1(e) (rather than one specimen per location)
- Impact test: all specimens taken from one of the areas in QW-463.1(f)

If we welded the entire pipe circumference, we would weld two 'identical' halves in the 5G vertical-up position, so welding and sampling only one half of the pipe would not make a significant difference to the test results.

I have searched ASME IX's intepretations, but I could only find references to performance qualification using two welders (each welding one half of the pipe). I guess because no one in their right mind would weld a 30" OD pipe for a procedure qual, but we do not see to have other options.

Is anyone aware of interpretaitons that address this scenario or do you have previous experience with a similar situation?

Thanks

 

[DekDee]

afocuf,
For procedure qualification you just need to weld enough to enable the required mechanical samples to be removed - there is no code mandated minimum size.
If welder qualification was required as well you would have a lot more requirements regarding length of weld, diameter of pipe, position of weld etc, etc but if it is just for WPS/PQR then you are fine with what you propose,
Regards,
DD

 

[afocuf]

Thanks DD,

My concern is that QW-202.1 states that "[test specimens]...shall be removed in a manner similar to that shown in Figures QW-463.1(a) through QW-463.1(f)." QW-463.1(e) shows bend tests removed 90° apart along the pipe circumference, so it seems to imply that the entire pipe shall be welded, which makes sense, espcially for a 5G or 6G fixed test positions. I guess that it is assumed that one would not choose to weld an unneccessary large pipe for a procedure qual. If I only weld a section of the pipe circumference, I do not comply with QW-202.1 and QW-463.1.

Even just 1/4 of the pipe circumference would be sufficient to extract tension, bend and impact test specimens, but by welding 1/2 the pipe circumference, I am trying to use engineering judgment and at the same time comply with QW-202.1 as much as possible.

 

[SectionIX]

Why not just use a P1, Group 2 plate of a reasonable size to get the required mechanicals?

 

[afocuf]

Thanks Section IX, I have already proposed this route, but the client requires X65 only. Sorry i forgot to specify this in my post.

 

[metengr]

There is no reason to weld a large pipe diameter for WPS qualification because for WPS qualification with certain welding processes, pipe diameter is not an essential variable, other essential welding variables are weld and base metal thickness. For welder performance qualification, the essential variable is pipe diameter but anything at or above 2 7/8" diameter qualifies for unlimited outer diameter.

Keep in mind the reference to pipe and sample removal is in the event welder performance is being done in conjunction with WPS qualification, which is very common. If all you are doing is a WPS qualification for material and filler metal, what you propose is fine or machine a flat plate out of the 30" pipe segment and qualify using a flat plate weld coupon, and call it a day.

 

[afocuf]

Thanks metengr, I could also thought of welding a longitudinal, rather than a girth weld and treat the pipe essentially as a plate. I will try to talk the client into one of these options.

 

[DekDee]

afocuf,
ASME IX introduced the P number system so manufacturers would not have to comply with a specific material.
If your client requires a specific material then they are going over and above code requirements and therefore should pay the extra costs.
Same as for what metengr has proposed - why do you need clients OK if you are supplying a code compliant WPS ?
I appreciate you want to stay in the clients "good books" but sometimes if you tell the client the truth and the bean counters get involved your proposal is instantly accepted anyway,
Cheers,
DD

 

[Ishack]

I would reply "NO" to your question as it won't allow to do so as per ASME Sec IX though it doesn't make any sense.