SMAW kj/in API 1104 ASME Sect IX

[NobigDEAL44]

Clearly I've been doing this wrong:/ So here I am.
Rejected welds based on kj/in. from actual values recorded during in-process welds.
So based on the WPS (not PQR) data below, can someone audit these numbers in accordance to API-1104 19th edition and maybe ASME Sect. IX (current)and tell me the allowable electrode diameter(s), travels speed(s) and kj/in. allowed per pass per code?

....................Electrode.............Dia .................AMP's .........VOLT...........Travel/Speed......KJ/IN
................................................MAX
ROOT.....SMAW.....E8010-P1........5/32"...DCRP....130 - 145.......25 to 28........10" to 14"......13.9 - 24.4
HOT.......SMAW.....E8010-P1........5/32"...DCRP....150 - 165.......26 to 29........10" to 15"......15.6 - 28.7

FILL.......SMAW.....E8010-P1.........5/32"...DCRP....140 - 145.......25 to 28........17" to 18"......11.7 - 14.3
or
FILL.......SMAW.....E8010-P1........3/16"....DCRP....145 - 180........27 to 30.........8" to 11".......21.4 - 40.5

CAP.......SMAW......E8010-P1.......3/16"... DCRP....130 - 165........28 to 30........12" to 15"......14.6 - 24.7

 

[kingnero]

I can't compare with the API standard, as I've got no experience with it, however the actual welding values seem spot on. I've got very similar PQR's.
The max heat input is high, but it is a max value after all. So, looks correct.

 

[NobigDEAL44]

This PQR/WPS has been tested. Tensile - Guided Bend - Toughness 10mmx10mm -Nick Breaks - RT - Hardness Survey, all acceptable /passing.
There is no question its a good procedure.
I'm trying to get help determining the elementary level items correct. 1) What are the electrode diameter(s) options allowed and 2) KJ(heat input allowed within code per electrode?.

 

[david339933]

Electrode diameter only becomes an issue for Sec. IX if increased to over 1/4" dia. Other than that dia. is non-essential and can change as you wish...assuming heat input isn't increased. Any increase in heat input beyond the maximum on the PQR for Sec. IX requires re-qualification.

 

[NobigDEAL44]

david339933 - agreed.
RANDOM? - WHY is there a Min. KJ/in. noted / on WPS?

We are only using 1/8", 5/32" & 3/16" dia. electrodes.

So based on the above Parameters when only using a 5/32"dia. electrode for all passes, what are my allowable KJ?

11.7-40.5kj/in? min max for each pass?

or do we have to be pass specific?

Root -
Hot -
Fill-
Cap-

 

[weldstan]

Per ASME IX, it is the maximum heat input recorded during qualification, irrespective of pass.

 

[david339933]

Allowable heat input is anything less than or equal to the max. measured during qualification. Normally as electrode diameter increases, so does amps and volts. Therefore travel speed must increase to not go over the max. heat input allowed.
Note this is Sec. IX only.

 

[NobigDEAL44]

WELDSTAN
So with that said the above heat in-puts are within the qualification parameters recorded which would then allow 11.7min to 40.5 max. kj/in. per pass?

 

[weldstan]

Yes per ASME IX. While I was on the API 1104 committee 40 years ago, I have no idea what it requires today regarding heat input today.