ASME Section IX - Welding Codes and Metallurgy

Attendees who successfully complete this course will be able to:

1. xxx
2. xxx
3. xxx
4. xxx
5. the last Learning Outcome to address the Welding Examiner exam preparation.

Inspectors, technologists, engineers, QA personnel, NDE technicians, maintenance and experienced tradespeople, who work for owner-user companies, EPCs, inspection companies, fabricators, maintenance service and repair companies, and inspection companies from refineries, upgrader plants, oil sands plants, SAGD plants, petrochemical plants, power plants, gas/oil pipeline companies, pulp mills, repair and maintenance shops, equipment manufacturers, third party inspection and NDE companies, and all supporting industries.

• Notebook with over 730 pages will be provided.
• Over XX Connecting-the-Codes Examples, including step-by-step instructions showing "how to" apply the code rules, along with the code "look-up tables" highlighted, underlined, and answer circled to clearly demonstrate the "how to" example.
• Review of XX ASME Section IX Code Interpretations
• Over XX practice questions to measure knowledge gained.
• Workshops with hands-on practice to use ASME Sec. IX and to write WPS for ASME B31.1, B31.3, and Sec. VIII-1.
• Welding Examiner tutorial exam preparation study material and post-classroom practice exams (online) for Papers #2 and #4.
• Welding Engineer tutorial exam preparation study material, including ASME Section IX post-classroom practice exam (online).

Alberta Safety Codes Acts

• Overview of Pressure Equipment Safety Regulations and Pipeline Codes in Canada
• Overview of CSA, ASME and related Codes for New Construction and In-Service Integrity
• Overview of Pressure Welders Regulation

General Review to ASME IX

• Detailed Review of Part QG – General Requirements
• Detailed Review of Part QW - Welding Articles
  • Article I – Welding General Requirements – QW-100
    • Test Positions and Specimen Removal
    • Tests: Tension, Guided-Bend, and Impact Specimens, and Acceptance Criteria
  • P-Numbers QW-420, F-Numbers QW-430, and A-Numbers QW-440
  • Article II – Welding Procedure Qualifications – QW-200
    • WPS and PQR Content, Changes, and Responsibilities (minimum requirements)
    • Welding Variables for WPS Qualification
      • How to use WPS Variable QW-250 Tables for SMAW, SAW, GMAW, and GTAW
  • Article III – Welder and Welding Operator Performance Qualifications (WPQ) – QW-300
    • Intent of Tests and Specimen Removal
    • Qualification by Mechanical Tests and Volumetric NDE, QW-302
    • How to use Welder Performance Essential Variable QW-350 and QW-416 Tables for SMAW, SAW, GMAW, and GTAW
    • Retests, Expiration, and Renewal of Qualification
    • Alberta Welders Regulations
      • Welder Performance Qualification Cards in Alberta
      • Expiration and Renewal of Qualification
    • Welding Operator Performance Essential Variables, QW-360
    • QW-423 Alternate Base Materials for Welder Qualification
      • How to Correctly Assign P-Numbers for Welder Performance Qualification Based on ABSA Guidelines
  • Article IV – Welding Data – QW-400
    • Procedure Qualification Thickness Limits and Test Specimens QW-451 Tables
    • Performance Qualification Thickness Limits and Test Specimens QW-452 Tables
    • Performance Qualification – Position and Diameter Limitations Table QW-461.9
    • Welding Documentation Forms
  • Article V – Standard Welding Procedure Specifications (SWPS) – QW-500

Introduction to Steels

• Ferrous/Nonferrous, Cast Irons and Steels
• Wrought Products: Rolling, Hot-Finishing, Drawing, Forging
• Steel Making, Heat of Steel, Residual and Unspecified Elements in Steels
• The Roles of Alloying Elements
• Defining Alloy Steels, Low-Alloy Steel, High-Strength Low Alloy Steel, Microalloy Steels
• Brief Introduction to Stainless Steels

Introduction to Steel Metallurgy

• Steel Microstructures and Phases: Ferrite, Fe-Fe₃C, Pearlite, Banite, Martensite
• Using the Fe-Fe₃C Phase Diagram in Practical Terms
  • Transformation Temperatures QW-407.1(2)
• Heat Treatment: Austenitizing, Annealing, Normalizing, Quench and Tempering QW-407
• ASTM Grain Size, Toughness, and Anisotropic
• Material Test Reports and What They Really Mean

Steel Welding Metallurgy and Steel Heat Treatment

• Weldment zones and fundamental principles of welding metallurgy of carbon steel
• Use of carbon equivalence to predict weldability
• Alloying steels and their effects on hardenability and weldability
• Residual stress and distortion of welded connections
• Hydrogen related cracking in welding (toe cracking, cold cracking, delayed cracking, HAZ cracking, and underbead cracking)
• Steel heat treatment, preheating and postweld heat treat in practical terms to avoid cracking and improve weldability

Introduction to Non-Destructive Examination and ASME Section V

• Imperfections and Types of NDE Methods
• Visual Testing (VT) - ASME V Article 9
• Radiographic Testing (RT) - ASME V Article 2
• Ultrasonic Testing (UT) - ASME V Article 4
• Liquid Penetrant (PT) Testing - ASME V Article 6
• Magnetic Particle (MT) Testing - ASME V Article 7

Base Metal and Filler Metal Specifications (ASME Section II Parts A and C)

• ASTM Specifications: Product Standards, General Standards, Supplementary Requirements
• ASTM Steel Standard Designations and Product Markings
• ASME SA-106, SA-516, SA-333, SA-387, and SA-312
• ASME SFA No. and AWS Classification of Filler Metals
• ASME SFA-5.1 and SFA-5.5

ASME Codes of Construction

• Review of welding requirements for:
• ASME B31.1 Power Piping
• ASME B31.3 Process Piping
• ASME Section VIII Div. 1 Pressure Vessels

Workshop: ASME Section IX P-No. QW-422 Table

• Review and compare the properties of materials listed in QW-422 for P-No. 1 Groups 1 to 4

Workshop: Developing a WPS for ASME Sec. VIII-1, B31.1, and B31.3

• Group workshop to write new construction and maintenance welding procedures in accordance with ASME Section VIII - Pressure Vessels, ASME B31.1 - Power Boilers and ASME B31.3 - Process Piping.
• These welding procedures will be reviewed and discussed in detail during the class.

All participants must bring the ASME Section IX code book to this class. This code book can be purchased from CASTI when you register for this course.