NCPWB

The Newsletter of the National Certified Pipe Welding Bureau

BULLETIN

What Happened at the Technical Committee Meeting

The Bureau introduced its new national welder database to members during the annual Technical Committee meeting. The program was well received and is in the process of being fine-tuned. The new database will reduce the amount of paper transactions between the national office and each chapter. As required by ASME code, the program will maintain continuity records for every welder and the process for which the welder is qualified. Since its early days, the Bureau has required that each welder be tested every five years to insure that a welder still has the ability to produce a sound weld. Since the joint UA/NCPWB program is gaining wider recognition, there is no need for the five-year retest. Therefore, the Bureau will no longer require welders to be tested every five years. Since the Bureau retest pro-

Attendees take an active part in discussions at the meeting. gram has been sold to some local officials by different chapters, each chapter has the option of maintaining this requirement if they choose.
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Meeting with Wisconsin Boiler Inspectors

The Bureau was invited by the Wisconsin chapter to participate in a discussion with the Wisconsin Boiler Inspectors regarding the joint UA/NCPWB welder certification program and interchangeability of welders records among NCPWB contractors. The Boiler Inspectors opinion is that a welder has to be employed by the contractor at time when the welder is being tested. The Bureau representativesopinion is that the Code uses the word employerto distinguish the contractor from other entities such as an independent testing laboratory that may test welders under other Codes, such as AWS D1.1. To support this position, Bureau participants pointed out that B31.1 defines an employer as:The owner, manufacture, fabricator, contractor, assembler, or installer responsible for the welding, brazing, and NDE performed July 2001 by his organization including procedure and performance qualifications. To further support the Bureaus position, it was pointed out that requiring the welder to be on the payroll of the contractor would not allow testing of traveling welders whose employment would be conditional upon passing the test. To clarify this matter, the Bureau has offered to submit the following daft inquiries to ASME: 1 Scope: ASME Section IX, QW-300.2 Background: Section IX requires that the manufacturer, contractor, assembler or installer be responsible for conducting tests to qualify the performance of welders, which his organization employs in construction of weldments built in accordance with the
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CHAIRMANS CORNER
It was great to see so many new faces once again at the Technical Committee meeting. Because participation is increasing at our meetings every year, we need to begin thinking about ways in which our programming can serve both newcomers and veterans in an educational and appealing manner. If you have any new ideas on subjects, programs, activities, or anything else you think might serve our members well, please submit your ideas and suggestions to Nick at the national office. Over the past few years, some people have complained that the chapter operations seminars, which take pace in conjunction with the Technical Committee meeting every Robert B. Waddy other year, take attendees away from their offices for too long of a period of time. We have heard your comments and discussed them at the Technical Committee meeting. Soon we will conduct a survey asking our members how they feel about a number of seminar format and scheduling options. I urge you to participate in this survey so that we can continue these important The Newsletter of the National Cer tified Pipe Welding Bureau seminars in a way that is convenient for members. is published periodically by the National Certified I was pleased with the response of so many of you at Pipe Welding Bureau at its national office. the Technical Committee meeting regarding your willingness to provide administrative support to contracB OA R D O F T R U S T E E S tors who are outside of your territories. By doing so Robert B. Waddy we would be able to provide witnessing contractors in Chairman areas where the UA has Authorized Testing Facilities Russell I. Mullican (ATF) but no chapter that could assist them in test Vice Chairman events. James J. Briggs, Jr. Treasurer At the Technical Committee you received a brief presentation of the new welder database. A lot of effort George B. Kearney Robert Silvia has been spent in developing the program and we Mark Jarnot G.W. Spohn, III would like it to be utilized by every chapter. The proJames Sekely Rick Taylor gram may not be the program to which each chapter has become accustomed, but in the long run it will pay dividends if we all have a uniform system of tracking Robert J. Durr, Sr. Dariush Nikpourfard Chairman Emeritus Executive Director welders records. We will continually fine-tune the proSteve Kelly Walter J. Sperko, P.E. gram as our budget permits; therefore, all the bells and UA Representative Consultant whistles will come in the future. I encourage everyone to begin using the program once they get the full go 1385 Piccard Drive Rockville, MD 20850-4340 ahead from the national office. Remember, our goal is (301) 869-5800 Fax (301) 990-9690 www.mcaa.org/ncpwb to operate with less paper exchangeno more paper WPQTs to be sent to the national office.

NCPWB

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TECHNICAL COMMITTEE MEETING

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In 2002, the Bureau will offer its welding performance specification and welder qualification records on the Internet for chapter members. This will allow each chapter to provide a hard copy to its members in a timely fashion. In an effort to create a pool of contractors that would be available nationwide to witness test events in areas where there is a UA Authorized Testing Facility but not a chapter that could be of assistance, the Bureau has sought chapters assistance in providing administrative support. This also will facilitate the interchangeability of welders records. In order to comply with all applicable code requirements dealing with internal mismatch of pipes that are to be welded, the typical joint designs for piping welds are to be revised to allow both 1/8 and 1/16 of mismatch to satisfy applicable code requirements. This change will impact the typical details that accompany the Bureaus Welding Procedure Specifications.

BOILER INSPECTOR MEETING

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2 Scope: ASME B31.1, Paragraph 127.5.1 and 127.5.3(B) Background: Paragraph 127.5.1 requires that welders be qualified in accordance with the requirements of ASME Section IX. Paragraph 127.5.13(B) requires that each employer shall be responsible for qualifying all the welders employed by him. A contractor provides supervision and control over a welder as required by Section IX while that welder is welding a performance qualification test coupon; however, the welder is not an employee of the contractor while he is welding the test coupon. Question: Is it a requirement that a welder be an employee of a contractor while he is welding a performance qualification test coupon? Proposed reply: No These questions have been presented to the Wisconsin Boiler Inspectors for their concurrence.

Code. It also requires that the manufacturer, contractor, assembler or installer provide supervision and control over welders while they are welding test coupons for performance qualification. Question: A contractor provides supervision and control over a welder during welding of a test coupon, but that welder is not an employee of the contractor at the time of the test. Is it required that the welder being tested be employed by the contractor at the time that he is being tested? Proposed reply: No

July 2001

Members Being Recognized for Participation in Technical Committee Meetings

The following members were presented with a recognition plaque for their five years of consecutive attendance and support of the Bureau: Robert Waddy, James Briggs, Robert Caraway, Warren Carpenter, Robert Durr, Sr., Robert Durr, Jr., John Fitzpatrick, Robert Gilligan, Mary Jo Goldstein, Beth Gray, Paul Hackl, Marvin Hammond, Mark Jarnot, Steven Klorer, Muggs Mullican, James Quinn, Philip Rellihan, James Sekely, Robert Silvia, John Siscel, William Spinner, Rick Taylor, Mac Terry, H. E. Wetzell, Jr., Dale Witte, G. W. Spohn, III, Vickie Barger, and Terrence Urbanek.

President Elect Bob FitzGerald Addresses the Technical Committee

MCAAs president-elect, Bob FitzGerald, addressed the NCPWB Technical Committee at its meeting in March. Mr. FitzGerald recognized NCPWB as a pillar of the MCAA. The MCAA and the NCPWB have become stronger because of shared resources, technical knowledge, and programs and services, said Mr. FitzGerald. He recognized the importance of the new national welder database and praised the joint welder certification program. Regarding the labor/skill shortages he informed members that MCAA is addressing labor/skill shortages by working with joint apprenticeship committees to recruit young people from high schools; by supporting the UA in creating regional training schools, distance learning programs, and with its Career Development Initiative. He asked members to let MCAA know what types of programs and/or services MCAA should provide its members.

Technical Committee Elects a New Chairman

The Bureau has elected Mr. Robert J. Silvia to replace Mr. Bill Spohn as the Technical Committee Chairman. At the March Technical Committee meeting, Mr. Spohn announced that he would be stepping down as the chairman to give others the opportunity to experience the chairmanship role and to bring new ideas and leadership to the committee. Mr. Spohn, who has provided strong leadership for over ten years, was recognized for his tireless effort and the professional manner in which he conducted his Technical Committee Meetings. His successor, Mr. Silvia, is the president of Process Engineers & Construction, Inc. in Rhode Island. He was elected to the NCPWB Board of Trustees in 1993. Mr. Silvia has been active in the pipe fitting industry in Rhode Island. He represents the NCPWB on ASME B31.3 and B31 F&E committee.

Robert J. Silvia

Bill Spohn

NCPWB BULLETIN

A MESSAGE FROM THE CONSULTANT

ast week, someone called and wanted a welding procedure for welding P-22 base metals. P-numbers are, as all NCPWB members know, a system used by ASME for grouping materials of similar weldability so that Code users dont have to qualify every material that is being welded. P-numbers are easily found by looking up the specification and grade of material to be welded in Section IX or in the B31 Code. Since NCPWBs welding procedure numbers start with the P-number as the first number of the welding procedure, and we have no welding procedures that begin with 22, the answer should have been a simple no. The question was, however, suspicious since P22 base metals are aluminum and NCPWB contractors rarely weld aluminum.

Walter Sperko NCPWB Technical Consultant

Upon further questioning, the contractor indicated that he was bidding on a power plant job, and that, in addition to needing procedures for P-11, he also needed welding procedures for welding P-11 and P-91! At that point it became clear that the contractor did not realize that the designation P-something was not unique to Section IX; it turns out that ASTM A335, which is a specification for seamless alloy pipe for high temperature service, also uses a P-something to designate alloys within A-335. The following table illustrates the assignment of grades by A-335 and the corresponding Section IX P-number assignment. Some other specifications for the same material as other product forms are also shown. As is evident from the table, the designation preceding the number is related to the description of the product form. That is, grade T-something is for tubes,F-someMaterial 1-1/4 Cr - 1/2 Mo Specification A-335 Pipe A-234 Fittings A-182 Forgings A-213 Tubing 2-1/4 Cr - 1/2 Mo A-335 Pipe A-234 Fittings A-182 Forgings A-213 Tubing 9 Cr - 1 Mo A-335 Pipe A-234 Fittings A-182 Forgings A-213 Tubing Grade P-11 WP-11 F-11 T-11 P-22 WP-22 F-22 T-22 P-91 WP-91 F-91 T-91 Section IX P-number 4 4 4 4 5A 5A 5A 5A 5B 5B 5B 5B

thing is for forgings, and obviously P-something is for pipe. The only non-obvious designation is WP which stands for Wrought Pipe which is pipe that has been hot-formed into another shape, like a tee or an elbow. Contractors should keep in mind that NCPWB has a wide variety of welding procedures covering a variety of products and that some product designations can be confusing. To find the correct welding procedure, look up the material specification number and grade in QW422 of Section IX (or the allowable stress table of any B31 Code Section) to find the P-number of the base metal; that number will be the first number of the WPS that you are looking for. If you still have trouble, call Nick! Uphill vs. Downhill Welding There is a common thought in the process piping industry that downhill welding is not permitted by Code. This is false. There is no Code prohibition against downhill welding. So just what is downhill welding? Imagine a pipe with its axis horizontal. With two pipes in this position end to end, the centerline of the weld between them would be oriented vertically (i.e., the 5G position for those in the know). The welder has to start welding at some point around the pipe circumference. If he starts welding at the bottom of the pipe and progresses towards the top, that is called uphill. welding. If he starts welding at the top of the pipe and welds downwards towards the bottom, that is called downhill welding. The Code refers to these directions of welding as uphill progression and downhill progression. Since the skill needed for welding uphill is different from that needed for welding downhill, a welder has to qualify for the progression that he will use. July 2001

Some welding processes and electrodes lend themselves to welding uphill only. GTAW and SMAW with EXX18 type electrodes are examples of this. SMAW with E6010, on the other hand, can be used in either progression, as can GMAW in the short-circuiting mode. Flux cored welding is typically done uphill, but some electrode types are designed for downhill. NCPWBs WPSs provide appropriate direction, so contractors do not have to figure out what to do once a WPS has been selected. The general perception is that downhill welding does not make welds that are as sound as welds made uphill. When radiographic quality welding to B31.1 is required, it is more reliable to weld uphill than downhill. When welding to other Codes where some incomplete penetration is permitted, downhill welding is sufficiently reliable. The difficulty is that it is slightly more difficult to tie together the place where one electrode stops and the next electrode begins (such as at a tack weld) when welding downhill than when welding uphill; this results in a tendency to get a small spot of incomplete penetration at the tie-in. Small incomplete penetration is acceptable under all codes except B31.1. Nevertheless, one may use downhill welding under B31.1 if the welders are sufficiently skilled in tying together at stop/start points. This usually requires feathering of tacks and stops adequately so that a clean tie-in occurs. There is also a perception that downhill welding is faster than uphill. This is both true and false. The rate at which a weld is made is mostly a function of amperage and the electrode type. For any given electrode type (e.g., E6010), the higher the amperage the welder uses, the faster he makes the weld. This means that a welder using a larger electrode will make a weld more quickly than a welder using a small electrode. The elec-

trode type also makes some difference; due to the presence of iron powder in the electrode coating, an E7018 electrode running at the same amperage as an E6010 electrode will deposit roughly 30% more weld metal per minute. Since E7018 deposits weld metal faster and it only welds uphill, it would seem that welding uphill would be faster. Welding is, however, never quite so simple. When welding downhill, a welder using E6010 can select a larger electrode to compensate for the lower deposition rate as compared to welding with E7018. In addition, welders using E6010 will use a slightly smaller bevel (30 vs 37-1/2), reducing the amount of weld metal that is needed. Also, welders welding downhill will make welds that have less reinforcement (smaller weld crown) than welders welding uphill. This further reduces the amount of weld metal needed and the time needed to make a weld. On this last item, it should be noted that there is no requirement to have weld reinforcement; welds only have to be flush with the surrounding base metal. When welding standard weight pipe, a weld with 1/8 inch of reinforcement can have as much as 140% more weld metal than the same weld with only 1/32 inch of reinforcement. This means that welding time is more than doubled from that necessary. Again, there is no requirement to have reinforcement, but there should be enough that the weld is not rejectable for underfill. Members are encouraged to direct their welders to make welds that have just enough reinforcement that the weld is obviously flush (1/32 inch), but not any more than is necessary.

WELCOME NEW MEMBERS

The Board has approved the following organizations as new members of the Bureau. We welcome their membership into the Bureau. Cincinnati, OH
Modular Systems, Inc.

Future Meetings
2001
October 14-16 Board Meeting Hollywood, FL Technical Committee Meeting Charleston, SC Board Meeting Pinehurst, NC

Iowa
Baker Group

Georgia/Florida
Williams Power Corp.

Mid-Michigan
T.H. Eifert, Inc.

Greater New York

Timbil Mechanical, Inc. V.P.H. Mechanical Corporation

Rochester, NY
Michael A Ferrauilo Plumbing & Heating

2002
April 14-17 October 13-15

Western PA
Dasco, Inc.

Heart of America
Richland Mechanical Contractors, Inc.

NCPWB BULLETIN