Qualified ASME Welding
Welders qualified under ASME Section IX for high-integrity joints in carbon steel, stainless steel and special alloys.
In short: Welding on pressure equipment is not like conventional structural welding. A defective weld on a boiler, heat exchanger or pressure vessel can cause a catastrophic failure with fatal consequences. That is why the ASME Code requires that welding procedures (WPS) be qualified through documented mechanical tests (PQR) and that each welder demonstrates his competence through individual performance tests (WPQ).
Welding on pressure equipment is not like conventional structural welding. A defective weld on a boiler, heat exchanger or pressure vessel can cause a catastrophic failure with fatal consequences. That is why the ASME Code requires that welding procedures (WPS) be qualified through documented mechanical tests (PQR) and that each welder demonstrates his competence through individual performance tests (WPQ). INCALCA maintains qualified welding procedures (WPS/PQR) under ASME Section IX for all processes and materials required by the Venezuelan process industry.
Qualified Welding Processes
INCALCA holds qualified WPS procedures for the main welding processes used in fabrication and repair of pressure equipment.
- TIG / GTAW — for high quality welds on precision joints
- MIG / GMAW — for higher productivity welding on carbon steel
- SMAW (Shielded Metal Arc) — for field work without gas availability
- Tube-to-tubesheet welding: TIG with or without filler
- Multi-pass groove welding: WPS qualified for 6mm to 100mm+ thickness
- Qualified welding positions: 1G, 2G, 5G, 6G and all positions
Welding Materials
INCALCA works with all metallic materials used in pressure equipment in the Venezuelan industry.
- Carbon steel: A-106, A-516, SA-179, SA-210
- Low alloy steel: A-335 P11/P22 (Cr-Mo for high temperature)
- Austenitic stainless steel: TP 304, 304L, 316, 316L, 321
- Duplex stainless steel: UNS S31803, S32205
- Aluminum bronze and copper alloys for special tubes
- Weld overlay (cladding) in stainless steel over carbon steel
WPS / PQR / WPQ Qualification
INCALCA's entire welding qualification system complies with ASME Section IX requirements and is audited periodically by the Authorized Inspector.
- WPS (Welding Procedure Specification): technical procedure document
- PQR (Procedure Qualification Record): mechanical test records for procedure qualification
- WPQ (Welder Performance Qualification): individual welder qualification
- Qualification renewals: continuity control per ASME Section IX
- Individual welder identification register with qualification number
- Annual audit by National Board Authorized Inspector
Field Welding and Confined Spaces
Operating plants often require in-situ welding in difficult conditions. INCALCA has the experience and equipment for these conditions.
- Portable TIG, MIG and SMAW welding equipment
- Work at height with certified scaffolding and specialized PPE
- Confined space welding with continuous atmosphere monitoring
- Wind and weather protection for field welds
- Pre-heat and post-weld heat treatment (PWHT) with heating blankets
- Immediate weld inspection by LP and/or UT in field
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