Welding Procedure Specification and Welder approval based on AWS D.1.1: Structural Steel Welding Code ASME IX: Welding and Brazing Qualifications API 1104: Welding of Pipelines

1. Welding Procedure
&
Welder Qualification
www.qualityinspector.co.uk

2. WPS
&
PQR

3. Welding Procedures
Producing a welding procedure involves:
 Planning the tasks
 Collecting the data
 Writing a procedure (PWPS)
 Making a weld and test it (PQR)
 Evaluating the results
 Approving the procedure
 Preparing the documentation

4. In most codes, reference is made to how the procedure are to be
devised and whether approval of these procedures is required.
The approach used for procedure approval depends on the code:
Example codes:
 AWS D.1.1: Structural Steel Welding Code
 ASME IX: Welding and Brazing Qualifications
 API 1104: Welding of Pipelines
Other codes and (project specification) may not specifically deal
with the requirement of a procedure but may contain information
that may be used in writing a weld procedure
Welding Procedures

5. Welding Procedures
Parent material
• Type (Grouping)
• Thickness
• Diameter (Pipes)
• Surface condition
 Welding process
• Type of process (MMA, MAG, TIG, SAW etc)
• Equipment parameters
• Amps, Volts, Travel speed
 Welding process
• Type of process (MMA, MAG, TIG, SAW etc)
• Equipment parameters
• Amps, Volts, Travel speed
 Welding Consumables
• Type of consumable/diameter of consumable
• Brand/classification
• Heat treatments/ storage
Components of a welding procedure

6. Welding Procedures
 Joint design
• Edge preparation
• Root gap, root face
• Jigging and tacking
• Type of baking
 Welding Position
• Location, shop or site
• Welding position e.g. 1G, 2G, 3G etc
• Any weather precaution
 Welding Variables
• Run sequences
• Back gouging
• Interpass temperatures
 Thermal heat treatments
• Preheat, temps
• Post weld heat treatments e.g. stress relieving

7. Welding Procedures
When the data has been collected (WPS), the
procedure must be validated by producing a test weld,
Procedure Qualification Record (PQR).
A number of standards provides information with
regards to approving a procedure, but normally this will
require the WPS to be tested by NDT and mechanical
testing.
The locations and tests required will be given in the
applicable code or standard
Most codes and standards provide a report format to
record the results
Approving the procedure:

8. Welding Procedures
Examination and testing requirements of a WPS for
procedure approval (ASME IX)

9. ASME IX does not specify any mandatory non-destructive
testing for welding procedure qualification, however, if a
procedure qualification test is also to be used for the
performance qualification of the welder/ welding operator
who makes the weld, the following two options are:
1- By carrying out additional radiography examination
(QW302.2).
2- By carrying out visual inspection (QW 194) and any
additional mechanical tests as required by QW-452 based
on the welding position

10. Welding Procedures
After the testing is completed and all the relevant results
collated, the results need to be assessed in accordance with
the relevant code/standard. The results are then recorded.
 pWPS: Preliminary Welding Procedure Specification
Before procedure approval.
 WPS: Welding Procedure Specification
After procedure approval
PQR: Welding Procedure Qualification Record
(Welding) Procedure Qualification Record

11. Welding Procedures
Once the welding procedure has been approved, If any
essential variable is changed during production the WPS may
require re-approval. Most codes/procedures dealing with
procedure qualifications provide a list of what is an essential
or non-essential variable.
Object of a welding procedure test
To give maximum confidence that the welds mechanical and
metallurgical properties meet the requirements of the
applicable code/specification.
Each welding procedure will show a range to which the
procedure is approved (extent of approval)
If a customer queries the approval evidence can be supplied
to prove its validity

12. Sample
Welding Procedure
Specification (WPS)

13. 3 steps used in reviewing a WPS/PQR
• Verify the WPS has been properly completed
and addresses the requirements of Section IX
and the construction/repair code.
• Verify the PQR has been properly completed
and addresses all the requirements of Section
IX and the construction and repair code.
• Confirm the PQR essential variable values
properly support the range specified in the
WPS.

14. Welder Approvals
(ASME Sec IX)

15. Welder Approval
ASME IX code is used for welder qualification for API 577
examination purpose.
Once the content of the procedure is approved the next
stage is to approve the welders, a welders test know as a
Welders Qualification Test (WQT).
Object of a welding qualification test
.To demonstrate that the welder skill to produce sound weld
as per WPS at the required welding position.
The test weld should be carried out on the same material
and same conditions as for the site welds
The welder who carries out the procedure qualification weld
automatically qualify when the procedure qualifies

16. Welder Approval
Information that should be included on a welders test
certificate are:
1. Welders name and identification number
2. Date of test and expiry date of certificate
3. Standard/code e.g. ASME IX code
4. Test piece details
5. Welding process
6. Welding parameters, amps, volts
7. Consumables, flux type and filler classification details
8. Sketch of run sequence, welding positions
9. Joint configuration details
10.Material type qualified, pipe diameter etc
11.Test results, remarks
12.Test location and witnessed by
13.Extent (range) of approval

17. PERFORMANCE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS

18. Table QW-452.3 Groove-Weld Diameter Limits
Table QW-
452.4 Small
Diameter
Fillet-Weld
Test

19. Welder Approval
The inspection of a welders qualification test.
 Under normal circumstances, only one test weld per welder
is permitted. Retesting of welder is subjected to welder
undergoing further training.
 The welded test coupon is done by bend that could be
substituted by a radiography.
Welding position is an essential parameter for WPQ but not
for WPS because welder should demonstrate his/her skill at a
specific welding position where as for a given WPS, weld
properties is independent of position of welding.

20. Table QW-452.1(a) Test Specimens

21. Example:
Welder Approval
Qualification
Certification