CSWIP 3.
Welding Procedure Specification
Welding Procedure
Specification
Course Reference WIS 10
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CSWIP 3.2
Welding Procedure Specification
Welding Procedure Specification (WPS)
A WPS that give detailed written instructions about
the welding conditions that must be used to ensure
that welded joints have the required properties.
So, a WPS is a document containes the steps
required to make a quality weld meeting the design
requirements.
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Welding Procedure Specification
A WPS is usually qualified by making a test weld to
demonstrate that the properties of weld joint satisfy the
requirements specified by the application standard
( Client / End user ).
Included angle
Angle of bevel
Angle of bevel
Root Face Root Face
Root Gap Root Gap
Single -V Butt Single Bevel Butt
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Welding Procedure Specification
According to EN ISO 15614/API 1104
ASME-IX / AWS D.1.1
AS/NZS 1554.1 / CWB
1. Preliminary welding procedure specification (pWPS).
2. Propose to the customer for approval
3. Welding procedure qualification record (WPQR).
3.1. Welder make a sample test and weld in
accordance with the content of pWPS
3.2. Visual Check, NDT and Destructive Test
4. Welding procedure specification (WPS).
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Welding Procedure Specification
Question: What is the main reason for carrying out a
welding procedure qualification test?
(What is the test trying to show?)
Answer: To show that the welded joint has the
properties* that satisfy the design
requirements (fit for purpose).
Properties*
Mechanical properties are the main interest – always
strength but toughness and hardness may be important
for some applications.
Test also demonstrates that the weld can be made
without defects.
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Welding Procedure Specification
1. Preliminary Welding Procedure
Specification (pWPS)
Welding Engineer writes a preliminary
Welding Procedure Specification (pWPS)
for each test weld to be made.
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Welding Procedure Specification
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Welding Procedure Specification
2. Welding Procedure Qualification
Record (WPQR)
a. A welder makes a test weld in accordance
with the pWPS.
b. A welding inspector records all the welding
conditions used for the test weld (referred to
as the 'as-run‘ conditions).
An Independent Examiner/ Examining Body/ Third Part
inspector may be requested to monitor the
qualification process.
The finished test weld is subjected to NDT in
accordance with the methods specified by the EN ISO
Standard - Visual, MT or PT & RT or UT.
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Welding Procedure Qualification
3. Welding Procedure Qualification
Record (WPQR)
a. Test weld is subjected to destructive
testing (tensile, bend, macro).
b. The Application Standard, or Client,
may require additional tests such
as impact tests, hardness tests
(and for some materials - corrosion
tests).
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Welding Procedure Qualification
4. Welding Procedure Qualification
Record (WPQR)
a. The welding conditions used for the test
weld
b. Results of the NDT.
c. Results of the Destructive Tests.
d. The welding conditions that the test weld
allows for production welding.
e. The Third Party may be requested to
sign the WPQR as a true record.
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Welding Procedure Qualification
5. Welding Procedure Specification
(WPS)
a. The welding engineer writes qualified
Welding Procedure Specifications
(WPS) for production welding.
b. Production welding conditions must
remain within the range of
qualification allowed by the WPQR.
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Welding Procedure Qualification
Welding conditions are called welding variables.
Welding variables are classified by the EN ISO
Standard as:
a. Essential variables.
b. Non-essential variables.
c. Additional variables.
Note: Additional variables = ASME/AWS
supplementary variables.
The range of qualification for production
welding is based on the limits that the EN ISO
Standard specifies for essential variables*
(* and when applicable - the additional variables)
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Welding Procedure Qualification
Welding essential variables
Question:
Why are some welding variables
classified as essential?
Answer:
A variable, that if changed beyond certain
limits (specified by the Welding Standard)
may have a significant effect on the
properties* of the joint.
* particularly joint strength and ductility.
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Welding Procedure Qualification
Welding additional variables
Question:
Why are some welding variables classified
as additional variables?
Answer:
A variable, that if changed beyond certain
limits (specified by the Welding Standard)
may have a significant effect on the
toughness and/or hardness of the joint.
Note: ASME/AWS calls variables that affect toughness
as supplementary essential variables (but does not
refer to hardness).
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Welding Procedure Qualification
Heat Input
Current
Amps = 200 Volts = 32
Travel speed = 240 mm/min
Heat input = 200 X 32 X 60
240 X 1000
V Voltage
Heat input = 1.6 kJ/mm
Distance travelled in 1 second
Heat input = Amps x volts
Travel speed mm/sec X 1000
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Welding Procedure Qualification
Heat Input
High heat input - slow cooling
Low toughness
Reduction in yield strength
Low heat input - fast cooling
Increased hardness
Hydrogen entrapment
Lack of fusion
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Welding Procedure Qualification
Some typical essential variables
a. Welding process.
b. Post weld heat treatment (PWHT).
c. Material type.
d. Electrode type, filler wire type (Classification).
e. Material thickness.
f. Polarity (AC, DC+ve/DC-ve).
g. Pre-heat temperature.
Some typical additional variables
a. Heat input.
b. Welding position.
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Welding Procedure Qualification
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
1. AWS D.1.1: Structural Steel Welding Code.
2. BS 2633: Class 1 welding of Steel Pipe Work.
3. API 1104: Welding of Pipelines.
4. BS 4515: Welding of Pipelines over 7 Bar.
5. ASME IX:
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Welding Procedure Qualification
Components of a welding procedure
Parent material
a. Type (Grouping).
b. Thickness.
c. Diameter (Pipes).
d. Surface condition.
Welding process
a. Type of process (MMA, MAG, TIG, SAW etc).
b. Equipment parameters.
c. Amps, volts, travel speed.
Welding consumables
a. Type of consumable/diameter of consumable.
b. Brand/classification.
c. Heat treatments/storage.
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Welding Procedure Qualification
Components of a welding procedure
Joint design
a. Edge preparation.
b. Root gap, root face.
c. Jigging and tacking.
d. Type of backing
Welding position
a. Location, shop or site.
b. Welding position e.g. PA, PB, PC etc.
c. Any weather precaution.
Thermal heat treatments
a. Preheat, temps.
b. Post weld heat treatments eg stress relieving.
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Welding Procedure Qualification
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Welding Procedure Qualification
Monitoring heat input
As Required by BS EN ISO 15614-1:2004 In accordance
with BS EN 1011-1:1998
a. When impact requirements apply, the upper limit of
heat input qualified is 25% greater than that used in
welding the test piece.
b. When hardness requirements apply, the lower limit of
heat input qualified is 25% lower than that used in
welding the test piece.
c. Heat input is calculated in accordance with BS
EN1011-1.
d. If welding procedure tests have been preformed at
both a high and low heat input level, then all
intermediate heat inputs are also qualified.
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Welding Procedure Qualification
BS EN ISO 15614-1-2-3
Specifies contents of WPS
"Shall give details of how a welding operation is
to be performed and contain all relevant
information".
Definitions
1. Processes to be designated in accordance with
BS EN ISO 4063.
2. Welding positions in accordance with
BS EN ISO 6947.
3. Typical WPS form.
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Welding Procedure Qualification
Note 1:
a is the throat as used for the test piece.
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Welding Procedure Qualification
Note 1:
a is the throat as used for the test piece.
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Welding Procedure Qualification
BS EN ISO 15614-1:2004 (Replaced BS EN 288-3)
Covers Arc & Gas Welding of Steels & Arc Welding of Nickel &
Nickel Alloys
111 - MMA 114 - FCAW - no gashield
121 - SAW 131 - MIG
135 - MAG 136 - FCAW - active gas
137 - FCAW - inert gas 141 - TIG
15 - PLASMA ARC 311 – Oxy-Acetylene
The principle of this European Standard may be applied to
other fusion welding processes
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Welding Procedure Qualification
TABLE 7 BS EN ISO 15614-1:2004
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Welder Qualification
Question:
What is the main reason for qualifying a
welder?
Answer:
To show that he has the skill to be able to
make production welds that are free from
defects.
Note: When welding in accordance with a Qualified WPS.
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Welder Qualification
An approved WPS should be available covering the
range of qualification required for the welder approval.
The welder qualifies in accordance with an approved
WPS.
A welding inspector monitors the welding to make
sure that the welder uses the conditions specified by
the WPS.
EN Welding Standard states that an Independent
Examiner, Examining Body or Third Party Inspector
may be required to monitor the qualification
process.
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Welder Qualification
The finished test weld is subjected to NDT by the
methods specified by the EN Standard - Visual, MT or
PT & RT or UT.
The test weld may need to be destructively tested – for
certain materials and/or welding processes specified by
the EN Standard or the Client Specification.
A Welder’s Qualification Certificate is prepared
showing the conditions used for the test weld and the
range of qualification allowed by the EN Standard for
production welding.
The Qualification Certificate is usually endorsed by a
Third Party Inspector as a true record of the test.
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Welder Qualification
The welder is allowed to make production welds within
the range of qualification shown on the Certificate.
The range of qualification allowed for production welding
is based on the limits that the EN Standard specifies for
the welder qualification essential variables.
A Welder’s Qualification Certificate automatically expires
if the welder has not used the welding process for 6
months or longer.
A Certificate may be withdrawn by the Employer if there
is reason to doubt the ability of the welder, for example
A high repair rate.
Not working in accordance with a qualified WPS.
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Welder Qualification
Essential variables
Question:
What is a 'welder qualification essential
variable'? (what makes the variable
'essential'?)
Answer:
A variable, that if changed beyond the limits
specified by the EN Standard, may require
more skill than has been demonstrated by the
test weld.
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Welder Qualification
Typical Welder Essential Variables
Welding process.
Material type.
Electrode type.
Material thickness.
Pipe diameter.
Welding position.
Weld backing (an unbacked weld requires
more skill).
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Welder Qualification
Numerous codes and standards deal with welder
qualification, eg BS EN ISO 9606
Once the content of the procedure is approved the next
stage is to approve the welders to the approved procedure.
A welders test know as a Welders Qualification Test (WQT).
Object of a welding qualification test:
To give maximum confidence that the welder meets the
quality requirements of the approved procedure (WPS).
The test weld should be carried out on the same material
and same conditions as for the production welds.
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Welder Qualification
Information that should be included on a welders
test certificate are:
Welders name and identification number.
Date of test and expiry date of certificate.
Standard/code eg BS EN ISO 9606.
Test piece details.
Welding process.
Welding parameters, amps, volts
Consumables, flux type and filler classification details.
Sketch of run sequence.
Welding positions.
Joint configuration details.
Material type qualified, pipe diameter etc.
Test results, remarks.
Test location and witnessed by.
Extent (range) of approval.
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Welder Qualification
The inspection of a welders qualification test
It is normal for a qualified inspectors usually from
an independent body to witness the welding.
Under normal circumstances only one test weld per
welder is permitted.
If the welder fails the test weld and the failure is not the
fault of the welder eg faulty welding equipment then a
re-test would be permitted.
The testing of the test weld is done in accordance
with the applicable code.
It is not normal to carry out tests that test for the
mechanical properties of welds eg tensile, charpy
and hardness tests.
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