Guidance to Prepare Welding Procedure Spec / Records (WPS & PQR)-Sec IX By JGC Annamalai

History / Developments :
1801 - First discovery of Electric Arc, by Sir David Humphry Davy
1885 - Perfection of Carbon Arc, by M.B.Bernardos,
1900 to 1940 - Many Failures / ruptures / Explosions of Boilers, Pressure Vessels , piping and structures and Heavy loss
of life and property, due to poor material, poor design, poor fabrication quality and welding defects etc. No Control.
1911 - ASME had set up a committee for the purpose of formulating standard rules for the construction of Steam
Boilers and other Pressure Vessels so that accidents and losses are controlled.
1912 - Development of Coated Electrodes
1934 - API/ASME Code , combined first edition issued. Many States of USA and Canada gradually enforced that
use of ASME Codes are mandatory requirement for all pressure containing parts, in their States.
1935 - Welding was authorized by ASME in Pressure Vessels manufacture. (Before 1940, pressure vessels were
mainly made by riveting)
1941 - ASME Section IX(Qualification Standard for Welding and Brazing Procedure. Welders, Brazers), first edition was published
At present, ASME Sec IX , is the most widely used Code for Welding Procedure Qualification(WPS) and Welder Qualification.
Often ASME Sec IX qualified, is accepted as substitute for API Pipeline Code and AWS Structural Code.
Sometime, Owners/Users may have their own specification, asking for additional requirements, over ASME Sec IX.
1. WPS-A Welding Procedure Specification (WPS) is a written document that provides direction to the welder or welding operator
for making production welds in accordance with Code requirements. WPS is to be prepared by the manufacturer/contractor.
Reference Codes: ASME Sec IX(Pressure Components, also used for Structures, Cross Country Piping) or AWS D.1.1(Structures)
or API-1104(Cross Country Piping). Most of the references here are related to ASME Sec IX.
2. Welding is done, following the Welding Procedure Specification (WPS)
3. The welded piece(originally, in the form of plate or pipe) is cut into test specimens/test coupens.
4. PQR-Procedure Qualificaiton Record: Test specimens are tested in the Lab(for Visual defects, Mechanical and Metallurgical
properties), welding parameters (during actual welding, PWHT etc ) are noted and test results are recorded.
If the PQR meets the test acceptance criteria, then the WPS is declared , as, "Qualified".
Reasons to have many WPS: For a new Fabricator, often requires at least one WPS made in their Shop. If the work load increases, the
Fabricator may use different materials, different welding processes, different welding groove details, different techniques, etc. It is not
necessarey to qualify WPS for each change.Sec IX allow the Fabricator, to qualify minium number of WPS. Sec IX specify the conditions
(including ranges, if any) under which welding must be performed. These conditions include the base metal, filler, preheat and postweld
heat treatment requirements, etc. Such conditions are referred in the Code as "Welding Variables." Preparation of WPS often requires,
reference to WPS Welding Variables, in different Codes (Sec IX, it is Tables like QW-253.1) and Welding Data.
Some Codes(like B31.1, B31.3), accept borrowed use of qualified WPS(with conditions and permission from leading Industries/ Agencies).
Nuclear Facilities & some other Industries, may insist to qualify more WPS than allowed in Codes and also they may not allow third party
WPS, to be used on their Plants and require in-plant WPS Qualifications.
Please refer Scribd/376810395/ASME-Sec-IX-Welding-WPS-Qualification-Essential-Non-Essential-Variables-Quick-Guide, by same author.

Welding Variables: Variables are classified as Essential Variables, Non-essential Variable, Supplementary Essential Variables.
(1). If a change is made in any essential variable, requalification of the procedure is required. (2). If a change is made in a
nonessential variable, the procedure need only be revised or amended to address the nonessential variable change(no need
requalification). (3). When notch toughness is required by the construction code, the supplementary essential variables become
additional essential variables and a change requires requalification of the procedure.
WPS Preparations
Study PO, Product, Prepare Weld Map, Study / Check
Welding Variables Prepare WPS, WPS List
Fab Dwgs Collect Welding Data
Welding & PQR
Start Change the weld
parameters in the WPS, Test Results are
reweld and retest. not satisfactory.
Prepare / Finalize WPS
Prepare additional test WPS is rejected.
coupons and retest.
Follow WPS and
complete the Welding Dress, mark, cut Metallurgical/ Prepare PQR / Test Results(PQR)
Test Coupens/Test Mechanical Lab Evaluate Test Results are satisfactory &
Specimen Testing with Spec OK. WPS is qualified.

• WPS-Each Manufacturer or Contractor is responsible for the welding done by his Organization and shall conduct the tests required in
Responsibility

Section IX to qualify the Welding Procedures he uses in the construction of the weldments built under this Code,
• PQR-These records shall be certified by a Signature or other means as described in the Manufacturer's or Contractor's Quality
Control System and shall be accessible to the Authorized Inspector.
• WPS/PQR may be Reviewed/Witnessed/Joint Certified by a TPI Inspector, as an additional Quality Control Check Point.
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