WPS, PQR, WPQ & their significance in Quality

CES-Inspection 06.05.2005

WPS- Welding Procedure Specification.

CES-Inspection 06.05.2005

Welding: It permanently fastens the similar/dissimilar metal parts.

It involves various elements and be identified in a standardized way.

Welding Procedure Specification (WPS)

manner of doing or the detailed elements (with prescribed values or range of values) of a process or method used to produce a specific result.
CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

In general a welding procedure consists of three parts as follows: 1. 2. 3. A drawing or sketch showing the weld joint design and the conditions for making each pass or bead . A detailed written explanation of how the weld is to be made. A record of the test results of the resulting weld.

CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

The variables involved in specifications are - Essential variables - Non-essential variables

Note: Essential & Non Essential variables are given separately for each welding process (GTAW,GMAW,SMAW,..)
CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

Essential variables are those factors which must be recorded and if there are any changes, the procedure must be retested and re-qualified.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. The welding process and its variation The method of applying the process The base metal type, specification, or composition The base metal geometry, normally thickness The base metal need for preheat or post-heat The welding position The filler metal and other materials consumed in making the weld The weld joint, that is, the joint type and the weld Electrical or operational parameters involved Welding technique

CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

Nonessential variables are usually of less importance and may be changed within prescribed limits and the procedure need not be re-qualified. 1. The travel progression (uphill or downhill) 2. The size of the electrode or filler wire 3. Certain details of the weld joint design 4. The use and type of weld backing 5. The polarity of the welding current.
CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

Significance in Quality: -

Procedures are written based on knowledge and experience

To produce the highest-quality weld required for the service involved,

To provide weld consistency, at the least possible cost

CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

Reproducibility and perfect qualityThe procedures qualification will become much more technical with added requirements, particularly in testing. Tests will become more complex to determine that the weld joint has the necessary properties to withstand the service for which the weld is designed.

CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

Necessary of WPS: 1. Maintain dimensions by controlling distortion

2.
3. 4. 5.

Reduce residual or locked up stresses

Minimize detrimental metallurgical changes Consistently build a weldment the same way Comply with certain specifications and codes.

CES-Inspection 06.05.2005

Welding Procedure Specification (WPS)

Welding procedures must be tested or qualified and they must be communicated to those who need to know.
This includes 1. 2. 3. 4. Designer Welding inspector Welding supervisor Welder last but not the least.
CES-Inspection 06.05.2005

PQR-Procedure Qualification Record.

CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Welding Variables Variables used in a welding procedure test are divided into 3 categories :1. Essential Variables Significant affect on the mechanical properties of a joint. No change except within the limits specified by this code.

2. Non-Essential Variables No significant affect on mechanical properties. Can be changed without re-qualification of the PQR.
CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

3. Supplementary Variables Affect on the impact properties of a joint. Classed as Non-Essential if impact testing is not required All variables listed as essential, non-essential or supplementary should be addressed on both the WPS and the PQR. If any of the variables do not apply to the particular application then they should be specified as not applicable.

CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Joint Configuration Either plate or pipe can be used for the test piece (plate approves pipe and vice versa ref. QW211) Any welding position approves all positions providing no impact tests are required ref. tables QW250 to QW265

CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Joint Configuration: Any joint geometry approves all geometry's, e.g. single V, double V, U prep, backed or un-backed. A butt or groove weld approves branch and fillet welds but not the converse, ref. QW202. Non pressure retaining fillet welds in pipe or plate can be tested but they must be double sided if plate and at least the dimensions illustrated in QW462.4a, ref. QW202.2c. Pressure retaining branch welds must be qualified by groove (butt) welds.
CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Material Grouping: -

Materials are assigned P numbers in QW420

Test in one P number approves all materials listed under that P number, except where impact tests are required, then approval is restricted to materials listed in the group number within the P number. Note: P5, 9 & 10 are divided into sub groups e.g. 5A,5B etc., Treat each sub group like a separate P Number

Dissimilar materials are acceptable.

For example P1 to P8, but this does not cover P1 to P1 or P8 to P8. P number covers an S number butCES-Inspection converse not the
06.05.2005

Procedure Qualification Record (PQR)

Consumables A change in consumable is only permissible providing it has the same F number and A number (if applicable) as the P.Q.R.. Thickness Limits: - QW403.6 The thickness 't' of deposited weld metal for each process involved is approved till 2t.

CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Non destructive testing: -

Welds are to be reasonably free from defects.

1. 2. Cracks are not allowed Inclusion of oxides are permitted to the allowable limits # Single porosity having a diameter of 20% t (where t is the weld thickness) or 2.0 mm maximum whichever is the lesser, may be accepted # Line porosity or small ( 0.5 mm) scattered porosity.

3. Excess weld metal or convexity, excess throat thickness and excess of penetration - the level C applies.
4. Other imperfections - level B in ISO/DIS 10042.2
CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Transverse tensile tests: The specimens are to be machined to the dimensions given in QW462 The tensile strength must meet the requirements stated against P.No given in QW422.

CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Bend test The specimens for bend tests are to be machined to the dimensions given in QW 462. For dissimilar or heterogeneous butt joints, longitudinal bend tests may be required instead of transverse bend tests. The bending angle is to be 180. After testing the test specimens shall not reveal any open defect in any direction greater than 3 mm. Defects appearing at the corner of the specimens may be disregarded.
CES-Inspection 06.05.2005

Procedure Qualification Record (PQR)

Macro examination: The test specimen is to be prepared and etched on one side to clearly reveal the fusion line the HAZ the build up of the runs the unaffected base metal. The examination shall reveal 1. a regular weld profile 2. complete fusion between adjacent layers of weld and base metal 3. the absence of defects such as cracks and lack of fusion

CES-Inspection 06.05.2005

WPQ- Welder Performance Qualification.

CES-Inspection 06.05.2005

Welder Performance Qualification (WPQ)

The purpose of this test is to determine the welders ability to deposit a sound weld. Materials: The base material is not considered as critical as it is in the PQR. Hence a performance test on any material in P groups 1 to 11 approves all those groups and sub groups, also P34 and P4X (P40P49). Providing a compatible consumable exists with the same F number used in the qualification test. (QW423.1)
CES-Inspection 06.05.2005

Welder Performance Qualification (WPQ)

Diameter limits: -

Diameter limits for all circular welds including groove welds, branch welds and fillet welds is given in QW452.3.
There are no upper limits on diameters approved and pipe covers plate

Thickness limits, groove welds: The thickness limit only applies to the deposited weld metal thickness not the plate thickness. Any groove weld approves all fillet weld sizes. For t greater than 12.5mm there is no restriction on the size that can be welded (Providing the test weld deposit contains at least 3 layers of weld).
CES-Inspection 06.05.2005

Welder Performance Qualification (WPQ)

Consumables: -

The F number cannot be changed without re qualification of the welder.

Except that for performance qualification only using SMAW (MMA) F numbers up to and including 4 approve all lesser F numbers for double sided or welds with backing only.

One Consumable from F41 To F45 approves any of these consumables, except SAW. Ref. QW404.11. Note: 'A' numbers do not apply to welder approval tests.

CES-Inspection 06.05.2005

Welder Performance Qualification (WPQ)

Joint Configuration: -

Joint geometry, a double V (or U) does not qualify a single V (or U)

But a single full penetration joint without backing qualifies all joint configurations.

Welding Position Approval Range (QW461.9): Period of Validity/Renewal of Qualifications (QW 322.2) : If welder uses the process for which he is qualified, then his qualification lasts indefinitely. If the welder does not use the welding process for a period of 6 months or more, then he must perform a new test.
CES-Inspection 06.05.2005

Welder Performance Qualification (WPQ)

Visual Examination (Ref QW 302.2 & QW 190): Performance test coupons must show complete joint penetration with full fusion of the weld metal and base metal. The welder performance test must follow a properly qualified W.P.S. Radiography ( Ref QW 191) : A length of at least 6" must be examined for plate or the entire circumference for pipe. If the pipe circumference is less than 6" then more samples must be welded up to a maximum of 4. Ref QW 302.2

CES-Inspection 06.05.2005

Welder Performance Qualification (WPQ)

Test Requirements for groove weld: -

Bend tests can in most cases be replaced by Radiography.

Radiography is optional and must be supplemented by bend tests when using GMAW (MIG/MAG) with dip transfer (Short Circuiting Arc) or when welding some special materials. Ref. QW304. Test requirements for fillet welds in plate (ref. QW452.5):One macro section (QW 184) and One fracture test (QW182). Note: - The welder who qualifies the P.Q.R. is automatically approved within the limits specified in QW304, QW305 and QW303. Ref QW301.2.
CES-Inspection 06.05.2005

CES-Inspection 06.05.2005