Welding Procedure and Welder Qualification

Eakkachai Warinsiriruk
Production Engineering (B. Eng) Master Degree of Welding Engineering (M. Eng) International Welding Engineering (IWE); TH-IWE-0043 Certified Assistant Welding Inspector (CAWI) Radiographic Films Interpretation (RI) ; KMUTT-RI-005/2006 Liquid Penetrant Testing Level II (ASNT/ASTM1417-05-Aerospace Component) UT/MT Level I; CGSB

Content
1 Objective of WPS, PQR and WQT/WOPQ. 2 Step for Welding Qualification. 3 Welding Procedure Qualification on AWS D1.1 4 Welder Performance Qualification on AWS D1.1 5 Case Study.

Meaning for WPS, PQR and WPQ

A Welding Procedure Specification (WPS) [1] is a written document that provides direction to the welder or welding operator for making production welds in accordance with Code requirement. The Procedure Qualification Record (PQR) [1] documents what occurred during welding the test coupon and results of testing of the coupon.
*** The purpose for qualification of a WPS is to determine that the weldment proposed for construction is capable of providing the required properties for its intended application. Welding procedure qualification establishes the properties of the weldment, not skill of the welder or welding operator.

In Performance Qualification [1], the basic criterion established for welder qualification is to determine the welders ability to deposit sound weld metal. The purpose of the performance qualification test the welding operator is to determine the welding operators mechanical ability to operate the welding equipment.
1: ASME BPV CODE Sec IX 2004

Scopes of the WPS, PQR, and WPQ. WPS

Specify: Variable ranges Essential variables Nonessential variables other directions

PQR
Record: Actual values Essential variables Test and result other data

WPQ
Record:
Values Test

Specify:
Range Qualified Record Test and Test Result

Suggested Format for WPS

Please see attached Documents

Suggested Format for PQR

Please see attached Documents

Suggested Format for WPQ

Please see attached Documents

Welding Application
Air Receiver Tank: SA 516M Gr 485 Follow on ASME BPV Code Sec VIII Division 1 2004

From Sawatudom Engineering (Rayong) Co., Ltd.

Example for Weld Map (Air Receiver Tank)

Welding Engineering shall be plan the welding methods and fabrication in these job.
- Material Characteristic?, Process?, Filler metal? - Plant Facilities? And Cost control? - How many use to welder/ welding operator? - How do to minimize test coupon? - How do to quality control during weld? - Other constraint?

Solution: 1) 2)

Qualification on AWS D1.1

Welding Procedure Qualification

See Table 3.1 ,Table 4.8 and Annex M

Graville Diagram
HSLA Steels Cr-Mo Steels QT Steels HTLA Steels TMCP Steels Low-carbon Steels

Weld Positions for Groove Weld

Weld Position on Plates

 Groove Weld on Pipes

Why 6G, 6GR qualified all positions

The engineering shall be consider to essential variables for these project. Because, that consideration is become to minimize PQR tests (minimize budgets for test).

***

AWS D1.1: 4.8 Method of Testing and Acceptance Criteria for WPS Qualification
Visual Inspection NDT Mechanical Test Macroetch Test Retest

***

How much for size of each specimens?

Welding Operation
Welder: One who performs manual or semiautomatic welding Welding, Manual: welding wherein the entire welding operation is performed and controlled by hand. Welding, Semiautomatic arc: arc welding with equipment which control only filler metal feed. The advance of the welding is manually controlled.

AWS A3.0/ CASTI Guidebook to ASME section IX: Welding Qualification

 Welding operator: one who operates machine or automatic welding equipment. Welding, Machine: welding with equipment that has controls that arc manually adjusted by the welding operator in response to visual observation of the welding, with the torch, gun or electrode holder held by mechanical device. Welding, Automatic: welding with equipment performs the welding operation without adjustment of the control by a welding operator. The equipment may or many not perform the loading and unloading of the work.

Welding Operation

http://www.windpower.org/en/tour/manu/towerwld.htm

AWS A3.0/ CASTI Guidebook to ASME section IX: Welding Qualification

Welder Performance Qualification

Case Study 1 2 3