WPS, PQR,

WPQ & their

significance in
Quality

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WPS- Welding Procedure

Specification.

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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.

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Welding Procedure Specification (WPS)

In general a welding procedure consists of three parts as

follows:
1.

A drawing or sketch showing the weld joint design

and the conditions for making each pass or bead .

2.

A detailed written explanation of how the weld is to

be made.

3.

A record of the test results of the resulting weld.

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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,..)

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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 requalified.
1.
2.
3.
4.
5.
6.
7.

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
8. The weld joint, that is, the joint type and the weld
9. Electrical or operational parameters involved
10. Welding technique

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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 CES-Inspection
of the welding current.

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

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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.

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Welding Procedure Specification (WPS)

Necessary of WPS:
1.

Maintain dimensions by controlling

distortion

2.

Reduce residual or locked up stresses

3.

Minimize detrimental metallurgical

changes

4.

Consistently build a weldment the same

way

5.

Comply with certain specifications and

codes.

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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.

Designer

2.

Welding inspector

3.

Welding supervisor

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PQR-Procedure Qualification
Record.

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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.

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Procedure Qualification Record (PQR)

3. Supplementary Variables
Affect on the impact properties of a joint. Classed as NonEssential 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.

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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

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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.

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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.

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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.

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Procedure Qualification Record (PQR)

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Procedure Qualification Record (PQR)

Non destructive testing: Welds are to be reasonably free from defects.

1.

Cracks are not allowed

2.

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.

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Other imperfections - level B in ISO/DIS 10042.2

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.

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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.

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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

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WPQ- Welder Performance

Qualification.

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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
(P40-P49).
Providing a compatible consumable exists with the same F
number used in the qualification test. (QW423.1)

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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).

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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.

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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.

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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

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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.

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