Weld Quality

Welding
Qualification

&
Certification

._._---~-----------~-------

-------

.ecture 14

--------- -- --------

-------

------_.~-------

p1

Lecture

~3cope

Need for welding qualification

Codes & standards requirements
- Welding procedure specifications
- Welding procedure qualification
- Welding operator qualification

Company certification

_ _ _. _ _.

. _ _.

----_ ..

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----_.

p2

Need IFor Weld Qualification

Many variables influence weld quality, related to
the parts to be joined, the welding process and
welding operator skill
The purpose of qualification is to demonstrate
that welding procedures and personnel are
adequately controlled and are capable of
acceptable results
Such tests cannot foretell performance in
produc::tion. Quality of the production welds
should be determined by inspection during and
after the actual welding.

Lecture 14

Codes & Standards

Application codes & standards that specify

qualification requirements for welding
include:
- ASME Boiler and Pressure Vessel Code

=~~~ ~~11 ~:~:~~i:e~~~~ Code

ill~.~lft

- API 1104 Standard for Welding Pipelines and Related

Facilities
- eSA W59 Standard for Welded Steel Construction

Standards for weld qualification

- AWS B2.1 Wt~lding Procedure and Performance
Qualification

-------------14

p4

Codes & Standards Requirements

A common approach to qualify welding
procedures is by preparation and testing of
standard test pieces. The qualification tests
need not be repeated unless the welding
procedure specification is changed.
Some' pressure vessel standards require test
plates to be welded at the same time as the
vessel seams and subsequently tested.
Other standards accept certain welding
procedures as "prequalified"

lecture 14

pSi

Welding I)rocedure Specification

Standards normally require the contractor to

prepare and qualify Welding Procedure
Specifications (WPS)
A WPS should define the welding variables in
sufficient detail to ensure that the required
quality is met
Standards differ with respect to the generality
or specificity of WPS
- Some standards are very specific in defining the content
of a WPS e.g. ASME Section IX. Other standards are
more general

--~---~-

------------------

---~-----

e14

---------

p6

r------~----

Welding Procedure Specifications

Typical VVPS Contents

scope
Base metal
to simplify qualifications,
standards often group base
metals by similar composition or
streng1h levels

Welding process
Filler metal
Type of current and range
Arc voltage
Travel speed
Heat input

Joint preparation _
Welding details
Welding positions
Preheat & interpass
temperatures
Post weld heat treatment
and finishing

--_._-------------

--~~-----------_._------------------------~

lecture 14

p7

ASME Salmple WPS

,14

p8

1992 SECI10N IX

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NONMANQA~AI'Pl!NDIX A

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WPS Clualification
The pu rpose of qualification is to show that
weldin!~ in accordance with the WPS willproduce sound welds with adequate
proper1~ies.

The WPS qualification requirements are

specifil:!d by the applicable standard.
Qualification may be achieved by:
1. Use of prequalified welding procedures
2. Qualification tests
3. Mock-up tests

Lecture 14

p9

-------------

WPS Qualification

Prequalified welding procedures

- The concept of prequalification is based on the reliability
of certain provl~n procedures as defined by the code or
standard (e.g. GSA W59, AWS 01.1)
- The contractor is nevertheless required to prepare WPS
documents and to accept responsibility for their use.
- Any deviation from the standard negates the prequalified
status

~~------------------

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e 14

------------------------

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P 10

WPS Clualification

Prequalified weldinq procedures

~

Qualification tests
- Qualifk~ation tests are intended to demonstrate that the
weldin!~ procedure results in sound welds with acceptable
mechanical properties
- Tests need not simulate the actual conditions for a given
job. They usually consist of conventional butt joints on
plates or pipes
- Base 2lnd filler materials, welding variables and heat
treatml~nts must follow production plans within specified
ranges.
- However, other variables such as joint geometry or
weldin!~ position might not be considered as qualification
variables

lecture 14

P 11

1-----

-------- -------------------,

WPS QUcllification

Prequalified welding procedures

Qualification tests
Mock-up te:sts
- Mock-up tests are intended to simulate actual production
or field conditions.
- Codes and standards do not require preparation of
welded mock-ups
- However, mc,ck-ups can help to anticipate or avoid
problems in production. They are also useful when difficult
access or other practical considerations may influence
results in-situ, such as repair welding of nuclear plants.

--------- ----- -----------------

---------

- - ---

P 12

Tests elf Qualification Welds

Specimens are removed from the sample
welds for examination and testing
The type and number of tests depend on the
require!ments of the particular standard
Commonly specified tests include:
- tensile tests
- guided bend tests
- Charpy notch toughness tests, or other fracture
toughness tests such as drop weight tests
- macro-etch tests
- non-de,structive examination

Lec:ture 14

-------l

p13

Mechanic:al Test Specimens

LONGITUDINAL WELD
SPECIMEN
IDENTICAL
DIMENSIONS

CHARPY.

TRANSVERSE
SPECIMEN

~~

MINATURE ROUND
SPECIMENS DEPENDING ON T

------------ -------------

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Face

8~

Root Bend Tests

FACE BEND

~~~~ROOT
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BEND
SIDE BEND

WELD JOINT

Lecture 14

P 15

Guided Bend Test Jigs

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Charp:v Impact Specimen

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Lecture 14

--- ----------

p17

,-----Recordin!~

Test Results

The we1dinn conditions and the test results are

entered on a Procedure Qualification Record
(PQR)
If the test re~sults meet the requirements of the
standard, the PQR is certified by the contractor
and the third-party inspector
The WPS may then be issued for production

--------

314

P 18

,----I
ASME Sample PQR

Lecture 14

P 19

1992 SEC110N IX

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176

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NONMANDATORY APPENDIX A

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_
iype and

number of tescs required by the Code.'

Changes in a qualified WPS

If a WPS is to be revised or modified beyond

the qualified ranges of the "essential variables"
it is necessary to do additional qualification
tests
If the changE~s are within the qualified ranges of
essential variables, then a revised WPS can be
issued without requalification
A PQR may support several WPS
Since the PQR is a certified record of a
qualification test, it should not be revised.
(

~14

p20

Welder Performance Qualification

WeJder or welding operator qualification tests
are per1formed to determine the ability of the
persons tested to produce acceptable welds

. __ ._--_._-~------~----------

---_._-_._._---_._.-

Lecture 14

---~. .

__ . .

p21

Performance Qualification Req'ts

Most standards require each welder or welding

operator to make one or more test welds in
plate or pipe
Variables that affect the ability of welders to
make sound welds are considered qualification
variables. These include:
-

welding proc:ess
filler metal
welding position
joint detail
plate thicknElss
welding tech nique

--

e14

------------'---

~------------------_._--

P 22

,-------------------------------~

Standard Welding Positions - Plates

Te,st Position 1G

Te!;t Position 3G

Test Position 2G

Test Position 4G

~---

---------------- - - - - - - - - - -------- - - - - - - - - - - - - - - - - - - - - - - -----------------------

Lecture 14

p23

,--------------

Welding Positions-Pipes

~~.

-t;2J.J-.l16.

Tellt Position 1G

Test Position 2G

Test Position 6G

'--------~-~._---_. -_._~

-----_._-------------~_._----------------

p24

- - - - - -

Perforrnance Qualification Tests

Test spl 3cimens may be groove welds or fillet

welds
- groove weld qualification usually qualifies the operator to
weld bClth groove and fillet welds
- fillet weld qualification limits the welder to fillet welds in
only thEI position qualified or less difficult positions

Tests consist of either bend tests, macro-etch

tests or radiography
The we Ider who prepares a test plate for a
procedure qualification is usually qualified
within the variables in the WPS.

--------

lecture 14

p25

Performan~::e

Qualification Records

Responsibility for performance qualification

records lies with the employer
After succe8sful qualification of a welder the
employer and third party inspector certify the
performancE~ qualification record.
Most codes limit the duration of qualification to
three to six months inactivity
For most codes qualification may be extended
indefinitely provided the welder performs
satisfactory work within the stated period
'-----------

- - - ~ - - --~-------'

----------

-~--------_._----

114

p26

----------

-----------------------,

CompClny Certification
Some standards extend qualification to the
company's organisational practices
- ASME Boiler and Pressure Vessel Code
requirE~ audit by ASME of a company's quality control program
before issuing a code symbol stamp for construction of
compcnents
Sectiol1 III for nuclear components requires a quality assurance
program

-CSA WS9/W47.1
requims employment of designated welding engineers and
welding supervisors, and preparation of welding standards and
WPS uudited by Canadian Welding Bureau

-ISO 9000
generalized quality assurance program

Lecture 14

p27