QUALIFICATION OF WELDING PROCEDURES AND WELDERS

1.0 INTRODUCTION
In general, the qualification of welding procedures is to ensure that the welding parameters chosen
such as amperage, voltage, welding speed, position, electrodes, etc would produce a weld having
the required properties for its intended applications. The procedures include preparation of a
welding procedure specification (WPS) and documentation of test results on a procedure
qualification record (PQR).
The welder performance qualification (WPQ) test for welders is to ensure the ability of a welder to
make sound weld, that is it does not have any weld defects such as porosity, lack of fusion and
anything that will degrade the weld itself.
The welding procedure specification (WPS) is a written welding procedure prepared to provide the
welder to set up the equipment and making welds to code requirements. The completed WPS
describes all of the essential and nonessential variables for each welding process. An example of the
AWS welding procedure specification is shown in Fig 1.0.
To support the WPS, it is necessary to test and certify the weld results. This is done by making the
welds describe in the WPS, machining them and testing the specimen in accordance with the code.
This is done by the procedure qualification record (PQR). This form indicates the essential
variables of the weld process or processes, base metals, filler metals and various mechanical test
results. A change in any essential variables requires requalification and must be recorded in another
PQR. An example of the AWS procedure qualification record is shown in Fig 1.1.
The essential variables are those weld variables (e.g. filler metal, base metal, edge preparation,
welding process etc) that need to maintain weld metal soundness.
The nonessential variables are considered nonessential where they will not affect the mechanical
properties or soundness of the weld (e.g. cleaning method by mechanical or chemical means). Any
change in nonessential variables requires only an updating of the WPS.

2.0 GUIDES TO WELDING PROCEDURES

The following guides from various standards or codes can be used for preparation of welding
procedures.
(a) ASME Boiler and pressure code.
(b) AWS Structural welding code.
(c) API standard 1104.
(d) Lloyds Register Rules of construction.
(e) ABS Rules for building & classing steel vessels.
(f) BS 4870 Approval testing of welding procedures.

3.0 WELDING PROCEDURE SPECIFICATION (WPS)

Details of WPS should be in accordance with the contract or purchase requirements. They should
also satisfy the requirements of the applicable code or rules.
A list of details that usually covered in WPS is as follows:
3.1 Scope
The types of welding process, material and governing specifications are listed in this introductory
statement.
3.2 Base Metals
They are specified either by chemical composition or by referring to the applicable specifications,
AISC, ASME,ASTM, ABS, or LLOYDS.
3.3 Filler Metals
Composition, identifying type or classification designation of the filler metal is always given so that
the welder can select correctly.
Electrode storage and handling requirements for satisfactory service especially for low hydrogen
electrodes.
3.4 Welding Process
The welding process is an important variable and must be clearly named.
Indicate whether the process is carried out using manual, mechanised or robotic methods.
3.5 Type of Current and Current Range
The type of current should be specified (AC, DCEN or DCEP) that is compatible with the process,
material type and thickness, type of joint and electrode. The current range instead of exact value
should be specified.
3.6 Welding Positions
The welding of the groove or fillet weld must be described according to applicable code (AWS)
terminology. If vertical welding is involved, it should be mentioned whether progression is upward
or downward.
3.7 Preheat and Interpass Temperatures
A minimum temperature shall be given as well as the maximum interpass temperature. The preheat
and interpass temperature must be kept within a well-defined specified range to avoid degradation
of properties in the HAZ. Temperatures can be determined by using temperature-indicating
crayons.
3.8 Post Weld Heat Treatment
Description of the treatment is to be included. Temperature range and time are to be indicated.
3.9 Gas
The shielding gas should be identified and if it is mixture, should be indicated. The shielding gas

flow rate should also be indicated.

3.10 Joint Edge Preparation
This may be done by cross-sectional sketches that show the thickness of the material and details of
the joint or by referring to standard drawing or specification. Tolerances should be indicated for all
dimensions.
3.11 Back-gouging of Full Penetration Joints
The full penetration joints that are to be back-gouged before carrying out back welding are to be
indicated. The back-gouging of the joints may be done by chipping, grinding or gouging.
3.12 Welding Techniques to control Distortion
Special welding techniques and sequences required to minimize distortion should be clearly
described. Welding sequences such as skip welding and backstep welding help minimize the
distortion. Buttering may be required to minimize or eliminate cracking near the fusion line.

4.0 WELDING PROCEDURE QUALIFICATION

Welding procedure qualification is to qualify the WPS, which is to prove that a weld made under
prescribed conditions will provide the necessary mechanical properties. This involves making test
plates according to the WPS and then testing the weld by mechanical means. Details are indicated
in procedure qualification record (PQR). The PQR is used with reference to a specific WPS.
Generally, the steps involved in a welding procedure qualification include the following:
(a) Preparation and Testing of Welds based on preliminary WPS
First, prepare and weld a suitable test weldment using the preliminary WPS. Plate or pipe
assemblies with a representative joint in the middle usually are used. Tests include guided bend,
tensile, hardness and impact. Types of tests conducted depend upon the requirements of a
particular code. Based on the AWS requirements, the preparation of test specimens for procedure
qualification from welded plates is shown in Fig 4.1.
(b) Recording and Evaluation of Test Results
Once the test specimens from a procedure qualification sample weld have been tested, the results
are recorded on the PQR. The results are then to be analysed by personnel who are responsible for
determining whether the test results meet the requirements of the applicable specification.

(c) Approval of Tests and Specifications

If all the requirements are met, the welding procedure qualification is considered qualified. The
approved PQR and WPS will then be issued. In general, inspection agency or customer approval of
the PQR and WPS is required before any production welding is done.

5.0 WELDER PERFORMANCE QUALIFICATION (WPQ)

Welder performance qualification (WPQ) tests determine the ability of those tested to produce
acceptably sound welds required by WPS i.e. the processes, materials and procedures that are to be
used in production. One of the controls that assist in obtaining satisfactory welds in finished
products is the welder performance qualification test.
The record of WPQ tests should include the essential variables, the type of test and test results for
each welder and welding operator. The guided bend tests are a normal requirement by the code.
Radiographic examination may be substituted for the bend tests.
An example of the welder performance qualification (WPQ) test record is shown in Fig 5.0.
Retesting of the welder or welding operator is required under the following circumstances: involve
in different welding procedure, change of employer, over a period of three months gap in work or
ability of a welder or welding operator is questioned.
As an example, the AWS structural welding code provides for groove weld test specimens for
welder qualification. The weld joint detail is a single V-groove weld as shown in Fig 5.1. A backup
bar is used. The specimens can be welded in different positions. These specimens are then cut and
given guided bend tests. For plate heavier than 9.5mm a side bend specimen is required.
6.0 GUIDED BEND TESTING
One of the objectives of the destructive testing is to stress the weld joint by bending it into a fixed
amount, controlled by the jig, to look for unsoundness. The bending test can be carried out by a
bend test jig based on AWS is shown in Fig 6.0. The tests are:
(a)
(b)
(c)

Root Bend: in which the root of the weld is in tension.

Face Bend: in which the top surface of the weld is in tension.
Side Bend: in which a vertical slice is cut transverse to the weld so that the cross-section of
the joint is in tension.

After the bend, convex surface of the specimen is examined for the appearance of cracks or other
open discontinuities. Any specimen in which a crack or other open discontinuity in any direction is
present after the bending is considered as having failed.

Fig 1.0 Welding Procedure Specification (WPS)

Fig 1.1 Procedure Qualification Record (PQR)

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Fig 4.1 Preparation of Test Specimens from Welded Plate

Fig 5.0 Welder Performance Qualification (WPQ) Test Record

Fig 5.1 Groove Weld Root Bend Test

Fig 6.0 Guided Bend Test Jig

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