Procedure Qualification Record (PQR)

PQR's are not required if Standard Welding Procedures are used, see below for
details.

This document contains details of the welding test, it must include details of all the
parameters listed as variables in tables QW250 to QW265 for each process involved
and all the destructive test results.

The relevant variables for each type of welding process are clearly defined in tables
QW250 to QW265. The left hand column of each table defines the section and
paragraph where each variable and its application to the table is explained in the code.

Welding Variables

Variables used in a welding procedure test are divided into 3 categories :-

 Essential Variables Are variables that have a significant affect on the

mechanical properties of a joint. They must not be changed except within the
limits specified by this code. e.g. Material thickness range, Material Group etc.

 Non-Essential Variables Are variables that have no significant affect on

mechanical properties. They can be changed without re qualification of the
PQR.

 Supplementary Variables Are variables that have an affect on the impact

properties of a joint. They are 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.

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 and any joint geometry approves all
geometry's, e.g. single V, double V, U prep, backed or unbacked.

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.

Material Grouping
Materials are assigned P numbers in QW420; a 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.
Other P number groupings are permissible ref. QW424.1 for details. Ref QW 424.1
for further details.

It is normally permissible if the material is not listed in QW422 to assign it to a P

number which lists materials with the same metallurgical and mechanical properties
although this is not in strict conformance with the code. Typically BS1501 151 430A
low carbon steel could be regarded as P1 and stainless steels such as 316, 304 as P8.

Note P5, 9 & 10 are divided into sub groups eg 5A,5B etc., Treat each sub group like
a separate P Number

Dissimilar materials are acceptable providing they are compatible. For example P1 to
P8, but this does not cover P1 to P1 or P8 to P8.

Note S numbers are for pipework to B31, a P number covers an S number but not the
converse

Consumables
The ASME code uses its own specifications for consumables SFA. which is almost
identical to the AWS specification.

NOTE 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
Thickness limits Groove welds. See QW451 for precise details.

 When Impact tests are required the minimum thickness approved is restricted.
See QW403.6
 More than one PQR may be required to qualify dissimilar thickness

The thickness little 't' of deposited weld metal for each process involved is approved
from 0 to 2xt except:-
  MIG/MAG (GMAW/FCAW) dip transfer weld of deposited thickness less than
½" approves maximum thickness of 1.1 x t only Ref: QW255 (QW403.10)

 If any Pass in a single or multipass weld > ½" then the thickness approval
equals 1.1xT

Dissimilar Thickness QW202.4:- The thicker and thinner part must be qualified,
Except P8 and P4X the thinner part can be qualified if no Impacts and test coupon >
6mm thick.

Thickness limits for fillet welds as per QW462.4a or QW462.4d qualify all fillet weld
sizes on all base material thicknesses and all diameters in one test.

Testing Requirements (Ref QW 463 for location of specimens)

Unlike EN288 there is no requirement for any non-destructive testing such as

radiography or MPI/DPI, although I would recommend radiography for butt welds.

The testing requirement for groove welds are as follows:-

 Two Transverse tensile tests (QW150).

 Two Root bends and Two face bends unless the plate thickness exceeds 3/8"
then 4 side bends are required. All bend tests should be done to QW160 using
the correct former ref. QW466 to an angle of 180 degrees. Longitudinal (all
weld) bend tests are not recommended unless the base/weld materials differ
markedly in bending properties. See QW 466 for exceptions and precise details.

The testing requirement for fillet welds on plate is 5 macro sections only, for Pipe
fillet welds 4 macro sections. No fracture test required.

Welding Procedure Specifications (WPS)

This document details the practical application of the Procedure Qualification Record
(PQR). It should contain enough information to give direction to the welder and
should address all variables associated with the welding process defined in QW250
including non essential and supplementary.
A WPS can combine welding processes from other PQR's but all the relevant
variables must be addressed including parent metal thickness. There is an exception to
this rule for root runs from PQR's that are greater than 1.5 inches thick (38.1mm), see
code for details.

Standard Welding Procedures Specifications (SWP's)

Standard welding procedures listed in annex E of ASME IX can be purchased from
the 'American Welding Society' and used without qualifying a PQR. Section V of
ASME IX gives details of essential variables and restrictions. A successful welder
performance qualification must be carried out to demonstrate the SWP's before a
manufacturer can use it.

Welder Performance Qualification (WPQ)

Materials
The purpose of this test is to determine the welders ability to deposit a sound weld
therefore 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)

Note a single sided weld is classed as a weld without backing and a double sided weld
or weld with sealing run is classed as a weld with backing

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.

Variables
For each welding process there is a list of essential variables in QW352 to QW357
and QW360 for welding operators, these are not necessarily the same as the ones for
the PQR. Essential variables cannot be changed. Explanations of all these variables is
given in section IV of the code.
Diameter and Thickness Ranges
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

Note for branch welds the diameter considered for the above limits is the one
containing the weld preparation.

Thickness limits, groove welds.

The thickness limit only applies to the deposited weld metal thickness not the plate
thickness and 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).

Thickness limits, fillet welds.

A test on plate greater than 3/16" approves all base metal thicknesses and fillet weld
sizes ref. QW452.5. (Note the above diameter limits apply unless the fillet weld is
qualified by a groove weld)

Joint Configuration
Joint geometry, a double V (or U) is considered the same as a joint with backing and
does not qualify a single V (or U) without backing, but a single full penetration joint
without backing qualifies all joint configurations.

Approval Range
Extent of approval is very well explained in QW461.9. Take particular note of
welding positions which are also explained in QW461, for example to qualify a fillet
weld in the normal horizontal-vertical position with a groove weld, the groove weld
must be qualified in at least the 2G position. The welding positions defined in
QW461.1.& QW461.2 should be referred to in the WPS. The position designations:
1G ,2G ,3G ,4G ,5G ,6G (Groove Welds) and 1F ,2F ,3F ,4F (Fillet Welds) are test
positions

Period of Validity/Renewal of Qualifications (QW 322.2)

Providing the welder uses the process for which he is qualified and there is no reason
to question his ability then his qualification lasts indefinitely.

If the welder does not use the welding process for which he is qualified for a period of
6 months or more then he must perform a new test in pipe or plate, any parent
material, thickness and position, if successful all the welder approvals for that welding
process are renewed in one test.
Testing Requirements
Test requirements for groove welds QW452 consists of either:-

 One face bend and one root bend except for welding positions 5G & 6G which
require 4 bends (Ref QW452.1 Note 4). If the plate exceeds 3/8" side bends
may be used. See QW 466 for precise details and exceptions.
Note:- Bend Tests can in most cases be replaced by Radiography {See
Below}.

 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.
Note:- Ultrasonic Examination in lieu of Radiography is not permitted

Test requirements for fillet welds in plate ref. QW452.5:-

 One macro section (QW 184) and One fracture test (QW182).

The location where each specimen has to be taken is defined in QW463

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.

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. Once qualified
the welder must always work within the extent of approval of any properly qualified
W.P.S. and his W.P.Q.

The welder who qualifies the P.Q.R. is automatically approved within the limits
specified in QW304, QW305 and QW303. Ref QW301.2.

Specialist Processes
Such as corrosion resistant overlay or hard facing are covered in QW 453.
Procedure variables are defined with all procedure variables in QW252 and in QW380
for welder approval.
Min base thickness approved = size welded or 1", QW 453

Min Deposit Size Approved:- Point Where Chemical analysis taken No upper limit
QW402.16 (462.5a) Welding Positions QW405.4 Performance Qualification approves
all deposit thickness’ No min.QW381

ASME Definitions, Consumables, Welding Positions

 ASME P Material Numbers Explained

ASME has adopted their own designation for welding processes, which are very
different from the ISO definitions adopted by EN24063.

Designation Description
OFW Oxyfuel Gas Welding
SMAW Shielded Metal Arc Welding (MMA)
SAW Submerged Arc Welding
GMAW Gas Metal Arc Welding (MIG/MAG)
FCAW Flux Cored Wire
GTAW Gas Tungsten Arc Welding (TIG)
PAW Plasma Arc Welding

Straight polarity = Electrode -ve

Reverse polarity = Electrode +ve

ASME F Numbers

F
General Description
Number
1 Heavy rutile coated iron powder electrodes :- A5.1 : E7024
2 Most Rutile consumables such as :- A5.1 : E6013
3 Cellulosic electrodes such as :- A5.1 : E6011
4 Basic coated electrodes such as : A5.1 : E7016 and E7018
5 High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16
6 Any steel solid or cored wire (with flux or metal)
 2X Aluminium and its alloys
3X Copper and its alloys
4X Nickel alloys
5X Titanium
6X Zirconium
7X Hard Facing Overlay

Note:- X represents any number 0 to 9

ASME A Numbers
These refer to the chemical analysis of the deposited weld and not the parent
material. They only apply to welding procedures in steel materials.

A1 Plain unalloyed carbon manganese steels.

A2 to A4 Low alloy steels containing Moly and Chrome Moly
A8 Austenitic stainless steels such as type 316.

ASME Welding Positions Graphic Representation

Note the welding progression, (vertically upwards or downwards), must always

be stated and it is an essential variable for both procedures and performance
qualifications.

Welding Positions For Groove welds:-

Welding Position Test Position ISO and EN

Flat 1G PA
Horizontal 2G PC
Vertical Upwards Progression 3G PF
Vertical Downwards Progression 3G PG
Overhead 4G PE
Pipe Fixed Horizontal 5G PF
Pipe Fixed @ 45 degrees Upwards 6G HL045
Pipe Fixed @ 45 degrees Downwards 6G JL045

Welding Positions For Fillet welds:-

Welding Position Test Position ISO and EN
Flat (Weld flat joint at 45 degrees) 1F PA
Horizontal 2F PB
Horizontal Rotated 2FR PB
Vertical Upwards Progression 3F PF
Vertical Downwards Progression 3F PG
Overhead 4F PD
Pipe Fixed Horizontal 5F PF

Welding Positions QW431.1 and QW461.2

Basically there are three inclinations involved.

 Flat, which includes from 0 to 15 degrees inclination

 15 - 80 degrees inclination
 Vertical, 80 - 90 degrees

For each of these inclinations the weld can be rotated from the flat position to
Horizontal to overhead.