UNIVERSITI KUALA LUMPUR

MALAYSIA FRANCE INSTITUTE

FWB 37104

GROUP 3: PRESSURE VESSEL (SADDLE)

Prepared By:

NAME: ID:
MUHAMMAD AMIR BIN 50215217036
KAMARUZAMAN
MOHD SHARULNIZAM BIN MOHD 50215217037
SAUPI
DANIEL HAIKAL BIN AZMI ZAM

UNIVERSITI
MUHAMMAD SAUFI KUALA LUMPUR
BIN OSMAN
MALAYSIA FRANCE INSTITUTE

1
Table of Contents

1.0 Introduction .......................................................................................................................... 1

1.1 Organization Chart .......................................................................................................... 2
1.2 Job Description ................................................................................................................ 3
1.3 Pressure Vessel (Saddle) Drawing ................................................................................ 4
1.4 Design of Saddle ............................................................................................................. 5
1.5 Design of Welded Joints ................................................................................................. 6
1.6 Weld Map ......................................................................................................................... 6
1.7 Welding Symbol............................................................................................................... 8
2.0 Welding Codes and Standard ............................................................................................ 9
2.1 SMAW Essential Variable ............................................................................................. 10
2.2 Material Selection .......................................................................................................... 12
2.3 Electrode Selection ....................................................................................................... 16
2.4 Grouping Number .......................................................................................................... 19
2.5 Fillet procedure and fillet qualified by group ............................................................... 19
2.6 Fillet Specimen .............................................................................................................. 20
2.7 Fracture Test.................................................................................................................. 21
2.8 Fillet Test Required ....................................................................................................... 21
2.9 Macro Examination........................................................................................................ 22
2.10 Macro Acceptance Criteria ........................................................................................... 23
5.0 Type of Testing .................................................................................................................. 25
5.1 Etching Test ............................................................................................................................ 25
5.1.1 Ammonium Persulfate ............................................................................................... 26
5.1.2 Iodine and Potassium Iodide. ................................................................................... 26
5.1.3 Nitric Acid ................................................................................................................... 26
6.0 Testing Requirements for Codes ..................................................................................... 30
6.1 Etching Test Equipment ................................................................................................... 30
7.0 Overview of The Preparation Approved WPS Document .............................................. 35
7.1 Material Specification (GROUP P NO) ........................................................................ 35
7.2 Thickness Range, Type of Joint ................................................................................... 36
7.3 Type of Joint .................................................................................................................. 37
7.4 Checklist (Before, During, After) .................................................................................. 38
7.5 Visual Inspection Form ................................................................................................. 43

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8.0 Overview of the WPQR..................................................................................................... 44
9.0 Overview of the Approved WPS ...................................................................................... 48
10.0 Conclusion ......................................................................................................................... 50

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3
1.0 Introduction
The purpose for this subject is to make sure the student can understand the
welding procedure before weld based on code and standard. This subject can
improve the knowledge about the procedures flow, documentations that used in
welding fabrication industries. This subject also want students familiar with this
code and standards when they in industry in future. They will learn about the
procedures, worksheets, workflows, acceptance criteria and the codes and
standards that will used in welding industries. Therefore, the students easy to
adapt this kind of things when they are in industry. The students also will learn how
to prepare the documents based on the code and standards such as WPS, PWPS,
PQR, WQT, welding testing and the welder certificates. This might help them a lot
and can ease the company when they have this kind of knowledge.

1
 1.1 Organization Chart

GENERAL MANAGER
MUHAMMAD SAUFI BIN OSMAN
Task: Project leader, prepare welding
procedure & fabrication, compile document

TECHNICIAN DT & NDT WELDER WELDING INSPECTOR

MUHAMMAD AMIR BIN
KAMARUZAMAN
Task: prepare dt & ndt
acceptance criteria,
prepare the specimen
and test report
DANIEL HAIKAL BIN
AZMI ZAM
Task: To weld the
specimen based on the
certification qualification
MOHD SHARULNIZAM
BIN MOHD SAUPI
Task: Checklist before,
during and after.
Complete the report.

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1.2 Job Description

1. Project Manager
• Lead, motivate the project member to work based on planned.
• Check daily activity process and make sure all planed running
smoothly.
• Ensure the project task run accordingly within the project time.
• Monitor the procedure of checklist before, during and after weld.
• Checking the documentation and endorse every workers job
check point.
2. Technician DT & NDT
• Perform highly technical mechanical or diagnostic system.
• Executing the test preparation and mechanical testing.
• Follow codes and standard acceptance criteria based on ASME
codes.
• Identify defect and discontinuities occur in the test sample.
• Perform documentation on result after testing completed.
• Make sure the result is accurate for documentation.
3. Welder
• Attend work on the schedule established by the employer and
without excessive absenteeism.
• Follow all the safe work practices.
• Maintain length of arc and speed of movement to form specified
depth of fusion and bead.
• Examine weld for bead size and other specifications
• Clean up work area daily.
4. Welding Inspector
• Ensure the process follow the ASME codes and standard.
Inspect on type of material and type of electrode.
• Inspect all stage of fabrication and fit-up before welding.
• Visual inspection take place after completed the welding process.
• Checking and endorse WPS form.
• Record and compiling quality record with evidence.

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1.3 Pressure Vessel (Saddle) Drawing

4
1.4 Design of Saddle

ASME VIII-1 appendix G-1

• A vessel supported in a vertical or horizontal position will have concentrated

loads imposed on the shell where the supports are attached. Calculations to resist
the forces involved are not given here because they involve so many variables
depending upon the size and weight of vessels, the temperature of service, the
internal pressure, the arrangement of the supporting structure, and the piping
attached to the vessel as installed.
• Flexible Saddle – the shear plate extends beyond the vertical supports. The
saddle wear plate extends beyond the vertical plates. The saddle flexibility
increases away from the vessel vertical centreline. Horn stresses are reduced –
this is important for large diameter or thin walled vessels.

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1.5 Design of Welded Joints

1.6 Weld Map

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7
Weld Map

1. WPS 01
• The WPS 01 will be used for longitudinal and circumferential joints.

2. WPS 02
• The WPS 02 will be used for head to shell joints. In this vessel, the heads are
tori spherical, and the thickness of the heads are 1.7 times of the shell and WPS
01 cannot be applied here since thickness range limitation.

3. WPS 03
• The WPS 03 will be used for boot welds. The shell and head materials are
carbon steel, and boot material is stainless steel so the WPS 01 and 02 cannot be
utilized for boot section since it has different P number.
• Depends on the equipment design it might have several WPS's, and we need
a map to show them in the drawing. The map also can be displayed in tabulated
format. There is no standard form for weld map, and each manufacturer has own
way to illustrate applied WPS's in the vessel/equipment drawing.

1.7 Welding Symbol

Process Location Symbol Meaning

of joint
Fillet Arrow
weld Side

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2.0 Welding Codes and Standard

Section IX of the ASME boiler and Pressure Vessel Code is a standard, prepared
by the American Society of Mechanical Engineers (ASME) Boiler and Pressure
Vessel Committee. ASME standards have been adopted as law by most states,
policies and by company policy which makes it mandatory for these standards to
be followed in the fabrication and repair of pressure retaining items.
Section IX specifies the requirements for the qualification of welders and the
welding procedures specification employed when welding in accordance with the
ASME Boiler and Pressure Code, and the ASME B31 Code for pressure piping.
Qualification of welders and the welding procedure specification they will use in
code construction involve a great many factors that are difficult to outline in a code
or standard.

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2.1 SMAW Essential Variable

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11
2.2 Material Selection

1. QW-403.6

• The minimum base metal thickness qualified is the thickness of the test coupon
T or 5/8 in. (16 mm), whichever is less. However, where T is 1/4 in. (6 mm) or less,
the minimum thickness qualified is 1/2T. This variable does not apply when a WPS
is qualified with a PWHT above the upper transformation temperature or when an
austenitic or P-No. 10H material is solution annealed after welding.

2. QW-403.9

• For single‐pass or multipass welding in which any pass is greater than 1/2 in.
(13 mm) thick, an increase in base metal thickness beyond 1.1 times that of the
qualification test coupon.

3. Base Metal Grouping (QW-420)

• P‐Numbers are assigned to base metals for the purpose of reducing the number
of welding and brazing procedure qualifications required. P‐Numbers are
alphanumeric designations: accordingly, each P‐Number shall be considered a
separate P‐Number (e.g., base metals assigned P‐No. 5A are considered a
separate P‐Number from those assigned P‐No. 5B or P‐No. 5C). In addition,
ferrous base metals have been assigned Group Numbers creating subsets of P‐
Numbers that are used when WPSs are required to be qualified by toughness
testing by other Sections or Codes. These assignments are based essentially on
comparable base metal characteristics, such as composition, weldability,
brazeability, and mechanical properties, where this can logically be done. These
assignments do not imply that base metals may be indiscriminately substituted for
a base metal that was used in the qualification test without consideration of
compatibility from the standpoint of metallurgical properties, postweld heat
treatment, design, mechanical properties, and service requirements. The following
table shows the assignment groups for various alloy systems:
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13
4. QW-424.1

• Base metals are assigned P‐Numbers in Table QW/QB-422; metals that do not
appear in Table QW/QB-422 are considered to be unassigned metals except as
otherwise defined for base metals having the same UNS numbers. Unassigned
metals shall be identified in the WPS and on the PQR by specification, type, and
grade, or by chemical analysis and mechanical properties. The minimum tensile
strength shall be defined by the organization that specified the unassigned metal
if the tensile strength of that metal is not defined by the material specification.

5. QW-424.2

• For welds joining base metals to weld metal build up or corrosion-resistant weld
metal overlay, the build-up or overlay portion of the joint may be substituted in the
test coupon by any P-Number base material that nominally matches the chemical
analysis of the build-up or overlay.

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15
2.3 Electrode Selection

16
1. QW-440 Weld Metal Chemical Composition

17
2. Table QW-423

18
2.4 Grouping Number

2.5 Fillet procedure and fillet qualified by group

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2.6 Fillet Specimen

1. QW-181 Procedure and performance qualification specimens

• QW-181.1 Procedure. The dimensions and preparation of the fillet‐weld test

coupon for procedure qualification as required in QW-202 shall conform to the
requirements in Figure QW-462.4(a) or Figure QW-462.4(d). The test coupon for
plate‐to‐plate shall be cut transversely to provide five test specimen sections, each
approximately 2 in. (50 mm) long. For pipe‐to‐plate or pipe‐to‐pipe, the test coupon
shall be cut transversely to provide four approximately equal test specimen
sections. The test specimens shall be macro‐examined to the requirements of
QW-183.

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2.7 Fracture Test

1. QW-182 Fracture Test

• The stem of the 4 in. (100 mm) performance specimen centre section in Figure
QW-462.4(b) or the stem of the quarter section in Figure QW-462.4(c), as
applicable, shall be loaded laterally in such a way that the root of the weld is in
tension. The load shall be steadily increased until the specimen fractures or bends
flat upon itself. If the specimen fractures, the fractured surface shall show no
evidence of cracks or incomplete root fusion, and the sum of the lengths of
inclusions and porosity visible on the fractured surface shall not exceed 3 /8 in.
(10 mm) in Figure QW-462.4(b) or 10% of the quarter section in Figure QW-
462.4(c).

2.8 Fillet Test Required

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2.9 Macro Examination

1. QW-183

• One face of each cross section of the five test specimens in Figure QW-
462.4(a) or four test specimens in Figure QW-462.4(d), as applicable shall be
smoothed and etched with a suitable etchant (see QW-470) to give a clear
definition to the weld metal and heat affected zone. The examination of the cross
sections shall include only one side of the test specimen at the area where the
plate or pipe is divided into sections i.e., adjacent faces at the cut shall not be
used. In order to pass the test.
• visual examination of the cross sections of the weld metal and heat‐affected
zone shall show complete fusion and freedom from cracks
• there shall be not more than 1/8 in. (3 mm) difference in the length of the legs
of the fillet.

2. QW-184 Performance Specimen

• The cut end of one of the end plate sections, approximately 1 in. (25 mm) long,
in Figure QW-462.4(b) or the cut end of one of the pipe quarter sections in Figure
QW-462.4(c), as applicable, shall be smoothed and etched with a suitable etchant
(see QW-470) to give a clear definition of the weld metal and heat-affected zone.
In order to pass the test.
• .Visual examination of the cross section of the weld metal and heat‐affected
zone shall show complete fusion and freedom from cracks, except that linear
indications at the root not exceeding 1/32 in. (0.8 mm) shall be acceptable.
• The weld shall not have a concavity or convexity greater than 1/16 in. (1.5 mm).

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2.10 Macro Acceptance Criteria

1. QW-192.1.4
• In order to pass the macro‐examination, each of five sectioned stud
welds and the heat‐affected zone shall be free of cracks when examined
at 10X magnification, which is required by QW-202.5 when studs are
welded to metals other than P‐No. 1.

2. QW-197.1.3
• The outline of the fusion zone shall be generally consistent in size and
regular in shape and uniformity of penetration.
• The examination of the weld area shall reveal sound weld metal,
complete fusion along the bond line, and complete freedom from cracks
in the weld metal and heat‐affected zone.

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3.0 Procedure Documentation

Qualification requires the formulation of three universally recognized documents:

•pWPS – Preliminary Welding Procedure Specification.

•WPQR – Welding Procedure Qualification Record.

•WPS – Welding Procedure Specification.

4.0 The Qualification Process Flow

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5.0 Type of Testing

5.1 Etching Test

• The surfaces to be etched should be prepared by filing, machining, grinding,

or polishing to delineate the macrofeatures of the specimen's weld and HAZ
after etching. With different alloys and tempers, the etching period will vary
from a few seconds to several minutes, and should be continued until the
desired contrast is obtained. As a protection from the fumes liberated during
the etching process, this work should be done under a hood. After etching,
the specimens should be thoroughly rinsed and then dried with a blast of
warm air. Coating the surface with a thin clear lacquer will preserve the
appearance. (Reference ASTM E340, Standard Test Method for
Macroetching Metals and Alloys, or other industry-accepted standards.)
• Etching solutions suitable for carbon and low alloy steels, together with
directions for their use, are suggested in QW-472.1 through QW-472.4.
QW-472.1 Hydrochloric Acid. Hydrochloric (muriatic) acid and water, equal
parts, by volume. The solution should be kept at or near the boiling
temperature during the etching process. The specimens are to be
immersed in the solution for a sufficient period of time to reveal all lack of
soundness that might exist at their cross‐sectional surfaces.

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5.1.1 Ammonium Persulfate

• One part of ammonium persulfate to nine parts of water, by weight.

The solution should be used at room temperature, and should be
applied by vigorously rubbing the surface to be etched with a piece
of cotton saturated with the solution. The etching process should be
continued until there is a clear definition of the structure in the weld.

5.1.2 Iodine and Potassium Iodide.

• One part of powdered iodine (solid form), two parts of powdered

potassium iodide, and ten parts of water, all by weight. The solution
should be used at room temperature, and brushed on the surface to
be etched until there is a clear definition or outline of the weld.

5.1.3 Nitric Acid

• One part of nitric acid and three parts of water, by volume.

CAUTION: Always pour the acid into the water. Nitric acid causes
bad stains and severe burns. The solution may be used at room
temperature and applied to the surface to be etched with a glass
stirring rod. The specimens may also be placed in a boiling solution
of the acid, but the work should be done in a well‐ventilated room.
The etching process should be continued for a sufficient period of
time to reveal all lack of soundness that might exist at the cross‐
sectional surfaces of the weld.

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5.2 Fracture Test

QW-182
• The stem of the 4 in. (100 mm) performance specimen center section
in Figure QW-462.4(b) or the stem of the quarter section in Figure
QW-462.4(c), as applicable, shall be loaded laterally in such a way
that the root of the weld iis in tension. The load shall be steadily
increased until the specimen fractures or bends flat upon itself. If the
specimen fractures, the fractured surface shall show no evidence of
cracks or incomplete root fusion, and the sum of the lengths of
inclusions and porosity visible on the fractured surface shall not
exceed 3/8 in. (10 mm) in Figure QW-462.4(b) or 10% of the quarter
section in Figure QW-462.4(c).

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5.3 Macro-Examination Performance Specimen

• The cut end of one of the end plate sections, approximately 1 in. (25
mm) long, in Figure QW-462.4(b) or the cut end of one of the pipe
quarter sections in Figure QW-462.4(c), as applicable, shall be
smoothed and etched with a suitable etchant (see QW-470) to give
a clear definition of the weld metal and heat-affected zone. In order
to pass the test
• visual examination of the cross section of the weld metal and heat‐
affected zone shall show complete fusion and freedom from cracks,
except that linear indications at the root not exceeding 1/32 in. (0.8
mm) shall be acceptable
• the weld shall not have a concavity or convexity greater than 1/16 in.
(1.5 mm)
• there shall be not more than 1/8 in. (3 mm) difference in the lengths
of the legs of the fillet.

5.4 Liquid Penetrant Examination

QW-195
• QW-195.1 The liquid penetrant examination in QW-214 for
corrosion‐resistant weld metal overlay shall meet the requirements
of Section V, Article 6. The acceptance standards of QW-195.2 shall
be met.

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 5.4.1 Acceptance Criteria Liquid Penetrant Examination

• Procedure and performance tests examined by liquid penetrant

techniques shall be judged unacceptable when the examination
exhibits any indication in excess of the limits specified in the
following:
• relevant linear indications
• relevant rounded indications greater than 3/16 in.(5 mm)
• four or more relevant rounded indications in a line separated by 1/16
in. (1.5 mm) or less (edge‐to‐edge)

5.5 Visual Examination

• Performance test coupons shall show no cracks and complete joint

penetration with complete fusion of weld metal and base metal.

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6.0 Testing Requirements for Codes
6.1 Etching Test Equipment
• Ammonium Persulfate

• Iodine and Potassium Iodide

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• Nitric-Acid

• Etching Equipment

31
6.2 Fracture Test Equipment

• Hydraulic Machine

32
6.3 Visual Examination Test Equipment
• Optical Comparator

• Fillet Weld Gauge

33
6.4 Liquid Penetrant Test Equipment
• Remover
• Penetrant Solution
• Developer

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7.0 Overview of The Preparation Approved WPS Document

PWPS – PRELIMINARY WELDING PROCEDURE SPECIFICATION.

7.1 Material Specification (GROUP P NO)

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7.2 Thickness Range, Type of Joint
QW-200.2
• A single WPS may cover several sets of essential variable ranges
as long as a supporting PQR exists for each essential and, when
required, supplementary essential variable [e.g., a single WPS may
cover a thickness range from 1/16 in. (1.5 mm) through 11/4 in. (32
mm) if PQRs exist for both the 1/16 in. (1.5 mm) through 3/16 in. (5
mm) and 3/16 in. (5 mm) through 11/4 in. (32 mm) thickness ranges].

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7.3 Type of Joint
UW-18 ASME VIII DIV 1
• (b) Corner or tee joints may be made with fillet welds provided the
plates are properly supported independently of such welds, except
that independent supports are not required for joints used for the
purposes enumerated in UG-55

G-6 HORIZONTAL VESSEL SUPPORTS

• Horizontal vessels may be supported by means of saddles or
equivalent leg supports. For other than very small vessels, the
bearing afforded by the saddles shall extend over at least one‐third
of the circumference of the shell. Supports should be as few in
number as possible, preferably two in the length of the vessel. The
vessel may be reinforced by stiffening rings at intermediate sections.

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 7.4 Checklist (Before, During, After)

Before welding Remarks

• Welding symbols
and weld sizes ACCEPTED
clearly specified in Yes ☐ No ☐ N/A ☐
drawing and related
documents.

• Weld joint designs Yes ☐ No ☐ N/A ☐

and dimensions
clearly specified in ACCEPTED
drawings and related
documents.

• Welding Yes ☐ No ☐ N/A ☐

consumables ACCEPTED
specified.

• Check that material Yes ☐ No ☐ N/A ☐

fit-up is adequate ACCEPTED

• Check the Yes ☐ No ☐ N/A ☐

cleanliness of the
joint. Excessive
levels of rust, oil,
dirt, paint and other ACCEPTED
contaminants are
detrimental to weld
quality.

• Check that proper Yes ☐ No ☐ N/A ☐

welding procedures
specification and
welder qualifications ACCEPTED
are in place and up to
date.

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 During Welding Remarks

• Check that all Yes ☐ No ☐ N/A ☐

parameters stated in the
Welding Procedure ACCEPTED
Specification are being
followed.
• Essential variables are Yes ☐ No ☐ N/A ☐
being met during ACCEPTED
welding.
• Check individual weld Yes ☐ No ☐ N/A ☐ ACCEPTED
passes.

• Check that proper Yes ☐ No ☐ N/A ☐ ACCEPTED

interpass temperature.

• Final weld reinforcement Yes ☐ No ☐ N/A ☐

and fillet weld size
meets work ACCEPTED
specifications and
drawings.
• Check for visual cues Yes ☐ No ☐ N/A ☐
that can indicate ACCEPTED
problems.

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 After Welding

• Size, length and location Yes ☐ No ☐ N/A ☐

of all welds conform to ACCEPTED
the drawings /
specifications / Code
• Dimensional and visual Yes ☐ No ☐ N/A ☐
checks of the weld don’t
BOTH DIMENSIONAL AND
VISUAL NEED TO BE
CHECK TO IDENTIFY
DISCONTINUITIES,
DISTORTION AND POOR
identify welding WORKMANSHIP
discontinuities,
excessive distortion and
poor workmanship
• Temporary attachments Yes ☐ No ☐ N/A ☐
IF IMPERFECTIONS ARE
FOUND THEN THESE
ATTACHMENT SHALL BE
BLENDED WITH BASE
and attachment welds METAL
removed and blended
with base metal.

• Discontinuities reviewed Yes ☐ No ☐ N/A ☐

against acceptance
criteria for defect
classification.

• Verify NDE is Yes ☐ No ☐ N/A ☐

performed at selected
locations and review ACCEPTED

40
 examiner’s findings.

• Specified locations Yes ☐ No ☐ N/A ☐ ACCEPTED

examined

• Inspector is in agreement Yes ☐ No ☐ N/A ☐

with examiners
interpretations and
findings.
• Perform a final audit of Yes ☐ No ☐ N/A ☐
the inspection dossier to
identify inaccuracies and
incomplete information.
• Inspection reports are Yes ☐ No ☐ N/A ☐
complete, accepted and
signed by responsible
parties

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 Sample Welding Procedure Specification (WPS) Form
Welding Procedure Specification (WPS) No. ______________
Contractor ____________________________________
Authorized by _________________________________ Revision No. ___________________________________
Supporting PQR Identification_____________________ Test Date _____________________________________
WELDING PROCESS: FCAW-S FCAW-G GMAW SMAW
WELD TYPE: Groove Fillet
JOINT TYPE: Direct Butt Indirect Butt T-Joint
Joint(s) Qualified (see Table 6.3)
_____________________________________________________________________
Position ________2F______________ Groove Type___________________N/A______________________________
Root Opening ___________________ Root Face ______________________ Groove Angle _________________
Backing: Yes No Backing Type ___________________________________________________
Backgouging: Yes No Backgouging Method _____________________________________________
TECHNIQUE: Stringers Weave
ELECTRICAL CHARACTERISTICS
Current: AC DCEP DCEN
Transfer Mode (GMAW): Short-circuiting Globular Spray

BASE METAL
Material Specification________________________________ Grade _______________________
Welded to: Material Specification________________________________ Grade _______________________
Maximum Carbon Equivalent _______ Bar size ________________________ Plate Thickness ______9 mm_____
Coated Bar: Yes No Type of Coating _________________________________________________
FILLER METAL
AWS Specification______________________________ AWS Classification ______________________________
Describe filler metal (if not covered by AWS specifications)
_________________________________________________

SHIELDING
Gas: Single Mixture Composition_____________________ Flow rate _____________________
PREHEAT/INTERPASS
Preheat/Interpass Temperature (Min) _______________ Interpass Temperature (Max) ______________________
WELDING PARAMETERS
Current Travel
Pass Electrode Amperage Volts Electrical Speed Joint
Number(s) Diameter Type Range Range Stickout ipm [mm/min.] Detail

3 3.2 100 2.5

Manufacturer or Contractor
__________________________________________________________________________

Authorized by _______________________________________________________ Date

___________________

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7.5 Visual Inspection Form

43
8.0 Overview of the WPQR

WPQR – WELDING PROCEDURE QUALIFICATION RECORD.

•Is a set of documents comprising the WPS detailing.

•The actual welding parameters recorded during the qualification testing as noted on
the pWPS.

•Results of any non-destructive and destructive tests.

•Material certification for the test piece.

•The range of the qualification if all tests are satisfactory.

•Based on the range of qualification a single WPQR may be used to qualify a various
number of WPS’.

•Essentially the WPQR is a documentary evidence to prove that the welding

parameters used in the qualification test piece do not adversely affect the mechanical
properties of the material.

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 FABRICATION AND JOINING SDN BHD

WELDER, WELDING OPERATOR, OR TACK WELDER

QUALIFICATION TEST RECORD

TYPE OF WELDER : HORIZONTAL FILLET WELD

NAME : DANIEL HAIKAL BIN AZMI ZAM IDENTIFICATION NO. : 50215117342
I.C / PASSPORT NO. : 960730-14-6019
WELDING PROCEDURE SPECIFICATION NO. :
FJ-O1 REV: 0
DATE: 17/03/2019

RECORD ACTUAL VALUE USED IN

QUALIFICATION RANGE
VARIABLES QUALIFICATION

PROCESS / TYPE: SMAW

ELECTRODE (SINGLE OR
MULTIPLE): SINGLE SINGLE
CURRENT / POLARITY: DCRP

POSITION: 1F 1F
WELD PROGRESSION: HORIZONTAL HORIZONTAL

BACKING (YES OR NO): NO NO

MATERIAL / SPEC. : SA516 GR70 ANY GROUP I STEEL
BASE METAL
THICKNESS: (PLATE):
GROOVE:
FILLET: 9MM 9MM
THICKNESS: (PLATE):
GROOVE:
FILLET:
DIAMETER: (PLATE):
GROOVE:
FILLET:

FILLER METAL
SPEC. NO. :
CLASS: E-7018
F-NO. 4 4 AND ABOVE

GAS / FLUX TYPE: N/A

OTHER:

45
46
47
9.0 Overview of the Approved WPS

WPS – WELDING PROCEDURE SPECIFICATION.

•A single sheet document, WPS is the final link in the chain of documents required to
demonstrate welding process control.

•It requires all the information required by the qualified welder to complete a welded
joint.

•Unlike the WPS accompanying the WPQR the which contains the actual welding
parameters recorded during the qualification test weld, the final WPS gives a allowable
range of welding parameters.

•The WPS must be readily available at the welder’s workplace to be put in practice.

48
49
10.0 Conclusion

This Welding Procedure Specification (WPS) well describes the welding

procedures, which provides direction to the welder or welding operators for making
sound and quality production welds as per the code requirements. The welding
procedure test method of approval is often a mandatory requirement of the
Application Standard. The documents provided were well prepared and able to
guide the welder to the accepted procedures so that repeatable and trusted
welding techniques are used. Frequent inspection and review need to be conduct
to unsure all the mandatory requirement and codes are following accordingly as
per direction the WPS. The WPS was also well developed for each material alloy
and for each welding type used.

This information needs to be provided with the updated revision within the industry
practice to reduce wastage on repairing and defect work. An optional of material
and welding type can be also suggested due to meet climate, surrounding and
nature of work necessity. The WPS is supported by a very good Procedure
Qualification Record (PQR/WPQR). The PQR recorded the performed test weld
and was ensured that the procedure will produce a good weld. This record needs
to be verified and review by all relevant parties to ensure satisfaction upon the
objective of WPS. The welder was certified with a qualification test documented in
a Welder Qualification Test Record (WQTR) that shows he well understands and
able to demonstrate his ability to work within the specified WPS. This qualification
test can be also conduct in some interval of time to ensure all qualified welder will
be asses and improve the quality of their weld work throughout the work. Overall,
it was a great team effort to prepare and provide a detailed and good WPS.

50
 MARKING SCHEME

EVIDEN SCORE
NO DESCRIPTION WRITTEN FORM FOTO/PIC
MARK
1 2 3 4 5
1 introduction

2 Welding
codes and
standard
3 Types of
testing
4 Test
requirements
5 Group Task/Lab/workshop
a PWPS

b WPQR

c WPS

6 Conclusion

7 PORTFOLIO PRESENTABLE

TOTAL MARKS

CHECK BY: VARIFY BY:

ABD.AZIZ DAWAM PROF.AZHAR MAHMUD

SIGN…………………… SIGN……………………
DATE:………………… DATE……………………..