CSWIP 3.

1 Welding Inspection

Welding Procedures

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TWI Training & Examination
Services

Course Reference WIS 5

Course notes section reference 6.0
 Welding Procedure Qualification
Question:
What is the main reason for carrying out a Welding Procedure
Qualification Test ?
(What is the test trying to show ?)
Answer:
To show that the welded joint has the properties* that satisfy
the design requirements (fit for purpose)

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* properties
•mechanical properties are the main interest - always strength but
toughness & hardness may be important for some applications
•test also demonstrates that the weld can be made without defects
 Welding Procedure Qualification
(according to EN ISO 15614)

Preliminary Welding Procedure Specification (pWPS)

Welding Procedure Qualification Record (WPQR)

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Welding Procedure Specification (WPS)
 Welding Procedure Qualification

Preliminary Welding Procedure Specification (pWPS)

Welding Engineer writes a preliminary Welding Procedure Specification

(pWPS) for each test weld to be made

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 Welding Procedure Qualification

Welding Procedure Qualification Record (WPQR)

• A welder makes a test weld in accordance with the pWPS

• A welding inspector records all the welding conditions used for the
test weld (referred to as the ‘as-run’ conditions)

An Independent Examiner/ Examining Body/ Third Party inspector

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may be requested to monitor the qualification process

The finished test weld is subjected to NDT in accordance with the

methods specified by the EN ISO Standard - Visual, MT or PT & RT
or UT
 Welding Procedure Qualification
Welding Procedure Qualification Record (WPQR)
Test weld is subjected to destructive testing (tensile, bend,
macro)
The Application Standard, or Client, may require additional
tests such as impact tests, hardness tests (and for some
materials - corrosion tests)
Welding Procedure Qualification Record (WPQR)
details: -

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The welding conditions used for the test weld
Results of the NDT
Results of the destructive tests
The welding conditions that the test weld allows for
production welding
The Third Party may be requested to sign the WPQR as a true record
 Welding Procedure Qualification

Welding Procedure Specification (WPS)

The welding engineer writes qualified Welding Procedure

Specifications (WPS) for production welding

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Production welding conditions must remain within the range of
qualification allowed by the WPQR
 Welding Procedure Qualification
(according to EN Standards)
welding conditions are called welding variables
welding variables are classified by the EN ISO Standard as:

•Essential variables
•Non-essential variables
•Additional variables

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Note: additional variables = ASME supplementary essential
The range of qualification for production welding is based on
the limits that the EN ISO Standard specifies for essential
variables*
(* and when applicable - the additional variables)
 Welding Procedure Qualification

(according to EN Standards)

WELDING ESSENCIAL VARIABLES

Question:
Why are some welding variables classified as essential ?
Answer:

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A variable, that if changed beyond certain limits (specified by
the Welding Standard) may have a significant effect on the
properties* of the joint
* particularly joint strength and ductility
 Welding Procedure Qualification
(according to EN Standards)

WELDING ADDITIONAL VARIABLES

Question:
Why are some welding variables classified as additional ?
Answer:
A variable, that if changed beyond certain limits (specified by
the Welding Standard) may have a significant effect on the

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toughness and/or hardness of the joint

Note: ASME calls variables that affect toughness as supplementary

essential variables (but does not refer to hardness)
 Welding Procedure Qualification
(according to EN Standards)
SOME TYPICAL ESSENTIAL VARIABLES
• Welding Process
• Post Weld Heat Treatment (PWHT)
• Material Type
• Electrode Type, Filler Wire Type (Classification)
• Material Thickness

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• Polarity (AC, DC+ve / DC-ve)
• Pre-Heat Temperature
SOME TYPICAL ADDITIONAL VARIABLES
• Heat Input
• Welding Position
 Welding Procedures

Producing a welding procedure involves:

• Planning the tasks
• Collecting the data
• Writing a procedure for use of for trial
• Making a test welds
• Evaluating the results

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• Approving the procedure
• Preparing the documentation
 Welding Procedures
Components of a welding procedure
Parent material
• Type (Grouping)
• Thickness
• Diameter (Pipes)
• Surface condition)
Welding process
• Type of process (MMA, MAG, TIG, SAW etc)
• Equipment parameters

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• Amps, Volts, Travel speed
Welding Consumables
• Type of consumable/diameter of consumable
• Brand/classification
• Heat treatments/ storage
 Welding Procedures

Components of a welding procedure

Joint design
•Edge preparation
•Root gap, root face
•Jigging and tacking
•Type of baking
Welding Position
•Location, shop or site
•Welding position e.g. 1G, 2G, 3G etc

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•Any weather precaution
Thermal heat treatments
•Preheat, temps
•Post weld heat treatments e.g. stress relieving
 Welding Procedures

Object of a welding procedure test

To give maximum confidence that the welds mechanical

and metallurgical properties meet the requirements of the
applicable code/specification.
Each welding procedure will show a range to which the
procedure is approved (extent of approval)

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If a customer queries the approval evidence can be
supplied to prove its validity
Welding Procedures

Example:
Welding
Procedure
Specification

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(WPS)
 Welding Procedures
PURPOSE OF A WPS
TO ACHIEVE SPECIFIC PROPERTIES
mechanical strength, corrosion resistance, composition

TO ENSURE FREEDOM FROM DEFECTS

TO ENFORCE QC PROCEDURES

TO STANDARDISE ON METHODS AND COSTS

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TO CONTROL PRODUCTION SCHEDULES

TO FORM A RECORD

APPLICATION STANDARD OR CONTRACT REQUIREMENT

 Welding Positions

PA 1G / 1F Flat / Downhand
PB 2F Horizontal-Vertical
PC 2G Horizontal
PD 4F Horizontal-Vertical (Overhead)
PE 4G Overhead
PF 3G / 5G Vertical-Up

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PG 3G / 5G Vertical-Down
H-L045 6G Inclined Pipe (Upwards)
J-L045 6G Inclined Pipe (Downwards)
 Welding Positions

ISO

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Welding Procedures

Monitoring Heat Input

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Monitoring Heat Input

ARC ENERGY &

HEAT INPUT

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 Monitoring Heat Input

• ARC ENERGY;
The amount of heat generated in the
welding arc per unit length of weld.
Expressed in kilo Joules per millimetre
length of weld (kJ/mm).

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Arc energy (kJ/mm)= Volts x Amps
welding speed(mm/s) x 1000
 Monitoring Heat Input

HEAT INPUT
The energy supplied by the welding arc to
the work piece.
Expressed in terms of;
arc energy x thermal efficiency factor

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Thermal efficiency factor is the ratio of
heat energy introduced into the weld to
the electrical energy consumed by the arc
 Monitoring Heat Input
Thermal efficiency factor k of welding processes

Process No Process Factor k

121 Submerged arc welding with wire 1.0

111 Metal-arc welding with covered electrodes 0.8

131 MIG welding 0.8

135 MAG welding 0.8

114 Flux-cored wire metal-arc welding without gas shield 0.8

136 Flux-cored wire metal-arc welding with active gas shield 0.8

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137 Flux-cored wire metal-arc welding with inert gas shield 0.8

138 Metal-cored wire metal-arc welding with active gas shield 0.8

139 Metal-cored wire metal-arc welding with inert gas shield 0.8

141 TIG welding 0.6

15 Plasma arc welding 0.6

 Monitoring Heat Input

EXAMPLE.
A MAG weld is made and the following
conditions were recorded;
Arc volts = 24
Welding amperage = 240
Travel speed = 300mm / minute.

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What is the arc energy and heat input?
 Monitoring Heat Input

AE (kJ/mm)= Volts x amps

Travel speed(mm/ sec) x 1000
= 24 x 240
(300/60) x 1000
= 5760

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5000
AE = 1.152 or 1.2kJ/mm
HI = 1.2 x 0.8 = 0.96kJ/mm
CSWIP 3.1 Welding Inspection

Welder Approval
Example BS EN 287

TWI Training & Examination

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Services

Course Reference WIS 5

Course notes section reference 6.0
 Welder Qualification
(according to EN Standards)
Question:
What is the main reason for qualifying a welder ?

Answer:
To show that he has the skill to be able to make production
welds that are free from defects

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Note: when welding in accordance with a Qualified WPS
 Welder Qualification

(according to EN 287 )

An approved WPS should be available covering the range of

qualification required for the welder approval.

• The welder qualifies in accordance with an approved WPS

• A welding inspector monitors the welding to make sure that

the welder uses the conditions specified by the WPS

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EN Welding Standard states that an Independent Examiner,
Examining Body or Third Party Inspector may be required to
monitor the qualification process
 Welder Qualification
(according to EN 287 )
The finished test weld is subjected to NDT by the methods
specified by the EN Standard - Visual, MT or PT & RT or UT

The test weld may need to be destructively tested - for certain

materials and/or welding processes specified by the EN
Standard or the Client Specification

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• A Welder’s Qualification Certificate is prepared showing the
conditions used for the test weld and the range of qualification
allowed by the EN Standard for production welding
• The Qualification Certificate is usually endorsed by a Third
Party Inspector as a true record of the test
 Welder Qualification
(according to EN 287 )
The welder is allowed to make production welds within the
range of qualification shown on the Certificate
The range of qualification allowed for production welding is
based on the limits that the EN Standard specifies for the
welder qualification essential variables

A Welder’s Qualification Certificate automatically expires if the

welder has not used the welding process for 6 months or

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longer

A Certificate may be withdrawn by the Employer if there is

reason to doubt the ability of the welder, for example
• a high repair rate
• not working in accordance with a qualified WPS
 Welder Qualification
(according to EN 287 )
ESSENTIAL VARIABLES
Question:
What is a ‘welder qualification essential variable’ ?
(what makes the variable ‘essential’ ? )
Answer:

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A variable, that if changed beyond the limits specified by the
EN Standard, may require more skill than has been
demonstrated by the test weld
 Welder Qualification
(according to EN 287 )

Typical Welder Essential Variables

• Welding Process
• Material Type
• Electrode Type
• Material Thickness

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• Pipe Diameter
• Welding Position
• Weld Backing (an unbacked weld requires more skill)
 Welder Qualification

Numerous codes and standards deal with welder qualification,

e.g. BS EN 287.
• Once the content of the procedure is approved the next
stage is to approve the welders to the approved procedure.
• A welders test know as a Welders Qualification Test (WQT).
Object of a welding qualification test:
• To give maximum confidence that the welder meets the

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quality requirements of the approved procedure (WPS).
• The test weld should be carried out on the same material and
same conditions as for the production welds.
 Welder Qualification
Information that should be included on a welders test
certificate are:
• Welders name and identification number
• Date of test and expiry date of certificate
• Standard/code e.g. BS EN 287
• Test piece details
• Welding process.
• Welding parameters, amps, volts
• Consumables, flux type and filler classification details
• Sketch of run sequence

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• Welding positions
• Joint configuration details
• Material type qualified, pipe diameter etc
• Test results, remarks
• Test location and witnessed by
• Extent (range) of approval
 Welder Qualification

The inspection of a welders qualification test.

• It is normal for a qualified inspectors usually from an
independent body to witness the welding.
• Under normal circumstances only one test weld per welder
is permitted
• If the welder fails the test weld and the failure is not the
fault of the welder e.g. faulty welding equipment then a re-
test would be permitted.

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• The testing of the test weld is done in accordance with the
applicable code,
• It is not normal to carry out tests that test for the
mechanical properties of welds e.g. tensile, charpy and
hardness tests.
Welder Qualification

Example:
Welder
Approval

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Qualification
Certification