WPS/PQR

153 Slides

30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 1

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A Welding Procedure is a recipe of variable welding
parameters, which will produce the same results of certain
quality & properties of weld if carried out in the same way
eachh time
ti
Or a procedure which has been welded and tested to a
specification such as ASME IX.

Welding procedure qualification established the properties of

weldment NOT the skill of the welder.
‰ It is a document of a qualified welding procedure
‰ used to give a welder the information which he
needs in order to carry out the work.
‰ It has been issued
iss ed as a res
result
lt of a ssuccessful
ccessf l
Welding Procedure test (WP test).
‰ Additional
ddi i l WPS’s can be b issued
i d on a successful
f l
WP test as long as they remain within the Extent
off Approval.
l

30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 3

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Drawing Draft WPS
Construction Code From all range of Welding of a
welding variables test coupon
Materials
9Essential; f
from th
the
Design
9 Nonessential; Range of
Impact testing variables
ABC 9 Supplementary
PWHT etc (if applicable).
applicable)

ABC WPS ABC PQR

W ldi
Welding Record of Record of welding variables
variables actual variable
9 Essential; and test results
9 Nonessential; certification
9 Supplementary 9Specimen preparation
(if applicable). Date
9Mechanical test
sign
9Documentation
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Once the welding of test coupon has been completed under
some welding variables , No Radiography or any
examination required
The test coupons shall be Mechanically tested to ensure that
the desired level of mechanical pproperties
p have been met

If all the desired properties have been met, then a procedure

qualification record (PQR) is completed with all the test
results reviewed, and the draft WPS then becomes qualified
From thi
F this data,
d t a workable
k bl document
d t for
f production
d ti weldingldi is
i
prepared and called a Welding Procedure Specification. (WPS)
and the welding work may proceed.
 QW-200.1 Each manufacturer and contractor shall
prepare written Welding Procedure Specifications which
are defined as follows.
(a) Welding Procedure Specification (WPS). A WPS
i a written
is i qualified
lifi d welding
ldi procedure
d preparedd to
provide direction for making production welds to Code
requirements The WPS or other documents may be
requirements.
used to provide direction to the welder or welding
operator
p to assure compliance
p with the,Code require-
q
ments.

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 QW-200.2 Each manufacturer or contractor shall be
required to prepare a procedure qualification record
which is defined as follows.
QW-200(a) Procedure Qualification Record (PQR). A
PQR iis a recordd off the
h welding
ldi data
d usedd to weld ld a test
coupon. The PQR is a record of variables recorded
during the welding of the test coupons.
coupons It also contains
the test results of the tested specimens. Recorded vari-
ables normallyy fall within a small range
g of the actual
variables that will be used in production welding.

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The terms “manufacturer” or “contractor” are:
9 Own the certificate of authorization,, can be a
conventional or a nuclear stamp(s), where required
9 Responsible for the welding
9 Can be an installer, assembler or fabricator
9 Can be an organization effective operational control of
welding qualification for TWO or more companies of
different name, see QW 201.

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‰ Question (1): If Company A reviews and approves
Section IX qualified WPS’s submitted by Companies B
and C for a given project, may Company A use Company
B and C‘s WPS’s?
‰ Reply
R l (1):
(1) No.
N
‰ Question (2): If Company A reviews and approves
S ti IX qualified
Section lifi d WPS’s
WPS’ submitted
b itt d Companies
C i B andd
C for a given project, may Company A authorize
company B to use Company C C‘ss WPS’s
WPS s on that project?
‰ Reply (2): No.

30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 9

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‰Question: May a contractor provide his qualified
welding
we d g procedure
p ocedu e spec
specifications,
ca o s, for
o use by hiss
subcontractors, to perform welding in accordance
with the requirements
q of ASME BPV Code
Section IX?

‰Reply: No.

30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 10

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‰ Question: In a contract involving piping construction work,
our company subcontracted the piping prefabrication work to a
subcontractor. This subcontractor is managedg by y our company
p y
but has a different name. The subcontractor proceeded to
qualify welding procedures which were conducted in the
presence and with the approval of our company’s welding
engineer
i who
h monitored
i d the
h welding
ldi off the
h test coupons andd
signed approval on the PQRs. The Quality Control System of
the subcontractor and our company fully described the
operational
e ti l controlt l off procedure
ed e qualifications.
lifi ti W our client
Was lie t
right in rejecting the use by our company of the subcontractor
qualified welding procedures for the erection work of the
prefabricated piping?
‰ Reply: This is a contractual issue, which ASME does not
address.

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‰ Three construction companies have participated in a
nuclear power plant construction project as a consortium
contractor. They have a unified Quality Assurance
Program, but the consortium does not hold a Certificate
of Authorization.
Authorization Each of the construction companies
holds its own Certificate of Authorization.
‰ Question: Does “two
two or more companies of different
names in an organization” in QW-201 apply to the
consortium described in the Background?
g
‰ Reply: No

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‰ Background Two companies are contracted by a client
company to undertake pipe work installation on its facility. All
stages
g of the Welding g Procedure QQualification Processes for
the two contracted companies are witnessed by the client
companies representative and the documentation duly stamped
and signed as accepted by the client.
‰ Question (1): May these procedures be used by the client
company?
‰ Reply
p y ((1):
) No.
‰ Question (2): Does the client company have to re-qualify these
procedures in order to perform in-house maintenance a t a later
date using all the same essential and nonessential variables
with its own qualified welders?
‰ Reply (2): Yes.

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 WPSs may be used by the new owner(s) without
requalification, provided all of the following are met:
(a) the new owner(s) takes responsibility for the WPSs and
PQRs
(b) the WPSs reflect the name of the new owner(s)
(c) the Quality Control System/Quality Assurance Program
reflects the source of the PQRs as being from the former
manufacturer or contractor

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‰ Background: Company A and Company B merge
divisions to form a new Company, C.
‰ Question (1):May the new Company C , use PQRs and
WPSs developed previously by Company A and
Company B?
‰ Reply (1): Yes, provided operational control is in
accordance with QW-201.
‰ Question (2): May the new Company, C, use the central
materials laboratory of Company A to develop WPSs and
PQRs?
‰ Reply (2): Yes, provided operational control is in
accordance with QW-201.
Q
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‰ Background: When one of a company' s plants is sold, it
is not clear if the new owner can use the Welding
Procedure Specifications (WPS) and Procedure
Qualification Records (PQR) qualified by the original
company when the original company wishes to continue
company.
using those WPS/PQR.
‰ Question: Company A sells one of its plants to Company
B. May both Company A and Company B use the
WPSs/PQRsQ ppreviously y qqualified by
y Company
p yA
‰ Reply: Yes. provided the requirements of QW-201.1 are
addressed by Company B.
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30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 17
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 (b)Contents
(b)C t t off the
th WPS.
WPS The
Th completedl t d WPS shall
h ll
describe all of the essential, nonessential, and, when
required, supplementary essential variables for each
welding process used in the WPS. These variables are
listed in QW-250 through QW-280 and are defined in
Article IV, Welding Data.
The WPS shall reference the supporting Procedure
Qualification
lifi i Record(s)
d( ) (PQR)
( ) described
d ib d in
i QW-200.2.
The manufacturer or contractor may include any other
information in the WPS that may be helpful in making
a Code weldment.

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 QW-401.1 Essential Variable
(Procedure) A change in a welding
(Procedure).
condition which will affect the mechanical
properties
ti (other
( th than
th notcht h toughness)
t h ) off
the weldment (for example, change in P-
Number, weld- ing process, filler metal,
electrode,, ppreheat or p
postweld beat
treatment, etc.).

30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 19

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 QW-401.3 Supplemental Essential Variable (Procedure). A change in
a welding condition which will affect the notch-toughness properties of a
weldment (for example, change in welding process, uphill or down vertical
welding heat input,
welding, input preheat or PWHT,
PWHT etc.).etc )
When a procedure has been previously qualified to satisfy all
requirements other than notch toughness, it is then necessary only to prepare
an additional test coupon using the same procedure with the same essential
variables,
i bl butb t additionally
dditi ll with ith all
ll off the
th required
i d supplementary
l t essential
ti l
variables, with the coupon long enough to provide the necessary notch-
toughness specimens.
When a pprocedure has been ppreviously y qqualified to satisfy
y all
requirements including notch toughness, but one or more supplementary
essential variable is changed, then it is only necessary to prepare an
additional test coupon using the same welding procedure and the new
supplementary essential variable(s), with the coupon long enough to
provide the necessary notch-toughness specimens. If a previously qualified
weld procedure has satisfactory notch-toughness values in the weld
metal, then it is necessary only to test notch-toughness specimens from the
heat affected zone when such are required.
required

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 QW-401.4 Nonessential Variable (Procedure). A
change in a welding condition which will not affect
the mechanical properties of a weldment (such as joint
design, method of back gouging or cleaning, etc.)

30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 21

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 ((c)) Ch
Changes to
t the
th WPS.
WPS Changes
Ch may be
b made d ini the
th
nonessential variables of a WPS to suit production
requirements without requalification provided such
changes are documented with respect to the essential,
nonessential, and, when required, supplementary essen-
tial variables for each process. This may be by amend-
ment to the WPS or by use of a new WPS.
Changes
h i essential
in i l or supplementary
l essential
i l (when
( h
required) variables require requalification of the WPS
(new or additional PQRs to support the change in
essential or supplementary essential variables).

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 Question: Does QW-200.l(c) require that there be a history
of changes such as margin notes or other record
documenting what specific changes were made in the
essential, nonessential, or supplemental variables each time
a WPS is revised?
Reply: No.

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 (d) Format of the WPS. The information required to be in the
WPS may be in any format, written or tabular, to fit the needs of each
manufacturer or contractor,
contractor as long as every essential
essential, nonessential,
nonessential
and, when required, supplementary essential variables outlined in
QW-250 through QW-280 is included or referenced.
Form QW-482 (see Nonmandatory Appendix B) has been
provided as a guide for the WPS. This Form includes the required
data for the SMAW, SAW, GMAW, and GTAW p processesIt is onlyy
a guide and does not list all required data for other processes. It also
lists some variables that do not apply to all processes (e.g., listing
shielding gas which is not required for SAW). The guide does not
easily lend itself to multiple process procedure specification (e.g.,
GTAW root with SMAW fill).

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30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 25
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Each manufacturer or contractor shall maintain a record of
the results obtained in welding procedure and welder and
welding operator performance qualifications. These
records shall be certified by a signature or other means as
described in the manufacturer’s
manufacturer s or contractor’s
contractor s Quality
Control System and shall be accessible to the Authorized
Inspector. Refer to recommended Forms in Non
mandatory Appendix B.

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Question: Is it acceptable to satisfy the requirements of QW-
103.2 for record maintenance, certification, and
accessibility by means of an electronic storage medium, e
.g., computer database?

Reply: Section IX does not address the media in which

records
d are required
i d to
t be
b maintained.
i t i d

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30 เมษายน 53 ASME Section IX, WPS/PQR Prepared by 28
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OFW Oxyfuel Gas Welding
SMAW Shield Metal-Arc Welding
SAW Submerged-Arc Welding
GMAW Gas Metal
Metal-Arc
Arc Welding
&FCAW & Flux-Core-Arc Welding
GTAW Gas Tungsten-Arc Welding
PAW Plasma-Arc
Plasma Arc Welding
ESW Electroslag Welding
EGW Electrogas Welding
EBW Electron Beam Weldingg
Stud & Inertia and Continuous Drive Friction Welding
Resistance Welding
LBW Laser Beam Weldingg
Flash Welding
Each welding process has its own welding variables (table QW-252 to 265)

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 QW-250 WELDING VARIABLES
QW-251 General
QW-251.1 Types of Variables for Welding
Procedure Specifications (WPS). These variables
(listed for each welding
elding process in tables QW-
QW
252 through QW-265) are subdivided into
essential variables,, supplementary
pp y essential
variables, and nonessential variables (QW-401).
The "Brief of Variables" listed in the Tables are
for reference only.
only See the complete variable in
Welding Data of Article IV.

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Question (1): Is it required that all of the essential and nonessential
variables listed in QW
QW-250
250 through QWQW-280280 for each welding process be
addressed in the WPS, even though some of these variables are not
applicable?
li bl ?
Reply (1): Yes.
Yes

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 QW-250 WELDING VARIABLES
QW-251.4 Special Processes
(a) The special process essential variables for corrosion
corrosion- resistant
and hard-surfacing weld metal overlays are as indicated in the
following tables for the specified process. Only the variables
specified, for special processes shall apply. A change in the
corrosion-resistant
i i t t or hardsurfacing
h d f i welding ldi process shall
h ll require
i
requalification.
QW-218 Applied Linings
QW 218 1 WPSs
QW-218.1 WPS forf attaching
tt hi applied
li d linings
li i shall
h ll be
b qualified
lifi d
in accordance with QW-202.2(a), (b), or (c).
QW-219 Flash Welding
Fl h welding
Flash ldi shall
h ll be
b limited
li it d to
t automatic
t ti electrical
l t i l resistance
it
flash welding of tubular cross-sections. Procedure qualification tests
shall be conducted in accordance with QW-199.1.

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QW-252 OFW QW-258 ESW
QW-252.1 OFW (special process) QW-258.1 ESW (special process)
QW-253 SMAW QW-259 EGW
QW 253 1
QW-253.1 SMAW (special
( i l QW 259 1
QW-259.1 EGW (special
( i l process))
process) QW-260 EBW
QW-254 SAW QW-261 Stud Welding
QW-254.1 SAW (special process) QW-262
Q Inertia and Continuous
QW-255 GMAW and FCAW Drive Friction Welding
QW-255.1 GMAW and FCAW QW-263 Resistance Welding
(special process) QW-264 LBW
QW 256
QW-256 GTAW QW-264 1
QW-264.1 LBW (special process)
QW-255.1 GTAW (special QW-265 Flash Welding
process) QW-290.4 Temper Bead
QW-257 PAW
QW 257 1
QW-257.1 PAW (special process)

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