Here is the shortcut to understand the step by step that how to make a WPS with

the initial information supplied from contract specification.

DEFINITION
Welding Procedure Specification (WPS) : A WPS is a written qualified welding
procedure prepared to provide direction for making production welds to code
requirements.

Procedure Qualification Record (PQR) : A PQR is a record of the welding data

used to weld a test coupon.

Test Coupon : A weld or Braze assembly for procedure or

performance qualification testing.

The coupon may be any product from plate, Pipe, tube, etc., and may be a fillet
weld, overlay, deposited weld metal, etc.

Test Specimen : A sample of a test coupon for specific test. The specimen may be
a bend test, impact test, chemical analysis, macro test, etc. A specimen may be a
complete test coupon, for example, in radiographic testing or small diameter pipe
tension testing.
REFERENCE

ASME SEC.IX Welding and Brazing Qualification

ASME SEC.II Part C: Specification for Welding Rods, Electrodes and Filler
Materials.

ASME B31.1, Power Piping

ASME B31.3, Process Piping

ASME VIII, Pressure vessel

API 1104, Welding of Pipelines and Related Facilities

AWS D1.1, Structural Steel Welding Code

API 650, Welded Oil Storage Tanks (If Necessary)

RESPONSIBILITY
The Construction Manager and QA/QC Manager are responsible for the
implement of qualification test for WPS and PQR.

Construction (Welding) Engineer is responsible for preparation and execution

of the qualification test of WPS and PQR. He is also responsible for providing of
WPS and PQR.

The QA/QC Engineer is responsible for witness, control and monitor welding
parameters during welding procedure qualification test (with Third party if
specification required- Class). He is also responsible for review the WPS and
PQR.

The QA/QC Manager or his designee is responsible for certification of WPS and
PQR
PROCEDURE
Preparation of Test coupon and welding consumables

‘Request for inspection’ of the Qualification Test shall be submitted to QA/QC

Engineer/Inspector with draft WPS.

Test coupon should be prepared in accordance with the draft WPS. And it should
have material classification including grade and heat number, and unrecognized
material shall not be used for test coupon.

The Procedure Qualification Test number and welder number or name should
be stamped on the surface of tack welded test coupon.

After preparation, test coupon shall be confirmed and verified with mill
certificate by QA/QC Engineer/Inspector.

Welding consumable such as electrodes should be stored and used according to

manufacturer instruction and Welding consumable control procedure. Before
qualification test, QA/QC Engineer/Inspector shall verify welding consumables
with mill certificate as per draft WPS.
 When all inspection and verification is completed for test coupon, install coupon
on the welding die, and QA/QC Engineer/Inspector verify coupon position (5G,
2G, etc) and mark ‘top position’ on the coupon.

Welding and monitoring

Welding should be carried out according to instruction of draft WPS.
The tools which measure the welding data shall be prepared.

Follow welding parameters as minimum shall be monitored and recorded by

QA/QC Engineer during welding of test coupon:

▪ Pre-heating
▪ Ampere and voltage for each pass
▪ Welding time to check travel speed
▪ Inter-pass temperature
▪ Welding sequence
▪ Deposit thickness for each process if multi process is used
▪ Consumable size
▪ Other essential variable if required

The welding parameters records should be verified by QA/QC Engineer/Inspector ,

if required.

Visual inspection should be done for welded coupon.

Post Weld Heat Treatment (PWHT) should be done if required.
The test coupon for AWS D1.1 radiographic test shall be done by accredited NDT
Company. However the test coupon for ASME Sec.IX the radiographic test may be
examined for information.

MT or PT examination may be done if required.

The test coupon which is accepted by visual inspection and NDT shall be sent to
accredited laboratory for the required mechanical test according to the
requirements of specification, code and standard.

If it is necessary to cut the welded coupon to several pieces because of

transportation to laboratory, it is required that PQR number, material classification
for each materials and original location of piece shall be verified by QA/QC
Engineer/Inspector.

There’re some special requirements for PQR testing depended on the project code
and specification. The detail will be discussed in further with separated topic.

An example of flowchart for reviewing a WPS/PQR based on ASME IX:

Now we will continue these steps to carry out Qualify Welder!

Welder qualification to perform the work follows an Approved WPS (

welding procedure specification. It has some steps as below:

1) Code & standard apply for testing:

In this case we use: ASME IX

2) Witness for Welder testing:

Each performance qualification welder testing shall be done under full

supervise and control by a third party. Normally, it is Classification ( ABS /
BV/ DNV-GL, LR, KR… )

This party have to sign on welder card / welder cert after the welder pass
examination.

3) Train The Welder For The Process To Be Qualified:

– Welder is trained to know skill in performing the Welding Process.
– He need have knowledge in operation of machine, precautions in storage &
usage of consumable, defects in welding, their causes and remedy.
– He practice welding in the particular position in which he is to be tested /
qualified.
 4) Testing procedure:

▪ Check WPS what is used for qualificaiton

▪ Check Essential variable for Welder testing: pls see Part 2:

Welder qualification follow ASME IX- Part 2: Essential Variable for Welder
Qualification!

5) Preparation Of Test Coupon:

Normally:

– Prepare A Test Coupon Out of 300 х 150 х (t) mm CS Plates/pipe: min

length at least 150mm
– Angle, Root Face & Root Opening Shall Be As Per The WPS
– Provide Run in & Run Out Coupon & Fix the Test Coupon In Any One Of
The Positions To Be Qualified.
– Weld The Groove Fully In The Position
– All Welding Variables Shall be Strictly Within The Qualified WPS

6) Base metal/welding material:

To follow WPS
7) Testing position:
8) Diameter of test coupon:
9) Thickness qualify:

10) Fillet weld test:

 11) Acceptance criterial:

+ Visual:

+ DT or NDT

Pls see previous part:

Welder qualification follow ASME IX- Part 1: Genenral

12) Expiration and Renewal of Qualification:

– QW-320 covers the requirements for retesting and renewing welder

qualification

– QW-322 Expiration and Renewal of Qualification:

▪ When the welder has not welded with the process within 6 months
▪ When there is a specific reason to question his ability to make welds that met
the specifications
Welding fabrication involves several operations which might have a
significant ergonomic impact.
This article aimed at providing an overview on these typical activities, and
the most confusion on terminology of Partly Mechanized and Fully
Mechanized processes during identify the welding personnel as a WELDER
or WELDING OPERATOR?

The role of welding personnel in welding processes:

Based on the level of automation, processes are defined by applicable

industrial standards as:
– Manual processes, involving welders;
– Partly mechanized (or semiautomatic) processes, involving welders;
– Fully mechanized (or automatic) processes, involving welding operators;
– Automatic and/or robotized processes, involving welding programmers,
operators.
Depending on the industrial needs, some processes may be used with
different levels of automation.

COMPARISION ON GMAW/FCAW WELDING PROCESS

Refer to EN ISO 9606-1 (manual or partly mechanized welding
processes) and EN ISO 14732 (mechanized and automatic
welding) definition:

Welder: One person who holds and manipulates the electrode holder, welding
torch or blowpipe by hand.

Welding operator: One who operates machine or automatic welding

equipment

According to EN ISO There are Two (2) Certification formats for Welder /
Operator respectively
COMPARISION ON SAW WELDING PROCESS
Refer to ASME IX (Two (2) Certification formats for Welder / Operator
respectively) definition:

Welder: One who performs manual or semiautomatic welding.

Welding operator: One who operates machine or automatic welding

equipment

Refer to AWS D1.1 (Only one (1) Certification format for Welder /
Operator) definition:

Welder: One who performs a manual or semiautomatic welding operation.

Welding operator: One who operates adaptive control, automatic,

mechanized, or robotic welding equipment.