Welding
Welding
Procedure
Procedure
Specification
Specification
(WPS)
(WPS)
By
Sarath Chandran
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How to write a Welding Procedure Specification (WPS)
A welding procedure specification (WPS) is a written document providing direction
to the welder (or welding operator). It contains all the necessary parameters viz.
joints, base metals, filler metals, positions, preheat, PWHT, gas etc. (including
ranges, if any) under which the welding process must be performed. These
parameters are known as variables (as per ASME Section IX). Three types of
variables are mentioned in the code, these are.
1. Essential Variable.
2. Non-essential Variable.
3. Supplementary Essential variable
Essential Variables (For WPS – QG-105.1 & QW-251.2): A change in
essential variable is considered to affect the mechanical properties (other than
toughness) of the welded joint. Hence the WPS must be requalified, if the essential
variable is changed.
Supplementary Essential Variables (QG-105.3 & QW-401.1): A change
in the supplementary essential variable will affect the toughness properties of the
joint, heat-affected zone, or base material. Hence supplementary essential variables
become additional essential variables in situations where procedure qualification
requires toughness testing. When procedure qualification does not require the
addition of toughness testing, supplementary essential variables are not applicable.
Nonessential Variables (QG-105.4 & QW-251.3): Nonessential variables
are those in which a change can be made without requalification of the existing WPS,
since it is not considered to affect the mechanical properties of the joint. Though a
change in the nonessential variable doesn’t require requalification of the WPS but
still it should be properly addressed in the welding procedure specification (WPS).
Some basic facts about WPS:
A welding procedure specification shall contain, as a minimum, the specific essential
and nonessential variables that are applicable to the welding process. When the
referencing Code, standard, or specification requires toughness qualification of the
welded joint, then applicable supplementary essential variables shall also be
provided in the WPS.
These variables are listed in tables from QW-252 to QW-257. Please note that for
each welding process, there is a separate table containing the list of all variables.
For example, list of variables (essential, nonessential and supplementary essential)
for Shielded Metal Arc Welding (SMAW) is given in table QW-253.
Please see the below table (Table-1) for a complete list of welding processes and
their corresponding tables for variables (as per ASME Section IX).
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Steps to be followed for preparation of WPS:
First of all, we need to identify the welding process which is to be used for example
weather it’s a SMAW or GMAW or GTAW or any other welding process or it’s a
combination of two or more welding processes. Once the welding process is decided
then we need to see the corresponding table (QW-252 to QW-257) for the complete
list of variables. With the help of the table, we can list out all the necessary variables
to be used in our WPS.
Once the minimum variables (essential, nonessential and supplementary variable, if
any) are decided a preliminary WPS (or proposed WPS also known as pWPS) is
prepared.
Based on the proposed WPS, Test coupon (or coupons) is prepared, and the coupon
is welded as per the values (or range) provided in the pWPS. All the real time data
(observed during the welding of test coupon) are recorded.
After successful welding, test coupon (or coupons) is subjected to destructive test,
and if the test coupon (or coupons) meets the minimum code requirement then the
same pWPS is finalized and approved for further job. In case of any change same
procedure is repeated till the test coupon doesn’t meet the minimum code
requirement.
All the real time data during welding of test coupon and destructive test report data
is compiled into one document known as Procedure qualification record (PQR).
After successful preparation of PQR, final WPS is prepared and produced to the
authorized welding inspector for final approval.
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Important Articles in ASME Section IX
➢ Article I Welding General Requirements
➢ QW-150 Tension Tests
➢ QW-153 Acceptance Criteria-Tension Tests
➢ QW-160 Guided-Bend Tests
➢ QW-163 Acceptance Criteria-Guided Bend Tests
➢ QW-171 Toughness Tests
➢ QW-172 Toughness Tests-Drop Weight
➢ QW-180 Fillet-Weld Tests
➢ QW-182 Fracture Tests
➢ QW-183 Macro Examination-Procedure Specimens
➢ Article II Welding Procedure Qualifications
➢ QW-200 General
➢ QW-210 Preparation of Test Coupon
➢ QW-250 Welding Variables (Refer Table-1)
➢ Article IV Welding Data
➢ QW-400 Variables
➢ QW-401.1 Supplementary Essential Variable (Procedure)
➢ QW-402 Joints
➢ QW-403 Base Metal
➢ QW-404 Filler Metal
➢ QW-405 Position
➢ QW-406 Preheat
➢ QW-407 Post Weld Heat Treatment
➢ QW-408 Gas
➢ QW-409 Electrical Characteristics
➢ QW-410 Technique
➢ QW-420 Base Metal Groupings
➢ Table QW/QB-422 Grouping of Base Metals for Qualification
➢ QW-430 F‐Numbers
➢ Table QW-432 Grouping of Electrodes and Welding Rods for Qualification
➢ QW-440 Weld Metal Chemical Composition
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➢ Table QW-442 A-Numbers Classification of Ferrous Weld Metal
Analysis for Procedure Qualification
➢ QW-450 Specimens
➢ Table QW-451.1 Groove-Weld Tension Tests and Transverse-Bend
Tests
➢ Table QW-451.2 Groove-Weld Tension Tests and Longitudinal-Bend
Tests
➢ Table QW-451.3 Fillet-Weld Tests
➢ Table QW-451.4 Fillet Welds Qualified by Groove-Weld Tests
➢ QW-461 Positions
➢ QW-461.3 Groove Welds in Plate-Test Positions
➢ QW-461.4 Groove Welds in Pipe-Test Positions
➢ QW-461.5 Fillet Welds in Plate-Test Positions
➢ QW-461.6 Fillet Welds in Pipe-Test Positions
➢ QW-462 Test Specimen Table QW-462.1(a) to QW-462.5(e) Fig
QW-463.1(a) to QW-469.2
➢ QW-470 Etching — Processes and Reagents
➢ Article V Standard Welding Procedure Specifications (SWPSs)
Thickness range for welder qualification and
procedure qualification (ASME Section IX)
Thickness range for performance qualification (welder qualification test):
ASME BPVC Section IX has provided guidelines for the thickness range up to which
a welder can weld. This can be found in Table – QW 452.1(b) of ASME BPVC Section
IX. A simplified version of that table is given below;
According to this table, three important points can be drawn:
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The maximum thickness which a welder can weld is 2T, where T is the thickness of
the deposited weld metal on the test coupon by that welder.
There are no criteria for minimum thickness
If a welder deposits weld metal of thickness 13 mm or more (with a minimum of three
layers) then he/she qualifies for an unlimited thickness, but the maximum
thickness which the welder can weld shall not be more than that specified in
the WPS range.
For the range of outside diameter of pipes (Groove weld) for which a welder can weld
is also provided in ASME BPVC Section IX. The table which we must refer to for this
is QW 452.3. A simplified version of that table is given below.
From the above table we can conclude that.
If the outside diameter of the test coupon is less than 25 mm (or 1 inch) then the
minimum outside diameter for which the welder gets qualified is the same that of the
test coupon and the maximum outside diameter which he can weld is Unlimited.
For outside diameter, 25 mm (or 1 inch) to 73 mm (or 2-7/8 inch), the minimum
Outside diameter for which the welder gets qualified is 25 mm (or 1 inch) and the
maximum outside diameter which he can weld is Unlimited.
If the outside diameter of the test coupon is more than 73 mm (or 2-7/8 inch) then
the minimum Outside diameter for which the welder gets qualified is 73 mm (or 2-7/8
inch) and the maximum outside diameter which he can weld is Unlimited.
One very important point can be observed from this table that ASME BPVC has not
given any limitation for the maximum outside diameter, there is the only restriction
for the minimum outside diameter of the pipe which a welder can weld.
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Thickness range for procedure qualification
(Procedure qualification record):
To qualify a proposed Welding procedure specification (PWPS), we need to carry
out the procedure qualification which includes the following steps.
1. Preparation of test coupon
2. welding of test coupon and
3. sending it to the lab for destructive test
During the welding of the test coupon, all real-time data is recorded and after a
satisfactory lab test report, the welding procedure specification (WPS) gets qualified.
It is also called as procedure qualification and all the real-time welding data along-
with the lab test report is known as Procedure qualification record (PQR).
Now, we have a thickness limit for procedure qualification too. It means that a
particular welding procedure specification (WPS) gets qualified for a particular
thickness range and if we must weld beyond that thickness range then we need a
new WPS and procedure qualification.
The thickness range for which a Welding procedure specification (WPS) gets
qualified is given in ASME BPVC section IX Table QW 451.1. A simplified version of
that table is given below.
From the above table, one can easily find out the thickness range for which a Welding
procedure can be qualified or a welding engineer can prepare a welding procedure
specification (WPS) accordingly.
One important point to be noted that for performance qualification (welder
qualification) the thickness which is considered is that of the deposited weld
metal but in the case of procedure qualification, it is the thickness of the test
coupon which is considered.
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P Number, F Number and A Number in welding (ASME
Section IX)
ASME Boiler and pressure vessel code (BPVC) has assigned certain numbers to
base metals (to be welded) as well as to filler metals (electrodes).
For base metals, ASME has assigned two number system, these are.
• P Numbers
• Group Numbers
For filler metals, the number system, which is assigned, are as follows;
• F Number
• A Number
These numbers can be found in ASME BPVC Section IX, please see Table–1 for
details.
Table – 1
BASE METAL GROUPING:
The main purpose of assigning this number system is to reduce the number of
procedure qualification records (PQR). Conducting a procedure qualification
requires a lot of time and money due to the following procedural requirements.
• Preparation of test coupon
• welding of test coupon and
• sending it to a lab for destructive test
Hence, to reduce these costly and time-consuming activities, ASME has done
groupings of base metals and has assigned certain P numbers to each group of
metals. This grouping of base metals has been done on the basis of the following
parameters.
• Material composition
• Weldability
• Mechanical property
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Though all materials of the same ‘P’ number don’t exhibit the same properties, but
after considering the above-mentioned parameters, ASME has done this logical
grouping.
Why is this grouping required?
Suppose if we change the base metal from an existing qualified WPS and if the new
base metal falls in the same ‘P’ number then the requalification of the existing WPS
is not required, it means no need for a new PQR.
But this doesn’t mean that one can easily substitute the base material, from existing
WPS, of same ‘P’ number at any time. Whenever there is a change in the base
material from existing WPS, the compatibility shall be considered with regards to the
following factors.
• Metallurgical property
• Mechanical property
• Design considerations
• Service requirements
• Heat treatment
Table–2 shows the assignment groups for various metals and their alloys (according
to ASME BPVC).
Table – 2
Now that we have understood ‘P’ numbers let’s move on to the group
numbers. Group numbers are subsets of ‘P’ numbers and assigned to ferrous-
based metals. Group numbers are assigned only to those materials which require
toughness testing for the qualification of its WPS.
We will take an example of SA516 Gr 65 from table QW/QB-422 (Page – 118 of
ASME Section IX, 2017 edition), we can find out the following values;
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Base material – SA516 Gr 65
• Tensile strength (min.) – 65 Ksi (or 450 Mpa)
• P-No. – 1
• Group number – 1
• Nominal composition – C-Mn-Si
• Typical product form – Plate
Another grouping of base metals was the ‘S’ numbers, but the ‘S’ number is not used
nowadays. It was deleted from ASME in 2009.
S Numbers were assigned to those materials which were acceptable for use by the
ASME B31 Code for Pressure Piping, or by selected Boiler and Pressure Vessel
Code Cases, but were not included in section II of ASME Boiler and Pressure Vessel
(BPVC). Base metals that were previously assigned ‘S’ Numbers were reassigned
the corresponding P Numbers or P Numbers and Group Numbers.
FILLER METAL (ELECTRODE/WELDING ROD) GROUPING:
The F Number: F number grouping (for filler metals) is done to reduce the number
of welding procedure specifications (WPS) and welder performance
qualifications. The basis for F number grouping is usability characteristics. The
usability characteristics fundamentally determine the ability of a welder to produce
sound welds with a given filler metal. Hence it is assumed if a welder can make a
satisfactory weld with a particular filler metal, he will be able to weld with all
the filler metals belonging to that ‘F’ number.
Table-3 shows a summary of ‘F’ and filler metals (according to ASME BPVC, Table:
QW-432).
Table – 3
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The ‘F’ number grouping doesn’t imply that one can easily substitute the filler metal
(electrode/welding rod), from existing WPS, of the same ‘F’ number at any time.
Whenever there is a change in the filler metal (electrode/welding rod) from existing
WPS, the compatibility shall be considered with regards to the following factors.
• Metallurgical property
• Mechanical property
• Design considerations
• Service requirements
• Heat treatment
The A Number: Another type of grouping for filler metal or welding rod is the ‘A’
Number. ‘A’ number grouping has been done on the basis of the chemical
composition of the deposited weld metal. This can be found in ASME BPVC Section
IX, Table – QW-442).
Preheating – How, When and Why
Heating the base metal to a specific desired temperature before welding is called
as preheating. The temperature at which the base metal is heated is called as the
preheat temperature. Preheat temperature can be determined by the applicable
code. Please see table 1 to know how to find the preheat temperature in the
respective code:
In absence of code, the following factors shall be considered for determining the
preheat temperature; these are:
• Base metal thickness
• Surrounding temperature
• Base metal composition
• Hydrogen content of electrode
• Operational requirements
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However, in general preheat is required above 25 mm thickness, but other factors
shall always be considered before determining the preheat temperature.
Why is preheating required?
Preheating is carried out for the following reasons.
• It slows down the cooling rate of weld metal, HAZ (heat affected zone) and
adjacent base metals, which yields a good microstructure to the metal,
prevents martensite formation at microstructural level and prevents from
cracking of the weld metal and HAZ.
• Preheating removes the diffusible Hydrogen from the base metal and hence
prevents the chances of Hydrogen induced cracking (HIC).
• It helps in reducing the expansion and contraction rate.
• It Burns the unwanted material or impurities (if any) present on the joint surface.
• Preheating also helps in achieving better mechanical properties such as
notch toughness.
Oxy-fuel heating torches, Induction heaters, Infrared radiant pane heaters and
electrical heaters are commonly used for preheating a joint. It is recommended to
preheat the joint from back side (other side), to ensure that the entire volume of
metal, surrounding the joint, has been heated.
Digital infrared pyrometers (Figure 1) or thermal chalks (Figure 2) can be used for
checking the temperature of the preheated item.
Figure 1 Figure 2
Once preheating is done, welding shall be started immediately and if metal thickness
is very high or if surrounding temperature is very less or otherwise, temperature
should be checked during the welding also. The interpass temperature shall also be
maintained, to continue the subsequent weld passes.
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