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1 Welding Inspection
Welding Procedures
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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 ?
Lý do chính để thực hiện một hàn Quy trình kiểm tra Trình độ chuyên môn là những gì?
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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)
Dựa theo EN ISO 15614)
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Welding Procedure Qualification
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Welding Procedure Qualification
• A welding inspector records all the welding conditions used for the
test weld (referred to as the ‘as-run’ conditions)
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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 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
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Welding Procedure Qualification
(according to EN Standards)
•Essential variables
•Non-essential variables
•Additional variables
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the limits that the EN ISO Standard specifies for essential
variables*
(* and when applicable - the additional variables)
Welding Procedure Qualification
(according to EN Standards)
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properties* of the joint
* particularly joint strength and ductility
Welding Procedure Qualification
(according to EN Standards)
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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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SOME TYPICAL ADDITIONAL VARIABLES
• Heat Input
• Welding Position
Welding Procedures
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• 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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• Type of consumable/diameter of consumable
• Brand/classification
• Heat treatments/ storage
Welding Procedures
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•Preheat, temps
•Post weld heat treatments e.g. stress relieving
Welding Procedures
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Welding Procedures
Example:
Welding
Procedure
Specification
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Welding Procedures
PURPOSE OF A WPS
TO ACHIEVE SPECIFIC PROPERTIES
mechanical strength, corrosion resistance, composition
TO ENFORCE QC PROCEDURES
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TO FORM A RECORD
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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H-L045 6G Inclined Pipe (Upwards)
J-L045 6G Inclined Pipe (Downwards)
Welding Positions
ISO
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Monitoring 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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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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the electrical energy consumed by the arc
Monitoring Heat Input
136 Flux-cored wire metal-arc welding with active gas shield 0.8
138 Metal-cored wire metal-arc welding with active gas shield 0.8 ©
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139 Metal-cored wire metal-arc welding with inert gas shield 0.8
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
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HI = 1.2 x 0.8 = 0.96kJ/mm
CSWIP 3.1 Welding Inspection
Welder Approval
Example BS EN 287
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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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Welder Qualification
(according to EN 287 )
Dựa theo EN 287
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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
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• 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
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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:
A variable, that if changed beyond the limits specified by the
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Welder Qualification
(according to EN 287 )
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• Weld Backing (an unbacked weld requires more skill)
Welder Qualification
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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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• Test results, remarks
• Test location and witnessed by
• Extent (range) of approval
Welder Qualification
applicable code,
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• 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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Certification