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TABLE OF CONTENTS

1.0

SCOPE

2.0

REFERENCE

3.0

RESPONSIBILITY

4.0

DEFINITION

5.0

PROCEDURE

6.0

ATTACHMENTS
Attachment 1A

Welding Procedure Specification

Attachment 1B

Welding Procedure Specification (Continuation)

Attachment 2A

Procedure Qualification Record

Attachment 2B

Procedure Qualification Record (Continuation)

Attachment 3

Welding Procedure Qualification Test Plan

Attachment 4

Index of WPS

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1.

SCOPE
This procedure applies to the instruction for qualification and control method of the Welding
Procedures Specification (WPS) and Procedure Qualification Record (PQR) in order that the
welding work conforms to the requirements of the applicable codes and standards

2.0

REFERENCE

2.1

Site Quality Plan (6423DA060-00-00200 00)

2.2

Document Control Procedure (6423MJ050-00-00010 00)

2.3

Welding and Brazing Qualification (ASME Section IX)

2.4

Structural Welding Code-Steel (AWS D1.1)

2.5

Power Piping (ASME B31.1)

2.6

Process Piping (ASME B31.3)

3.0

RESPONSIBILITY

3.0

The Construction Manager is responsible for ;


(1) Requesting the Quality Manager to provide the required WPS.
(2) Supporting PQ Test performed by the Quality Team.

3.1

The Quality Manager is responsible for ;


(1) Ensuring that all procedure qualifications are carried out in accordance with this
procedure.
(2) Approval of WPS and certification of PQR

3.2

The Welding Engineer is responsible for ;


(1) Preparation of Welding Procedure Qualification Test Plan
(2) Preparation and maintenance of WPS and PQR
(3) Manufacturing of test specimen and request of test
(4) Preparation of test report

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(5) Review of Subcontractors WPS & PQR.

4.0

DEFINITION

4.1

WPS

Welding Procedure Specification.

4.2

PQR

Welding Procedure Qualification Record

4.3

PQT

Welding Procedure Qualification Test

4.4

Welder :

Welder or Welding Machine Operator

5.0

PROCEDURE

5.1
5.1.1

Establishment of Welding Procedure Qualification Test Plan


The Welding Engineer shall prepare the Welding Procedure Qualification Test Plan
(Attachment 3) through review of technical specifications and drawings in order to prepare
the WPS to be applied for construction work.

5.1.2

Attention shall be paid to the following during review of the technical specifications and
drawings:
(1) Limitation for the welding process
(2) Base metal
(3) Limitation for the welding material
(4) Preheat and post weld heat treatment
(5) Welding position
(6) Gas
(7) Electrical characteristic
(8) Joint design
(9) Reference to applicable approval code, i.e. ASME IX, AWS D1.1

5.1.3

The Welding Engineer shall prepare the draft WPS with all the information in accordance
with applicable Code and Standards.

The WPS (Attachment 1A & 1B) shall be approved

when the procedure qualification testing is completed and a PQR (Attachment 2A & 2B) is
certified by Quality Manager and accepted by OWNER.
5.2

The Numbering System is as follows.

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5.2.1

Welding Procedure Specification (WPS)


DZ01-

Where
DZ01 : Project Identification
1

P-No of Base Metal (refer to ASME Sec. IX)

Classification of PWHT (A: No heat treatment, P: Heat treatment)

P-No of Base Metal (refer to ASME Sec. IX)

SM :

Shielded Metal Arc Welding (SMAW)

GT

Gas Tungsten Arc Welding (GTAW)

GS :

GTAW + SMAW

FC :

Flux Cored Arc Welding (FCAW)

TG

TGX + GTAW

TS :

TGX + SMAW

ST

Stud Welding

5.2.2

: Classification of welding process (refer to following abbreviation)

: Serial number (Issue order of WPS,

Welding Procedure Qualification Record (PQR)


DZ01 -

PQR -

Where
DZ01 : Project Identification
PQR : Welding Procedure Qualification Report
1

: Serial number (ex.:

01, 02,........)

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ex. : 01, 02,........)

5.2.3

Tension Test, Bend Test, Notch-toughness Test and Hardness Test shall be performed in
accordance with ASME Sec. IX QW-150, QW-160 and QW-171.

5.3.
5.3.1

Test Preparation
The Welding Engineer shall review contractual documentation and applicable Code
requirements to identify those design and material requirements necessitating the
preparation of new welding procedure qualification.

5.3.2

The Quality Team shall give a minimum formal notice of two (2) days to OWNER prior to
commencing welding of the test coupon.

5.3.3

The PQ Test shall be performed by the skilled Welder or Welding Machine Operator.

5.3.4

The Construction Team shall prepare the test coupon for Welding Procedure Qualification
Test.

5.4

Performance of Test

5.4.1

The welder performing welding work for the PQ Test shall be under the supervision
of the Welding Engineer, and the welding work performed by other personnel shall

not

be permitted in the test area.

5.4.2
5.4.3

The Procedure qualification test may be witnessed by OWNER.


The completed procedure qualification test welds shall first be subjected to visual
inspection by Welding Engineer and OWNER.

5.4.4

The test specimens to be tested for PQ Test shall be prepared by the same method as the
applicable codes and standards by the Quality Team. The type and quantity of test
specimens shall be prepared in accordance with the requirements of applicable code,
standard and technical specification.

5.4.5

The test method and acceptance criteria shall comply with the requirements of applicable
code, standard and technical specification. If any test specimen required by applicable codes
and standards does not conform to applicable acceptance criteria, the test coupon shall be
regarded as rejected and a new test coupon shall be prepared.

5.4.6

Welded test coupons shall show complete joint penetration with complete fusion of weld
metal and base metal in accordance with the applicable code requirements.

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5.4.7

Welder who is involved in the welding of a procedure qualification which is subsequently


proved to be acceptable will automatically be qualified to carry out that procedure weld
requirements/criteria/range.

5.5

5.5.1

Welding Procedure Qualification Record (PQR)


The PQR shall be prepared by the Welding Engineer who supervised the PQ Test
and the test results. The original reports of the WPS and PQR which ha recorded test results
shall be submitted to OWNER for approval.

5.5.2

The actual variables used during the welding of the test coupons are recorded on a
PQR. The completed PQR shall be documented with all essential and supplementary
essential variables (when required) for each welding process. A separate data run
sheet shall be attached to PQR as applicable.

5.5.3

The nonessential or other variables used during welding of test coupon may be recorded
on the PQR.

5.5.4

Variables shall be followed as required by the code and technical specification.

5.5.5

The PQR shall be certified by the Quality Manager.

5.5.6

Any other Daewoo E&Cs PQRs that meet the contract criteria and applicable code
requirements shall be considered acceptable for this project..

5.6

5.6.1

Welding Procedure Specification (WPS)


The Welding Engineer shall prepare the WPS to be used for the permanent welding
based on the PQR certified. The WPS shall be submitted to OWNER for approval.

5.6.2

The WPS shall describe all essential, supplementary essential (if required) and
non-essential variables for each welding process specified in applicable code and standard
and all requirements of the technical specification.

The WPS shall include supporting

PQR number(s).

5.6.3

The Welding Engineer shall prepare and maintain an Index of Welding Procedure
Specification (Attachment 4) which identifies qualified Welding Procedure Specification

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5.6.4

All WPS and Index of Welding Procedure Specification shall be distributed in accordance
with the Document Control Procedure.

5.6.5

When there is a specific reason to question the Welding Procedure Specification, the
Quality Manager or the OWNER representative may require re-qualification.

5.7

5.7.1

Records
All WPS and PQR and related data of qualification shall be maintained on file by the
Welding Engineer.

5.7.2

All WPS and PQR and related data of qualification shall be controlled as QA Records in
accordance with the Quality Records Control Procedure.

6.0

ATTACHMENTS
Attachment 1A

Welding Procedure Specification (WPS)

Attachment 1B

Welding Procedure Specification (WPS) - Continuation

Attachment 2A

Welding Procedure Qualification Record (PQR)

Attachment 2B

Welding Procedure Qualification Record (PQR) - Continuation

Attachment 3

Welding Procedure Qualification Test Plan

Attachment 4

Index of Welding Procedure Specification

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Attachment 1A

WELDING PROCEDURE SPECIFICATION(WPS)

Project

name

AOFP

Project

NO.

DZ01

Prepared by
Checked by
Approved by

WPS No.:

Rev:

Date

Supporting PQR No(s)


Welding Process(es)

Type(s)

Applicable Code
Joints (QW402)
Joint Design:
Backing:

Yes

No

Backing Material
JOINT DETAIL (TYPICAL

Other
Base Metal (QW-403)
P. No.:

Group No:

to P. No

Group No:

Specification Type & Grade

to

Chem. Analysis & Mech. Prop.

to

Thickness Range:

Fillet

Pipe Dia. Range:


Other
Filler Metals (QW-404)

Root / Fill

F. No:

A. No.

Spec No. (SFA)

AWS. No. (Class)

JIS No.

Size:
Deposited Weld Metal
Brand Name of Electrode or Filler Metal
Wire Type for GMAW
Electrode-Flux (Class)
Brand Name of Flux
o

Drying Condition: Temp


Other
Position (QW-405)
Position of Groove
Welding Progression :

Up

Down

Position of Fillet
Other

6423DA060-005-01A(0)

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Time

hours

Attachment 1B

WELDING PROCEDURE SPECIFICATION (WPS)


Contd/...

Project name

AOFP

WPS NO

Preheat:(QW-406)

Post Weld Heat Treatment ;(QW-407)

No

Yes
o

Preheat Temp:
Interpass Temp;

Yes

No

Post Heat Temp

Holding Time

min

C
o

Method

Method

Other:

Other

Gas (QW-408)
Shielding Gas(es)

Flow Rate:
%

Percent Composition

L /min

No

Yes

Gas Backing

Trailing Shielding Gas Composition

Other
Electrical Characteristics & Technique (QW-409)
Tungsten Electrode Size

mm

Type

Mode of Metal Transfer for GMAW


Electrode Wire Feed Speed Range
Technique (QW-410)
Bead:

String

Weave

Initial & Interpass Cleaning:

Pass (per side )

Orifice or Gas Cup Size

Brushing

Multi

Grinding

Single

mm
Other

Electrode:

Method of Back Gouging

Brand

Singl

Travel
Speed

Current

Welding
Process

Other
Filler Metal

Weld
Layer

Multi

Class

Dia: (mm)

Type Polarity

6423DA060-005-01B(0)

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Amperage
Range

Voltage
Range

Range
(cm/min)

:
Attachment 2A

WELDING PROCEDURE QUALIFICATION RECORD


(PQR)
PQR No.

Project name
Project NO
Prepared by
Checked by
Certified by

AOFP
DZ01

Date:

WPS No.

Date:

Welding Process(es)
Type (Manual, Automatic, Semi-Auto.)
Applicable Code
Joint/ Design of Test Coupon (QW-402)
Material
Backing
No
Yes

BASE METALS (QW-403)


Material Spec

POSTWELD HEAT TREATMENT (QW-407)


Temperature

Type of Grade
P. No

Time
to P. No

Thickness

Other
mm

Diameter
Other
FILLER METALS (QW-404)
Weld Metals Analysis A. No.

GAS (QW-408)
Shielding

Size of Electrode

Type of Gas or Gases

Filler Metal F. No.

Flow Rate

SFA Specification

Composition of Gas Mixture

AWS Classification

Other

Trailing

Backing

Brand Name
POSITION (QW-405)

ELECTRICAL CHARACTERISTICS (QW-409)

Position of Groove

Current

Weld Progression (Uphill, Downhill)

Polarity

Other

Amps.
Tungsten Electrode Type

PREHEAT (QW-406)

TECHNIQUE (QW-410)
Travel Speed

Preheat Temp

String or Weaver Bead


Oscillation

Interpass Temp.

Multiple or Single Pass (per side)

Other

Single of Multiple Electrode


Other

6423DA060-005-02A(0)

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Volts
Size

Attachment 2B

(QW-483)
PQR No. :
Tensile Tests (QW-150)
Specimen

Width

Thickness

Area

No.

mm

mm

mm

Ultimate

Ultimate

Character of

Total Load

unit Stress

Failure &

Kg

kg/mm

Location

Guided Bend Tests (QW-160)


Type & Specimen No.

Specimen
No.

Notch
Location

Result-Satisfactory :
Macro-Result

Notch Type

Yes

Result

Toughness Tests (QW-170)


Test Temp.
Impact
Lateral Exp.
Values
% Shear
mm

No

Fillet Weld Test (QW-180)


Penetration into Parent Metal : Yes

Drop Weight
Break

No Break

No

Other Test
Type of Test
Deposit Analysis
Welder Name

Stamp No.

Tests conducted by

Laboratory Test No.

Witnessed

We certify that the statements in this record are correct and that the test welds were prepared welded and tested in
accordance with the requirements of _______________________________________
(Applicable Code)

6423DA060-005-02B(0)

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Attachment 3

Welding Procedure Qualification Test Plan

Seq.
No

PQR No

Base Metals(ASTM)

P-No

Group
No

Filler
metals
(AWS)

Qualified thickness (mm)


PWHT
(time)

Type and number of tests required

Impact

( )

Material

6423DA060-005-03(0)

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GTAW

SMAW

GTAW +
SMAW

Tension

Face
bend

Remarks
Root bend

Impact(B/W/H)

Attachment 4

INDEX OF WPS

S/N

WPS No.

Supporting

P-NO

Thickness

PQR No.

(GR No.)

Range (mm)

6423DA060-005-04(0)

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Base Metal

Filler Metal

PWHT

Impact

Temp.( )

Remarks