200 Welding Qualification

Abstract
This section describes the development of a welding procedure specification, the
qualification of that specification, and the qualification of the welder using that
specification. It focuses on the ASME Boiler and Pressure Vessel Code, Section IX,
because this code is most frequently used for qualifying weld procedures and
welders (except for pipelines, offshore structures and shipbuilding).

Contents Page

210 Introduction 200-2

220 ASME Section IX 200-2
221 Welding Procedure Specification (WPS)
222 Procedure Qualification Record (PQR)
223 Articles of Section IX
230 Welding Procedure Qualification 200-4
240 Welding Procedure Variables 200-5
241 Variables
242 Variable Groupings
243 Essential Variables
250 Welder Performance Qualification 200-10
251 Performance Qualification Tests
252 Test Coupons
260 Welder Performance Variables 200-11
270 Company Qualified Welding Procedures 200-11
271 WPS Form
272 PQR Form
280 New Welding Procedure Qualifications 200-13

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210 Introduction
It is often mandatory to use qualified welders and procedures to meet codes and
standards. Even when not required, this practice is advisable. Qualifying welders
and procedures provides a standard for quality as well as agreement between the
fabricator and the user, whether welding is done by an outside contractor or by
Company personnel.
Figure 200-1 shows the relationships between various Company welding applica-
tions, their appropriate fabrication code, and the document that therefore governs
the welding qualification. Figure 200-2 illustrates the steps necessary to qualify
welding procedures and welders, and where to find this information within the
section.

Fig. 200-1 Relationship of Welding Applications and Welding Qualification Requirements

Application Fabrication Code Code to Qualify Welding
Boilers and pressure vessels ASME Sections I and VIII ASME Section IX
Oil storage tanks API 650 ASME Section IX
Pressure piping ANSI/ASME B31.3 ASME Section IX
Power piping ANSI/ASME B31.1 ASME Section IX
Pipelines ANSI/ASME B31.4 API 1104(1)
and B31.8 ASME Section IX
Pipeline maintenance welding API 11071 API 11071
Offshore steel structures AWS Code D1.1 AWS Code D1.1
Ship construction ABS Rules ABS Rules
(1) Company preference

This section discusses welding qualifications using ASME Code Section IX as the
model. For a discussion of welding qualification for pipelines, see Section 600 of
the Pipeline Manual. For offshore structures, see Section 600 of this manual.

220 ASME Section IX

ASME Code Section IX specifies the qualification of both the procedures
employed in welding and the performance of welders and welding operators. Qual-
ified welding procedures are divided into two parts:
Welding Procedure Specification (WPS)
Procedure Qualification Record (PQR)

221 Welding Procedure Specification (WPS)

The WPS is an instruction sheet for performing the welding. It provides written
directions for welding to assure compliance with the Code and other requirements.
Each WPS is required to describe all of the variables for the specified welding

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Fig. 200-2 Flow Chart for Qualification of Welding Procedures and Welders

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process. For a blank WPS form, see Appendix D; for an example of a completed
form, see Section 271.

222 Procedure Qualification Record (PQR)

The PQR is a record of the welding data used to weld a test coupon according to the
variables outlined in a specific WPS. The coupon is tested mechanically to verify
the properties of the weld. The PQR also contains the test results for the test speci-
mens. For a blank form, see Appendix D; for an example of a completed form, see
Section 272.

223 Articles of Section IX

Section IX is divided into two parts: Part 1: Welding, and Part 2: Brazing (not
covered in this manual). Section IX contains four articles covering welding:
Article I Welding General Requirements
Article II Welding Procedure Qualifications
Article III Welding Performance Qualifications
Article IV Welding Data

Article I covers the general welding qualification requirements concerning test

positions for groove and fillet welds, types of tests and examinations, and accep-
tance criteria.
Article II covers the requirements for qualification of welding procedures. The
WPS and PQR are also defined and discussed. The welding variables are explained
and listed for each welding process.
Article III covers the requirements for welding performance qualification. The
qualification requirements for welders and welding operators are explained and
listed for each welding process.
Article IV covers the welding data referred to in the other articles. All of the
welding variables for welding procedure specifications and welder qualifications are
listed. Also listed are the test specimen requirements and thickness limits for qualifi-
cation of welding procedures and welders. A graphics section is included that illus-
trates test positions, position and diameter limitations for performance
qualifications, test specimen dimensions, removal of test specimens, test jigs, and
test joints. A section on weld etching and definitions of common terms relating to
welding is also included.

230 Welding Procedure Qualification

Welding procedure qualification consists of two steps: (1) a WPS must be devel-
oped for the desired welding job; and, (2) a PQR must be prepared to document that
the procedure outlined in the WPS can meet the required mechanical properties.

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Each WPS must list the supporting PQR; more than one PQR may be used for each
WPS to increase its range of application. This is done because recorded welding
variables in the PQR normally only fall within a small range of the actual variables
that may be used in production. Therefore, in order to use a single WPS, it may be
necessary to develop more than one PQR. For example, if more than one welding
process is needed for a production joint, separate PQRs can be prepared for each
process and combined into one WPS.
PQRs are required to be certified by the manufacturer or contractor as a true record
of the welding variables, and must certify that the test results are in compliance with
Section IX. Changes to PQRs are normally not permitted except for editorial
changes that do not require recertification.

240 Welding Procedure Variables

241 Variables
Welding variables in Section IX are categorized as being one of three types: essen-
tial, nonessential, and supplementary essential. Changes in essential variables
require that the welding procedure be requalified. Changes in nonessential vari-
ables require only that the WPS be amended to reflect the change. Supplementary
essential variables cover impact testing requirements and are considered essential
variables when those tests are required; otherwise, they are considered to be nones-
sential.
To determine the variable type, consult the ASME Code Section IX, Tables QW-
252 through QW-262. (See Figure 200-3 and Figure 200-4 for examples of Tables
QW-253 and QW-253.1.)
Variables include things like base metal type, filler metal type, thickness, welding
position, electrical characteristics, joint type, heat treatment, etc. They are placed in
one of the three categories, based on the welding process used. A more detailed
description of each variable is given in the paragraph in the Code that is referenced
by the table.
Several variables, such as groove design, filler metal diameter, and welding posi-
tion, are listed in the table as nonessential (as long as impact tests are not required).
Any of these nonessential variables may be changed without requalifying the
welding procedure. However, should an essential variable be changed, then a new
WPS must be developed and qualified.

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Fig. 200-3 Essential, Nonessential, and Supplementary Essential Variables for the SMAW Process (Table QW-253,
ASME Section IX) (Courtesy of ASME)
QW-253WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)
Shielded Metal Arc Welding (SMAW)
Supplementary
Paragraph Brief of Variables Essential Essential Nonessential
.1 Groove design X
.4 Backing X
QW-402
Joints .10 Root spacing X
.11 Retainers X
.5 Group Number X
.6 T Limits impact X

QW-403 .7 T/t Limits > 8 in. X

Base metals .8 T Qualified X
.9 t Pass > 1/2 in. X
.11 P-Number qualified X
.13 P-Number 9/10 X
.4 F-Number X
.5 A-Number X

QW-404 .6 Diameter X
Filler metals .7 Diam. > 1/4 in. X
.12 AWS class X
.30 t X
.33 AWS class X
.1 + Position X
QW-405
.2 Position X
Positions
.3 Vertical welding X
.1 Decrease > 100F X
QW-406
.2 Preheat maint. X
Preheat
.3 Increase > 100F (IP) X
.1 PWHT X
QW-407
.2 PWHT (T & T range) X
PWHT
.4 T Limits X
QW-409 Electrical .1 or > heat input X
characteristics
.4 Current or Polarity X X
.8 Type or & E range X
.1 String/weave X
.5 Method cleaning X
QW-410
Technique .6 Method backgouge X
.25 Manual or automatic X
.26 Peening X
Legend: Change
+ Addition Deletion
> Increase/greater than < Decrease/less than
Uphill Downhill
Forehand Backhand

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Fig. 200-4 Welding Variables Procedure Specifications (WPS) Shielded Metal-Arc (SMAW) (Table QW-253.1, ASME
Section IX) (Courtesy of ASME)
QW-253.1WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)
Shielded Metal-Arc (SMAW)
Special Process Essential Variables
Hardfacing Overlay Corrosion-Resistant Overlay
Paragraph (QW-216) (QW-214)
QW-402 Joints .16 < Finished t < Finished t
QW-403 .20 P-Number P-Number
Base Metals .23 T Qualified T Qualified
.12 AWS class
QW-404
.37 A-Number
Filler Metals
.38 Dia. (1st layer) Dia. (1st layer)
QW-405 .4 + Position + Position
Positions
QW-406 .4 Dec. > 100F preheat Dec. > 100F preheat
Preheat > Interpass > Interpass
QW-407 .6 PWHT PWHT
PWHT
QW-409 Electrical .4 Current or polarity Current or polarity
Characteristics
.22 Inc. > 10% 1st layer Inc. > 10% 1st layer
QW-410 .38 Multi- to single-layer Multi- to single-layer
Technique
Legend:
+ Addition
- Deletion
> Increase/greater than
< Decrease/less than
Change

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242 Variable Groupings

The variables are further classified within each category as follows:
P-numbers
Group Numbers
F-numbers
A-numbers
P-numbers. To reduce the number of welding procedure qualifications required,
P-numbers have been assigned to base materials based on characteristics such as
composition, weldability and mechanical properties. The P-number is an essential
variable for all welding processes listed in Section IX. Many materials are covered
by a single P-number. For example, Types 304, 309, 316, 316L, 321, and 347 stain-
less steel, among others, all have P-number 8. Therefore, for a welding procedure
qualified on Type 304 stainless steel, any of these other base metals with P-number
8 may be welded using that same procedure without requalification. All that is
required is that the WPS be amended to reflect the change.
Examples of P-numbers for different materials as listed in Section IX Table
QW-422 are:
Material P-Number
SA-285 Gr C (carbon steel) 1
SA-204 Gr C (C-1/2 Mo) 3
SA-387 Gr 11 (1-1/4 Cr-1/2 Mo) 4
SA-387 Gr 22 (2-1/4 Cr-1 Mo) 5
SA-240, Type 410 (13 Cr) 6
SA-240, Type 410S (13 Cr, low C) 7
SA-240, Type 304 8

Group Numbers. Group numbers are assigned for steel and steel alloys for proce-
dure qualifications where notch toughness requirements are specified.
F-numbers. F-numbers have been developed to categorize filler metals. F-number
groupings are based primarily on usability characteristics. For example, E6010 elec-
trodes have F-number 3 while E7018 (low hydrogen) electrodes have F-number 4,
because different welder abilities are required for each of these filler metals. A
complete listing of F-numbers appears in QW-432.
A-numbers. A-numbers have also been developed to categorize filler metals.
A-number groupings are based on chemical composition. For example, A-number 1
is for mild steel filler metal, A-number 2 is for carbon-molybdenum steel,
A-number 3 is for low chromium-molybdenum steel, etc. A-numbers are listed in
QW-442.

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243 Essential Variables

The essential variables given for the welding processes commonly used by the
Company (SMAW, GTAW, GMAW and SAW) are summarized in Table QW-415
of Section IX, and are briefly described below. The Code should be consulted for a
full understanding of the essential variables for these and other welding processes.
Base material. A change in base material from one P-number in Table QW-422 to
another P-number, or to a material not listed, requires requalification. When welds
are made between two base metals that have different P-numbers, requalification is
required even though the two base metals have been independently qualified using
the same procedure. An exception to this is for base metals of P-numbers 1, 3, 4 and
5 Grp 1 (2-1/4 Cr-1 Mo and 3 Cr-1 Mo). For these base materials, a procedure qual-
ification test with one P-number metal is also qualified for that P-number metal
welded to each of the lower P-number metals, but not vice versa.
Filler metal. Changes in filler metal F-number (usability characteristic) or A-
number (chemical composition) require requalification except that qualification
with A-number 1 (mild steel) also qualifies A-number 2 (carbon-moly) and vice
versa.
Impact testing. For procedures where impact testing is not required, qualification
performed in any position qualifies for all other positions providing the welding
process and welding consumables are compatible with those positions.
Change in process. A change from one welding process to another process or
combination of processes requires requalification. However, more than one welding
process can be used for a procedure if each process has been qualified separately or
in combination, within the thickness limits of the Code. See QW-200.4.
Change in groove design. Welding procedures qualified on groove welds qualify
for fillet welds, but not vice versa. Test welds made with either plate or pipe
coupons qualify welding for both plate and pipe. Groove design is not an essential
variable, but the type of groove (i.e., Vee-groove, U-groove, single bevel, double
bevel, etc.) must be shown in the WPS.
Preheat temperature. A decrease in preheat temperature of 100F or more requires
requalification.
PWHT. The addition or deletion of postweld heat treatment requires requalifica-
tion.
PWHT time. Increasing the holding time for postweld heat treatment does not
require requalification except where impact testing is a requirement (test coupon
must have at least 80% of the aggregate time of the production weld).
Thicknesses. Qualification on thicknesses less than 1-1/2 inches qualifies for thick-
ness up to two times the thickness of the PQR test coupon, and qualification on
thicknesses 1-1/2 inches and over qualifies for thicknesses up to 8 inches (the ranges
are defined in Table QW-451.1).

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Shielding gas. In gas shielded welding, a change of shielding gas composition or

omission of shielding gas requires requalification.
Number of passes. A change from multiple passes per side to single pass per side
does not require requalification except when impact testing is a requirement.

250 Welder Performance Qualification

Welder performance qualification requirements are different and less stringent
than welding procedure qualification requirements. The purpose of welder perfor-
mance qualification is to determine the ability of the welder to deposit sound weld
metal. Similarly, welding operator performance qualification is used to determine
the mechanical ability of the welder to operate fully automatic or machine guided
equipment.

251 Performance Qualification Tests

The purpose of these tests is to determine the ability of welders and welding opera-
tors. Each welder must be qualified for each welding process and position used in
production welding. The performance qualification test is to be performed in accor-
dance with the variables outlined in a qualified WPS, except that preheat and
PWHT requirements may be omitted. A blank welder performance qualification
form can be found in Appendix D.
Welders and welding operators are generally required to pass mechanical testing of
test coupons for groove and fillet weld qualifications, but alternate rules also permit
radiography for testing of either groove weld test coupons or a specified length of
production weld, for most materials and welding processes.
Each manufacturer or contractor should be responsible for conducting the tests to
qualify the performance of his welders and welding operators in accordance with a
qualified WPS. The manufacturer or contractor should be responsible for the full
supervision and control of the tests.
Welder qualifications have a specific time limit for which they are valid unless the
welder or welding operator uses the process or processes for which he is qualified.
Qualification expires in three months if a process is not used. If another welding
process is used, the period can be extended up to six months.

252 Test Coupons

The test coupon material used for qualification does not have to be the same as
designated in the WPS, and liberal substitutions are permitted. In general, P-1 mate-
rial (carbon steel) can be substituted for a wide range of materials including low
alloy steels, stainless steels and nickel-base alloys.
Test coupons for welder qualifications are generally either plate or pipe. Groove
qualification on pipe sizes 24 inches or less qualify for pipe sizes down to 2-1/2
inches in all positions. Plate groove qualifications also qualify pipe sizes down to 2-

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1/2 inches in the flat and horizontal positions. Groove weld qualifications also
qualify for fillet welding but not vice versa. Test coupon thickness less than 3/4 inch
qualifies for welding on thicknesses up to two times the thickness of the test
coupon, but test coupon thicknesses 3/4 inch and over qualify for the maximum
thickness to be welded.

260 Welder Performance Variables

Variables for welder performance qualification are categorized by the Code as either
essential or nonessential. There are no supplementary essential variables for perfor-
mance qualification.
As with procedure qualification, changes in essential variables require requalifica-
tion while changes in nonessential variables do not. Therefore, it is not necessary to
requalify welders for a new job if the essential variables in the existing welder qual-
ification tests are not changed. However, it is important to note that variables that
are essential for performance qualification are often nonessential variables for
procedure qualification and vice versa. The Code should be consulted to determine
which variables are essential and which are not.
The variables for performance qualification are listed for each welding process in
QW-350 and are defined in Article IV, Welding Data. Welding operator qualifica-
tions are limited by the essential variables given in QW-360 for each type of weld
(fully automatic or machine guided welding). A summary of essential variables for
common welding processes is shown in Table QW-416.

270 Company Qualified Welding Procedures

Many welding procedures have been qualified within the Company, particularly in
Chevron U.S.A. The welding procedures qualified by the Company may be used by
any Company facility for the fabrication and repair of pressure vessels and piping
provided the welders are qualified in accordance with ASME Section IX.
It is acceptable for Company qualified welding procedures to be used by individual
contract welders doing work directed and supervised by the Company (i.e., where
the welders are, in effect, temporary Company employees) provided they have also
passed the required welder performance qualifications tests.
A summary of the welding procedures that have been qualified by the Company are
listed in Appendices B and C:
Appendix B lists the welding procedures in numerical order by their WPS
number.
Appendix C lists the welding procedures by base material and welding process.
The welding procedures have been generally qualified in accordance with ASME
Section IX, but a few pipeline procedures have been qualified in accordance with
API Standard 1104. (For more details on this API, see Section 600 of the Pipeline
Manual.)

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If complete welding procedures are needed for a job or for review by a National
Board Inspector in connection with Code work, copies of individual procedures can
be obtained from the Engineering Technology Department (ETD) Materials Divi-
sion at Richmond. A complete set of qualified procedures can be obtained through
ETDs Technical Standards Division, San Ramon, CA.
Often, Company welding procedures must be altered slightly to be applicable for a
specified welding job. (Refer to the earlier discussion of nonessential and essential
variables, Section 240.)

271 WPS Form

Refer to Figure 200-5 for an example of a WPS form filled out from a Company
qualified welding procedure. The categories on the form are defined below:
A. General Information. This section contains general information, including the
company that developed the procedure, an identification number (WPS
number), the supporting PQR number, and the welding process. The welding
process is an essential variable; therefore, changes require requalification.
B. Joints. For most common processes including SMAW, all joint details are
nonessential variables. The illustrated procedure has been qualified using a
single V-joint, but since this variable is nonessential, this procedure can be
used to weld other types of joints as well. The same applies for other joint
details.
C. Base Metal P-number. This procedure calls for welding P-number 1, Group 1
(carbon steel) to itself. Since P-number is an essential variable, this procedure
can only be used to weld P-number 1 material. The group number is a supple-
mentary essential variable, so it only applies if impact testing is required. The
Code should be consulted to determine the P-number and the group number for
a specific material.
D. Base Metal Thickness. The thickness range listed in the WPS is determined by
the Code and the thickness of the test coupon used in the supporting PQR. This
is an essential variable, so thicknesses outside this range would require requali-
fication.
E. Filler Metal Characteristics. This section lists the filler metal F-number and
A-number used for qualification. These are both essential variables. Therefore,
this procedure can only be used to weld an F-number 3 root pass with F-
number 4 fill passes. The A-number for both of these filler metals is 1.
F. Filler Metal Size. This section lists the electrode size used for qualification.
However, because this variable is nonessential, it may be changed without
requalification.
G. Position. The codes used in this section are defined in QW-461. If impact tests
are not required, these variables are nonessential. If impact tests are required,
consult QW-405.2.

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H. Preheat and Postweld Heat Treatment. This procedure does not require
preheat or PWHT. If preheat were to be added, the procedure would not need to
be requalified, but if PWHT was added, requalification would be necessary.
Consult the Code, QW-406 and QW-407 for more information on heat treat-
ment.
I. Gas. Because this procedure is for the SMAW process, there are no require-
ments for gas. Consult the Code for procedures that require gas (GMAW,
GTAW, etc.).
J. Electrical Characteristics. This section lists the current, polarity, amperage,
and voltage used. These variables are nonessential for SMAW unless impact
tests are required. Consult the Code if impact tests are needed.
K. Technique. These variables are all nonessential for SMAW. They can there-
fore be varied without requalification.

272 PQR Form

Refer to Figure 200-6 for an example of a PQR form filled out from a Company
qualified welding procedure. The categories on the form are defined below:
A. General Information. This section lists the same general information that
appears in the accompanying WPS.
B. Joints. This section is used to record the joint details used for the qualification
tests.
C. Welding Variables. The variables used to weld the test coupon are recorded
here.
D. Test Results. This section lists the results of tensile tests, bend tests, impact
tests (if required), and fillet weld tests (if required), which are used to ensure
that the welding procedure can produce quality welds.
E. Welder. The name of the welder who welded the test plate appears on the PQR
in this section. By performing the welding operation in the PQR, this welder is
therefore qualified for that procedure.
F. Certification. PQRs are required to be certified by the manufacturer or
contractor as a true record of the welding variables, and must certify that the
test results are in compliance with Section IX. Changes to PQRs are normally
not permitted except for editorial changes that do not require recertification.

280 New Welding Procedure Qualifications

Any Company facility that qualifies new welding procedures should send copies of
the WPS and PQR to the Engineering Technology Department (ETD) Materials
Division, Richmond, CA, for inclusion in the Qualified Welding Procedures
Manual.

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Fig. 200-5 Copy of a WPS from a Company Qualified Weld Procedure (1 of 2)

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Fig. 200-5 Copy of a WPS from a Company Qualified Weld Procedure (2 of 2)

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Fig. 200-6 Copy of a PQR from a Company Qualified Weld Procedure (1 of 2)

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Fig. 200-6 Copy of a PQR from a Company Qualified Weld Procedure (2 of 2)

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