WELDING PROCEDURE QUALIFICATION Qualification Process for Welding Procedures

 Detailed written instructions about the welding  Some alternative ways that can be used for writing
conditions that must be used to ensure that welded qualified WPSs for some applications are:
joints have the required properties. - Qualification by adoption of a standard welding
 Welding inspectors need to refer to WPSs when procedure – test welds previously qualified and
checking that welders are working in accordance documented by other manufacturers.
with the specified requirements (fit for purpose). - Qualification based on previous welding experience –
 Welders need to be able to understand WPSs have weld joints that have been repeatedly made and
the skill to make welds that are not defective and proved to have suitable properties by their service
demonstrate these abilities before being allowed to record.
make production welds.  Sequence for welding procedure qualification by means of
a test weld:
Qualified Welding Procedure Specifications
 Welding procedure is qualified by making a test weld
to demonstrate that the properties of the joint
satisfy the requirements specified by the application
standard and the client/end user.
 Purpose
- Demonstrating the mechanical properties of the
joint,
- Showing that a defect-free weld can be produced

Welding Standards for Procedure Qualification

 European and American Standards have been
developed to give comprehensive details about:
- How a welded test piece must be made to
demonstrate joint properties.
- How the test piece must be tested.
- What welding details need to be included in a
WPS.
- The range of production welding allowed by a
particular qualification test weld.
 European Standards:
EN ISO 15614 Specification and qualification of
welding procedures for metallic materials –
Welding procedure test
Part 1 Arc and gas welding of steels and arc
welding of nickel and nickel alloys
Part 2 Arc welding of aluminium and its alloys

 American Standards:
ASME Section IX Pressurized systems (vessels
and pipework)
AWS D1.1 Structural welding of steels
AWS D1.2 Structural welding of aluminium
 Variable Range for Procedure Qualification
Welding process No range – process qualified must
be used in production.
PWHT Joints tested after PWHT and only
qualify PWHT production joints.
Relationship between a WPQR
Joints tested a WPS only qualify  Examples of WPS essential variables according to
andas-welded
 Once a WPQR has been produced,
as-welded the welding
production joints. European Welding Standards
Parent
engineer material
is able to writeParent materials
qualified of similar
WPSs for the
type composition
various production weld joints that need to be and mechanical
made. properties are allocated the same
Material Group No; qualification
 The welding conditions that are allowed to be
only allows production welding of
written on a qualified WPS are
materials withreferred to asGroup
the same the No.
qualification range Consumables for production
Welding
 consumables
Welding conditions are referred
welding to as
must welding
have the same
variables by EuropeanEuropean and American designation
Welding– as a
Standards and are classified into: general rule.
Material A thickness
- Essential variable: A variable that range
has is
anallowed
effect on–
thickness below and above the test coupon
the mechanical properties of the weldment (and
thickness.
Typeif changed
of currentbeyond the limits
AC only specified
qualifies for AC;by DC
thepolarity
standard will require (+vetheor WPS to be re-qualified).
-ve) cannot be changed;
- Non-essential variable: pulsedAcurrent
variableonlythat qualifies
must be for
pulsed current
specified on a WPS but does not have a production welding.
Preheat
significant effectThe preheat
on the temperature
mechanical properties used
offor
temperature the test is the minimum that must
the weldment (and can be changed without need
be applied.
for re-qualification
Interpass Thebut will require
highest interpassa new WPS to
temperature
be written).
temperature reached in the test is the maximum
 If a welder makes a production weld using
allowed.
Heat input (HI)
conditions outside When impact requirements
the qualification range given on apply
maximum HI allowed
a particular WPS, there is danger that the welded is 25% above
joint will not have the requiredtest HI.properties
When hardness and
requirements apply minimum HI
there are then two options:
allowed is 25% below test HI.
i. Make another test weld using similar
welding conditions to those used for the
affected weld and subject this to the same
tests used for the relevant WPQR to
demonstrate that the properties still
satisfy specified requirements.
ii. Remove the affected weld and re-weld the
joint strictly in accordance with the
designated WPS.
 WELDER QUALIFICATION cont. Qualification Process for Welders
 The use of qualified WPSs is the accepted method
 Stages for qualification of a welder:
for controlling production if the welders are able to
understand and work in accordance with them.
 Welders also need to have the skill to consistently
produce sound welds (free from defects).

Welding Standards for Welder Qualification

 European Standards:
EN 287-1 Qualification test of welders – Fusion
welding
Part 1 Steels

EN ISO 9606-2 Qualification test of welders –

Fusion welding
Part 2 Aluminium and aluminium alloys

EN 1418 Welding personnel – Approval testing of

welding operators for fusion welding and resistance
weld setters for fully mechanised and automatic
welding of metallic materials
 American Standards:
ASME Section IX Pressurized systems (vessels
and pipework)
AWS D1.1 Structural welding of steels
AWS D1.2 Structural welding of aluminium

Qualification Process for Welders

 Qualification testing of welders requires test welds
to be made and subjected to specified tests to
demonstrate that the welder is able to understand
the WPS and to produce a sound weld.
 For manual and semi-automatic welding: to
demonstrate the ability to manipulate the electrode Welder Qualification and Production Welding Allowed
or welding torch.  The welder is allowed to make production welds within
 For mechanized and automatic welding: the range of qualification recorded on his Welder
demonstrating that welding operators have the Qualification Certificate.
ability to control particular types of welding  The range of qualification is based on the limits specified
by the Welding Standard for welder qualification
equipment.
essential variables – defined as:
- A variable that if changed beyond the limits specified
by the Welding Standard may require greater skill than
has been demonstrated by the test weld.
 Variable Range for welder qualification
Welding No range – process qualified is
process process that a welder can use in
production.
Type of weld Butt welds cover any type of joint
except branch welds.
Fillet welds only qualify fillets.
Parent Parent materials of similar
material type composition and mechanical
properties are allocated the
same Material Group No;
qualification only allows
production welding of materials
with the same Group No. but the
Groups allow much wider
composition ranges than the
procedure Groups.
Filler material Electrodes and filler wires for
production welding must be of
the same form as the test (solid
wire, flux-cored etc); for MMA
coating type is essential.
Material A thickness range is allowed; for
thickness test pieces above 12mm
allow  5mm.
Pipe diameter Essential and very restricted for
small diameters:
Test pieces above 25mm
allow  0.5 x diameter
used (minimum 25mm).
Welding Position of welding very
positions important; H-L045 allows
all positions (except PG).
 Welder qualification essential variables according to
European Welding Standards
Prolongation of Welder Qualification
A welder’s qualification certificate can be prolonged
every two years by an examiner/examining body
Conditions for prolongation
- Records/evidence are available that can be traced to
the welder and the WPSs used for production
welding.
- Supporting evidence must relate to volumetric
examination of the welder’s production welds (RT or
UT) on two welds made during the six months prior
to the prolongation date.
- Supporting evidence welds must satisfy the
acceptance levels for imperfections specified by the
European welding standard and have been made
under the same conditions as the original test weld.
Welding Procedure
Involves:
-Planning the task - Evaluation of result
-Collecting the data - Approving the procedure
- Writing a procedure - Preparing the document
for use on trial
- Making a test weld
Components:

Period of Validity for A Welder Qualification Certificate

 A welder’s qualification begins from the date of
welding of the test piece.
 The European Standard allows a qualification
certificate to remain valid for a period of two years,
provided that:
- The welding co-ordinator, or other responsible
person, can confirm that the welder has been
working within the initial range of qualification.
- Working within the initial qualification range is
confirmed every six months.
 Position:  Welding Process
111 - MMA 114 - FCAW no gas shield
12 - SAW 131 - MIG
135 - MAG 136 - FCAW
311 - Oxy-Acetylene 141 - TIG
15 - Plasma Arc

Arc Energy
 Is the amount of heat generated in welding arc per
unit length of weld
 Unit: kJ/mm
Volts x Amps
 Arc energy =
Welding Speed (mm /s) x 1000
BS EN ISO 15614-1:2012 (Old: BS EN 288-3)
 Range of qualification Monitoring heat input:
Thickness of Range of Qualification  Heat input is the energy supplied by the welding arc
test piece, t Single run Multi run to workpiece
t≤3 0.7t to 1.3t a 0.7t to 2t a
 Heat input, Q
3< t≤12 0.5t (3 min) to 1.3t a 3 to 2t a
12< t≤100 0.5t to 1.1t 0.5t to 2t
t>100 Not applicable 50 to 2t

 BS EN ISO 15614-1:2004
-Plate
Thickness Range of Qualification
of test Material Throat Thickness
piece, t Thickness Single run Multi run
0.75 a to No
t≤3 0.7 to 2t
1.5 a restriction
0.5t(3 0.75 a to No  Impact requirement applies: upper limit of heat
3< t<30 input >25% of that used in welding of test piece
min) to 2t 1.5 a restriction
No  Hardness requirement applies: lower limit of heat
t≥30 ≥5 a input <25% of that used in welding of test piece
restriction

-Pipe
Diameter of test piece Range of Qualification
D a,mm
D≤25 0.5D to 2D
D>25 ≥0.5D (25 mm min)
NOTE For structural hollow sections, D is the dimension
of the smaller side
ᵃ D is the OD of the pipe or the OD of the branch pipe