The purpose of welding procedure specification

(WPS) and Procedure Qualification Record (PQR) is

to determine that the welding operation
proposed for fabrication are capable of
producing welds with required properties for
intended application.
 A WPS is a written document to provide
direction for making production welds which
will meet code requirements.

 A PQR is a record of the welding data used to

weld a test coupon.
 i. Essential Variables: These are variables which
have a marked and significant effect on the weld
properties if changed
 ii. Non Essential Variables: these will not, have
any significant effect on weld properties if
changed.
 Iii. Supplementary essential variables: these will
effect the impact properties of the material.
 These variables are listed for each welding
process in QW-252 through QW-265 in ASME
Sec. IX.
 A completed WPS shall describe all essential
and non-essential variables for each welding
process used in WPS.
 The WPS shall also mention the supporting
procedure qualification records.
 A WPS may be written in any format suitable
to the manufacturer. It should ensure that all
essential and supplementary essential
variables are listed in the WPS.
 A WPS should be made available for reference
and review by the inspector. It should also be
made available with welding supervisors, welders
actually involved in production of the weld.
 A PQR should be certified by the Manufacturer.
 Changes to PQR are not permitted. However,
correction can be made for example, if P No. or F
No. or any other information is wrong then the
same can be corrected.
 . Prepare a preliminary WPS
 2. Prepare and weld a suitable test piece
using preliminary WPS.
 3. Conduct required NDT and Destructive
Tests w.r.t the ASME section IX.
 4. Evaluate Results of prep, welding, testing
 5. Document results on PQR
 6. Issue approved PQR
 7. Issue approved WPS
 Types of test conducted.
 Number of test conducted. Results of tests.
 Additional information can be incorporated at
a later date provided it can be substantiated
as having been part of original qualification
condition by some lab :-Record or similar
document
 Form QW 483 of section IX can be used as a
guide to prepare PQR.
 PQR used for supporting WPS should be
available for review by the inspector. PQR
need not be available to welding operator or
welder.
DESCRIPTION

 Enter the complete company name and address in this section.

 Each company should have its own method of numbering welding procedure data
sheets. This can range from a relatively simple consecutive number system to
one that identifies the process, position, groove type and electrode.
 Record the PQR number that applies to this WPS.
 Enter the date the welding procedure data sheet was prepared and the revision
number
 The welding process & Type of process to be specified in this section. The letter
designation may be used to identify the process. One of the four process modes
should be checked in this section based on the following definitions.
a. Manual welding. Welding with the torch, gun or electrode holder held and
manipulated by hand.An example is SMAW or GTAW.
b. Semi-automatic welding. Manual welding with equipment that automatically
controls one or more of the welding conditions. Examples are FCAW, GMAW
c. Machine welding (mechanized welding). Welding with equipment that requires
manual adjustment of the equipment controls in response to visual observation
of the welding, with the torch, gun or electrode holder held by a mechanized
device. SAW is an example.
d. Automatic welding. Welding with equipment that requires only occasional or no
observation of the welding and with no manual adjustment of the equipment
controls. An example is a robotic application.
JOINTS (QW 402):

 Joint Design & Details – A sketch of the joint configuration with the welding
symbol and a typical sequence of the layers and passes should be included in
this section of the form. It is recommended that the sketch be drawn in the
correct welding postion. The joint configuration should include the following
information: • thickness of parts,• root opening, root face, bevel angle, groove
angle, depth of preparation, radius (for HSS), diameter (for solid
bars/tubing/pipe), effective throat thickness (ETT)

 Backing (material and thickness) : Backing is a material or device placed against

the back side of the joint adjacent to the joint root to support and shield
molten weld metal. If steel backing is used enter the material and thickness of
backing in the space provided. Non-permanent backings can be made from
materials such as ceramic, copper or flux. If they are used enter the material,
type and form of the backing in the space provided.

 Back gouging: Back gouging (Yes/ No, Method, Depth) : Back gouging is the
removal of weld metal and base metal from the weld root side of a welded joint
to facilitate complete fusion and complete joint penetration upon subsequent
welding from that side.
BASE METALS( QW-403) :

 P.No. (Parent Metal No’s) & Group No’s: Materials are grouped in certain P No’s.
The material which having similar base metal characteristics, such as
composition, weld ability, braze ability & Mechanical properties are grouped in to
one P.No:s.

 Specification & type/grade :- In Table no. QW/QB-422 FERROUS/NONFERROUS P-

NUMBERS Material have been arranged by Specification No’s, Type or grade , UNS
no., P. no. Group No., Nominal Composition & product form for the
understanding of the Material perfectly.

 Base Metals & Pipe dia range : As per QW-451 Procedure Qualification Thickness
Limits and Test Specimens w.r.t the test piece thickness.
FILLER METALS( QW-404):

 SFA No.,AWS No.,F. No. (Filler Metal No.) : In Table QW 432 Grouping of Electrodes and
Welding Rods for Qualification Filler metals / Electrode have designated separately in F
No’s, ASME specification, AWS Specification.
 Position (QW-405)

 QW-120 TEST POSITIONS FOR GROOVE WELDS

 Plate Positions :- Flat Position 1G ,Horizontal Position 2G, Vertical Position 3G,
Overhead Position 4G.

 Pipe Positions:- Flat Position 1G. Pipe with its axis horizontal and rolled during
welding so that the weld metal is deposited from above.

 Horizontal Position 2G. Pipe with its axis vertical and the axis of the weld in a
horizontal plane. Pipe shall not be rotated during welding.

 Multiple Position 5G. Pipe with its axis horizontal and with the welding
groove in a vertical plane. Welding shall be done without rotating the pipe.

 Multiple Position 6G. Pipe with its axis inclined at 45 deg to horizontal. Welding shall
be done without rotating the pipe.
 QW-130 TEST POSITIONS FOR FILLET WELDS
 QW-131 Plate Positions

 Flat Position 1F- Plates so placed that the weld is deposited with its axis
horizontal and its throat vertical.

 Horizontal Position 2F-Plates so placed that the weld is deposited with its axis
horizontal on the upper side of the horizontal surface and against the vertical
surface.

 Vertical Position 3F-Plates so placed that the weld is deposited with its axis
vertical.

 Overhead Position 4F-Plates so placed that the weld is deposited with its axis
horizontal on the underside of the horizontal surface and against the vertical
surface.
 QW-132 Pipe Positions
 Flat Position 1F. Pipe with its axis inclined at 45 deg to horizontal and rotated
during welding so that the weld metal is deposited from above and at the point of
deposition the axis of the weld is horizontal and the throat vertical.

 Horizontal Positions 2F and 2FR : (a) Position 2F. Pipe with its axis vertical so that
the weld is deposited on the upper side of the horizontal surface and against the
vertical surface. The axis of the weld will be horizontal and the pipe is not to be
rotated during welding.
 (b) Position 2FR. Pipe with its axis horizontal and the axis of the deposited weld in
the vertical plane. The pipe is rotated during welding.

 Overhead Position 4F. Pipe with its axis vertical so that the weld is deposited on the
underside of the horizontal surface and against the vertical surface. The axis of the
weld will be horizontal and the pipe is not to be rotated during welding.

 Multiple Position 5F. Pipe with its axis horizontal and the axis of the deposited weld
in the vertical plane. The pipe is not to be rotated during welding
 A change from any position to the vertical position uphill progression.
Vertical-uphill progression (e.g., 3G, 5G, or 6G position) qualifies for all
positions.

 Qualification in the horizontal, vertical, or overhead position shall also

qualify for the flat position. Qualification

 in the horizontal fixed position, 5G, shall qualify for the flat, vertical, and
overhead positions. Qualification in the horizontal, vertical, and overhead
positions shall qualify for all positions. Qualification in the inclined fixed
position, 6G, shall qualify for all positions.
 Pre heat(QW-406) & PWHT (QW-407):

Material Pre. Heating B31.1(Table PWHT B31.1 (Table 132 )

Classification Pipe Tube
P No: 131.4) Holding temp. Holding Time
SA179/192,17 600 - 650 °C Up to 2
( 80°C if Carbon Over 2 inch
C.S 1 SA106 GrA/B/C 8 PWHT is not inch(50mm)
Content is excess of
SA334 Gr 1/6 mandatory
0.3% & t > 25mm )
C.S(Impact) 1 SA 333 Gr 1/6 if t < 19mm
SA161 T1 600 - 650 °C
PWHT is not
( 80°C when t > mandatory
C-1/2 Mo 3 SA 335 P1 13mm ) If t ≤ 16mm,
SA213 T2 C content is ≤
1/2 Cr-1/2 Mo 3 SA 335 P2 0.15%)
1Cr -1/2 Mo 4 SA 335 P12 SA213 T12 700 - 750 °C
PWHT is not
mandatory 2hr plus 15 min. for
( 120°C for all material 1Hr/inch
If t ≤ 13mm, Cr ≤ each additional inch
SA213 T11 thickness)
3%,
C content is ≤
1 1/4 Cr -1/2 Mo 4 SA 335 P11 0.15%)
2 1/4 Cr -1/2 Mo 5A SA 335 P22 SA213 T22 700 - 760 °C
5 Cr -1/2 Mo 5B SA 335 P5 SA213 T5 PWHT is not
1)200°C if Cr is >6% &
mandatory
7 Cr -1/2 Mo 5B SA 335 P7 SA213 T7 t>13mm
if
9 Cr -1Mo 5B SA 335 P9 SA213 T9 2)150°C for all other
t ≤ 13mm, Cr ≤
9Cr-1Mo-1/4V- SA213 T91 materials
3%, C content
0.4Ni 15E SA 335 P91 is ≤ 0.15%

1) Preheating ---> To Slow down the cooling rate.

2) PWHT --> It is necessary to remove the residual stresses left in the joint , which can
cause brittle fracture.
3) Post heating ---> To maintain the homogeneous structure.
 To be remembered :
1) When two metals of different thickness is welded, Heat treatment for the higher
thickness shall be applied.
2) When the joint is of 2 different P no: , Heat treatment for higher P no: will be
applied.
3) Heating Band --> Width = 3times of the base metal thickess from the centre of
the joint on each side.
4) Insulation --> Width = 6 times of the base metal thickness from the centre of
the joint on each side, Thickness = Minimum 25mm with insulating material.
5) Thermo couple shall be placed at a distance of 1.5 times of the base metal
thickness from the centre, it should be welded by Spot welding,
6) K,S,B,R types thermocouples --> K type ( Chromel - Alumel )
7) Tolerances --> For Rate of heating & Cooling ±10°C & for Soaking temp. --> ±
15°C
8) Thermocouple: Up to 4"OD---> 1 (Top of Bottom), 4-10"OD --->2 (T/B), 10-
16"OD ---> 3(120°apart), >16" OD (90° apart)
 Gas Flow (QW-408)

 Shielding gases are inert or semi-insert gases that are commonly used in several welding processes, most notably
gas metal arc welding and Gas tungsten arc welding (GMAW and GTAW, more popularly known as MIG and TIG,
respectively).
 Their purpose is to protect the weld area from oxygen and water vapour. Depending on the materials being welded,
these atmospheric gases can reduce the quality of the weld or make the welding more difficult.
 Other arc welding processes use other methods of protecting the weld from the atmosphere as well – shielded
metal arc welding,for example, uses an electrode covered in a flux that produces carbon dioxide when consumed, a
semi-inert gas that is an acceptable shielding gas for welding steel.
 Improper choice of a welding gas can lead to a porous and weak weld, or to excessive spatter causes loss of
productivity due to the labor needed to remove the scattered drops.
 The shielding gas flow rate should be high enough to maintain adequate shielding for the arc but not so high that
it causes turbulence in the weld pool. The gas flow rate to be used depends on a number of factors such as the
process, welding position, shielding gas, electrode extension and operating parameters.
 Backing/Purging: This method is used for the prevention of the oxidation.
 Electrical Characteristics(QW-409)

 Enter the current and polarity for the electrode, electrode-gas or electrode- flux combination being used.
also Tungsten electrode size with type of electrode will be mentioned here.
 Direct current electrode positive (DCEP) is the arrangement of direct current welding leads in which the
electrode is the positive pole and the work piece is the negative pole of the welding arc.
 Direct current electrode negative (DCEN) is the arrangement of direct current welding leads in which the
electrode is the negative pole and the work piece is the positive pole of the welding arc.
 Current : The current to be used depends on many factors including electrode type, size, welding position,
joint design. Measure the amperage using a calibrated clamp type amp meter. Measure the amperage as
close to the gun/holder as possible without interfering with the operator. This usually is about 3 or 4 feet
from the gun/holder.
 Voltage : When measuring voltage, different techniques can be used depending on the welding process
being used. For the SMAW and GMAW processes the voltage can be taken between the cable terminals on
the welding machine. For the GMAW and FCAW processes, the voltage can be taken between the work lead
at the work connection clamp and the electrode lead at the contractor in the wire feed unit. If not practical,
the voltage can also be taken between terminal or between the cable terminals on the welding machine.
For the SAW process, the voltage can be taken between the electrode lead connection at the torch and the
work lead clamp.
 Arc Travel Speed/ Welding Speed
The arc travel speed can be measured by recording the time taken to weld a specific length of weld, then
convert the measured time and length to inches/minute or millimeters/minute.
ATS (ins/min) = Measured Weld Length in inches x 60
Measured Time in Seconds
or
ATS (mm/min) = Measured Weld Length in millimeters x 60
Measured Time in Seconds
 TECHNIQUE(QW-410):

 Gun movement during welding:

 Stinger weave means : Steady movement along the seam
 Weave Bead: Side to side movement along the seam.
 Gas cup size & nozzle dia., Initial & inter pass cleaning method , Method of Back
gouging, Multiple or single pass will be mentioned w.r.t the proposed WPS.
P-01 to P-01
SA210 Gr. C to SA 210 Gr. C
Process – GTAW + SMAW
Test Piece Thickness : 9.5mm
P No.-5B + P No.-5B
SA213 T91 + SA213 T91
Process – GTAW + SMAW
Test Piece thickness : 10mm
P No.-15E + P No.-15E
SA335 P91+ SA335 P91
Process – GTAW + SMAW
Test Piece Thickness: 65mm
THANKS