Welding Procedure Qualification

Why

To prove weld would be mechanical and

metallurgical compatible with parent metal

To ensure only sound welding practices

are employed in fabrication
 Welding Procedure Qualification
• Weld soundness and strength are
dependent on a variety of interacting
welding variables.
• Procedure qualification tests generally
evaluate joint design, position, base
material, filler material, welding process,
welding parameters etc.
• Many Governing codes or specifications
demand qualification of welding procedure
specifications.
 Welding Procedure Qualification
• The requirements may include tensile
strength, yield strength, elongation,
reduction in area, impact strength,
hardness tests, corrosion resistance tests,
fracture toughness and X-ray soundness

• The specific tests/requirements depend on

the code involved.
 Welding Procedure Qualification
The following are some product codes or
specifications:
• ASME Section VIII , Division I & II – for Pressure
Vessels and Boilers
• ASME B 31.1 High Pressure Piping
• ASME 31.3 Process Piping
• ASME 31.4 Liquid Transportation Systems for
Hydrocarbon
• ASME 31.8 Gas Transmission Piping systems
• PD 5500 Unfired Fusion Welded Pressure
Vessel
 Welding Procedure Qualification
• ASME Section IX Boiler &Pressure Vessel code
• API 1104 Welding of Pipelines and Related
Facilities
• AWS D 1.1 Structural Welding Code
• BS 4515-1 Welding of steel pipelines on land
and offshore—Part 1: Carbon & Carbon
Manganese steel pipelines
• BS 4515-2 Welding of steel pipelines on land
and offshore—Part 1: Duplex stainless steel
pipelines
 Welding Procedure Qualification

• BS EN 288-3 Specification & approval of welding

procedures for metallic materials Part 3: Welding
procedure tests for the arc welding of steels

• BS EN 288-9 Specification & approval of welding

procedures for metallic materials Part 9: Welding
procedure tests for pipeline welding on land and
offshore site butt welding of transmission lines
Welding Procedure Qualification

Welding procedure specification (WPS) is a

written qualified welding procedure to
provide direction for making production
welding to Code requirements
Welding Procedure Qualification
Contents of WPS

1. Essential Variables

2. Supplementary Essential Variables

when Required

3. Nonessential Variables
Welding Procedure Qualification
Essential Variable:

• A change in welding condition which will

affect the mechanical properties (other
than notch toughness) of weldment
• e.g. P- Number, welding process, filler
metal, preheat, PWHT etc.
Welding Procedure Qualification
Supplementary Essential Variable:

• A change in welding condition which will

affect the notch toughness properties of
weldment

• e.g. Change in welding process, deletion

of backing, electrode, F number, technique
Welding Procedure Qualification
Nonessential Variable:

• A change in welding condition which will

not affect the mechanical properties of a
weldment

• e.g. joint design, method of back gouging

or cleaning
Welding Procedure Qualification
Welding variable as per ASME Section IX
• Weld joint
• Base Metal
• Filler Metals
• Welding Positions
• Preheat
• PWHT
• Shielding Gas
• Electrical characteristics
• Welding Technique
Welding Procedure Qualification
Welding variable as per API 1104

• Base Metal
• Joint design
• Position
• Wall Thickness
• Filler Metal
• Electrical characteristics
• Time between Passes
• Direction of welding
Welding Procedure Qualification
Welding variable as per API 1104

• Shielding gas and flow Rates

• Shielding Flux
• Speed of travel
• Preheat
• PWHT
 Welding Procedure Qualification

• A welding procedure specification (WPS)

shall be established for each type of joint,
material, position, and process to be used
in a particular structure or weldment.
 Welding Procedure Qualification
Steps in qualifying a WPS
• Identify the need to qualify a WPS
• Establish Preliminary/provisional WPS
• Obtain endorsement by Welding TA-2
• Conduct welding test
• Carry out NDT (visual, MT and/or RT)
• Prepare specimens for destructive testing
• Carryout mechanical testing at PDO approved
testing Laboratory
• Prepare procedure qualification record
• Obtain endorsement by Welding TA-2
• Prepare WPS based on PQR
• Obtain Endorsement by Welding TA-2 on WPS
 Welding Procedure Qualification
The following shall be verified before testing

• WPS endorsed “Approved for qualification”

• Material certificates
• Welding consumables batch certificates
• Approved consumable handling procedure
• Fit-up report
 Welding Procedure Qualification
The following shall be recorded during testing
• Welding Process
• Base material Spec. & Grade, thickness , dia.
• Current, voltage, travel speed
• Preheat temperature & PWHT details if any
• Inter-pass temperature
• Filler metal/electrode used: ASME
specification, AWS classification, size
• Position
• Welding Progression
 Welding Procedure Qualification
Tests Required to qualify procedures in
accordance with ASME Section IX
• Mechanical (Mandatory)
• Transverse Tension Test 2
• Transverse Face Bend Test 2
• Transverse Root Bend Test 2
or
• Transverse Side Bend Test 4
• If supplementary Variable apply
• Impact testing of Weld and HAZ
 Welding Procedure Qualification
Additional (SP-1173)
• Visual Examination
• Radiographic Examination
• Macroscopic and Hardness test (sour service :
250 HV10-root and mid thickness, 275 HV10-
cap; Non-sour 350 HV10)
• Charpy V-notch Impact testing at root WCL, FL,
FL+ 2mm- if required by ASME B 31.3
• Charpy V-notch Impact testing at cap WCL, FL,
FL+ 2mm-when thickness > 19 mm, if required
by ASME B 31.3
• Corrosion Test- for austenitic stainless steels (A
262 Practice E)
 Welding Procedure Qualification
Tests Required to qualify procedures in
accordance with API 1104
• Tensile
• Nick Break
• Root Bend
• Face Bend
or
• Side Bend
 Welding Procedure Qualification
Additional Testing (SP-1174/1177):
• Visual Examination
• Magnetic particle testing
• Radiographic testing
• Macroscopic Examination and
Hardness testing (sour service : 250
HV10-root and mid thickness, 275
HV10-cap; Non-sour 350HV10)
Welding Procedure Qualification
Additional Testing (SP-1174/1177):
• Charpy V-notch Impact testing at root WCL, FL, FL+
2mm
• Charpy V-notch Impact testing at cap WCL, FL, FL+
2mm-when thickness > 20 mm
• Test Temperature
• Nominal wall thickness Test Temperature
• t <16 mm Minimum Design Temperature
• 25> t>16 mm Minimum Design Temperature
- 10C
• t> 25mm Minimum Design Temperature
- 20C