Navigating the Test

Requirements for Weld

Procedure Qualifications
by Franco du Plessis

OVERVIEW
Welding codes and standards
Procedure documentation
Qualification process flow
Types of testing
Test requirements
Conclusion

WELDING CODES AND STANDARDS

PROCEDURE DOCUMENTATION
Qualification requires the formulation of three universally
recognized documents:
pWPS Preliminary Welding Procedure Specification.

WPQR Welding Procedure Qualification Record.

WPS Welding Procedure Specification.

OVERVIEW OF THE pWPS

pWPS Preliminary Welding Procedure Specification.
Produced by the companies welding engineer or responsible welding
coordinator.
A reference document used by the welder to complete the welding
procedure qualification test piece.
Containing key variables of the welding procedure to be qualified.
Dimensions
Joint configuration
Consumable type
Current
Voltage
Travel speed
Based on knowledge and / or past experience.

pWPS EXAMPLE

OVERVIEW OF THE WPQR

WPQR Welding Procedure Qualification Record.
Is a set of documents comprising the WPS detailing:
The actual welding parameters recorded during the qualification
testing as noted on the pWPS.
Results of any non-destructive and destructive tests.
Material certification for the test piece.
The range of the qualification if all tests are satisfactory.
Based on the range of qualification a single WPQR may be used to
qualify a various number of WPS.
Essentially the WPQR is a documentary evidence to prove that the
welding parameters used in the qualification test piece do not
adversely effect the mechanical properties of the material.

WPQR EXAMPLE

OVERVIEW OF THE WPS

WPS Welding Procedure Specification.
A single sheet document, WPS is the final link in the chain of
documents required to demonstrate welding process control.
It requires all the information required by the qualified welder to
complete a welded joint.
Unlike the WPS accompanying the WPQR the which contains the
actual welding parameters recorded during the qualification test
weld, the final WPS gives a allowable range of welding parameters.
The WPS must be readily available at the welders workplace to be
put in practice.

THE QUALIFICATION PROCESS FLOW

Develop a preliminary
welding procedure
specification (pWPS)
Testing based on
specification
requirements

Complete a welding
test procedure

Complete a welding
procedure qualification
record (WPQR)
Prepare a welding procedure
specification (WPS) based
on the WPQR

TYPES OF TESTING
Destructive testing:

Fillet Weld tests

CTOD (Crack Tip Opening Displacement)

STRESS STRAIN CURVE

TYPES OF TESTING - continued

Non-destructive testing (NDT):
Visual and optical testing (VT)
Penetrant testing (PT)
Magnetic particle testing (PT)
Radiographic testing (RT)
Ultrasonic testing (UT)

TESTING REQUIRMENTS FOR CODES

ASME Boiler and Pressure Vessel Code
Section IX Qualification Standard for Welding and Brazing
Procedures.
AWS D1.1 American Welding Society
Structural Welding Code Steel.
EEMUA 158
Construction Specification for Fixed Offshore Structures in the
North Sea.

TENSILE TESTING
TEST

TENSION
TESTS

ASME SECTION IX: PART QW WELDING

(QW 150)
Reduced Section - Plate (QW-151.1)
Reduced Section - Pipe (QW-151.2
Turned Specimens (QW-151.3)
Full-Section Specimens for Pipe (QW-151.4)

ASME Section IX

AWS D1.1/D1.1M
(Section 4.8)
Reduced Section - Plate (4.8.3.4). Fig. 4.14
Reduced Section - Pipe (4.8.3.4). Fig. 4.14
Fig. 4.18 Turned All-Weld
All-Weld Tension Specimen (4.8.3.6) . Fig. 4.18
ASTM A370 refers.

EEMUA 158
(Section 4.4.4 a & b)
BS 709 & BS EN 895 refers.

BS 709 & BS EN 895 refers. / Fig. 7 in EEMUA.

Tensile strength not less than:

the minimum strength of base
metal.
if the specimen breaks in the
base metal outside of the weld
metal, the test shall be
accepted.

GUIDED BEND TESTING

TEST
GUIDED BEND
TESTS

ASME SECTION IX: PART QW WELDING

AWS D1.1/D1.1M

(QW 160)
Transverse Bend Tests:
Side Bend (QW-161.1)
Face & Root Bends (QW-161.2 & QW-161.3)
Sub-size Face & Root Bends (QW-161.4)

(Section 4.8)
Transverse Bend Tests:
Face, Root & Side Bends (4.8.3.1).
Fig. 4.12 and Fig. 4.13

Longitudinal Bend Tests:

Longitudinal Bend Tests (QW 161.5)
Face & Root Bends (QW-161.6 & QW-161.7)

Longitudinal Bend Tests:

Longitudinal Bend Specimen (4.8.3.2).
Fig. 4.12

Requirement:
No open discontinuity in the
weld or heat affected zone
exceeding 3mm.
No evidence of lack of fusion,
slag inclusions or internal
discontinuities.

EEMUA 158
Not applicable.

Failure due to slag deposit in weld metal / fusion line.

GUIDED BEND TESTING JIGS

Wrap around bend jig.

Plunger and Die Jig.

TOUGHNESS TESTING
TEST
NOTCH
TOUGHNESS
TESTS

ASME SECTION IX: PART QW WELDING

(QW 170)
When required by other sections.
Charpy V-Notch (QW-171.1)
Requirement: SA-370 referred.
Drop Weight (QW-172.1)
Requirements: ASTM E208 referred.

AWS D1.1/D1.1M
(Annex III)
Based on contract drawings and specifications.
Charpy V-Notch:
General (III1)
Test Locations (III2)
CVN Tests (III3)
Requirements (III4)
Fig. III-1 Specimen locations. (See III2.1)

EEMUA 158
(Section 4.4.4 e)
Section 4.4.4 e
Fig. 9a to 9c - Specimen locations

ASTM E23 & ASTM A370 refers

EEMUA 158
Notch toughness requirement
HAZ notch locations
Specimen locations
Locations in weld
Brittle fracture

Ductile fracture

FILLET WELD TESTING

TEST

ASME SECTION IX: PART QW WELDING

(QW 180)
FILLET WELD
QW-181 Procedure and Performance
TESTS /
Qualification Specimens
MACRO
Procedure (QW-181.1)
EXAMINATION Performance (QW-181.2)
/ FRACTURE
Fillet welds in plate Procedure QW-462.4(a)
TESTS
Fillet welds in plate Performance QW-462.4(b)
Fillet welds in pipe Performance QW-462.4(c)
Fillet welds in pipe Procedure QW-462.4(d)
Fillet welds Fracture Tests Performance QW-182
Macro Examination Procedure (QW-183)
Macro Examination Procedure (QW-184)

AWS D1.1/D1.1M
(Section 4.11)
Fillet Weld Test Section 4.11.2
Fillet welded T-joint for plate Fig. 4.19
Fillet welded T-joint for pipe Fig. 4.20

EEMUA 158
(Section 4.4.4 c)
Section 4.4.4 c
Preparation with 600 grit paper.
Requirements 7.5.4

Macroetch Test Section 4.8.4

Macro etch Sample

HARDNESS SURVEY TESTING

TEST

ASME SECTION IX: PART QW WELDING

(QW 180)
FILLET WELD
QW-181 Procedure and Performance
TESTS /
Qualification Specimens
MACRO
Procedure (QW-181.1)
EXAMINATION Performance (QW-181.2)
Fillet welds in plate Procedure QW-462.4(a)
Fillet welds in plate Performance QW-462.4(b)
Fillet welds in pipe Performance QW-462.4(c)
Fillet welds in pipe Procedure QW-462.4(d)
Macro Examination Procedure (QW-183)
Macro Examination Procedure (QW-184)

AWS D1.1/D1.1M
(Section 4.11)
Fillet Weld Test Section 4.11.2
Fillet welded T-joint for plate Fig. 4.19
Fillet welded T-joint for pipe Fig. 4.20

EEMUA 158
(Section 4.4.4 c)
Section 4.4.4 c
Preparation with 600 grit paper.
Requirements 7.5.4

Macroetch Test Section 4.8.4

HARDNESS SURVEY EXAMPLES

Fillet weld

Plate Single Bevel

CONCLUSION
Test requirements vary based on standards and application.
Welding engineers are responsible for testing requirements.
Laboratory conduct the testing according to specified
standards.
COMMUNICATION.