)( WPS

TELEGRAM :

@SpecialAlloys


.
.
WPS .
WPS WPS
WPS PQR
. ) test plate test coupon (
. ) (specimen
. .
WPS WPS .
WPS .
. .
Welder Performance Qualification WPQ .
. WPQ WQR Welder
Qualification Record .

:
)ASME Sec.IX (Boiler and Pressure Vessel Code
)ASME B31.1(Power Piping
)ASME B31.3 (Process Piping
)AWS D1.1 (Structural Welding Code-Steel
)API 650 (Welded Steel Tanks for Oil Storage
)API 1104 (Welding of Pipelines and Related Facilities
)EN 288 (Specification and Approval of Procedures for Welding Metallic Materials

PQR ,WPS WPQ .

)( .

.
.
)CEN .
( 1994 EN 729
. EN
729 . ) ISO ( EN 729 ISO 3834
2005 ) EWF . ( EN 729
 ISO EN 3834 .
EN 729 BS 4870 .

EN 729/ISO 3834 .
ISO 9001 .

WPS
. ASME " WPS
" . WPS .

. .
WPS .

WPS
WPS
1 4 .
. .
 -1 WPS AWS D1.1
 -2 WPS API 1104
 -3 WPS EN 288-2
 -4 WPS ASME Sec.IX
 WPS ASME Sec.IX
WPS 4 . WPS .
QW-482 . ASME Section IX QW QB QW
Article ) Q Qualification ( :
QW-100 General introduction to testing requirements etc.
QW-200 Procedure qualification details.
QW-300 Performance qualifications (welder approvals) details.
QW-400 Welding data .This is the biggest section of the code and covers data for both procedure and
performance qualification.It includes:
-Material and consumable data
-Approval range for thickness, diameter, joint
-Configuration and welding positions.
-Definitions used in code.
)QW-500 Standard Welding Procedure Specifications (SWPSs
) QW-200.1(d ASME Section IX B WPS
) Nonmandatory Appendix B (
SMAW, SAW, GMAW GTAW
. ) SAW
( ) GTAW
SMAW ( .
)(Company Name
. WPS
.
)(By
ASME Section IX ) (authorization or certification WPS
. By
WPS ) (Prepared by
) (Checked by ) (Approved by .
(WPS No.) WPS
ASME Section IX WPS
WPS ) (unique WPS
. WPS
. 134 :
)1 = ASME P-No. 1 (Carbon Steel Base Metals
3 = F-No. 3 (E6010) SMAW
4 = F-No. 4 (E7018) SMAW

T-2 P-11 Piping .

WPS .
.
 )(Date
WPS .
)(Revision
WPS 0 . WPS
WPS . 1
. ) QW-200.1(c .
)(Revision Date
WPS . WPS
.
(Supporting PQR No.(s)) PQR
) QW-200.1(b PQR WPS .
) (essential variable PQR
.
))(Welding Process(es
QW-253 ) (essential variable QW-401
. WPS .
. 5 .
1 .
. ) (
. .
. 4 :
:
.
4 : ) ( ) ( )
( ) (.
.
. .
) ( .
.
.
.
.
4 .
:
.

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.
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: .
.
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.
: .
: .
.
: .
.
: ) ( .
: .
.
. :

.
.
:

.
6 .
 -5
Letter
Welding Process
Designation
SMAW(USA) Shielded Metal Arc Welding

MMA(UK) Manual Metal Arc Welding

Stick Welding
GMAW(USA) Gas Metal Arc Welding

MIG(UK) Metal Inert Gas Welding

MAG(UK) Metal Active Gas Welding (CO2)

GTAW Gas Tungsten Arc Welding

TIG(UK) Tungsten Inert Gas Welding

FCAW Flux Cored Arc Welding
PAW Plasma Arc Welding
OFW Oxy-Fuel Gas Welding
ESW Electro Slag Welding
EGW Electro Gas Welding
EBW Electron Arc Welding
SAW Submerged Arc Welding
 -6

)(Type
) (Manual) (Automatic ) (Semi-Automatic
) (Machine . ) (
. FCAW GMAW
. 2
.
 -2

)(Joint Design
WPS . ) (Joint
. 7 .
: ) (Butt joint
) (Lap joint ) .(T joint ) (Groove Weld
) .( Fillet Weld
8 .

- 7
 - 8

.
) (Bevel .
. .
) (Single sided ) (Double Sided .
. ) (Distortion
. 9
.
 - 9

. 10
.

- 10
. . WPS
WPS .
 . 11
.
. AWS A2.4 .
. BS 499-2 ,EN 22553,ISO 2553 : . 12
. 13 .

11

- 12
 - 13

)(Backing

.
14 .
))(Backing Material (Type
.
:
- -
- - CO2
 - 14

WPS ) (Bead .
) (Distortion .
) .(15 WPS
.

- 15

)(Base Metals
WPS .
.
(P-No.) P
WPS PQR P .
Group No. .
. P Gr.
. 3 P No.
 . P No. QW-422 ). 17 QW-422
(
P No 9 5 10 QW-403.13 . 16
) . P No. 2 !!(

P ASME IX

1-11 QW-422.11 QW-422.1

21-25 QW-422.25 QW-422.21 Al

31-35 QW-422.35 QW-422.31 Cu

41-47 QW-422.47 QW-422.41 Ti

61-62 QW-422.62 QW-422.61 Zr

-3 P

- 16 P
 - 17 QW-422

17 ASME SA .
:
ASME Boiler and Pressure Vessel Code, Section II, Part A and B
ASTM ASME " " S ASTM
ASME.
Part A Section II ASME Part B .
ASME ASTM .
ASME SA 516/SA-516M-01 Grade 70 - Pressure Vessel Plates, Carbon Steel, for Moderate - and Lower
Temperature Service
ASTM A 516/516-01 Grade 70 " " SA ASME
.
QW-420.2 S No. . ASME B 31 ASME Section
II ASME S No. .
Appendix D ASME Sec. IX P No. .
) (Specification ) (Type & Grade ) (Chemical Analysis
) (Mechanical Properties WPS .
 )(Thickness Range
. QW-451.1 WPS
:
- )1/16 in. (1.6mm
3/8 in. (10mm) - < )1/16 in. (1.6mm
< 3/4 in. (19mm) - < )3/8 in. (10mm
< 1 in. (38mm) - )3/4in. (19mm
- ) 1 in. (38mm

)(Pipe Diameter Range

WPS .
O.D. I.D QW-452.3 . .
- )1 in. (25mm
< 27/8 in. (73mm) - )1 in. (25mm
27/8 in. (73mm) -

)(Filler Metals
.
.
. :
(
(
(
(
( ) (
(
(
(

) (Electrode ) (Rod . Filler Metal AWS

A5.1 A5.31 . ASME AWS SF
AWS A5.12 SFA5.12 Part C Section II ASME . 18 Filler Metals
. Filler Metals
) .(EN 12072,EN 785,EN 499,ISO 2560
 - 18 Filler Metals

:
- E 70xx 6.4mm
6.4mm .
- E 7x 8mm .
- - E 70S-x 8mm .
- E 70T-x 8mm .
 - . . AWS A5.1
.
AWS A5.5 1 2 ) 350-430C
( 120-150C . 2 .
.
QW-404 WPS .

(F-No) F
F-No QW-432 .
WPS PQR . 4 F-No
19 .

QW F-No

432.1 1-6
432.2 21-24 Al
432.3 31-37 Cu
432.4 41-45 Ni
432.5 51 Ti
432.6 61 Zr
432.7 71-72

F-No -4

- 19 F-No
 (A-No) A
A-No . QW-404.5 A ) . (5
- SMAW, GTAW, PAW
. .
- ESW GMAW .
.
- SAW
.

-5 A-No

)(Spec. No.
AWS . ASME SF .
18 20 .

SFA-5.1
SFA-5.2
SFA-5.3
SFA-5.4
SFA-5.5
SFA-5.6
SFA-5.7
SFA-5.8
SFA-5.9
SFA-5.10
SFA-5.11
SFA-5.12
)(Solid Surfacing SFA-5.13
SFA-5.14
SFA-5.15
SFA-5.16
SFA-5.17

SFA-5.18

SFA-5.20
)(Composite Surfacing SFA-5.21

SFA-5.22

SFA-5.23
SFA-5.24
SFA-5.25
SFA-5.26
SFA-5.28
SFA-5.29
SFA-5.30

SFA-5.31

- 20 Filler Metals

AWS ))(AWS No. (Class No.

. A 5.1 E xxxx .
E . E ksi )
( E 11013G:
 E 60xx, E 70xx, E 80xx, E90xx, E 110xx, E120xx
:
: E xx1x - ) (OH,H,V,F .
: E xx2x - ) (H,F .
: E xx3x - ) (F .
AWS 0 8
6 .
A 5.4 ASTM
E . E 316 L-16 E 310 E 304
OFW E G G 316
AWS .

- 21

)( )( 0
)( ) (
1
2
3
4
5
6
7
8
9

-6
 )(Size of Electrode
) ( .
: .
.
. V K
.
.
:

-1
3/25 . 4 5 .
2/5 3/25 4
.
-2 V
4 5 .
-3 5 .
3/25 4 . 10 3/25 4
.

)(Deposited Weld Metal Thickness Range

WPS QW-451 .

) ( ) )( Electrode- Flux (Calss

SFA-5.17
SFA-5.23 .
. 4 22
. 23 .
 4 - 22

- 23
 )( Consumable insert
.
ASME Sec.ll, Part C, SFA 5.30 . SFA 5.30
F.No QW-432 .

)( Other
.

) ( Positions
:
(1 Flat
(2 Horizontal
(3 Vertical
(4 Overhead
QW-405 . ASME Sec. IX QW-461
. :

)(Position(s) of Groove / Position(s) of Fillet

7 24 ).
( :
.

-7
 - 24

)(Welding Progression
) (Upward .

) (Preheat
... .
-
) - (Tempering . .
.
. 18 0C .
76 ) 3 ( . QW-406 .
:
 ) )( Preheat Temp.(min
.
. :

ASME B31.1 ASME B31.3 table 330.1.1 AWS D1.1 table 3.2 ASME Sec. Vlll Div.1

. ) (IIW
) (CE 8 ). K
( 8 ) : QW-403.26 (

-8 IIW

CE 6.1.3 API 5L .

) )( Interpass Temp.(max
AWS D1.1 table 3.2 .
) (Tempering . P No. l 300 0C .
 ) (Preheat Maintenance
WPS .

) ( )(Post Weld Heat Treatment

QW-407 . P.No 1 , 3 , 4 , 5 , 6 , 9 , 10
11 :
- PWHT
PWHT-
PWHT- ) (
PWHT- ) (
PWHT- .
WPS . .

) ( Temperature Range
) ( .
:
- )590 0C (1100 0F
- )650 0C (1100-1200 0F
- ) 600 0F(315 0C .
- 315 0C 220 0C/hr . 220/t t
.
- 4.6m 140 C .
0

- 83 0C .
- 260 0C/hr . 260/t t
.
-2 D+1270/120 D
.
:

AWS D1.1 item 5.8 , ASME B31.3 table 331.1.1

) (Time Range
. -
. .
 )(Other

WPS WPS
.

)(Gas
. WPS
QW-408 . :
(1 (2 (3

))(Shielding Gas(es
Ar CO2 He N2 .
.
. ).
( . ) (OFW
: . 9
.

-9

))(Percent Composition (Mixture

.
. Co2-99% : .Co2-20% + Ar-80% WPS OFW
.
).
10 (
 -10
) (Flow Rate

. .
5-15 lit/ min . 11 .

-11

)( Electrical Characteristics

. .
QW-409 . :
 :

)(Current AC or DC
DC AC . DC .
. AC .

) (Polarity
DC . .
.

.
( : DC
DCEP: Direct Current Electrode Positive
DCRP: Direct Current Reverse Polarity
( : DC
DCEN: Direct Current Electrode Negative
DCSP: Direct Current Straight Polarity

) )(Amps ( Range
.... . SMAW
1 45 -30 ). 12 13 (

GTAW
)Tungsten Size (mm )Current(A )Volts(v )Travel Speed (Cm/min.
1 50-80 7-13 5-10
1.6 60-140 7-13 5-10
2.4 80-160 7-13 5-10
3.2 150-300 7-13 5-10
4.0 250-500 7-13 5-10

-12
 SMAW

Travel Speed
Position Diameter Polarity )Current(A )Volts(v
)(Cm/min.

2.5 80-120 16-20 10-20

& Flat 3.2 AC or 110-150 18-22 10-20

Horizontal DCRP
4.0 150-200 19-25 10-20

5.0 200-250 19-25 10-20

& Vertical 2.5 AC or 80-100 16-20 8-13

Overhead 3.2 DCRP 80-120 18-22 8-13

4.0 100-160 19-25 8-13
5.0 160-220 19-25 8-13

-13

))(Volts ( Range
. 20-24 50-60
) 30-40 ( . .
14 .
 -14

) (Tungsten Electrode Size and Type

GTAW . .
:
- - . - 0.8 2.2
. .
) AWS A 5.12 EN 26848 ( . 15
.

-15
 (Mode of Metal Transfer for GMAW) GMAW
GMAW . :
) (Short Circuiting ) (Spray ) (Globular ...

.

.
.
. .
. 25 .

- 25

) (Eloctrode Wire Feed Speed Range

.

)(Technique
QW-410 . :
.1 ) ( ) (
.2
.3
.4
.5
.6
.7
.8
.9
.10
 ) (String or Weave Bead
) ( .
. 8 .
) 26 (

- 26

) (Orifice or Gas Cup Size

.

) (Initial and Interpass Cleaning (Brushing , Grinding,)(.....

) (
. ...
.
) (Method of Back Gouging
:
( Electric Arc gouging
Oxyfuel gouging (
Grinding and Chipping (

)(Oscillation
. ...
.
 )(Contact Tube toWork Distance
GMAW SAW . ESO
Electrical Stick-Out . TWD
Tip to Work Distance ). 27 (

-27

))( Multiple or Single Pass(per side

.

)(Multiple or Single Electrode

SAW .
.

))(Travel Speed(range
.

)(Peening

.
 WPS
WPS . ASME
:
.a
.b
.c
) : ( Essential Variables WPS PQR .
) : (Supplementary Essential Variables WPS PQR
.
) : ( Nonessential Variables WPS PQR .
ASME Sec.IX QW-252 QW-262 .
WPS
WPS . PQR WPS
.

)(Standard WPSs
.
) (WPS . WPS WPS
PQR . PQR .
!!.
.
) (PreQualified WPSs AWS D1.1
. WPS . AWS
.
. WPS PQR .
WPS
PQR AWS D1.1 Section 3 ) . (
ASME AWS ASME IX Article V ) .
2000( AWS PQR
. ASME

PQR QW-510(d)) . (

AWS .

.
... .
.
:
8 .
6/4 6/4 .
4 EXX14 .
4
.
6/4 .
:
9/5 .
8 .
12/7 .
:
3 .
4 .

210C . .
.
....
.
.

.
.
. 8 .
6/4 . 12/7 .
 15/9 .
.

600
. 1000 .

) (
4 2/4 2 .
12/7 9/5
8 .
GMAW 6 /4 .
12/7 . 15/9
.
FCAW 6/4 .
12/7 .
15/9 .

. .
. .
210C . .
.
....
.
GMAW .
5 .
... .
.