WELDING PROCESS

REFERENCE PROCEDURE
Details of:
a) Base metal selection and test requirements
b) Welding consumables selection, storage and usage (as
applicable)
c) Preparation and Certification of WPS, PQR and WQT
d) Actual welding process execution (SMAW)

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REVISION HISTORY

Revision
Date Details of Revision
No.
00 December 07, 2017 Initial Issue

Added detailed information for AWS-Certified Welding Inspector and

01 August 12, 2018
requirement on Charpy V-Notch and other mechanical tests

Full modification of the procedure to be in-line with organization standard

02 March 14, 2019
welding process requirements

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 CONTENT
TITLE PAGES
1 SCOPE ………………………………………………………………………………………… 4
2 ACCEPTANCE CRITERIA / REFERENCES ………………………………………… 4
3 OVERVIEW …………………………………………………………………………………. 4
4 PROCEDURE ……………………………………………………………………………….. 6
4.1 BASE METAL SELECTION AND TESTING REQUIREMENTS …….. ………………. 6
4.2 CONTROL OF WELDING ELECTRODES (SELECTION, STORAGE AND
USAGE) ………………………………………………………………………………………….…….. 7

4.3 WPS, PQR AND WQT PREPARATION AND DOCUMENTATION …………….. 8

4.4 WELDING PROCESS EXECUTION …………………………………………………………... 11

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1 SCOPE

This welding procedure document covers the detailed instruction and requirements
regarding the preparation of WPS (Welding Procedure Specifications), PQR (Procedure
Qualification Records) and WQT (Welder Qualification Test) in reference with conducted welding
qualification with specific parameters and performed testing (e.g. radiography, charpy V-notch
test, impact test, bend test and tensile test) as applicable on welded steel products and as per
customer requirements.

This will also cover the preparation and execution of actual welding activities with the detailed
information regarding base metal selection and test requirements and welding electrode
selection, storage, usage and its baking process, if necessary as per provided manufacturers’
recommendation or as standard reference (AWS D1.1:2015, 23rd edition).

2 ACCEPTANCE CRITERIA / REFERENCES

This welding procedure document was prepared according to the standad references related to
welding process preparation and execution:
 AWS D1.1:2015, 23rd edition including the acceptance criteria for cyclically loaded
structures to be applied for critical weld of masts and derricks
 API Spec 4F, 4th edition 2013, with Addendum 1 (December 2016)
 ASME SEC IX, 2017
 ASTM A370 (Standard Test Methods and Definitions for Mechanical Testing of Steel
Products)
 Project owner specification and construction code

3 OVERVIEW

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A base metal is also called the parent metal. This is the metal in the welding practice that has
been cut by the various forms of cutting, then prepared to be welded. Welding is performed to
join one section of the base metal to another section of base metal by means of the various
welding processes.

Welding electrode is used to conduct current through a workpiece to fuse two pieces together.
For a direct current system, the weld rod or stick may be a cathode for a filling type weld or an
anode for other welding processes.

Shielded Metal Arc Welding (SMAW) also known as Manual Metal Arc Welding (MMA or
MMAW) or Flux Shielded Arc Welding is a process that uses consumable electrode covered with
a flux to lay the weld. An electric current, in a form of direct current (DC) from a welding power
supply is used to form an electric arc between the electrode and the metals to be joined. The
workpiece and the electrode melts forming a pool of molten metal (weld pool) that cools to
form a joint. As the weld is laid, the fluc coating of the electrode disintegrates, giving off vapors
that serve as a shielding gas and providing a layer of slag, both of which protect the weld area
from atmospheric contamination.

Welding Procedure Specification (WPS) is a formal written document that

describes welding procedures, which provides direction to the welder or welding operators for
making sound and quality production welds as per the code requirements. The purpose of the
document is to guide welders to the accepted procedures so that repeatable and trusted
welding techniques are used. A WPS is developed for each material alloy and for each welding
type used. Specific codes and/or engineering societies are often the driving force behind the
development of a company's WPS.

Procedure Qualification Record (PQR or WPQR): A WPS is supported by a PQR which is a record
of a test weld performed and tested (more rigorously) to ensure that the procedure will produce
a good weld. Individual welders are certified with a qualification test documented in a Welder
Qualification Test Record (WQTR) that shows they have the understanding and demonstrated
ability to work within the specified WPS. A PQR is required when it is necessary to demonstrate
that your company has the ability to produce welds possessing the correct mechanical and
metallurgical properties.

Welder Qualification Test, WQT (also known as Welder Certification) is a process which
examines and documents a welder's capability to create welds of acceptable quality following a
well-defined welding procedure specification (WPS). It is based on especially designed tests to
determine a welder's skill and ability to deposit sound weld metal. The welder's tests consist of
many variables, including the specific welding process, type of metal, thickness, joint design,

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position, and others. Most often, the test is conducted in accordance with a particular code. The
tests can be administered under the auspices of a national or international organization, such as
the American Welding Society (AWS), or American Society of Mechanical Engineers (ASME), but
manufacturers may specify their own standards and requirements as well. Welders can also be
certified in specific welding related professions: for example, American Welding Society certifies
welding inspectors and instructors. This AWS-Certified Welding Inspector is a mandatory
requirement in conducting welding inspection of welded on-process and finish products
internally by either existing competent personnel being trained as AWS-CWI or Third Party with
the same training course and competency.

4 PROCEDURE
4.1 BASE METAL SELECTION AND TEST REQUIREMENTS

Base metals (material grade) to be used in qualification must be in-line with the declared
requirements for the preparation of WPS and PQR to qualified the existing welders in the
organization. WPS to be prepared will be uniquely applicable to a particular base metal
(material grade) to be qualified in parallel with welding process type to be used (e.g.
SMAW).

Base metal will have a specific mill test certificate (MTC) defining all the details of the
material grade mechanical properties (e.g. yield strength, tensile strength) and chemical
analysis for a particular lot number (heat number) where the base metal have been
manufactured.

Test requirement details, as defined by the customer must be available. Generally, for a
charpy V-notch test requirements, below are list of steel material grade and/or material
specified yield strength in ksi to verify the the needed temperature in conducting the test:

Charpy V-Notch Energy Absorption Requirements by Specified Yield Strength (ksi)

Material Yield Strength (ksi) Ave. Energy (ft.lbf) Min. Energy (ft.lbf) Test Temperature
35 20 12 -20⁰C (-4⁰F)
36 20 12 -20⁰C (-4⁰F)
46 20 16 -20⁰C (-4⁰F)
50 20 16 -20⁰C (-4⁰F)
60 20 16 -20⁰C (-4⁰F)
70 20 16 -20⁰C (-4⁰F)
90 22 17.6 -60⁰C (-76⁰F)

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 95 22 17.6 -60⁰C (-76⁰F)
100 22 17.6 -60⁰C (-76⁰F)
105 22 17.6 -60⁰C (-76⁰F)

Charpy V-Notch Energy Absorption Requirements by Steel Material Grade

Material Ave. Energy (ft.lbf) Min. Energy (ft.lbf) Test Temperature
A36 / A53 Gr. B 20 16 -20⁰C (-4⁰F)
A500 Gr. B 20 16 -20⁰C (-4⁰F)
A572 Gr. 50 20 16 -20⁰C (-4⁰F)
A992 Gr. 50 20 16 -20⁰C (-4⁰F)
A514H,P,Q < 2” thick 30 24 -20⁰C (-4⁰F)
A514H,P,Q < 2-4” thick 22 17.6 -60⁰C (-76⁰F)
Weld Metal 20 16 -30⁰C (-22⁰F)

Values for percent shear and lateral expansion must be recorded for CVN testing. Weld
metal impact testing must be performed in accordance with standard, AWS D1.1:2015.

Unavailable details of this CVN test on the base metal mill test certificate or having
different applied temperature as declared above will require a material test to be done by
certified Third Party under approved external provider by the organization.

4.2 CONTROL OF WELDING ELECTRODES (SELECTION, STORAGE AND USAGE)

Electrodes for SMAW must be conformed to the requirements of the of AWS A5.1/A5.1M,
Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding, or to the
requirements of AWS A5.5/A5.5M, Specification for Low-Alloy Steel Electrodes for Shielded
Metal Arc Welding.
All electrodes having low-hydrogen coverings conforming to AWS A5.1 and AWS A5.5 must
be purchased only in hermetically sealed containers.
After opening the hermetically sealed container, the electrode exposure to the
atmosphere will not exceed to maximum of four hours (for AWS A5.1 class) and ½ hour
(for AWS A5.5 class).
Electrodes exposed to the atmosphere for periods less than mentioned above may be
returned to a holding oven with minimum maintained temperature of 120⁰C. These
electrodes must be keep inside the oven for a minimum of four hours before re-issue for
usage.
Electrodes exposed to the atmosphere for periods greater than mentioned above must be
disposed and never used for further welding activities.

Keep in mind: Electrodes that have been wet must be disposed and never used for further

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 welding activities.
Welding electrodes safety practices define as follows (as per manufacturer reminder):
a. Welding fumes and gases are hazardous to health and may damage lungs
and other organs, used adequate ventilation.
b. Always read the product label for material specific warnings.
c. Electric shock can kill. Do not touch live electrical parts and be insulated
from work and ground. Stay dry and do not perform welding if clothing or
gloves are wet.
d. Use respirator when welding in confined spaces.
e. Arc rays and sparks can injure eyes and burn skin. Spooled wire can spring.
Wear proper personal protective equipment (PPE).

4.3 WPS, PQR AND WQT PREPARATION AND DOCUMENTATION

WPS / PQR: A welding procedure must be qualified in accordance with the requirements
of an appropriate welding procedure standard, such as AWS D1.1:2015, as follows:

1. Produce a preliminary welding procedure specification (pWPS). This is being prepared

by considering the essential and non essential variables noted in applicable code. Job
requirements, client specification and construction codes shall be referred and
considered for pWPS preparation.
2. Weld a test piece in accordance with the requirements of your specification. The joint
set up, welding and visual examination of the completed weld should be witnessed by
a certified welding inspector such as an AWS-CWI or an Inspection Body. The details of
the test such as the welding current, pre-heat etc., must be recorded during the test.
3. Once the welding is complete the test piece must be subjected to post weld heat
treatment (as required), destructive and non-destructive examination such as
radiography and mechanical tests (e.g. charpy V-notch, tensile, bend, impact test) in
accordance with welding procedure standard, AWS D1.1:2015. This work must be
carried out in a qualified laboratory but the Inspection Body may require witnessing
the tests and viewing any radiographs.
4. If the test is successful, the test / witnessing body completes the appropriate
documents such as PQR and final WPS with complete signatories before endorsement.

Prepare preliminary WPS and get approval from client

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 Perform procedure qualification test in accordance to pWPS

Perform visual, NDT and mechanical testing as per applicable reqt.

Prepare PQR with reference to test result

Prepare WPS from PQR

Get final approval from client

WQT: must be qualified in accordance with the requirements of an appropriate welding

procedure standard, such as AWS D1.1:2015, as follows:

1. Complete a weld test as stated above. The test should simulate production conditions
and the welding position should be the position that the production welds are to be
made in or one more severe.
2. For maximum positional approval a pipe inclined at 45 degrees (referred to as the 6G
position) approves all positions except vertical down.
3. Test the completed weld in accordance with the relevant standard to ensure that the
weld is clean and fully fused.
4. For butt welds, normally a visual examination followed by radiography / bend tests.
5. Once the test is completed the necessary forms have to be completed by you or the
test body and signed by the test body’s surveyor.

Note: Any changes that require a new welding procedure specification (WPS) may also
apply to the welder’s approval, in reference with standard, AWS D1.1:2015.

Acceptance Criteria: In general welds must show a neat workman like appearance. The
root must be fully fused along the entire length of the weld, the profile of the cap should
blend in smoothly with the parent material and the weld should be significantly free from
imperfections. Reference should be made to the acceptance standard for precise details.

Select the proper WPS

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 Arrange the specimen as per job requirement

Conduct welding and monitor at each stage

Perform visual, NDT and mechanical testing as per applicable reqt.

Prepare WQT certificate

Get final approval from client

WPS, PQR AND WQT QUALIFIED RANGES: While preparing final WPS approved ranges to
be provided for all items / values obtained in PQR. Ranges may have mentioned for base
material (P no.), Filler material (F No.), thickness, diameter, preheat, PWHT, heat input etc.
which to be according to reference standard AWS D1.1:2015.

While preparing WQT document, approved ranges may have mentioned for base material
(P no.), Filler material (F No.), thickness, diameter, position etc. which is also according to
reference standard AWS D1.1:2015

WPS, PQR AND WQT STANDARD FORMAT: Documented WPS, PQR and WQT as per issued
by witnessing Third Party will be as per below format, as approved by the organization:

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4.4 WELDING PROCESS EXECUTION

Welding process to be performed and executed by the qualified welders with valid WQT
(Welder Qualification) in reference with documented WPS and PQR.

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Qualified welders can performed welding process depending on ranges of qualification as
declared on their individual WQT certificate in-line with reference WPS. This WQT
certificate will be valid for six (6) months period and to be renewed under the same
external provider witnessed the welders’ performance during qualification.

A documented evidence to support the continuous satisfactory performance of individual

welders must be provided and to be updated by assigned Site Supervisor for each welding
activities to be executed by a particular welder (Welder Performance Continuity Log Sheet
TR-L4-PD-F17-Ryy).

This evidence document will be the reference records of the external provider to declare
that a particular welder performed well and satisfactory on the past six (6) months period
resulting of updation of his welder qualification to be valid for the another six (6) months
period, and so on.

Failure to provide evidence document for the welding activities performed on the last six
(6) months period will result of conducting re-qualification of the involve welder as per the
documented WPS, to ensure his satisfactory performance on welding process.

WORKMANSHIP AND TECHNIQUE

The actual welding technique utilized depends on the electrode, the composition of the
workpiece, and the position of the joint being welded. The choice of electrode and
welding position also determine the welding speed. Flat welds require the least operator
skill, and can be done with electrodes that melt quickly but solidify slowly. This permits
higher welding speeds.

Sloped, vertical or upside-down welding requires more operator skill, and often
necessitates the use of an electrode that solidifies quickly to prevent the molten metal
from flowing out of the weld pool. However, this generally means that the electrode melts
less quickly, thus increasing the time required to lay the weld.

For striking an arc, two techniques have been determined:

 Scratch-start technique mostly preferred for AC welding; drag electrode across
workpiece like striking a match; immediately lift electrode slightly after touching
work. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece,
use a quick twist to free it.

 Tapping technique by bringing electrode straight down to workpiece; then lift

slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks

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 to workpiece, use a quick twist to free it.

Welding activity execution output results must be recorded on a registered form, Welding
Validation Sheet (TR-L4-PD-F04-Ryy) or Welding Map Reference Sheet (TR-L4-PD-F14-Ryy)
depending on the quantity of joints to be welded, to validate the process and maintain for
future reference.

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