Welding Inspector

WPS – Welder Qualifications

Section 5
 Welding Procedure Qualification 5.1
Question:
What is the main reason for carrying out a Welding Procedure
Qualification Test ?
(What is the test trying to show ?)
Answer:
To show that the welded joint has the properties* that satisfy
the design requirements (fit for purpose)

* properties
•mechanical properties are the main interest - always strength but
toughness & hardness may be important for some applications
•test also demonstrates that the weld can be made without defects
 Welding Procedures 5.1

Producing a welding procedure involves:

Planning the tasks
Collecting the data
Writing a procedure for use of for trial
Making a test welds
Evaluating the results
Approving the procedure
Preparing the documentation
 Welding Procedures 5.2
In most codes reference is made to how the procedure are to
be devised and whether approval of these procedures is
required.
The approach used for procedure approval depends on the
code:
Example codes:
• AWS D.1.1: Structural Steel Welding Code
• BS 2633: Class 1 welding of Steel Pipe Work
• API 1104: Welding of Pipelines
• BS 4515: Welding of Pipelines over 7 Bar

Other codes may not specifically deal with the requirement of

a procedure but may contain information that may be used in
writing a weld procedure
• EN 1011Process of Arc Welding Steels
 Welding Procedure Qualification 5.3

(according to EN ISO 15614)

The welding engineer writes qualified Welding Procedure

Specifications (WPS) for production welding

Production welding conditions must remain within the range of

qualification allowed by the WPQR
Welding Procedure Qualification 5.3

(according to EN Standards)

welding conditions are called welding variables

welding variables are classified by the EN ISO Standard as:

•Essential variables
•Non-essential variables
•Additional variables
Note: additional variables = ASME supplementary essential
The range of qualification for production welding is based on
the limits that the EN ISO Standard specifies for essential
variables*
(* and when applicable - the additional variables)
Welding Procedure Qualification 5.3

(according to EN Standards)

WELDING ESSENTIAL VARIABLES

Question:
Why are some welding variables classified as essential ?
Answer:
A variable, that if changed beyond certain limits (specified by
the Welding Standard) may have a significant effect on the
properties* of the joint
* particularly joint strength and ductility
Welding Procedure Qualification 5.3
(according to EN Standards)
SOME TYPICAL ESSENTIAL VARIABLES
• Welding Process
• Post Weld Heat Treatment (PWHT)
• Material Type
• Electrode Type, Filler Wire Type (Classification)
• Material Thickness
• Polarity (AC, DC+ve / DC-ve)
• Pre-Heat Temperature
• Heat Input
• Welding Position
 Welding Procedures 5.3

Components of a welding procedure

Parent material
Type (Grouping)
Thickness
Diameter (Pipes)
Surface condition)
Welding process
Type of process (MMA, MAG, TIG, SAW etc)
Equipment parameters
Amps, Volts, Travel speed
Welding Consumables
Type of consumable/diameter of consumable
Brand/classification
Heat treatments/ storage
 Welding Procedures 5.3

Components of a welding procedure

Joint design
Edge preparation
Root gap, root face
Jigging and tacking
Type of baking
Welding Position
Location, shop or site
Welding position e.g. 1G, 2G, 3G etc
Any weather precaution
Thermal heat treatments
Preheat, temps
Post weld heat treatments e.g. stress relieving
 Welding Procedures 5.3

Object of a welding procedure test

To give maximum confidence that the welds mechanical
and metallurgical properties meet the requirements of the
applicable code/specification.
Each welding procedure will show a range to which the
procedure is approved (extent of approval)
If a customer queries the approval evidence can be
supplied to prove its validity
 Welding Procedures
Summary of designations:
pWPS: Preliminary Welding Procedure Specification
(Before procedure approval)

WPAR (WPQR): Welding Procedure Approval Record

(Welding procedure Qualification record)

WPS: Welding Procedure Specification

(After procedure approval)
 Example:
Welding
Procedure
Specification
(WPS)
 Welder Qualification 5.4

Numerous codes and standards deal with welder qualification,

e.g. BS EN 287.
• Once the content of the procedure is approved the next
stage is to approve the welders to the approved procedure.
• A welders test know as a Welders Qualification Test (WQT).

Object of a welding qualification test:

• To give maximum confidence that the welder meets the
quality requirements of the approved procedure (WPS).
• The test weld should be carried out on the same material and
same conditions as for the production welds.
 Welder Qualification 5.4 & 5.5

(according to EN Standards)
Question:
What is the main reason for qualifying a welder ?

Answer:
To show that he has the skill to be able to make production
welds that are free from defects
Note: when welding in accordance with a Qualified WPS
 Welder Qualification
(according to EN 287 )
5.5

The welder is allowed to make production welds within the

range of qualification shown on the Certificate
The range of qualification allowed for production welding is
based on the limits that the EN Standard specifies for the
welder qualification essential variables

A Certificate may be withdrawn by the Employer if there is

reason to doubt the ability of the welder, for example
• a high repair rate
• not working in accordance with a qualified WPS

The qualification shall remain valid for 2 years provided there is certified
confirmation of welding to the WPS in that time.
A Welder’s Qualification Certificate automatically expires if the welder has not
used the welding process for 6 months or longer.
Welding Procedure Qualification 5.7
(according to EN ISO 15614)
Welding Engineer writes a preliminary Welding Procedure
Specification (pWPS) for each test weld to be made

• A welder makes a test weld in accordance with the pWPS

• A welding inspector records all the welding conditions used

for the test weld (referred to as the ‘as-run’ conditions)

An Independent Examiner/ Examining Body/ Third Party

inspector may be requested to monitor the qualification
process

The finished test weld is subjected to NDT in accordance with

the methods specified by the EN ISO Standard - Visual, MT or
PT & RT or UT
 Welding Procedure Qualification 5.7
(according to EN ISO 15614)

Test weld is subjected to destructive testing (tensile, bend,

macro)
The Application Standard, or Client, may require additional
tests such as impact tests, hardness tests (and for some
materials - corrosion tests)

A Welding Procedure Qualification Record (WPQR) is prepared

giving details of: -
• The welding conditions used for the test weld
• Results of the NDT
• Results of the destructive tests
• The welding conditions that the test weld allows for
production welding
The Third Party may be requested to sign the WPQR as a true
record
 Welder Qualification 5.9
(according to EN 287 )

An approved WPS should be available covering the range of

qualification required for the welder approval.

• The welder qualifies in accordance with an approved WPS

• A welding inspector monitors the welding to make sure that

the welder uses the conditions specified by the WPS

EN Welding Standard states that an Independent Examiner,

Examining Body or Third Party Inspector may be required to
monitor the qualification process
 Welder Qualification 5.9

(according to EN 287 )

The finished test weld is subjected to NDT by the methods

specified by the EN Standard - Visual, MT or PT & RT or UT
The test weld may need to be destructively tested - for certain
materials and/or welding processes specified by the EN
Standard or the Client Specification

• A Welder’s Qualification Certificate is prepared showing the

conditions used for the test weld and the range of qualification
allowed by the EN Standard for production welding
• The Qualification Certificate is usually endorsed by a Third
Party Inspector as a true record of the test
 Welder Qualification 5.10

Information that should be included on a welders test certificate are,

which the welder should have or have access to a copy of !

• Welders name and identification number

• Date of test and expiry date of certificate
• Standard/code e.g. BS EN 287
• Test piece details
• Welding process.
• Welding parameters, amps, volts
• Consumables, flux type and filler classification details
• Sketch of run sequence
• Welding positions
• Joint configuration details
• Material type qualified, pipe diameter etc
• Test results, remarks
• Test location and witnessed by
• Extent (range) of approval