wis5 wps 05

8/13/2019 WIS5 WPS 05

1/22

Copyright 2005 TWI Ltd World Centre for Materials Joining Technology

WI 3.1

M.Rogers

Weld Procedures

Welding Inspection

Course notes section reference 5

8/13/2019 WIS5 WPS 05

2/22


WI 3.1

M.Rogers

Welding Procedures

Example Code: BS EN 288


8/13/2019 WIS5 WPS 05

3/22


WI 3.1

M.Rogers

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

8/13/2019 WIS5 WPS 05

4/22


WI 3.1

M.Rogers

In most codes reference is made to how the procedure are to bedevised 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 aprocedure but may contain information that may be used in writinga weld procedure

EN 1011Process of Arc Welding Steels

Welding Procedures

8/13/2019 WIS5 WPS 05

5/22


WI 3.1

M.Rogers

Parent material

Type (Grouping)ThicknessDiameter (Pipes)Surface condition)

Welding processType of process (MMA, MAG, TIG, SAW etc)Equipment parametersAmps, Volts, Travel speed

Welding ConsumablesType of consumable/diameter of consumableBrand/classificationHeat treatments/ storage

Components of a welding procedure

Welding Procedures

8/13/2019 WIS5 WPS 05

6/22


WI 3.1

M.Rogers

Joint design

Edge preparation

Root gap, root faceJigging and tacking

Type of baking

Welding Position

Location, shop or siteWelding position e.g. 1G, 2G, 3G etc

Any weather precaution

Welding Variables

Run sequences

Back gougingInterpass temperatures

Thermal heat treatments

Preheat, temps

Post weld heat treatments e.g. stress relieving

Welding Procedures

8/13/2019 WIS5 WPS 05

7/22Copyright 2005 TWI Ltd World Centre for Materials Joining Technology

WI 3.1

M.Rogers

When the data has been collected, the procedure mustbe validated by producing a test weld,weld procedu re

test (WPT).

A number of standards provides information with

regards to approving a procedure, but normally this will

require the WPT to be tested by NDT and mechanical

testing.

The locations and tests required will be given in theapplicable code or standard

Most codes and standards provide a report format to

record the results

Approving the procedure:

Welding Procedures

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Examination and testing requirements of a WPT for

procedure approval (BS EN 288)

Welding Procedures

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

After the testing is completed and all the relevant results

collated, the results need to be assessed in accordance withthe relevant code/standard. The results are then generally

recorded.

pWPS:Preliminary Welding Procedure Specification

Before procedure approval.

WPS: Welding Procedure Specification

After procedure approval

WPAR (WPQR):Welding Procedure Approval Record

Welding procedure test record

Welding Procedures

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Once the welding procedure has been approved, If any

essential variableis changed during production the WPS mayrequire re-approval. Most codes/procedures dealing with

procedure qualifications provide a list of what is an essential

ornon-essential variable.

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

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Example:

Welding

Procedure

Specification

(WPS)

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Welder Approval

Example Code: BS EN 287


8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

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 Quali f ication Test(WQT).

Object of a welding qualification test

.To give maximum confidence that the welder meets the

requirements of the approved procedure (WPS).

The test weld should be carried out on the same materialand same conditions as for the site welds

The welder who carries out the procedure qualification weld

would automatically qualify when the procedure qualifies

Welder Approval

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Information that should be included on a welders test

certificate are:1. Welders name and identification number

2. Date of test and expiry date of certificate

3. Standard/code e.g. BS EN 287

4. Test piece details

5. Welding process.

6. Welding parameters, amps, volts

7. Consumables, flux type and filler classification details

8. Sketch of run sequence, welding positions

9. Joint configuration details10.Material type qualified, pipe diameter etc

11.Test results, remarks

12.Test location and witnessed by

13.Extent (range) of approval

Welder Approval

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

BS EN 287

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Range of approval according to electrode flux type

Range of approval

according materialgroups

BS EN 287

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

The inspection of a welders qualification test.

It is normal for a qualified inspectors usually from anindependent body to witness the welding.

Under normal circumstances only one test weld per welder

is permitted

If the welder fails the test weld and the failure is not the fault

of the welder e.g. faulty welding equipment then a re-test

would be permitted.

The testing of the test weld is done in accordance with the

applicable code, but it is not normal to carry out test that test

for the mechanical properties of welds e.g. tensile, charpy

and hardness tests.

Welder Approval

M R

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Tests methods required for welder qualification

(BS EN 287)

Welder Approval

M R

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Example:

Welder Approval

Qualification

Certification

M Rogers

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

pWPS

Stages in Welding and Welder Approval

DEVELOPMENT

OF PROCEDURE

Application standardContract

Project specifications

APPROVAL

OF PROCEDURE

BE 288ASTM IX

AWS D1.1

WPAR/WPQR

WELDER APPROVAL

CERTIFICATE

6 MONTHS +PROLONGATION

FINALISATION OF

PROCEDURE

RELEASE WPS FOR

PRODUCTION

Welding Procedure Specification

WORK INSTRUCTIONS

M Rogers

8/13/2019 WIS5 WPS 05


WI 3.1

M.Rogers

Any Questions

M Rogers

8/13/2019 WIS5 WPS 05

22/22

WI 3.1

M.Rogers

QU 1. State six essential variables in a welding procedure.

QU 2. What do you understand by the term extent of approval and

give four examples.

QU 3. Describe what you understand by a welding procedurespecification, A welding procedure approval record and a

welder certificate

QU 4. What is the reason for approving a welding procedure and

a welder

QU 5. Give three reasons why a welder may require re-

qualification.

Questions

Welding Procedures

wis5 wps 05

Documents