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    WPS

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    joehodoh
    This document discusses welding procedure specifications (WPS) and procedure qualification records (PQR). [1] A WPS provides direction for making production welds according to code requirements and specifies welding variables. [2] A PQR documents welding data and test results used to qualify a welding procedure. [3] WPS and PQR define essential variables that could affect weld properties, such as material, process, filler metal, and positions.

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    WPS

    Uploaded by

    joehodoh
    222 views42 pages
    This document discusses welding procedure specifications (WPS) and procedure qualification records (PQR). [1] A WPS provides direction for making production welds according to code requirements and specifies welding variables. [2] A PQR documents welding data and test results used to qualify a welding procedure. [3] WPS and PQR define essential variables that could affect weld properties, such as material, process, filler metal, and positions.

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    WPS

    Original Title

    162159079-WPS

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    This document discusses welding procedure specifications (WPS) and procedure qualification records (PQR). [1] A WPS provides direction for making production welds according to code requirements and specifies welding variables. [2] A PQR documents welding data and test results used to qualify a welding procedure. [3] WPS and PQR define essential variables that could affect weld properties, such as material, process, filler metal, and positions.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    222 views42 pages

    WPS

    Uploaded by

    joehodoh
    This document discusses welding procedure specifications (WPS) and procedure qualification records (PQR). [1] A WPS provides direction for making production welds according to code requirements and specifies welding variables. [2] A PQR documents welding data and test results used to qualify a welding procedure. [3] WPS and PQR define essential variables that could affect weld properties, such as material, process, filler metal, and positions.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 42
    At a glance
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    The key takeaways are that a Welding Procedure Specification (WPS) establishes the welding parameters and conditions required to produce welds meeting the intended application requirements. It must be qualified by testing to ensure the weld properties are suitable.

    The main components of a WPS are that it is a written document that specifies the welding conditions (ranges) under which welding must be performed, called variables. It addresses essential, supplementary essential and non-essential variables. A WPS must also be qualified by the manufacturer through Procedure Qualification Records (PQR).

    The different types of variables addressed in a WPS are essential variables which must be followed, supplementary essential variables where some changes are allowed, and non-essential variables which have little effect on the mechanical properties of the weld. Essential variables include things like material, thickness, process, filler metal, etc.

    Welding Procedure Specification

    ASME SEC IX
    Purpose of WPS Qualification

    To determine that the weldment is capable of


    providing the required properties for the
    intended application.

    WPS establishes the properties of the weldment


    and not the skill of the welder.
    Welding Procedure Specification
    It is a written document that provides direction to
    the welder for making production welds in
    accordance with code requirements.
    WPS specifies the conditions (ranges) under
    which welding must be performed called
    variables.
    WPS addresses essential, supplementary
    essential and non essential variables
    Any WPS must be qualified by the manufacturer.
    Procedure Qualification
    When two or more procedures (diff
    processes or other essential variables) are
    used in one joint, the applicable range of
    thickness of weld metal qualified is also
    specified.
    One or more processes from a
    combination may be deleted provided
    remaining metal meets the requirements.
    Procedure Qualification
    Several WPSs may be prepared from one PQR.
    Example.
    1G plate PQR may support WPSs in 2G, 3G,
    4G, pipe 5G, 6G etc provided other parameters
    are kept same.
    A single WPS may cover several PQRs

    Example. A single WPS may cover 1.6 mm to


    32 mm thickness if PQRs for 1.6 to 4.8 mm
    and 4.8 mm to 32 mm thickness ranges are
    available.
    Considerations for establishing WPS

    Material Preheat/Postheat/
    PWHT requirements
    Thickness
    Skill of welder
    Configuration
    Good welding m/c
    Detailed drawing of with accessories
    weldment
    Process
    Code of construction
    WPS preparation

    WPS Welding Procedure Specification

    is prepared based on the

    PQR Procedure Qualification Record


    Procedure Qualification Record
    It documents what occurred during welding the test
    coupon and the results of the test coupon.

    PQR documents the essential variables and other


    specific information and the results of the required
    testing. In addition, when notch toughness is
    required for procedure qualification, the applicable
    supplementary essential variables shall be recorded.
    Procedure Qualification
    PQR is a record of welding data used to weld a
    test coupon. It also contains test results.

    Completed PQR shall document all essential


    variables including ranges.

    PQR to be certified accurate and shall not be


    subcontracted.

    If more than one process is involved then


    weld deposit thickness for each process and
    filler metal to be recorded.
    Variables
    Base metal
    Welding Process Essential
    Filler metal
    Shielding medium Non-essential
    Joint design
    Backing material Supplemental
    Preheat essential
    PWHT
    Back gauging
    Variables
    Essential
    Changes in which are considered to affect the
    mechanical properties of the weldment

    Supplementary essential
    Required for meeting notch toughness requirements

    Non-essential
    Changes can be made with out requalification
    WPS for SMAW

    Essential variables
    Change in qualified Thickness
    Change in P no
    Change in F no of filler metal
    Change in A no of filler metal
    Change in deposited metal thickness
    Decrease of more than 55C in preheat
    Change in PWHT
    WPS for SMAW

    Supplementary Essential variables


    Change in Group no of base metal
    Change in T limits for impact test
    Change in dia of filler metal > 6 mm
    Change in AWS class of filler metal
    Change in welding position
    Increase of more than 55 C in preheat
    Change in PWHT Time and temp range
    Change in current or polarity
    WPS for SMAW
    Non Essential variables
    Change in Groove design, backing, root spacing,
    retainers etc
    Change in dia. of filler metal
    Change in AWS class of filler metal
    Change in welding position
    Change in preheat maintenance
    Change in current or polarity
    Change in string/weave, cleaning, back gouging,
    peening, manual/automatic
    WPS for GTAW
    Essential variables
    Change in qualified Thickness
    Change in P no
    Change in F no & A no of filler metal
    Addition/deletion of filler metal
    Change in size of filler metal, product form
    Decrease of more than 55 C in preheat
    Change in PWHT
    WPS for GTAW

    Essential variables (cond)

    Change in single, mixture % gas


    Deletion of backing gas
    Change in shielding / trailing gas
    Change in Closed to out chamber technique
    WPS for GTAW
    Supplementary Essential variables
    Change in Group no of base metal
    Change in T limits
    Change in AWS class of filler metal
    Change in welding position
    Increase of more than 100 F in preheat
    Change in PWHT Time and temp range
    Change in current/polarity, incr. in heat input
    Change in multi to single pass, electrodes
    Procedure Qualification Thickness limits
    T mm Range Max t Tests
    of T Weld (transverse bend)

    <1.6 T - 2T 2t 2Tr Ten,2 FB,2 RB


    1.5 to 10 1.5 - 2T 2t -do-
    10 to <19 5 - 2T 2t -do-
    19 to 38 5 - 2T 2t if t<19 2Tr Ten, 4 SB
    2Tif t>19
    >38 38 to 200 2t if t<19 -do-
    8 if t>19
    Weld positions & orientation
    Weld Positions
    Plate groove positions 1G, 2G, 3G, 4G
    Pipe groove positions 1G, 2G, 5G, 6G
    Plate fillet positions 1F, 2F, 3F, 4F
    Pipe fillet positions 1F, 2F, 2FR, 4F, 5F

    Weld orientations
    1F - 0 to 30
    2F - +15 -10 wrt 45
    4F - 0 - 125
    3F - 125 - 235
    Base Metal Classification

    P nos depend on composition, weldability &


    mechanical properties.

    Group nos classify metals within P nos for


    procedure qualification where notch
    toughness requirements are specified. But
    base metals can not be indiscriminately
    substituted.
    Base Metal P Numbers

    P1 - P11 Steel
    P21 - P25 Al alloys
    P31 - P35 Cu alloys
    P41 - P47 Ni alloys
    P51 - P53 Ti alloys
    P61 - P62 Zr alloys
    Base Metal P Numbers
    Examples of P nos for steel
    P1 C Steel
    P3 1/2 Mo steels
    P4 1 Cr 1/2 Mo steels
    P5A 2 1/4 Cr 1 Mo steels
    P6 13 Cr steel
    P7 17 Cr steel
    P8 ASS
    P9A 2 1/2 Ni steels
    P10A Mn - 1/2 Ni - V steels
    P11 9 Ni steels
    Base Metal for WPS
    Material combinations qualified
    Test Coupon Base Metals qualified
    Px Px Px
    Px Py Px - Py
    P3 - P3 P3 ( P3 / P1)
    P4 - P4 P4 ( P4 / P3 / P1)
    P5A - P5A P5A ( P5A / P4 / P3
    / P1)
    P5A (P4 / P3 / P1) P5A (P4 / P3 / P1)
    P4 (P3 / P1) P4 (P3 / P1)
    Filler Metal F Numbers
    Based on usability characteristics i.e ability of
    welders to make satisfactory welds with given
    filler
    F1 E XX20
    F2 E XX12, E XX13
    F3 E XX10, E XX11
    F4 E XX18
    F5 ASS, Duplex SS
    F6 Bare rods
    Weld Metal A Numbers
    Based on chemical composition
    A1 Mild steel
    A2 C - Mo steel
    A3 Cr - Mo steel (Cr 0.4 - 2%)
    A4 Cr - Mo steel (Cr 2 - 6%)
    A5 Cr - Mo steel (Cr 6 - 10.5%)
    A6 Cr Martensitic
    A7 Cr Ferritic
    A8 Cr Ni steels (Cr 14.5 - 30% Ni 7.5 - 15%)
    A9 Cr Ni steels (Cr 19 - 30% Ni 15 - 37%)
    A10 Ni steels (Ni 0.8 - 4%)
    A11 Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)
    A12 Ni Cr Mo steels (Cr 1.5% Mo 0.25-0.8%
    Ni 1.25 -2.8%)
    Procedure Qualification Thickness limits

    T Range Max t Tests


    of T of weld (longitudinal bend)

    1.6 T - 2T 2t 2T, 2 FB, 2 RB


    1.6 to 19 1.6 - 2T 2t -do-
    19 1.6 - 2T 2t -do-

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