Define of WPS and PQT

1. WPS

1.1 The define of WPS

A WPS (Welding Procedure Specification) is a written qualified welding procedure prepared to provide direction for making

production welds to Code requirement. The WPS or other documents may be used to provide direction to the welder or welding

operator to assure compliance with the Code requirements.

1.2 The contents of WPS

The completed WPS shall describe all of the essential, nonessential and supplementary essential variables (when required) for each

welding process used in the WPS.

1.3 The define of essential, nonessential and supplementary essential variables

1.3.1 Essential variables are those in which a change, as described in the specific variables, is considered to affect the mechanical

properties of the weldment, and shall require requalification of the WPS.

1.3.2 Supplementary essential variables are required for metals for which other Section specify notch-toughness tests and are in

addition to the essential variables for each welding process.

1.3.3 Nonessential variables are those in which a change, as described in the specific variables, may be made in the WPS without

requalification.

1.3.4 The Tables of the variables in SMAW, SAW and GTAW

Table 1: QW-253SMAW (Shielded Metal Arc Welding)

Paragraph Brief of Variables Essential Supplementary Essential Nonessential

QW-402 .1 φ Groove design X

Joints .4 - Backing X

.10 φ Root spacing X

.11 ± Retainers X

QW-403 .5 φ Group Number X

Base .6 T Limits impact X

Metals .7 T/t Limits > 8 in. (203 mm) X

.8 φ T Qualified X

.9 T Pass > 1/2 in. (13 mm) X

.11 φ P-No. qualified X

.13 φ P-No. 5/9/10 X

QW-404 .4 φ F-No. X

Filler .5 φ A-No. X
Metals .6 φ Diameter X

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 Define of WPS and PQT

.7 φ Diameter > 1/4 in. (6 mm) X

.12 φ AWS classification X

.30 φt X

.33 φ AWS classification X

QW-405 .1 + Position X

Positions .2 φ Position X

.3 φ↑↓Vertical welding X

QW-406 .1 Decrease > 100 F (56 C) X

Preheat .2 φ Preheat maint. X

.3 Increase> 100 F (56 C) (IP) X

QW-407 .1 PWHT X

PWHT .2 φ PWHT (T & T range) X

.4 T limits X

QW-409 .1 > Heat input X

Electrical .4 φ Current or polarity X X

Characteris .8 φ I & E range
X
tics

QW-410 .1 φ String/weave X

Technique .5 φ Method cleaning X

.6 φ Method back gouge X

.9 φ Multiple to single pass/side X X

.25 φ Manual or automatic X

.26 ± Peening X

Legend:

+ Addition > Increase/greater than ↑Uphill ←Forehand φ Change

- Deletion < Decrease/less than ↓Downhill →Backhand

Table 2: QW-253.1 SMAW (Shielded Metal Arc Welding)

Special Process Variables

Essential Variables
Nonessential Variables for
Paragraph Hard-Facing Overlay (HFO) Corrosion-Resistant Overlay
HFO and CRO
(QW-216) (CRO) (QW-214)

QW-402
.16 < Finished t < Finished t
Joints

QW-403 .20 φ P-No. φ P-No.

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 Define of WPS and PQT

Base
.23 φ T Qualified φ T Qualified
Metals

QW-404 .12 φ AWS classification

Filler .37 φ A-No.

Metals .38 φ Diameter (1st layer)

QW-405
.4 + Position + Position
Positions

QW-406
.4 Dec. > 100 F (56 C) preheat Dec. > 100 F (56 C) preheat
Preheat

QW-407
.6 φ PWHT φ PWHT
PWHT

QW-409 .4 φ Current or polarity φ Current or polarity

Electrical

Characteris .22 φ Inc. > 10% 1st layer φ Inc. > 10% 1st layer
tics

.1 φ String/weave

QW-410 .5 φ Method of cleaning

Technique .26 ± Peening

.38 φMultiple to single pass/side φMultiple to single pass/side

Legend:

+ Addition > Increase/greater than ↑Uphill ←Forehand φ Change

- Deletion < Decrease/less than ↓Downhill →Backhand

Table 3: QW-254 SAW (Submerged Arc Welding)

Paragraph Brief of Variables Essential Supplementary Essential Nonessential

QW-402 .1 φ Groove design X

Joints .4 - Backing X

.10 φ Root spacing X

.11 ± Retainers X

QW-403 .5 φ Group Number X

Base .6 T Limits impact X

Metals .7 T/t Limits > 8 in. (203 mm) X

.8 φ T Qualified X

.9 T Pass > 1/2 in. (13 mm) X

.11 φ P-No. qualified X

.13 φ P-No. 5/9/10 X

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 Define of WPS and PQT

QW-404 .4 φ F-No. X

Filler .5 φ A-No. X
Metals .6 φ Diameter X

.9 φ Flux/wire class X

.10 φ Alloy flux X

.24 φ ± Supplemental X

.27 φ Alloy elements X

.29 φ Flux designation X

.30 φt X

.33 φ AWS class X

.34 φ Flux type X

.35 φ Flux/wire class X X

.36 Recrushed slag X

QW-405 .1 + Position
X
Positions

QW-406 .1 Decrease > 100 F (56 C) X

Preheat .2 φ Preheat maint. X

.3 Increase> 100 F (56 C) (IP) X

QW-407 .1 PWHT X

PWHT .2 φ PWHT (T & T range) X

.4 T limits X

QW-409 .1 > Heat input X

Electrical .4 φ Current or polarity X X

Characteris .8 φ I & E range
X
tics

.1 φ String/weave X

.5 φ Method cleaning X
QW-410
.6 φ Method back gouge X
Technique
.7 φ Oscillation X

.8 φ Tube-work distance X

.9 φ Multi to single pass/side X X

.10 φ Single to multi electrodes X X

.15 φ Electrode spacing X

.25 φ Manual or automatic X

.26 ± Peening X

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 Define of WPS and PQT

Legend:

+ Addition > Increase/greater than ↑Uphill ←Forehand φ Change

- Deletion < Decrease/less than ↓Downhill →Backhand

Table 4: QW-254.1 SAW (Submerged Arc Welding)

Special Process Variables

Essential Variables
Nonessential Variables for
Paragraph Hard-Facing Overlay (HFO) Corrosion-Resistant Overlay
HFO and CRO
(QW-216) (CRO) (QW-214)

QW-402
.16 < Finished t < Finished t
Joints

QW-403 .20 φ P-No. φ P-No.

Base Metals .23 φ T Qualified φ T Qualified

.6 φ Nominal size of electrode

.12 φ AWS classification

± orφ> 10% ± orφ> 10%

QW-404 .24
in supplemental filler metal in supplemental filler metal
Filler Metals
.27 φ Alloy elements

.37 φ A-No.

.39 φ Nominal flux comp. φ Nominal flux comp.

QW-405
.4 + Position + Position
Positions

QW-406
.4 Dec. > 100 F (56 C) preheat Dec. > 100 F (56 C) preheat
Preheat

QW-407
.6 φ PWHT φ PWHT
PWHT

QW-409 .4 φ Current or polarity φ Current or polarity

Electrical

Characteristic .22 φ Inc. > 10% 1st layer φ Inc. > 10% 1st layer
s

QW-410 .1 φ String/weave

Technique .5 φ Method of cleaning

.7 φ Oscillation

.8 φ Tube to work distance

.15 φ Electrode spacing

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 Define of WPS and PQT

.25 φ Manual or automatic

.26 ± Peening

.38 φMultiple to single pass/side φMultiple to single pass/side

.40 - Supplemental device

.50 φ No. of electrodes φ No. of electrodes

Legend:

+ Addition > Increase/greater than ↑Uphill ←Forehand φ Change

- Deletion < Decrease/less than ↓Downhill →Backhand

Table 5: QW-256 GTAW (Gas Tungsten Arc Welding)

Paragraph Brief of Variables Essential Supplementary Essential Nonessential

.1 φ Groove design X

QW-402 .4 - Backing X

Joints .10 φ Root spacing X

.11 ± Retainers X

.5 φ Group Number X

.6 T Limits impact X

QW-403 .7 T/t Limits > 8 in. (203 mm) X

Base Metals .8 φ T Qualified X

.11 φ P-No. qualified X

.13 φ P-No. 5/9/10 X

.3 φ Size X

.4 φ F-No. X

.5 φ A-No. X

.12 φ AWS class X

QW-404 .14 ± Filler X

Filler Metals .22 ± Consum. insert X

.23 φ Filler metal product form X

.30 φt X

.33 φ AWS class X

.50 ± Flux X

.1 + Position X
QW-405
.2 φ Position X
Positions
.3 φ↑↓Vertical welding X

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 Define of WPS and PQT

QW-406 .1 Decrease > 100 F (56 C) X

Preheat .3 Increase> 100 F (56 C) (IP) X

.1 PWHT X
QW-407
.2 φ PWHT (T & T range) X
PWHT
.4 T limits X

.1 ± Trail or φ comp. X

.2 φ Single, mixture, or % X

QW-408 .3 φ Flow rate X

Gas .5 ± or φ Backing flow X

.9 - Backing orφ comp. X

.10 φ Shielding or trailing X

.1 > Heat input X

QW-409
.3 ± Pulsing I X
Electrical
.4 φ Current or polarity X X
Characteristic
.8 φ I & E range X
s
.12 φ Tungsten electrode X

.1 φ String/weave X

.3 φ Orifice, cup, or nozzle size X

.5 φ Method cleaning X

.6 φ Method back gouge X

.7 φ Oscillation X
QW-410
.9 φ Multi to single pass/side X X
Technique
.10 φ Single to multi electrodes X X

.11 φ Closed to out chamber X

.15 φ Electrode spacing X

.25 φ Manual or automatic X

.26 ± Peening X

Legend:

+ Addition > Increase/greater than ↑Uphill ←Forehand φ Change

- Deletion < Decrease/less than ↓Downhill →Backhand

Table 6: QW-256.1 GTAW (Gas Tungsten Arc Welding)

Special Process Variables

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 Define of WPS and PQT

Essential Variables
Nonessential Variables for
Paragraph Hard-Facing Overlay (HFO) Corrosion-Resistant Overlay
HFO and CRO
(QW-216) (CRO) (QW-214)

QW-402
.16 < Finished t < Finished t
Joints

QW-403 .20 φ P-No. φ P-No.

Base
.23 φ T Qualified φ T Qualified
Metals

.3 φ Wire size

QW-404 .12 φ AWS classification

Filler .14 ± Filler metal ± Filler metal

Metals .23 φFiller metal product form φFiller metal product form

.37 φ A-No.

QW-405
.4 + Position + Position
Positions

QW-406
.4 Dec. > 100 F (56 C) preheat Dec. > 100 F (56 C) preheat
Preheat

QW-407
.6 φ PWHT φ PWHT
PWHT

QW-408 .2 φ Single, mixture, or % φ Single, mixture, or %

Gas .3 φ Flow rate

QW-409 .4 φ Current or polarity φ Current or polarity

Electrical .12 φ Tungsten electrode

Characteris
.26 1st layer – Heat input > 10% 1st layer – Heat input > 10%
tics

QW-410 .1 φ String/weave

Technique .3 φ Orifice/cup or nozzle size

.5 φ Method of cleaning

.7 φ Oscillation

.8 φ Tube to work distance

.15 φ Electrode spacing

.25 φ Manual or automatic

.26 ± Peening

.38 φMultiple to single pass/side φMultiple to single pass/side

.50 φ No. of electrodes φ No. of electrodes

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 Define of WPS and PQT

.52 φ Filler metal delivery

Legend:

+ Addition > Increase/greater than ↑Uphill ←Forehand φ Change

- Deletion < Decrease/less than ↓Downhill →Backhand

1.4 The define of P-No., F-No. and S-No.， A-No.

1.4.1 P-No.: To reduce the number of welding and brazing procedure qualifications required, base metals have been assigned P-

Numbers, and for ferrous base metals which have specified impact test requirements, Group Numbers within P-Numbers.

1.4.2 F-No.: F-Number grouping of electrodes and welding rods in QW-432 is based essentially on their usability characteristics,

which fundamentally determine the ability of welders to make satisfactory welds with a given filler metal. This grouping is

made to reduce the number of welding procedure and performance qualifications, where this can logically be done.

1.4.3 S-No.: S-Numbers are a listing of materials which are acceptable for use by the ASME B31 Code for Pressure Piping, or by

selected Boiler and Pressure Vessel Code Material Specifications (Section II). There materials are grouped in S-No. or S-

No. plus Group Number groupings similar to the P-No. groupings. There is no Mandatory requirement that S-No. be used.

1.4.4 A-No.: Classification of Ferrous Weld Metal Analysis for Procedure Qualification

1.5 What is the P-No. of the materials that follow(QW-422)?

SA 240 316 SS P-No. 8 Group No. 1

SA 240 304 SS P-No. 8 Group No. 1

SA 516 Gr 60 P-No. 1 Group No. 1

Gr 70 P-No. 1 Group No. 2

SA 105 P-No. 1 Group No. 2

SA 106 Gr B P-No. 1 Group No. 1

SA 283 A P-No. 1 Group No. 1

B P-No. 1 Group No. 1

C P-No. 1 Group No. 1

D P-No. 1 Group No. 1

1-1/4CrMo P-No. 5C Group No. 1

SA 542 2-1/4CrMo P-No. 5C Group No. 1

Electrode:

F No.: ASME Specification AWS Classification A-No.

5 SFA-5.4 austenitic and duplex EXXX(X)-16 8

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 Define of WPS and PQT

1.6 Define

1.6.1 Preheat: The application of heat to the base metal immediately before a welding or cutting operation to achieve a specified

minimum preheat temperature.

1.6.2 Interpass temperature: The highest temperature in the weld joint immediately prior to welding, or in the case of multiple

pass welds, the highest temperature in the section of the previously deposited weld metal, immediately before the next pass is

started.

1.6.3 Postheating: The application of heat to an assembly after welding, brazing, soldering, thermal spraying, or thermal cutting.

2. PQR

2.1 The define of PQR

Procedure Qualification Record (PQR): A PQR is a record of the welding data used to weld a test coupon. The PQR is a record

of variables recorded during the welding of the test coupons. It also contains the test results of the tested specimens. Recorded

variables normally fall within a small range of the actual variables that will be used in production welding.

(2) The PQR is a document that supports the WPS and a Record of the actual values of the Essential Variables (and other variables if

desired) used when welding a test coupon.

3. WPQ

3.1 The define of WPQ

The WPQ (Welder/Welding Operator Performance Qualification) record is a document used to record that welders have been

qualified by the manufacturer to determine that they are capable of using the WPS’s to be used in fabrication.

3.2 Before WPQ, it should be performed WPS and PQR.

3.3 Type of test required

3.3.1 Mechanical tests

3.3.2 Radiographic examination

3.3.3 Test coupons in pipe

3.3.4 Visual examination

3.4 Alternate Base Materials for Welder Qualification (QW 423.1)

Base metal welder qualification may be substituted for the specified in the WPS in accordance with the following in-test table.

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 Define of WPS and PQT

Base Metal(s) Used for Welder Qualification Base Metal(s) Used for Which the Welder is Qualified

P-No.1 ~ P-No.11, P-No.34, or P-No.41 ~ P-No.47 P-No.1 ~ P-No.11, P-No.34, or P-No.41 ~ P-No.47

P-No.21 ~ P-No.25 P-No.21 ~ P-No.25

P-No.51 ~ P-No.53, or P-No.61 ~ P-No.62 P-No.51 ~ P-No.53, or P-No.61 ~ P-No.62

3.5 Performance Qualification Thickness Limits and Test Specimens

3.5.1 Groove weld test

The following tables identify the required type and number of tests and the thickness of weld metal qualified.

3.5.1.1 Test Specimens

Type and Number of Examinations and Test Specimens Required

Thickness of Weld
Visual Examination Side Bend Face Bend QW-462.3(a) or QW- Root Bend QW-462.3(a) or
Metal, in.(mm)
per QW-302.4 QW-462.2 462.3(b) [Note (1), (2)] QW-462.3(b) [Note (1), (2)]

Less than 3/8 (10) X …. 1 1

3/8 (10) to less

X 2 [Note (3)] Note (3) Note (3)
than 3/4 (19)

3/4 (19) and over X 2 … …

GENERAL NOTE: The “Thickness of Weld Metal” is the total weld metal thickness deposited by all welders and all processes in the

test coupon exclusive of the weld reinforcement.

NOTES:

(1) To qualify using positions 5G or 6G, a total of four bend specimens are required. To qualify using a combination of 2G and 5G in

a single test coupon, a total of six bend specimens are required. See QW-302.3. The type of bend test shall be based on weld

metal thickness.

(2) Coupons tested by face and root bends shall be limited to weld deposit made by one welder with one or two processes or two

welders with one process each. Weld deposit by each welder and each process shall be present on the convex surface of the

appropriate bent specimen.

(3) One face and root bend may be substituted for the two side bends.

3.5.1.2 Thickness of weld metal qualified

Thickness, t, of weld metal in the coupon, in.(mm) [Note Thickness of weld metal qualified [Note (3)]

(1) and (2)]

All 2t

1/2 (13) and over with a minimum of three layers Maximum to be welded

NOTES:

(1) When more than one welder and/or more than one process and more than one filler metal F-Number is used to deposit weld metal

in a coupon, the thickness, t, of the weld metal in the coupon deposited by each welder with each process and each filler metal F-

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 Define of WPS and PQT

Number in accordance with the applicable variables under QW-404 shall be determined an used individually in the “Thickness, t,

of weld metal in the coupon” column to determine the “Thickness, t, of weld metal qualified”.

(2) Two or more pope test coupons with different weld metal thickness may be used to determine the weld metal thickness qualified

and that thickness may be applied to production welds to the smallest diameter for which the welder is qualified in accordance

with QW452.3.

(3) Thickness of test coupon of 3/4 in.(19 mm) or over shall be used for qualifying a combination of three of more welders each of

whom may use the same or a different welding process.

3.5.2 Groove weld diameter limits

Outside Diameter of Test Coupon, in. Outside Diameter of Qualified, in.(mm)

(mm) Min. Max.

Less than 1 (25) Size welded Unlimited

1 (25) to 2-7/8 (73) 1 (25) Unlimited

Over 2-7/8 (73) 2-7/8 (73) Unlimited

General Notes:

(a) Type and number of tests required shall be in accordance with QW-452.1.

(b) 2-7/8 in. (73 mm) O.D. is the equivalent of NPS 2-1/2.

3.5.3 Small diameter fillet weld test

Outside Diameter of Test Coupon, in. Minimum Outside Diameter of

Thickness Qualified
(mm) Qualified, in.(mm)

Less than 1 (25) Size welded All

1 (25) to 2-7/8 (73) 1 (25) All

Over 2-7/8 (73) 2-7/8 (73) All

General Notes:

(a) Type and number of tests required shall be in accordance with QW-452.5

(b) 2-7/8 in. (73 mm) O.D. is considered the equivalent of NPS 2-1/2

3.5.4 Fillet weld test

Thickness of test Type and Number of Tests Required

Type of
coupon as Range Qualified [QW-462.4(b) or QW-462.4(c)]
joint
welded, in.(mm) Macro Fracture

Tee fillet 3/16 ~ 3/8 (4.8 All base material thicknesses, fillet sizes, and 1 1
~ 10)
diameters 2-7/8 (73) O.D. and over [Note (1)]

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 Define of WPS and PQT

Less than 3/16 T to 2T base material thickness, T maximum fillet

(4.8) 1 1
size, and all diameters 2-7/8 (73) and over [Note (1)]

General Note: Production assembly mockups may be substituted in accordance with QW-181.2.1. When production assembly

mockups are used, range qualified shall be limited to the fillet sizes, base metal thicknesses, and configuration of the mockup.

Note:

(1) 2-7/8 (73) O.D. is considered the equivalent of NPS 2-1/2. For smaller diameter qualifications, refer to QW-452.4 or QW-452.6

3.5.5 Fillet qualification by groove weld tests

Thickness of test coupon

Type of joint Range qualified Type and Number of test required
as welded, in.(mm)

Any groove All thicknesses All base material thicknesses, fillet Fillet welds are qualified when a

sizes, and diameters welder/welding operator qualifies on a

groove weld test

3.6 Test positions

3.6.1 Groove welds in plate: 1G 2G 3G 4G

1G Flat groove weld in plate 3G Vertical groove weld in plate

2G Horizontal groove weld in plate 4G Overhead groove weld in plate

3.6.2 Groove welds in pipe: 1G 2G 5G 6G

1G Flat groove weld in rotated pipe 5G Vertical groove weld in pipe

2G Horizontal groove weld in pipe 6G Inclination groove weld in pipe

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 Define of WPS and PQT

3.6.3 Fillet welds in plate: 1F 2F 3F 4F

1F Horizontal fillet weld in plate 3F Vertical fillet weld in plate

2F Horizontal fillet weld in plate 4F Overhead fillet weld in plate

3.6.4 Fillet welds in pipe: 1F 2F 2FR 4F 5F

1F Horizontal fillet weld in rotated pipe 4F Overhead fillet weld in pipe

2F Horizontal fillet weld in pipe 5F Vertical groove fillet weld in pip

3RF Vertical fillet weld in rotated pipe

3.6.5 Stud weld: 1S 2S 4S

1S Horizontal stud weld 2S Vertical stud weld

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 Define of WPS and PQT

4S Overhead stud weld

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3.7 Graphics (QW-460)

3.7.1 Positions of welds-Groove welds