Welding Procedures and Documentation

Welding procedures and
documentation .
WPS /PQR/WQT
Welding procedures.
 Welding procedure is written to give the direction to welder
and welding inspector to produced defect free welds the
second reason for to writing as to understand or make sure
that the joint properties satisfied the client requirements.
 CODES AND STANDARDS :-
 Standards :-
 A document that is established by consensus and approved by
a recognized body .
 A standard provides , for common and repeated use ,guide
lines ,rules ,characteristics for activities of the optimum
degree of order in a given content .
 To write a procedure for welding we need to refer standards
 Standards for general welding procedure:-
 1. ASME sec IX –General welding .
 2. BSEN 288/ISO 15614.
 3.BS 4570 : Specification for fusion welding of steel castings .
 Standards for pipe line :-
 1.API 1104-Cross country pipe line .
 2.ASME B 31.3 – process pipe line .
 3.BS 4515 : welding of pipelines over 7 bar.(on shore and off
shore).
 4. BS 4677 :- Specification for arc welding of austenitic
stainless steel pipe work for carrying fluids .
 5.BS 3604 : steel pipes and tubes for pressure purposes
ferrite alloy steel with specified elevated.
 6.temperature properties for pressure purposes standards
used for structural .
 1. AWS D 1.1 – STRUCTURAL WELDING OF STEELS.
 2.AWS D 1.2 – STRUCTURAL WELDING OF
ALUMINIUM.
PWPS(preliminary welding procedure
specification)
PWPS
Test coupon .
NDT DT
REPORTS -VE
PQR
WPS
 PQR  PROCEDURE QUALIFICATION RECORD.
 A COPY OF PWPS .
 DRAWINGS.
 REPORTS .
 NOTE :- WPS – SUPPORTING PQR .
WELDING VARIABLES .
 ESSENTIAL VARIABLES:-A variable that has an effect on the
mechanical properties of the weldment condition if changed
beyond the limits specified by the standard will require the
WPS to be re –qualified.
 NON – ESSENTIAL VARIABLES :- A veriable that must be
specified on a WPS but does not have a significant effect on
the mechanical properties of the weldment (and can be
changed with out need for re –qualification but will require a
new WPS to be written .
 Supplementary variables :- The supplementary variables are
the additional essential variables which can add information
for the essential variables.
 ESSENTIAL VARIABLES :-
 1. QW – 402 – JOINTS.
 2. QW – 403 – BASE METALS.
 3. QW – 404 – FILLER METALS .
 4. QW – 405 –WELDING POSITIONS.
 5. QW – 406 – PREHEAT .
 6.QW – 407 – PWHT (SR).
 7.QW – 408 – SHIELDING GAS .
 8.QW – 409 – ELECTRICAL CHARACTERISTICS.
 9.QW – 410 – TECHNIQUE.
QW – 402 – JOINTS .
 JOINT TYPE .
 JOINT WELDES .
 ROOT GAP.
 ROOT FACE.
 BEVEL ANGLE .
 INCLUED ANGLE.
 BACKING STRIP TYPES .
QW – 403 – BASE METALS.
 TYPE OF THE MATERIAL.
 MATERIAL GRADE .
 MATERIAL THICKNESS.
 P (PARENT METAL ) NUMBER.
 GROUP NUMBER.
QW – 404 – FILLER METALS.

 TYPE OF FILLER ROD.
 SIZE OF THE ELECTRODE (OR) FILLER ROD.
 AWS CLASIFICATION .
 F(FILLER METRIAL ) NUMBER.
 SFA NUMBER .
 A NUMBER
QW – 405 – WELDING POSITIONS .
 1G,2G,5G,6G.
 1F,2F,4F.
QW – 406 – PREHEAT.
 PRE HEATING TEMPERATURE .
 PRE HEATING TIME .
 METHOD OF PR HEATING.
 INTER PASS TEMPERATURE.
 POST HEAT TEMPERATURE.
 POST HEAT TIME .
 METHOD OF POST HEATING .
QW – 407 – PWHT(we heat 600°C)
 HEATING TEMPERATURE.
 HEATING RATE.
 SOAK TEMPERATURE.
 SOAK TIME .
 COOLING RATE.
QW – 408 – SHIELDING GAS.

 SHIELDING GAS MIXTURE .
 BACK PURGING GAS TYPE.
 BACK PURGING GAS FLOW RATE . MIXTURE
PROPOSITION.
QW – 409 – ELECTRICAL
CHARACTERISTICS .
 WELD PASSES .
 WELDING PROCESS.
 AWS CALISIFICATION OF ELECTRODE.
 ELECTRODE TYPE.
 SIZE OF THE ELECTRODE .
 CURRENT AND POLARITY .
 AMP (WELDING CURRENT).
 WELDING VOLTAGE .
 TRAVEL SPEED .
 HEAT INPUT .
QW – 410 – TECHNIQUE .
 STRING BEAD (OR) WEAVE BEAD (REST OF THE
WELDING PROCESS)
 GAS CUP SIZE (TIG).
 INTERPASS CLEANING(GRANDING ).
 BACK BOUGING METHOD .
 CONTACT TUBE TO WORK PICES DISTANCE.
 SINGLE PASS AND MULTIPASS .
 PEENING.
 For essential variables ,non essential variables
,supplementary variables refer QW 252 onwards .
 For P number , group number nominal /composition refer
QW422.
 METIRIAL GRADE :- P21,P22,P91.
 CHEMICAL COMPISTITION BEHAVIOR :-
A106,A53,316,316L,316H,327,348,P21,P22,P91.
 For F NUMBER SFA NO AWS classification refer QW 432.
 For A NUMBER refer QW 442.
WELDERS QUALIFICATION .
 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. BSEN 287.
 Test piece process.
 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 .
 Extent (range) of approval.

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What are the standards used for welding procedures and documentation?

What are the essential variables that need to be specified in a welding procedure specification?

Welding procedures and

QW – 404 – FILLER METALS.

QW – 408 – SHIELDING GAS.

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