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Welding Procedures
Welding Inspection
Course Reference WIS 5
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The Welding Procedure

•A welding procedure gives the precise details of
the steps by which the welding of certain type of
joint or ‘weldment’ is to be carried out.
•It contains the necessary details or range of details
for the control variables used in welding and
specifies the materials and joint design to be used
•The procedure thus controls the quality of the
weld controlling each individual step required to
be taken.
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Class of work
•There are many classes of work which require
engineering materials to be joined by welding e.g.
pressure vessel,bridges,oil rigs,earth moving
equipment,however, the requirements in respect to
the quality o f the joint differ immensely and must
be controlled in respect to the ‘fitness for purpose
approached’
•Pressure vessel – withstand stress induced by high
temperature
•Bridges – the effect of differing vehicle loads and
wind loading
•Oil rigs – to withstand the effect of wave
formation
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Class of work
•Code or standard number class of work
•BS 5500 Unfired fusion welded pressure vessel
•ASME IX Procedure and welding and approvals
•AWS D 1.1 Structural welding code
•BSEN 288 Welding procedure approvals
•BSEN 287 Welder approvals
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The welding Procedures

•Items to be included in the procedure are the main contained with the
appropriate standard or code and listed below are the essentials
details :-
•Welding process
•Parent material -S,T,C
•Whether shop or site welding
•Edge preparations
•Method cleaning
•Fit up of joint (sketch)
•Welding position
•etc
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WELDING PROCEDURE
SPECIFICATION
 A DOCUMENT PROVIDING IN DETAIL
THE REQUIRED VARIABLES FOR A
SPECIFIC APPLICATION TO ENSURE
REPEATABILITY.
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PROCEDURE QUALIFICATION
RECORD
 A RECORD COMPRISING ALL
RELEVANT DATA FROM THE
WELDING OF A TEST PIECE NEEDED
FOR APPROVAL OF A WELDING
PROCEDURE SPECIFICATIONS AS
WELL AS ALL RESULTS FROM THE
TESTING OF THE WELD TEST
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WELDER QUALIFICATION
TEST
 TO DETERMINE THE WELDER’S ABILITY
TO DEPOSIT SOUND WELD METAL.
 THE PURPOSE OF THE QUALIFICATION
TEST FOR THE WELDING OPERATOR IS TO
DETERMINE THE WELDING OPERATOR’S
MECHANICAL ABILITY TO OPERATE THE
WELDING EQUIPMENT.
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PRELIMINARY WELDING PROCEDURE

SPECIFICATION (pWPS )

 A TENTATIVE WELDING PROCEDURE

SPECIFICATION, WHICH IS ASSUMED TO BE
EDEQUATE BY THE MANUFACTURER , BUT
WHICH HAS NOT BEEN APPROVED
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WELDING VARIABLES

 ESSENTIAL VARIABLES
 - 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 e .g base metal
thickness,P no, F no etc.
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WELDING VARIABLES

 NON ESSENTIAL VARIABLES

 - NON ESSENTIAL VARIABLES ARE THOSE IN
WHICH A CHANGE, AS DESCRIBED IN THE
SPECIFIC VARIABLES, MAY BE MADE IN IN
THE WPS WITHOUT REQUALIFICATION e.g
change groove design,etc.
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WELDING VARIABLES

 SUPPLIMENTARY ESSENTIAL VARIABLES

 VARIABLES ARE REQUIRED FOR METALS
FOR WHICH OTHER SECTION SPECIFY
NOTCH - TOUGHNESS TESTS ARE IN ADDITION
TO THE ESSENTIAL VARIABLES FOR EACH
WELDING PROCESS e.g
 change group no, base metal thickness limit PWHT,
preheat temperature etc.
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RANGE OF APPROVAL

 THE EXTEND OF APPROVAL FOR AN

ESSENTIAL VARIABLES.
 e.g base metal thickness , diameter of pipe welding
position etc
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SHALL

A MANDATORY PRACTICE WHICH WILL REQUIRED

CHANGE OF WPS IF NOT FOLLOWED

SHOULD
A RECOMMENDED PRACTICE WHICH WILL NOT
REQUIRED ANY NEW WPS IF NOT FOLLOWED
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SAMPLES OF WELDING PROCEDURE

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WELDING PROCEDURE SPECIFICATION

SECTION IX, ASME BOILER AND PRESSURE VESSEL

Company name : Doc No :

Date :
WPS No :
Revision No :

Supporting WPQR:
Type ( S ) :
Welding process :

JOINT ( QW - 402 ) JOINT DESIGN

Joint Design :
Backing : Yes No
Backing Material

Metal

Non Metal

Non Fusing Metal

Other
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BASE METAL ( QW - 403 )

P No : Group No : to P No : Group No :

Specification Type and Grade : To

Specification Type and Grade : To

OR
Chemical Analysis and Mechanical Properties :

Chemical Analysis and Mechanical Properties :

THICKENESS RANGE
Base Metal : Fillet :

PIPE DIAMETER RANGE

Groove: Fillet :

Others :
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FILLER METAL ( QW - 404)

Spec No ( SFA )
AWS No
A No
Size of filler Metals

WELD METAL
Thickness : Groove
Fillet

Electrode - Flux ( class )

Flux Trade name
Consumable Insert

Others : Storing & Redrying

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POSITION ( QW - 405 ) POSTWELD HEATREATMENT ( QW - 407 )
Position ( S) of groove :
Temperature Range :
Welding Progression : UP Down
Time Range :
Position of fillet :

PREHEAT ( QW - 409 ) GAS ( QW - 407 )

Preheat temperature : Min Gases % Com/mix Flow rate

Interpass Temperature : Shielding :
Preheat Maintenance Trailing :
( Continue or Special heating where Applicable should be Backing :
recorded )

ELECTRICAL CHARACTERISTICS ( QW - 409)

Current AC or DC :
Amps ( Range ) : Volts :
( Amps and volts should be recorded for each electrode size ,
position and thickness and etc. This information may be listed in
a tubular form similar to that shown below)

Tungsten Electrode Size, Type :

Mode of Transfer :
Electrode wire speed range :
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TECHNIQUE ( QW -409 )
String or Weave Bead :
Orifice or gas cup :
Initial and Interpass Cleaning
( brushing , grinding and etc )
Method of back Gouge :
Oscillation :
Contact tube to work distance :
Multiple or Single Electrodes :
Travel Speed ( range) :
Peening :
Filler Metal Current Voltage Range Travel Speed Heat
Weld layer Process class Type of (cm/min ) input
Dia ( mm ) Amperage
polarity (kj/cm)
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SAMPLES OF PROCEDURE QUALIFICATION RECORDS

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PROCEDURE QUALIFICATION RECORDS (PQR)

SECTION IX, ASME BOILER AND PRESSURE VESSEL

Company name : Thermo Industrials Boilers and Vessels Doc No : EPMI /VE/02
Date : 6/06/2002
PQR No : FW/006/2002
Revision No : 0

WPS NO : FW /006/2002 -1

Welding process : GTAW and SMAW

Type ( S ) : Manual
JOINT ( QW - 402 )

4
3
2

1
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BASE METAL ( QW - 403 ) POST WELD HEAT TREATMENT( QW - 407 )

Materials specification : SA 106 Temperature : N/A

Other : N/A
Type and Grade : GR B

P No : 1 to P.NO 1
OR
Thickness of test coupon : 5.5 mm

Diameter of test coupon : 88.9 mm

Others :
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FILLER METAL ( QW - 404) GAS ( QW - 408)

Spec No ( SFA ) : 5.18 ( G) , 5.5 (S) Gases(es) (Mixture) Flow rate

AWS No : ER 70 S – 6 , E 7018 - G Shielding Argon 99.9% 5-9 L/pm
Filler metal F No : 6 4 Trailing - - -
Weld metal analysis A : 1 1 Backing - - -
ELECTRICAL CHARACTERISTICS (QW – 40)
Size of filler metal : 2.4 mm 2.5 mm
Current : Direct current
Others
Polarity : Straight
Deposited weld metal : 2 mm 3.5 mm
Amps : 85 ( G) , 100 (S) Volts : 17(G) , 25(S)
POSITION (QW – 405)
Tungsten electrode size : 2..4 mm ( G) , 2.5 ( S )
Position of groove: 6G
TECHNIQUE ( QW – 410 )
Weld progression : Uphill
Travel speed : 3.6 mm/min ( G) , 6.5 mm/min ( S)
Others :
String or weave bead : String (G) ,weave ( S)
Oscillation :-
PREHEAT (QW – 406)
Multipass or single pass : Single ( G) , Multi (S)
Preheat temperature : 380 C
Single or Multiple Electrodes : Single
Interpass temperature : 2000 C
Other :
Others :
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Filler Metal Current Voltage Travel Speed Heat
(cm/min ) input
Weld layer Process Dia ( mm )
class Type of Amperage (kj/cm)
polarity

1 TIG ER 70S – 6 2.4 DCSP 87 37 3.6 35.65 Kj/cm

2 SMAW E 7018 -G 2.5 DCSP 76 40 4.2 43.42 Kj/cm
3 SMAW E 7018 – G 2.5 DCSP 97 51 6.5 45.66 Kj/cm
4 SMAW E 7018 - G 2.5 DCSP 141 25 4.7 45.0 Kj/cm
 Tensile test ( QW – 150)

Specimen Thickness Area Ultimate Ultimate Results

Width
No mm Sq - mm Total Load ( kg) Unit stress ( N/mm2)
T1 ( Top ) 19.22 22..10 424.78 23895 551.70 Ductile broke
at base metal
T1 ( Bottom ) 19.49 21.45 418.06 238805 558.43 Ductile broke
at base metal
T1 ( Top ) 19.26 22..28 429.11 23895 546.10 Ductile broke
at base metal
T1 ( Bottom ) 19.31 22..16 427.91 24240 555.54 Ductile broke
at base metal

Bend Test ( QW – 150)

Type and Specimen No Results

Side bend – S1 No visible defects

Side bend – S1 No visible defects

Side bend – S1
No visible defects

Side bend – S1 No visible defects

 Toughness test ( QW – 150)

Specimen Notch type Test Temperature Impact value Drop breaks

Notch weight (y/s)
No location Joule % Shear Mils
1.2.3 Weld metal (top) V - 20 0 C 30.86.162 - - -

1.2.3 HAZ(top) V - 20 0 C 146.44.158 - - -

1.2.3 Weld metal (center) V - 20 0 C 122.86.168 - - -

1.2.3 HAZ (center) V - 20 0 C 206.192.150 - - -

Comments : Satisfactory
Fillet Welds Test ( QW – 180 ) – N/A
Results satisfactory :__________________ No. __________________ Penetration I nto parent metal : Yes _____ No _______
Macro results : Satisfactory
Type of test : Hardness Test
Deposit Analysis : See attachment documents
Other :______________________________________________________________________

Welder Name : John Bloggs I/C No . 550-727-08-5479 Stamp No . FWW 79

Test conducted by : Thermo Industries Boilers and Vessels Sdn Bhd Laboratory Test No . MAT/3748- 01/98
We certify that the statements in this records are correct and that the test welds were prepared , welded and tested in accordance with the
requirements of section IX of the ASME code.
Manafacturer : Thermo Industrial Boilers and Vessels Sdn Bhd
Date : 12/2/98 By :
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WELDER / WELDING OPERATOR QUALIFICATIONTEST SECTION IX ASME BOILER AND PRESSURE VESSEL CODE
Welder’s name : Joe Bloggs

IC No : 680510-08-5553

Stamp NO : FWW 255

Welding process (s) used : SMAW /SAW Type : Manual

Iden tification of WPSFollowed by welder during welding of test coupon : TIBV – 004
Base metal (s) welded SA 516 Gr .70 Thickness : 19.05 mm

Manual or semi automatic variables for each process ( QW – 350 ) Actual Values Range Qualified
Backing ( Metal , weld metal , welded from both side, flux,etc) (QW – 350 with out with and with out
ASME P.No 1 To ASME P No ( QW – 403 ) 1 P 1 To P 11
Plate ( ) Pipe ( Enter diameter, if pipe, groove ) Plate OD 24’’ and over
Filler metal specification (SFA) 5.1/5.17 classification ( QW – 402 ) E 7018/EL 12 N/A
Filler metal F- no 4/6 4,3,2,1 / All no 6
Consumable insert for GTAW or PAW N/A N/A
Weld deposit thickness for each welding process ( Groove weld ) 3 mm / 16.05 mm 6 mm / 32.1 mm
Welding progression ( 1G,5G,etc ) ( QW – 405 ) 1G Flat
Progression ( Uphill ,Downhill ) N/A N/A
Backing gas for GTAW, PAW or GMAW; fuel gas for OFW ( QW – 408 ) N/A N/A
 Actual Values Range Qualified

GMAW transfer mode ( QW – 409 ) N/A N/A

1 P 1 To P 11

Machine variables for the process Actual values Range of qualified

Direct remote visual control N/A N/A
Automatic voltage N/A N/A
Automatic joint tracking N/A N/A
Welding position 1G Flat
Consumables insert N/A N/A
Backing ( Metal,weld metal ,welded from both side,flux ,etc Weld metal with backing

GUIDED BEND TEST RESULTS