Welding Procedures Specification
(WPS)
Design for beginner
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Welding Procedures
Example Code: ISO 9606-1 and
BS EN 288
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Copyright © 2005 TWI Ltd World Centre for Materials Joining Technology
Welding Procedures
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
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Welding Procedures
In most codes reference is made to how the procedure are to be
devised 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 Barls
Other codes may not specifically deal with the requirement of a
procedure but may contain information that may be used in writing
a weld procedure EN 1011 Process of Arc Welding Steels
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Welding Procedures
Components of a welding procedure :
Welding Process
• Type of process (MMA, MAG, TIG, SAW etc)
• Equipment parameters
• Amps, Volts, Travel speed
Welding Position
• Location, shop or site
• Welding position e.g. 1G, 2G, 3G, PA, H-J045 etc
• Any weather precaution
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Welding Procedures
Parent material
• Type (Grouping)
• Thickness
• Diameter (Pipes)
• Surface condition
Welding Consumables
• Type of consumable/diameter of consumable
• Brand/classification
• Heat treatments/ storage
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Diameter :
• Minimum and Maximum
Thickness :
• Minimum and Maximum
Joint design
• Edge preparation
• Root gap, root face
• Jigging and tacking
• Type of baking
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Welding Variables
• Run sequences
• Back gouging
• Interpass temperatures
Thermal heat treatments
• Preheat, temps
• Post weld heat treatments e.g. stress
relieving
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Approving the procedure:
When the data has been collected, the procedure must
be validated by producing a test weld, weld procedure
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.
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Approving the procedure (cont’d):
The locations and tests required will be given in the
applicable code or standard
Most codes and standards provide a report format to
record the results
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Examination and testing requirements of a WPT for
procedure approval (BS EN 288)
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After the testing is completed and all the relevant results collated,
the results need to be assessed in accordance with the 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
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Once the welding procedure has been approved, If any essential
variable is changed during production the WPS may require
re-approval. Most codes/procedures dealing with procedure
qualifications provide a list of what is an essential or non-
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 13
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Example of Welding Procedures
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EXAMPLE OF WELDING PROCEDURE QUALIFICATION RECORD
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Welder Approval
Example Code: ISO 9606-1
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Copyright © 2005 TWI Ltd World Centre for Materials Joining Technology
Welder Approval
Numerous codes and standards deal with welder qualification, e.g. ISO 9606 - 1.
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 Qualification 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 material and same
conditions as for the site welds
The welder who carries out the procedure qualification weld would
automatically qualify when the procedure qualifies
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Welder Approval
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. ISO 9606-1
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 details
10. Material type qualified, pipe diameter etc
11. Test results, remarks
12. Test location and witnessed by
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13. Extent (range) of approval
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Welder Approval
The inspection of a welders qualification test.
It is normal for a qualified inspectors usually from an independent 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.
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Welder Approval
Tests methods required for welder qualification ISO 9606-1
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Welder Approval
Tests methods required for welder qualification (BS EN 287)
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Example:
Welder Approval
Qualification
Certification
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ISO 9606-1
BS EN - 288
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Stages in Welding and Welder Approval
Application standard
Contract DEVELOPMENT OF PROCEDURE
Project specifications
pWPS
ISO 9606-1, BE 288,
ASTM IX, AWS D1.1, APPROVAL OF PROCEDURE
API STD 1104 etc.
WPAR/WPQR
WELDER APPROVAL CERTIFICATE FINALISATION OF PROCEDURE
Welding Procedure Specification
6 MONTHS + PROLONGATION
RELEASE WPS FOR PRODUCTION
WORK INSTRUCTIONS
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Any Questions
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Questions
Welding Procedures :
Q - 1. State six essential variables in a welding procedure.
Q - 2. What do you understand by the term extent of approval and
give four examples.
Q - 3. Describe what you understand by a welding procedure
specification, A welding procedure approval record and a
welder certificate
Q - 4. What is the reason for approving a welding procedure and
a welder
Q - 5. Give 3 reasons why a welder may require re- qualification.
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