Procedure qualification

Welder and Procedure Qualification
BY
SRSREDDY, IAU

Definitions
Welding procedure specification [WPS]:
is a written document that provides direction to the
welder or welding operator for making production
welds in accordance with code requirements. The
completed WPS shall describe all the essential ,
non essential and when required supplementary
essential variables for each welding process used
in the WPS.

Definitions
Procedure Qualification record [PQR]:
is a record of the weld data used to weld a test
coupon. It also contains the test results of the
tested specimens. The completed PQR shall
document all the essential when required
supplementary essential variables for each welding
process used during the welding of test coupon.
Non essential variables used during the welding of
the coupon may be recorded.

Definitions
Welder performance qualification [WPQ]:
is a record of the weld data used to weld a test coupon. It also
contains the test results of the tested specimens. The
completed WPQ shall document only the essential variables
for each welding process used during the welding of test
coupon.
A welder or welding operator may be qualified by radiography of a
test coupon, radiography of his initial production welding or by
bend tests taken from a test coupon

Definitions
Essential variable: 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.
Non essential variables: are those in which a change
as described in the specific variables may be
made in the WPS with out requalification..
Supplementary essential variables: are required for
materials for which other sections specify notch
toughness tests and are in addition to the essential
variables for each welding process

Definitions
Manual welding: Welding where in entire
welding operation is performed and
controlled by Hand [Example : SMAW]
Semi automatic welding: Welding with
equipment which controls only the filler
metal feed. The advance of welding is
manually controlled. [Example: MIG, MAG,
FCAW]

Definitions
Automatic welding: Welding with equipment which
performs the welding operation with out adjustment
of controls by a welding operator. The equipment
may or may not perform the loading and unloading
of the work
Machine welding: Welding with equipment that has
controls that are manually adjusted by the welding
operator in response to visual observation of the
welding with the torch, gun or electrode holder by a
mechanical device. [Example – SAW]

Definitions
Welder: One who performs Manual or Semi
automatic welding
Welding operator: One who operates Machine
or Automatic welding equipment

Definitions
P number: P numbers are assigned to base
metals dependent on characteristics such
as composition, weldability, and mechanical
properties where this logically can be done.
Group number – are assigned additionally to P
Numbers to classify the metals for the
purpose of procedure qualification where
notch toughness requirements are
specified.

Definitions
S number: S numbers are assigned to materials that are
acceptable for use by the ASME B31 code for pressure piping
or by selected boiler and pressure vessel code case , but
which are not included within ASME Boiler and pressure
vessel code material specifications [Section II].
Qualification using a P number material qualifies corresponding S
number materials; Qualification using an S number material
qualifies corresponding S number materials but not
corresponding P- Number materials ; qualification of welders
using a P number material qualifies them to weld on
corresponding S- number materials and Vice versa.

Definitions
F number: grouping of electrodes and welding
rods is based on essentially on their
usability characteristics. This grouping is
made to reduce the number of welding
procedure and performance qualifications
where this can logically be done.
A number: is given based on weld metal
analysis for procedure qualification.

Definitions
Position of welding: Flat, Horizotal, Overhead,
Vertical
Test positions – see the figs

Procedure Qualification record
Review:
 Ensure that all essential and supplementary
essential variables of welding process are
listed in the PQR format and the actual
values are filled.
 Check the type and no of tests required as
per QW 451 and review test results.

Welding procedure specification
Review:
 Ensure that all essential, Non essential and
supplementary essential variables [when
required] of welding process are listed in the
WPS format and the qualified ranges of
each variable are listed as per QW 451
based on the approved PQR.

Welder Performance Qualification
Review:
 Ensure that all essential variables are listed
and filled.
 Check the type and no of tests required as
per QW 452 and review test results.

Qualification Requirements
END PRODUCT /
CODE / STANDARD
SPECIFIED QUALIFICATION
REQUIREMENTS
ASME
Section I Power Boilers‑
Section III Nuclear Components‑
Section VIII Pressure Vessels‑
ASME Sec. IX
ASME Sec. IX
ASME Sec. IX
ASME
B3 1.1 Power Piping‑
B31.3 Refinery/Chemical Piping‑
B31.4 Liquid Petroleum Transportation‑
Piping
B31.8 Gas Transmission Distribution‑
Piping
ASME Sec. IX
ASME Sec. IX
API 1104 or ASME Section IX‑
API 1104 or ASME IX or Appendix A of B31.8API
AWS
D 1.1 Structural Code Steel‑ ‑
D1.3 Sheet Steel in Structures‑
DIA Structural Code Reinforcing Steel‑ ‑
D3.5 Steel Hull Welding‑
D14.1 Industrial and Mill Cranes‑
D14.3 Heavy Equipment‑
D14.4 Machinery Equipment‑
Contained in D 1. 1
Contained in D1.3
Contained in DIA
U.S. Navy/U.S. Coast Guard/Bureau of Ships
Specifications
Contained in D14.1 or may use ASME Section IX
Contained in D 14.3 except use AWS D 10. 9 for
Pipe/Tube
Contained in D14.4
Qualification requirement for different codes

Validity of WPS, PQR and WPQ
 WPS, PQR and WPQ made in accordance with the
requirements of the 1962 edition or any later edition
of ASME Section IX may be used in any construction
built to the ASME Boiler and pressure vessel code or
the ASME B 31 code for pressure piping.
 Qualifications made in accordance with the
requirements of the editions of section IX prior to
1962, in which all the requirements of the 1962
edition or later editions are met, may also be used.

Expiration and Renewal of Welder
Qualification
The performance qualification of welder or welding operator shall
be affected when one of the following conditions occurs:
a) When welder/ welding operator has not welded with a process
during a period of 6 months or more, his qualification for that
process shall expire ; unless with in the 6 months period prior
to his expiration of qualification
1. A welder has welded using a manual or semi automatic
welding process that will maintain his qualification for manual
and semi automatic welding with that process.
2. A welding operator has welded with a machine or automatic
welding process that will maintain his qualification for machine
and automatic welding with that process


Expiration and Renewal of Welder
Qualification
b) When there is a specific reason to question
his ability to make welds that meet the
specification , the qualifications that support
the welding he is doing shall be revoked. All
other qualifications not questioned remain in
effect.

Welding repairs in service – Pressure
vessels [API 510]
 The welding procedures and qualified
welders as per ASME Section IX can be
used for repair welding.
 When preheat or controlled deposition
welding methods are used for repair welding,
the weld procedures are required to be
qualified as per API 510 Cl 7.2.3

Welding repairs in service – Piping
 The welding procedures and qualified
welders as per ASME B 31.3 or the code to
which the piping system was built can be
used to perform weld repairs

Applicable Aramco engineering
procedures
 SAEP 321:specifies the minimum requirements for
the testing, certification and registration of Saudi
Aramco welders working for Maintenance.
 SAEP 323:specifies the minimum requirements for
the testing, certification and registration of contract
welders and brazers working directly for, and under
the supervision of, Saudi Aramco Maintenance.
 SAEP 324:specifies the welding requirements for
certification review and registration of contract
welders that will be used on new projects in Saudi
Aramco.

Weld repair rate
 SAES-W series standards require that the
Contractor review and track project and
Welder repair rates daily. PID will monitor
and evaluate production weld repair rates
and welder performance weekly. The target
for maximum project repair rate (calculated
on a joint basis) should normally not to
exceed 5%.

Procedure qualification

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