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WPS PREPARATION

AS PER
ISO-15614-1
Welding Procedure Specification
and
Procedure Qualification Record
What is the need for WPS

• To ensure the safety of the welded


constructions
• Bhopal tragedy,three mile island
accident, Chernbyl accident,
Breakage of ship in the midsea
Why qualification & certification?

• To ensure that design practices,


manufacturing practices, fabrication
techniques, & inspection techniques are
performed by personnel who are
qualified in accordance with good engg.
practices and standards
Selecting Your Welding Process
1. The joint to be welded is analyzed in terms of
its requirements.

2. The joint requirements are matched with the


capabilities of available processes. One or
more of the processes are selected for further
examination.
3. A checklist of variables is used to determine
the ability of the selected processes(s) to
meet the particular application

4. Finally, the proposed process or processes


deemed most efficient are reviewed
What is a WPS?
A WPS is a "Welding Procedure Specification"
or "Welding Procedure" as it is commonly
called. It contains the combination of variables
used to make a certain weld. This includes the
process (SMAW, FCAW etc.), the electrode type,
electrical characteristics, base metal used,
preheat and interpass temperatures, travel speed
and position, post weld heat treatment, shielding
gas and flow rate, and the type of joint being
welded.
What is WPS in a layman view
point
• WPS lists all the parameters required to produce a
sound weld to the specific code
• Specific parameters such as process,
technique,filler,current,voltage,etc., to be included
• It should list a range on each parameter such as
amps = 110-150, voltage =17-22 with the more
essential or critical parameters more closely defined
or limited
• It should give enough details so that any qualified
welder could follow and produce the desired weld.
Steps involved in qualifying the
welding procedure
• A tentative welding procedure is prepared
• Test samples welded with the above and
parameters recorded on PQR
• Tested as per required codes
• If test is passed, the procedure has
completed qualification.
• If test is not passed, the tentative WPS
value of the parameters are changed as
deemed feasible
Steps involved in qualifying the
welding procedure
• The welder making the test samples to be used in
qualifying the procedure is normally considered
qualified.
• Other welder to be qualified weld test samples
as per WPS and the samples are tested as per
applicable requirements.
• A qualified WPS is usable for an indefinite length
of time
• The welder’s qualification is normally considered
effective for an indefinite period of time, unless
the welder is not engaged in the specific process
of welding for which he is qualified for a period of
exceeding 6 months
Purpose of WPS Qualification
To determine that the weldment is
capable of providing the required
properties for the intended application.

WPS establishes the properties of the


weldment and not the skill of the
welder.
Welding Procedure Specification
It is a written document that provides
direction to the welder for making
production welds in accordance with
code requirements.
Any WPS must be qualified by the
manufacturer.
WPS specifies the condition (ranges)
under which welding must be performed
called variables.
WPS addresses essential and non
essential variables
Procedure Qualification Record
It documents what occurred during
welding the test coupon and the results
of the test coupon.

PQR documents the essential variables


and other specific information and the
results of the required testing.
Points to be considered for
establishing WPS
• Code of • Contract/Customer/
construction Code/TPI
• Detailed drawing • Preheat/Postheat/
of weldment PWHT requirements
• Material • Skilled welder
• Thickness • Good welding m/c
with accessories
• Configuration
• Application
• Process
• Preheat
Variables
• PWHT
• Joint design
• Backing material • Essential
• Base metal
• Welding Process
• Filler metal
• Electrode
• Electrical characteristics
• Gas Non-
• Technique essential
• Method of back gauging
Essential Variables

A change in welding condition which


will affect the mechanical properties
of the weldment.
(Change in base metal, welding
process, Filler metal, Electrode, Pre-
heat, PWHT, etc.)
Non Essential Variables

A change in welding condition which


will NOT affect the mechanical
properties of the weldment.
(Change in Methods of Back gauging,
Cleaning, etc.)
Joints
Joint Design
Root gap
Root face
Groove angle
Bevel angle
Backing
Baking
Material
Type
Type of joint/weld
• a) Butt welds qualify full and partial
penetration butt welds and fillet welds.
• Fillet weld tests shall be required where this
is the predominant form of production
welding.
• b) Butt joints in pipe also qualify branch
connections with an angle ≥ 60º;
• c) T joints butt welded only qualify T joints
butt welded and fillet welds (see a);
Type of joint/weld
• d) Welds made from one side without backing
qualify welds made from both sides and welds with
backing;
• e) Welds made with backing qualify welds made
from both sides;
• f) Welds made from both sides without gouging
qualify welds made from both sides with gouging;
• g) Fillet welding qualifies fillet welding only;
• h) It is not permitted to change a multi-run deposit
into a single run (or single run on each side) or vice
versa for a given process.
Base Metal Grouping
( ISO/TR 15608 )
Why grouping of base metal?

To reduce the number of welding procedure


qualifications, base metals have been assigned
Group numbers as per ISO/TR 15608.

Group numbers are based on composition,


weldability & mechanical properties.

Group numbers are further classified into sub-


groups.
Base Metal Grouping
• Separate welding procedure qualifications are
required for each parent material or parent
material combinations not covered by the
grouping system.
• If one parent material belongs to two groups
or sub-groups, it shall always be classified in
the lower group or subgroup
• Permanent backing material shall be
considered as a parent metal within the
approval (sub-)group
Base Metal Grouping
Base Metal Grouping
Base Metal range of qualification

a Covers the equal or lower specified yield strength steels of the same group
b Covers steels in the same sub-group and any lower sub-group within the same group
c Covers steels in the same sub-group
Base Metal

• Group Number and Sub Group


Number
• Specification
• Chemical Analysis & Mechanical
Properties
• Thickness Range
• Pipe Diameter Range
Range of qualification
Range of qualification
Base Metal Range of qualification
Filler Metals

• specification • Size of Filler metal


• Flux type
• Consumable insert
• Electrode flux class


Filler Metal
Filler materials cover other filler materials as
long as they have:
1 equivalent mechanical properties,
2 same type of covering core or flux,
3 same nominal composition
4 the same hydrogen content or
5 lower hydrogen content
according to the standard for the filler material
concerned.
It is permitted to change the size of the filler
material provided the heat input shall be the
same.
Preheat
• Preheat temperature
• Inter-pass temp.
• Preheat maintenance
calculated in accordance with EN1011-2

Saferian method:
1) Calculate CE as per IIW formula
CE= C+(Mn+Si)/6 + (Cr+Mo+V)/5 +(Ni+Cu)/15

2) Modified CEm= CE(1+0.005t) ,


t= thickness of material

3)Preheat temperature in Celsius = 350 (CEm - 0.25)1/2


PWHT

• Temperature range
• Time range
• Thickness range
Gases(ISO: 14175 )

• Gases Mixture % , Flow rate


(e.g. 75% Ar 25%CO2)
• Shielding
• Trailing
• Backing
• Burging
Trail shield
GAS Main group
*The letter codes and numbers used for the main groups are:
⎯ I: inert gases and inert gas mixtures;

⎯ M1, M2 and M3: oxidising mixtures containing oxygen and/or carbon dioxide;

⎯ C: highly oxidising gas and highly oxidising mixtures;

⎯ R: reducing gas mixtures;

⎯ N: low reactive gas or reducing gas mixtures, containing nitrogen;

⎯ O: oxygen;

⎯ Z: gas mixtures containing components not listed or mixtures outside the composition
ranges listed in Table 2.
Gas Sub-group
• The main groups, except Z, are divided into sub-
groups based on the presence and level of different
components having an influence on the reactivity
(see Table 2). The values indicated in Table 2 are
nominal values.

• Classification examples
• EXAMPLE 1 For a gas mixture containing 6 %
carbon dioxide, 4 % oxygen in argon:
• Classification: ISO 14175 – M25
Gas
• EXAMPLE 2 For a gas mixture containing 30 % helium in
argon:
• Classification: ISO 14175 – I3

• EXAMPLE 3 For a gas mixture containing 5 % hydrogen


in argon:
• Classification: ISO 14175 – R1

• EXAMPLE 4 For a gas mixture containing 0,05 % of


oxygen in argon
• Classification: ISO 14175 – Z
DESIGNATION OF GAS

Gases and gas mixtures are designated by the


classification and the symbols of their chemical
components as below, followed by the
corresponding nominal composition in volume
percent
DESIGNATION OF GAS
Designation examples

• EXAMPLE 1 For a gas mixture containing 6 % carbon dioxide, 4 %


oxygen in argon:
• Classification: ISO 14175 – M25
• Designation: ISO 14175 – M25 – ArCO – 6/4

• EXAMPLE 2 For a gas mixture containing 30 % helium in


argon:
• Classification: ISO 14175 – I3
• Designation: ISO 14175 – I3 – ArHe – 30
DESIGNATION OF GAS
• EXAMPLE 3 For a gas mixture containing 5 % hydrogen in argon:
• Classification: ISO 14175 – R1
• Designation: ISO 14175 – R1 – ArH – 5

• EXAMPLE 4 For a gas mixture containing 7,5 % argon, 2,5 % carbon


dioxide in helium:
• Classification: ISO 14175 – M12
• Designation: ISO 14175 – M12 – HeArC – 7,5/2,5
DESIGNATION OF GAS

• EXAMPLE 5 For a gas mixture containing 0,05 % of


oxygen in argon:
• Classification: ISO 14175 – Z
• Designation: ISO 14175 – Z – ArO – 0,05

• EXAMPLE 6 For a gas mixture containing 0,05 % of


xenon, chemical symbol Xe, in argon:
• Classification: ISO 14175 – Z
• Designation: ISO 14175 – Z – Ar+Xe – 0,05
DESIGNATION OF GAS
DESIGNATION OF GAS
Electrical Characteristics

• Current (AC/DC)
• Polarity (EP/EN)
• Amps & Volts in range
• Tungsten Electrode type & size
• Mode of Metal Transfer
• Electrode Wire Feed Speed range
• Pulsing Current
Techniques
• Stringer or Weave Bead
• Orifice/Gas Cup Size
• Initial or Interpass Cleaning
• Method of Back Gauging
• Oscillation
• Contact Tip to Work Distance
• Multiple or Single Pass
• Multiple Or Single Electrode
• Electrode Spacing
• Peening
• Others
Weld Position(ISO-6947)
Plate groove positions PA,PC,PE,PF,PG
Plate fillet positions PA,PB,PC,PD,PE,PF,PG
Weld Position
• Welding of a test in any one position
(pipe or plate) qualifies for welding in
all positions (pipe or plate) except for
PG and J-L045 where a separate
welding procedure test shall be
required.
Weld Position
• When impact and/or hardness requirements
are specified impact tests shall be taken
from the weld in the highest heat input
position and hardness tests shall be taken
from the weld in the lowest heat input
position in order to qualify for all positions.
• For example, butt welds in plate the highest
heat input position is normally PF and the
lowest PC.
• For fixed pipe welds the hardness tests shall
be taken from the overhead welding
position.
Procedure Qualification

When two or more procedures (diff


processes or other essential variables) are
used in one joint, use table for determining
the applicable range of thickness qualified.
Carry out tension test for each weld metal.
Procedure Qualification
PQR is a record of welding data to weld
a test coupon. It also contains test
results.

Completed PQR shall document all


essential variables including ranges.

If more than one process then weld


deposit thickness for each process and
filler metal to be recorded.
Procedure Qualification

Several WPSs may be prepared from one


PQR.

Several PQRs may be supported for


single WPS.
Welding procedure test
• The welded joint to which the welding procedure
will relate in production shall be represented by
making a standardized test piece or pieces, as
specified in 6.2.

• Where the production/joint geometry requirements


do not represent the standardized test pieces as
shown in this standard, the use of EN ISO 15613
shall be required.
Shape and dimensions of test pieces
• The length or number of test pieces shall be sufficient to allow all
required tests to be carried out.

• Additional test pieces, or longer test pieces than the minimum size,
may be prepared in order to allow for extra and/or for re-testing
specimens

• For all test pieces except branch connections and fillet welds the
material thickness, t,shall be the same for both plates/pipes to be
welded.

• If required by the application standard, the direction of plate rolling


shall be marked on the test piece when impact tests are required to be
taken in the Heat Affected Zone (HAZ).
Welding of test pieces
• Preparation and welding of test pieces shall be
carried out in accordance with the pWPS, and under
the general conditions of welding in production
which they shall represent.

• If tack welds are to be fused into the final joint they


shall be included in the test piece.

• Welding and testing of the test pieces shall be


witnessed by an examiner or an examining body.
*
*
Examination and testing of the test pieces

Test piece Type of test Extent of Foot


testing note
Butt joint with Visual 100 % -
full Radiographic or ultrasonic 100 % a
penetration - Surface crack detection 100 % b
Figure 1
and Figure 2 Transverse tensile test 2 specimens -

Transverse bend test 4 specimens c

Impact test 2 sets d


Hardness test Required e
Macroscopic examination 1 specimen -
Examination and testing of the test pieces
Test piece Type of test Extent of Foot note
testing
Fillet welds – Visual 100 % f
Figure 3
and Surface crack detection 100 % b and f
Figure 4
Hardness test Required e and f

Macroscopic examination 2 specimens f


Examination and testing of the test pieces

Test piece Type of test Extent of Foot note


testing
T- joint with full Visual 100 % f
penetration -
Figure 3
Surface crack detection 100 % b and f
Branch connection Ultrasonic or
with radiographic 100 % a, f and g
full penetration -
Figure 4
Hardness test Required e and f
Macroscopic examination 2 specimens f
Foot note
• a Ultrasonic testing shall not be used for t < 8 mm and not
for material groups 8, 10, 41 to 48.
• b Penetrant testing or magnetic particle testing. For non-
magnetic materials, penetrant testing.
• c For bend tests, see 7.4.3.
• d 1 set in the weld metal and 1 set in the HAZ for materials
> 12 mm thick and having specified impact properties.
• Application standards may require impact testing below 12
mm thick. The testing temperature shall be chosen by the
manufacturer with regard to the application or application
standard but need not be lower than the parent metal
specification. For additional tests see 7.4.5.
Foot note
• e Not required for parent metals: -sub-group 1.1, and
groups 8, 41 to 48.

• f Tests as detailed do not provide information on the


mechanical properties of the joint. Where these properties
are relevant to the application an additional qualification
shall also be held e.g. a butt weld qualification.

• g For outside diameter £ 50 mm no ultrasonic test is


required. For outside diameter > 50 mm and where it is not
technically possible to carry out ultrasonic examination, a
radiographic examination shall be carried out provided that
the joint configuration will allow meaningful results.
Bend test
• Specimens and testing for bend testing for butt
joints shall be in accordance with EN 910
(ISO 5173).
• For thicknesses < 12 mm two root and two face
bend test specimens shall be tested.
• For thicknesses ³12 mm four side bend specimens
are recommended instead of root and face bend
tests.
• For dissimilar metal joints or heterogeneous butt
joint in plates, one root and one face longitudinal
bend test specimen may be used instead of four
transverse bend tests.
Transverse tensile test

• Specimens and testing for transverse tensile


testing for butt joint shall be in accordance
with EN 895 (ISO 4136).
Macroscopic examination
• The test specimen shall be prepared and
etched in accordance with EN 1321
(ISO 17639)on one side to clearly reveal the
fusion line, the HAZ and the build up of the
runs.
• The macroscopic-examination shall include
unaffected parent metal and shall be
recorded by at least one macro
Reproduction per procedure test.
Impact testing

• Test specimens and testing for impact tests


shall be in accordance with this standard for
location of specimens and
• temperature of testing, and with EN 875
(ISO 9016) for dimensions and testing.
Hardness testing

• Vickers hardness testing with a load of


HV10 shall be performed in accordance
with EN 1043-1 (ISO 9015).
• Hardness measurements shall be taken in
the weld, the heat affected zones and the
parent metal in order to evaluate the range
of hardness values across the welded joint
Acceptance levels
• A welding procedure is qualified if the
imperfections in the test piece are within the
specified limits of quality level B in EN 25817
(ISO 5817) except for imperfection types as follows:
• excess weld metal,
• excess convexity,
• excess throat thickness
• excessive penetration,
for which level C shall apply.
• *

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