The Welding Engineer (WE)

The Welding Engineer of the fabricator shall be responsible for:

Conducting the welding procedure tests in accordance with AWS D1.1/ASME SEC IX or
any other standard as applicable;
Conducting all applicable mechanical tests as per the applicable standard and Customer
requirements;
Preparing the welding procedure qualification documents.
All welding procedures of the fabricator shall be qualified, as per International standards
such as:
AWS D1.1
For structural work;
ASME SEC.IX
For piping and pressure vessel work;
DnV-OF-OS-01
For pipeline work; API 1104

For pipeline work.

ISO 9001:2008 Requirements related to WPS/PQR Qualification
ISO 9001 clause 7.5.2 states as follows:
7.5.2 Validation of processes for production and service provision
The organization shall validate any processes for production and service provision where
the resulting output cannot be verified by subsequent monitoring or measurement and, as a
consequence, deficiencies become apparent only after the product is in use or the service
has been delivered. Validation shall demonstrate the ability of these processes to achieve
planned results.
ASME IX is divided in 4 parts
PART QG , General requirements
PART QW , Welding

PART QB, brazing

PART QF, plastic fusing
What are the steps in writing a welding procedure specification? What are to be referred for
writing a WPS?
THE WELDING PROCEDURE
A welding procedure is a way of controlling the welding operation.
Purpose of procedure:
1)
To prove a joint can meet design procedure - consistency
2)
Instruction for welder
3)
Ensure repeatability
Producing a weld procedure involves;
Planning the tasks

Collecting the data

Writing a procedure for use or for trial
Making test welds
Evaluating the results of the tests
Approving the procedure of the relevant code
Preparing the documentation
The approach used depends on the code, for example:
BS 2633 (Class 1 arc welding of ferritic steel pipe work for carrying fluids) provides
general comments on various aspects of a suitable weld procedure.
AWS D.1.1 (Structural welding code - steel) favours more specific instructions for different
joints and processes that are, in effect, pre-qualified procedures.
Other codes do not deal specifically with the details of the weld procedure but refer to
published documentation, e.g. BS 5135 process of arc welding carbon and carbon
manganese steels.
COMPONENTS OF A WELD PROCEDURE
Items to be included in the procedure can be some of the following:
Parent Metal
a. Type
b. Thickness (for pipe this includes outside diameter)
c. Surface condition
d. Identifying marks
Welding Process
a. Type of process (MMA, TIG, SAW etc.)
b. Equipment
c. Make, brand, type of welding consumables
d. When appropriate, the temperature and time adopted for drying and
electrodes and / or consumables
Joint Design
a. Welding position
b. Edge preparation
c. Method of cleaning, degreasing etc.
d. Fit up of joint
e. Jigging or tacking procedure
f. Type of backing
Welding Position
a. Whether shop or site weld
b. Arrangement of runs and weld sequence
c. Filler material, composition and size (diameter)
d. Welding variables - voltage, current, travel speed
e. Weld size
f. Back gouging
g. Any specific features, e.g. heat input control, run-out length

baking of

Thermal Treatment
a. Preheat and interpass temperatures including method and control
b. Post weld treatment including method and control
to be referred for writing a wps :
ASME IX , API 1104 , AWS D1.1 , EN ISO 1561
ABBREVIATIONS
WPS welding procedure specification - an approved and accepted welding procedure; an
authorised document.
PQR
procedure qualification records - proof the procedure works - record of tests
undertaken to qualify procedure.
WAC
welder approval certificate - required to ensure a particular welder is capable
of welding to a procedure.
WATC
welder approval test certificate.
WAR
welder approval record.
WPAR
welding procedure approval record.
WQT
welder qualification test.
PWPS
preliminary WPS - unauthorised (contains all essential variables and, after
welding the test piece and all NDT and destructive tests have been accepted,
then the WPS can be approved).
PWPS and WPAR give final WPS (various WPS can derive from one PWPS).
Section IX of the ASME Boiler and Pressure Vessel Code
Overview
The forms listed below form the basis for verifying welding procedures and welder
performance:

WPS - welding procedure specification

PQR - procedure qualification record
WPQ - welder performance qualification

Another way of conceptualizing these requirements is shown below:

WPS (QW-482)

Specify:
Variable Ranges
Essential Variables
Nonessential Variables

PQR (QW-483)

Record:
Actual Variables
Essential Variables
Tests And Results

WPQ (QW-484A)

Record:
Actual Variables
Specify Ranges Qualified
Tests And Results

WQT (QW-484B)
SWPS (QW-485)
Tensile Test(QW-150)

Guided Bend Test(QW-160)

Toughness Test(QW-170)
Fillet Weld Test(QW-180)

Outline of Articles in ASME Section IX

Article I - Welding General Requirements QW-100
Article I covers the scope of ASME Section IX, the purpose and use of the WPS,
PQR and WPQ, responsibility, test positions, types and purposes of tests and
examinations, test procedures, acceptance criteria, visual examination, and
radiographic examination.
Article II - Welding Procedure Qualifications QW-200
Article II covers the rules for the preparation of WPS and PQR. Each process is
listed separately in QW-250 with the essential, supplementary essential, and
nonessential variables.
The WPS shall specify a value or range for each essential, nonessential and,
when necessary, each supplementary essential variable listed for each welding
process.
The PQR shall record the value for each essential and, when necessary, each
supplementary essential variable used.
When a change is made in an essential variable, the WPS must be revised, and
requalified with a new PQR, unless the revision can be supported by an existing
PQR.
Similarly, when the code requires notch-toughness, supplementary essential
variables become additional essential variables.
When a change is made in a supplementary essential variable, the WPS must
be revised, and requalified by a new PQR, unless the revision can be supported
by an existing PQR for notch-toughness applications.
Article III - Welding Performance Qualifications QW-300
Article III covers the preparation of WPQ records. Each welding process is
listed separately in QW-350 with the essential variables for welding
performance.
The WPQ form must record a value for each essential variable used and must
list a range qualified for each of these essential variables.
Article III covers responsibility, type of tests, records, welder identification,
positions, diameters, expiration and renewal of qualifications.

Welders and Welding Operators may be qualified by visual and mechanical

tests, or by radiography of a test coupon, or by radiography of the initial
production weld.
Article IV - Welding Data QW-400
Article IV covers welding variables that are used in the preparation and
qualification of the WPS, PQR or the WPQ as applicable. Some of the welding
variables are listed below:

Joints
Base Materials
Positions

Preheat
Post weld Heat Treatment
Gas
Electrical Characteristics
Technique

Filler Materials

Article IV also includes assignments of P-Numbers (ASME base materials),

SNumbers (other materials), F-Numbers (grouping of filler metals) and
ANumbers (weld metal chemical analysis).
Tables for WPS qualification thickness limits and tables for WPQ thickness and
diameter limits are also included.
There are tables for welding positions signifying that a welder who qualifies in a
particular position is qualified to weld within a range of positions as
appropriate. Furthermore, test coupons, the removal of test specimens, and the
test jig dimensions are identified.
Article V - Standard Welding Procedure Specifications (SWPS) QW-500
Article V covers rules for the adoption, demonstration, and application of the
Standard Welding Procedure Specifications, (SWPSs).
What is the main reason for carrying out a Welding Procedure Qualification? To
show that following a given set of parameters will produce a welded joint that
has the properties that satisfy the design requirements
What is the main reason for carrying out a Welder Qualification Test? To
test the ability of a welder to follow verbal or written instructions and
verification that the weld produced meets the required standard.

WPS Weld Procedure Specification:

Qualified instructions on how to complete the weld
A WPS is a written (qualified) welding procedure prepared to provide direction for the
making of production welds
WPS shall describe the entire essential, nonessential, and when required, supplementary
essential variables for each welding process used in the WPS.

The WPS shall reference the supporting PQR.

The manufacturer may include any other information in the WPS that may be helpful in
making a code weldment.
The written form of the welding procedure for making a specified kind of weld joint using
specified base and filler metals.
.
PQR Procedure Qualification Record (ASME) & WPAR Weld Procedure Approval
Record:
Record of the welding parameters and test results
A PQR is a record of welding data used to weld a test coupon
Is a record of the welding data used to weld a test coupon, it is also contains the test results
of the tested specimens
The purpose of welding procedure specification (WPS) and procedure qualification record
(PQR) is to determine that the weldment proposed for construction is capable of providing
the required properties for its intended application
WPQ: A Welder Performance Qualification is a document recording the ability of a welder to
deposit welds in the manner described in the WPS.

In performance qualification, the basic criterion established for welder qualification is to

determine the welders ability to deposit sound weld metal.
The purpose of the performance qualification test for the welding operation is to determine
the welding operators mechanical ability to operate the welding equipment.
Welder Qualification Test certificate & Welder Performance Qualification (ASME): Record
of Welder test results and range of approval
PWPS Preliminary welding Procedure Specification
WPAR Welding Procedure Approval Record, is a statement of the results of accessing
each test piece including re-tests.
Certifying Authority (CA)/ 3rd party Customer appointed inspection agency for the
project, such as ABS, BV, DnV, Lloyds etc.
WELDING VARIABLES:
General (QW-401)
Essential variable (procedure, QW-401.1)
Essential variable (performance, QW-401.2)
Supplementary essential variable (performance, QW-401.3)
Non-essential variables (QW-401.1)

ESSENTIAL VARIABLES:
To affect the mechanical properties of weldment. (For example, Change in P-number,
welding process, filler metal, Electrode, Preheat or Post weld heat treatment, etc.)
Any changes comes in these variables, requires requalification of the WPS/PQR.
Essential variables are specific variables.
NON ESSENTIAL VARIABLES:
Non-essential variables are those in which a change may be made without requalification of
WPS/PQR. (Such as, Joint design, Method of Back gouging, Cleaning, etc.)
SUPPLEMENTRY ESSENTIAL VASRIABLES:
Supplementary essential variables are those in which affect the notch toughness properties of
weldment. (Such as, Uphill or Downhill vertical welding heat input, Preheat or time Temp.
range of Post Weld Heat Treatment PWHT, etc.)
When a procedure has been previously qualified to satisfy all requirements other than notch
toughness, it is then necessary only to prepare an additional test coupon using the same
essential variables and supplementary variables but additionally with all of the required
supplementary essential variables, with coupon long enough to provide the necessary
notchtoughness specimens.
When a procedure has been previously qualified to satisfy all requirements including notch
toughness, but one or more supplementary requirements including notch toughness, but one
or more supplementary essential variable is changed, then it is only necessary to prepare an
additional test coupon using the same welding procedure and the new supplementary
essential variables, with the coupon long enough to provide the necessary notch-toughness
specimens.
APPLICABLE RULES:
1.

For WPS Qualification, a qualification in may position qualifies the procedures for
all positions.

2.

A welder or welding operator making and passing the WPS qualification test is
thereby qualified for the position tested.

3.

The base metals may consist of either plate, pipe or other product forms.
Qualification in plate also qualifies for pipe welding and vice versa.

4.

The test coupon shall be welded using a type of welding groove proposed in the
WPS for use in construction. The type and dimensions of the welding groove are not
essential variable.

5.

For welding procedure qualification, 2 nos. of tension test and 4 nos. of bend test (2
root bend and 2 face bend specimens) are to be done.

6.

Four side bend tests are substituted for the required face and root bend tests, when
thickness T is inch and above.

7.

Longitudinal bend tests may be used in lieu of the transverse side, face and root bead
tests for testing weld metal or base metal combinations which differ markedly in
bending properties between-

8.

a)

The two base metals; or

b)

The weld metal and the base metal.

Thickness limits for base metal and deposited weld metal to be used in production
are given in the table below:

Thickness T of test Range of thickness T of base Thickness t of deposited

coupon welded (inch)
metal qualified (inch)
weld metal qualified
(inch)
Minimum

Maximum

Maximum

2T

2t

1/16 to 3/8 Over 3/8 but 1/16

less than
3/16

2T

2t

2T

2t

to less than 1-1/2

3/16

2T

2t when t <

to less than 1-1/2

3/16

2T

2T when t >

1-1/2 and over

3/16

2t when t < 3/4

1-1/2 and over

3/16

8 when t >

Less than 1/16

CHANGES TO WPS:
Changes in essential or supplementary essential variable require requalification of the WPS.
Changes may be made in the nonessential variables of a WPS to suite production
requirements and it does not required requalification. This may be amendment to the WPS or
by use of a new WPS.
A WPS MAY REQUIRE THE SUPPORT OF MORE THAN ONE PQR, WHILE
ALTERNATIVELY, ONE PQR MAY SUPPORT A NUMBER OF WPSS.
Any change in the WPS requires a revision of the WPS.
SOME SPECIFIC TERMS USED IN WPS:
P Numbers:
To reduce the number of welding procedure qualification required, base metals have been
assigned P Numbers.
These assignments are based essentially on comparable base metal characteristics, such as
1. Chemical composition,
2. Weldability,
3. Mechanical properties.

4. Mechanical properties.
P Numbers
1
3
4
5
6
7
8
9
10 & 11
21 25
31 35
41 47
51 53
61 62
F Numbers:

Types of Material
Carbon-Manganese steel
Carbon - % Mo.
1 % Cr % Mo.
2 % Cr 1 % Mo, 5 Cr.
Ferritic stainless steel
Martensitic stainless steel.
Austenitic stainless steel.
Nickel steel.
Quenched & Tempered Steel.
Al & Al base Alloys
Cu & Cu base Alloys
Ni & Ni base Alloys
Ti & Ti base Alloys
Zr & Zr base Alloys.

F Numbers are used for filler metal designation is to reduce the number of welding
procedure and performance qualifications, where this can logically be done.
F Numbers are used for filler metal designation.
F Number is grouping of electrodes & welding rods.
It is based essentially on their usability characteristics.
F Numbers
1
2
3
4
5
6
21 25
31 37
41 45
51 54
61
71 72

Class. Of Filler Metals

Low hydrogen electrode.
All stainless steel electrode. (SMAW)
Bare wires/Core wires of CS, SS &LAS
Al & Al base alloys.
Cu & Cu base alloys.
Ni & Ni base alloys.
Ti & Ti alloys.
Zr & Zr alloys.
Hard-facing weld metal.

A Numbers:
A Numbers are used to identify the weld metal chemical composition of ferrous metals.
filler metal is nonessential variable.
ANALYSIS
A.
NO.

Types of weld deposit

Cr

Mo

Ni

Mn

Si

Mild steel

0.20

---

---

---

1.60

1.00

Carbon-Molybdenum

0.15

0.50

0.4-0.65

---

1.60

1.00

Chrome (0.4% to 2%)-Mo

0.15

0.4-2.0

0.4-0.65

---

1.60

1.00

Chrome (2% to 6%)-Mo

0.15

2.0 6.0

0.4-1.50

---

1.60

2.00

Chrome (6% to 10.5%)-Mo

0.15

6.0-10.5

0.4-1.50

---

1.20

2.00

Chrome-Martensitic

0.15

11-15

0.70

---

2.0

1.00

Chrome-Ferritic

0.15

11-30

1.0

---

1.0

3.00

Chrome-Nickle

0.15

14.5-30

4.0

7.5-15

2.50

1.00

Chrome-Nickle

0.30

25-30

4.0

15-37

2.50

1.00

10

Nickle to 4%

0.15

---

0.55

0.80-4.0

1.70

1.00

11

Mn-Mo

0.17

---

0.25-0.75

0.85

1.25-2.25

1.00

12

Ni-Cr-Mo

0.15

1.50

0.25-0.80

1.252.80

0.75-2.25

1.00

Joints (QW-402 Sec-IX)

Following are some of the variables:
(1)
Groove design
(2)
Backing/backing material.
(3)
Root spacing.
Joint design is Non-Essential variable.
BASE METAL (QW-403) It is essential
variables for all welding processes.
P-Number and Group Number of base metal in shall be mentioned in the WPS format.
Thickness of base metal shall be written in WPS
A change in a base metal thickness beyond the range qualified in following table (As per
qw4541) requires the requalilfication of WPS.
Thickness of test coupon
Range of thickness of base Thickness t of deposited
welded, mm
metal (T) qualified, mm
weld metal qualified, mm
Max,
Min.

Max.

Less than 1.6

2T

2t

1.6 to 9.5

1.6

2T

2t

9 to 19.05

4.8

2T

2t

19.05 to 38.1

4.8

2T

2t

19.05 to 38.1

4.8

2T

2T, when t < 19.05

38.1 & over

4.8

203.2(*)

2t, when t < 19.05

38.1 & over

4.8

203.2(*)

203.2(*) when t > 19.05

(*) For welding processes of QW-403.7 only otherwise 2T or 2t whichever is applicable.

FILLER METAL (QW-404)
F-Number and A-Number of filler metal (for ferrous steels) shall be mentioned in WPS.
Filler metal should be selected which is compatible to base metal chemical composition
(Sec.II_A/B). They must have same/similar chemical composition.
For filler metal chemical composition, we have the refer ASME SEC-II C.
Diameter of filler metal is generally from 1.6 to 5mm diameter of filler metal is nonessential
variable.
Then we have to write AWS Specification (E-7018, E-309, etc) and ASME specification
(SFA 5.1, SFA 5.16 etc.)
Generally, root pass is carried out with small electrode diameter and the diameter is
increased with layer number.
When full penetration is required & where chip backing is not possible then root run is
carried out with TIG welding.
POSITION (QW-405)
Position is supplementary essential variable.
1G, 2G, 3G, etc, are different types of welding positions (as per QW-461 Sec IX)
The progression like vertical uphill shall be mentioned. Vertical uphill position qualified for
all positions.
PREHEAT (QW-406)
It can be determine from ASME SEC VIII, Division 1, Appendix R.
Decrease in preheat temperature more than 100 0F (56
WPS/PQR.

C) requires requalification of

Increase of more than 100 0F (56 0 C) in interpass temperature requires requalification of

WPS/PQR.
In WPS, we may mention the method of preheating like gas preheating, or electric
resistance preheating.
Any change in preheating required requalification of WPS.
POST WELD HEAT TREATMENT (PWHT) (QW 407)

ASME SEC VIII, DIV- I, Per. UCS-56 describes PWHT temperature and time range for
specific material with respect to P Number.
Any change in PWHT requires requalification of WPS. In WPS, we must have to mention
the method of PWHT like gas PWHT or electric resistance PWHT.
GASES (QW 408) Three types of gases
are described in WPS.
1) Shielding gas.
2) Backing gas.
3) Trailing gas.
4)
We have to write the flow rate (LPM Liter Per Minute) of every gas used in process.
ELECTRICAL CHARACTERISTICS (QW 409)
We have to write Current, Polarity, and Voltage as electrical characteristics.
Electrical characteristics are nonessential variables. Only increase in heat input or an increase
in volume of weld metal deposited per unit length of weld requalification of WPS, if WPS is
not qualified with PWHT above upper transformation temperature.
Heat input can be calculated by following formula.
H =

V x Amperage x 60 Joule/in.

Travel Speed (in/min)

TECHNIQUE ( QW 410) It is
determined manually with respect to
1) Joint design.
2) Material type.
3) Material thickness.
4)
We have to also mention the travel speed. For better penetration, slow travel speed is used.
Method of cleaning is also including in this critical. In welding of costly material like
Titanium, aluminium, etc.
Cleaning plays key role to get quality welding especially in materials like Titanium,
Aluminium etc.
WELDER QUALIFICATION TEST:
A welder or welding operator may be qualified by mechanical bending tests, radiography of
a test plate or radiography of the initial production weld.
APPLICABLE RULES:
1.Performance Qualification thickness limits:
Type of
joint

Thickness of
deposited weld

Type and number of tests

required.

Groove
Groove

Thickness of
test coupon
welded(inch)
Less than
and over

metal qualified
(inch) max.

Side
bend

2t
Max. to be welded

-2

Face
bend
01
--

Root Bend

01
--

For, test coupons made on pipe in position 5G or 6G, bend tests are carried out on 4
specimens.
Welders and welding operators who pass the required tests for groove welds shall also be
qualified to make fillet welds in all thickness and pipe diameters of any size within the limits
of the welding variables.
When the welder is qualified by radiographic examination, the minimum length of coupon to
be examined shall be 6 inch and shall include the entire weld circumference for pipe.
For fillet welding qualification, one of the test specimens shall be fracture tested and the other
shall be macro examined.
RETESTS :
Immediate retest using mechanical testing :
When an immediate retest is made, the welder shall make two consecutive test coupons for
each position which he has failed, all of which pass the test requirements.
Immediate retest using radiography:
The retest shall be to radio graphically examine two 6 inch plate coupons. Fro pipe, to
examine two pipes for a total of 12 inch of weld, which shall include the entire weld
circumference for pipe.
The welder who has failed the test in production weld may be retested by radiographing an
additional 12 inch length of the same production weld. If this length of weld passes the test,
the welder is qualified.
EXPIRATION OF QUALIFICATION:
When he has not welded with a process during a period of 6 months or more, his
qualification for that process shall expire.
When there is a specific reason to question his ability to make welds that meet the
specification, the qualification shall be revoked
GROOVE WELD DIAMETER LIMITS FOR WELDER QUALIFICATION:

Outside diameter of test coupon (inch)

Outside diameter qualified (inch)

Less than 1(<25.4 mm)

Minimum
Size welded

Maximum
Unlimited

1 to less than 2-7/8(25.4-73.4 mm)

-do-

2-7/8 and over(>73.4mm)

2-7/8

-do-

Note: 2-7/8 inch OD is the equivalent of NPS 2-1/2

FOR FERROUS METALS:
HYDROCHLORIC ACID :
HCL and water, equal parts, by volume
NITRIC ACID:
1 part of HNO3 and 3 parts of water by volume.
FOR NONFERROUS METALS:
Material

Formula

For nicked- chromium & iron

(600 & 800)

Aquaregia.

(Inconel 600 & Incoloy 800)

(HNO3-1 part + HCL-2 parts)

MATERIAL GROUPINGS:
P NUMBERS:
To reduce the number of welding qualification required, base metals have been assigned
Pnumbers and for steel and steel alloys group numbers are assigned additionally to
PNumbers
Notch toughness requirements are mandatory for all P-NO. 11 quenched and tempered
metals, for low temperature applications of other metals as applied to section VIII and for
various classes of construction required by section III.
Base metal

P NO.

a)

Steel and steel alloys

b)

Aluminium and aluminum

P NO. 21 through P.No-25 Base alloys

c)

Copper and copper base

Alloys.

P NO. 31 through P.No-35

d)

Nickel and nickel base

P NO. 41 through P.No-47 Alloys

e)

Titanium and titanium

Base alloys.

P NO. 51 through P.No-53

f)

Zirconium and zirconium

Base alloys.

P NO. 61 through P.No-62

F- NUMBERS:

P NO. 1 through P.No-11

F-number grouping of electrodes and welding rods is based essentially on their usability
characteristics which fundamentally determine the ability of welders to make satisfactory
welds with a given filler metal. This grouping is made to reduce the number of welding
procedure and performance qualifications
Steel and steel alloys

F. No. 1 to 6

b)

Aluminum and aluminum

Base alloys.

F No. 21 to 24

c)

Copper and copper base alloys

F No. 31 to 37

d)

Nickel and nickel base alloys

F. No-41 to 45.

Materials
The purpose of this test is to determine the welders ability to deposit a sound weld therefore
the base material is not considered as critical as it is in the PQR. Hence a performance test
on any material in P groups 1 to 11 approves all those groups and sub groups, also P34 and
P4X (P40-P49). Providing a compatible consumable exists with the same F number used in
the qualification test. (QW423.1)
Note a single sided weld is classed as a weld without backing and a double sided weld or
weld with sealing run is classed as a weld with backing
Consumables
The F number cannot be changed without re qualification of the welder except that for
performance qualification only using SMAW (MMA) F numbers up to and including 4
approve all lesser F numbers for double sided or welds with backing only.
One Consumable from F41 to F45 approves any of these consumables, except SAW. Ref.
QW404.11.
Note 'A' numbers do not apply to welder approval tests.
Variables
For each welding process there is a list of essential variables in QW352 to QW357 and
QW360 for welding operators, these are not necessarily the same as the ones for the PQR.
Essential variables cannot be changed. Explanations of all these variables is given in section
IV of the code.
Diameter and Thickness Ranges
Diameter limits for all circular welds including groove welds, branch welds and fillet welds
is given in QW452.3. There are no upper limits on diameters approved and pipe covers plate
Note for branch welds the diameter considered for the above limits is the one containing the
weld preparation.
Thickness limits, groove welds.
The thickness limit only applies to the deposited weld metal thickness not the plate
thickness and any groove weld approves all fillet weld sizes.
For t greater than 12.5mm there is no restriction on the size that can be welded (Providing the
test weld deposit contains at least 3 layers of weld).

Thickness limits, fillet welds.

A test on plate greater than 3/16" approves all base metal thicknesses and fillet weld sizes
ref. QW452.5. (Note the above diameter limits apply unless the fillet weld is qualified by a
groove weld)
Joint Configuration
Joint geometry, a double V (or U) is considered the same as a joint with backing and does
not qualify a single V (or U) without backing, but a single full penetration joint without
backing qualifies all joint configurations.
Approval Range
Extent of approval is very well explained in QW461.9. Take particular note of welding
positions which are also explained in QW461, for example to qualify a fillet weld in the
normal horizontal-vertical position with a groove weld, the groove weld must be qualified
in at least the 2G position.
The welding positions defined in QW461.1.& QW461.2 should be referred to in the WPS.
The position designations: 1G ,2G ,3G ,4G ,5G ,6G (Groove Welds) and 1F ,2F ,3F ,4F
(Fillet Welds) are test positions
Period of Validity/Renewal of Qualifications (QW 322.2)
Providing the welder uses the process for which he is qualified and there is no reason to
question his ability then his qualification lasts indefinitely.
If the welder does not use the welding process for which he is qualified for a period of 6
months or more then he must perform a new test in pipe or plate, any parent material,
thickness and position, if successful all the welder approvals for that welding process are
renewed in one test.
Testing Requirements
Test requirements for groove welds QW452 consists of either:One face bend and one root bend except for welding positions 5G & 6G which require 4
bends ( Ref QW452.1 Note 4). If the plate exceeds 3/8" side bends may be used. See
QW
466 for precise details and exceptions.
Note:- Bend Tests can in most cases be replaced by Radiography {See Below}.
Radiography is optional and must be supplemented by bend tests when using GMAW
(MIG/MAG) with dip transfer (Short Circuiting Arc) or when welding some special
materials. Ref. QW304.
Note:- Ultrasonic Examination in lieu of Radiography is not permitted
Test requirements for fillet welds in plate ref. QW452.5:One macro section (QW 184) and One fracture test (QW182).
The location where each specimen has to be taken is defined in QW463
Radiography Ref QW 191
A length of at least 6" must be examined for plate or the entire circumference for pipe.
If the pipe circumference is less than 6" then more samples must be welded up to a
maximum of 4. Ref QW 302.2.
Visual Examination Ref QW 302.2 & QW 190

Performance test coupons must show complete joint penetration with full fusion of the weld
metal and base metal.
The welder performance test must follow a properly qualified W.P.S. Once qualified the
welder must always work within the extent of approval of any properly qualified W.P.S. and
his W.P.Q.
The welder who qualifies the P.Q.R. is automatically approved within the limits specified in
QW304, QW305 and QW303. Ref QW301.2.
Specialist Processes
Such as corrosion resistant overlay or hard facing are covered in QW 453.
Procedure variables are defined with all procedure variables in QW252 and in QW380 for
welder approval.
Min base thickness approved = size welded or 1", QW 453
Min Deposit Size Approved:- Point Where Chemical analysis taken No upper limit
QW402.16 (462.5a) Welding Positions QW405.4 Performance Qualification approves all
deposit thickness No min.QW381
Approved Welding Processes
The GTAW process shall be used for all passes for butt welds in nozzles less than 1 inch nominal
diameter.
The GTAW process shall be used for the root pass of butt welds without backing in nozzles of 2 inch
nominal diameter or less.

Submerged Arc Welding (SAW).

The short-circuiting (dip) mode shall not be used except for:
a)Structural attachments to the outside surface of the vessel shell, including seal welds.
Tacking (including continuous tacks) that will be completely removed by backgouging and
backwelding
Flux-Cored Arc Welding (FCAW).
The FCAW process shall not be used for the root pass on full penetration, groove joints
that are welded from one side only without backing (backing may be used if it is removed
after welding).
Thermit Welding using a copper alloy is permitted for attaching electrical grounding or
cathodic protection cables to structural members. Thermit welding shall not be used on
stainless steel materials.
Stud Welding is permitted for attaching insulation fasteners and heat conductors.
Welding Consumables

Low hydrogen consumables (defined as less than or equal to 8 ml of hydrogen per 100 g of
deposited weld metal, measured in accordance with AWS A4.3) shall be used except for:
The root pass of closure seams on P-No. 1 (carbon steel) vessels in non-hydrocarbon
service with less than 12.7 mm wall thickness where the inside is not accessible.
Any dissimilar metal welds (DMW), i.e.;
Use of stainless steel or nickel-based filler metals on ferritic steels, shall be restricted as
follows:
Are not permitted for pressure-containing welds in sour service (welds in clad systems are
acceptable if the DMW interface with the ferritic steel is not in contact with the sour fluid).
Are permitted for non-sour hydrocarbon service if made with a nickel-based consumable.
Austenitic stainless steel consumables may be used only for the following applications and
if the maximum design temperature is below 300C:
External structural attachments (e.g., name plates). Non-sour,
non-hydrocarbon (e.g., water) services.
Commentary Note:
Nickel-based consumables may not be suitable for direct exposure to sulfur or
hydrogensulfur reducing environments at temperatures exceeding 400C due to possible
sulfidation attack.
SMAW electrodes shall be limited as follows:
F-Nos. 1, 2, and 3 electrodes shall not be used on materials requiring impact tests either by
Code or job specification.
F-Nos. 1 and 2 electrodes shall not be used for pressure-retaining welds.
Shielding Gases
Shielding gases shall conform to the following requirements:
Carbon dioxide (CO2): Federal Specification BC-C-101, Type B or Compressed Gas
Association CGA G-6.2, Type F.
Argon (Ar): Compressed Gas Association CGA G-11.1, Grade A.
Special Qualification Requirements
Tube-to-tubesheet welding, including seal welds, shall be qualified in accordance with
ASME SEC VIII, Division 2, Article F-3. For seal welds, the required weld throat
thickness shall be as specified by the designer.
Procedure variables
The following additional restrictions shall be considered essential variables for procedure
qualification:
For field repair and modification, the following materials shall be considered as P-No. 1
and do not require separate qualifications as "unlisted" materials:
API 5L Gr. B
API 5L Gr. X52
A707 L3
A707 L5
A350 LF6
A350 LF787
A change from A-No. 1 to A-No. 2 is not permitted for sour service applications without
requalification.
Aluminum flake weldable primers (e.g., "Bloxide", "Deoxaluminite", or other brand
approved by CSD) may be used without requalification of the procedure. The welding
procedure specification shall indicate the use of the type and brand of weldable primer. The
maximum coating thickness shall not exceed 0.050 mm.

The direction of welding for the vertical position shall be an essential variable (i.e., a
change from vertical-up to vertical-down or vice-versa shall be considered an essential
variable). If the procedure was not qualified in the vertical position, then the direction of
welding shall be vertical-up.
For automatic, semi-automatic, or mechanized welding, the position limitations listed in
ASME SEC IX, QW-461.9 shall be considered as an essential variable for procedure
qualification.
Deletion of a backing strip in a single-sided groove weld shall be considered an essential
variable and shall require requalification.
For full penetration, double-sided joints, the WPS shall require backgouging (see 11.3.3) for
all processes except for the following:
Deletion of a backing gas purge or a change in the backing gas composition for a joint
welded or brazed from one side without backing material shall require requalification.
Special requirements for procedures requiring impact testing
If the PQR thickness exceeds 12 mm and multiple processes or consumables are used, then
separate impact test specimens shall be conducted for each process or consumable. If the
Welding Procedure Qualification Hardness Testing Hardness testing is required for all
PQRs for:
a) Hydrogen service vessels of any wall thickness.
b) Sour service vessels of any wall thickness.
Exemptions:
Hardness testing need only comply with all NACE MR0175 requirements for the
following:
i)The vessel is made using austenitic stainless steel or nickel-based alloys for all wetted
pressure boundary materials.
ii)If all internal surfaces of the vessel are clad or weld overlaid with austenitic stainless
steel or nickel-based alloys. Strip lining (partial or complete) or partial cladding or partial
overlay are not exempt from hardness testing requirements.
For vessels in any service if the shell or head wall thickness is greater than 38 mm.
Exemptions:
Hardness testing is not required if the weld procedure is to be used on external structural
attachments only, and the vessel wall at the attachment point is at least 25 mm thick. This
exemption applies only if no other hardness testing requirement applies.
The hardness testing shall be in accordance with Standard Drawing W-AB-036386. The
maximum allowable hardness is VHN 250.
Only the Vickers test method (in accordance with ASTM E92) is acceptable, with a
maximum test load of 10 kg.
Preparation of Test Coupons
For groove welds, the test coupons shall be radiographed and shall meet the acceptance
criteria of ASME SEC VIII D1, UW-51.
Welder and Welding Operator Qualification Joint Details All
pressure-containing welds shall be made with multiple passes.
Corrosion Resistant Cladding, Overlays, and Linings Technique And Workmanship The
maximum allowable SMAW electrode sizes that can be used are given below. The
ability of each welder to use the maximum sizes listed in the table shall be checked by the
Inspector as early as possible during fabrication. a)Low hydrogen electrodes 5 mm for
the 1G/1F position.
4 mm for all other positions.

b)Non-low hydrogen electrodes (not normally used) 5

mm for all positions.
Welding Environment
The wind velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall not
exceed 8 kph (2.2 m/s).
Foreign matter shall be removed from the weld surface and at least 25 mm of adjacent base
metal prior to welding, including any such coatings on temporary attachments or supports.
Flame cutting and arc-air gouging
A minimum of 1.5 mm depth shall be removed by grinding or machining from thermally cut
or gouged surfaces of air-hardenable materials (e.g., Chrome-Moly steels).
Stainless steel and nonferrous materials shall be cleaned with grinding wheels or stainless
steel brushes not previously used on other materials.
Tack welds
All tack welds shall be made by qualified welders.
Tack welds shall be of sufficient size to maintain joint alignment.
Back purging
An inert backing gas shall be used for GTAW or GMAW root passes on single-sided
groove welds for materials of ASME P-No. 5 and higher.
For P-No. 5 and higher materials, any back purging shall be maintained until at least 10 mm
of the weld deposit thickness has been completed.
The back purge shall be sufficient to reduce the oxygen level below 1%. The
use of nitrogen as a backing gas for austenitic stainless steels is prohibited.
QUALIFICATION OF WELDER
BASE METAL:
For selection refer Tables in Chapter II.
TEST COUPON:
Depending on the range to be qualified, choose the appropriate test coupon from Table
A4.1
For plate butt welds, details of edge preparation shall be as per Figure-4.
For pipe butt welds, details of edge preparation shall be as per Figure-5.
For structural tack welds, refer Figure-1.
REQUIREMENT OF TESTS:
For Structural Tack Welders:
Break Test as per Figure-2.
For Plate Butt Welds:
Minimum of 2 specimens for bend test; one for root bend and other for face bend. Width of
specimen shall be 38 mm for plate thickness upto 10 mm. For Plate thickness greater than
10 mm, side bend test ( 2 Specimens) shall be done and the width of specimens shall be 10
mm .
For Pipe Welder :

The order of removal of test specimens shall be as per Figure-6. For

width and number of bend specimens, refer below:

OD

No. of Bend Specimens

Face
Root
Side

> 101.6
38.0
2
2
(**)
50.8 - 101.6
19.0
2
2
(**)
< 50.8
10.0
2
2
(**)
<= 25.4
(++)
2
2
(**) for thickness greater than 10.0 mm, side bend test of width 10.0 mm may be
substituted.
(++) Cut into 4 equal sections (with allowance for saw cuts or machine cutting);
sharp corners to be rounded off.
OD - Outer diameter of pipe in mm.
W - Width of bend test specimen in mm.
For bend test jig refer Figure-7, for thickness of bend specimen 10.0 mm; for other thicknesses
(t) the dimension shall be as below :
A
B
C
D

=
=
=
=

4t
2t
6t + 3.2 mm
3t + 1.6 mm

The above values are nominal.

Radiographic examination of test welds may be carried out in lieu of bend tests.
Procedure and acceptance criteria are as per NDE Manual
.
ESSENTIAL VARIABLES :
Changes to the following variables require requalification.
Process :
Example : Change from GTAW to SMAW or vice versa.
Joint :
A change from one type of bevel to another. Example : vee bevel to u bevel.
Base Metal :
A change in thickness or pipe diameter beyond the limits prescribed in Table- A4.1
Filler Metal:
A change from one F number to another F-number, except as specified in Table-A4.1
Positions:
This procedure envisages qualification of welders to perform in all positions. Deviation to this is
not recommended.

Gas:
This procedure envisages test to pre-prescribed gas as for production welds. Deviation to this is
not recommended.
Electrical Characteristics:
a)

AC to DC and vice versa.

b)

In DC, DCEN (Electrode Negative) to DCEP (Electrode Positive) and vice versa.

Technique :
This procedure envisages only use of uphill progression technique.
ACCEPTANCE CRITERIA :
Structural Tack Welding :
No cracks.
No lack of fusion.
Undercut not exceeding 1 mm.
Not more than 1 porosity (max. diameter of porosity 2 mm).
Plate/Pipe Welding : Visual
Inspection :
No cracks.
No lack of fusion or incomplete penetration.
Not more than 1 porosity in a length of 100 mm of length of weld (max. porosity diameter 2mm).

Acceptance Criteria - Bend Tests ( ASME Sec IX- QW-163 )

The weld and heat-affected zone of a transverse weld-bend specimen shall be completely within the bent portion of the specimen after testing.
The guided bend specimens shall have no open discontinuity in the weld or heat- affected zone exceeding 1/8 in.(3 mm), measured in any direction on the convex surface of the specimen after
bending. Open discontinuities occurring on the corners of the specimen during testing shall not be considered unless there is definite evidence that they result from lack of fusion, slag
inclusions, or other internal discontinuities. For corrosion resistant weld overlay cladding, no open discontinuity exceeding 1/16 in. (1.5 mm), measured in any direction, shall be permitted in
the cladding, and no open discontinuity exceeding 1/8 in.(3mm) shall be permitted along the approximate weld interface.
RETESTS:
A welder who fails to meet the acceptance criteria for one or more test specimens, may be retested as per this procedure after adequate practice.
VALIDITY:
When a welder meets the requirements of this procedure, the validity will be for a maximum of 2 years from the date of test, limited to validity specified by statutory authority, as applicable.
The validity may be extended by one year each time, based on satisfactory performance, with sufficient back up records.
REQUALIFICATION:
Requalification is required for the following:
Where there is a specific reason to doubt the skill of the welder.
Due to non-engagement of the welder for a continuous period of 6 months.
RECORDS:
The welding in charge at site shall maintain the following records:

a)

Record of Welder Performance qualification Test (as per format).

b)

Register of qualified welders (employer-wise) containing the following details:

1)

Name of welder.

2)

Age.

3)

Tested for pipe / tube / plate / tack.

4)

Performance Test No.

5)

Validity.

6)

Welder Code. 7)

Remarks.

The above register shall be updated for deletions also.

Copies of welder identity card (including details as in 9 b and relevant variables qualified). Pertinent radiography reports.

WELDER QUALIFICATION REQUIREMENTS

Sl.No.

Test For

Structural tack

6
Base
Metal
Note 1
P1 Gr 1

Test
Coupon
Dimension
OD, t
t=10mm or
12mm

Electrode
6

to be used
Note
2, 4
(E6013) F2
(E7018) F4

Plate Welder
(Structural)
Plate Welder
(Other than
structural)

Pipe Welder

Weld
Positions

Reference
Figure

Range
Qualified
Dia. & T

Position
Qualified

Electrode
Qualified
Note 2, 4

3F & 4F

Fig. 1 & 2

T-Unlimited

All

F2, F1

3F & 4F

Fig. 1 & 2

T-Unlimited

All

3.2mm*

F4

3G & 4G

Fig.3

t<25mm

F4

3G & 4G

Fig.3

t 13mm

F4

t<13mm

F4

OD<25mm

F4

6G

Fig.3

F4

6G

Fig.3

F4

6G

Fig.3

t<13mm

F4

6G

Fig.3

T 2t

All

t 13mm

F4

6G

Fig.3

T-Unlimited

All

- do -

- do -

- do -

t 25mm

OD 25m
m&
73mm
OD>73mm

2G, 3G &
4G
2G, 3G &
4G

* Also qualifies for welding fillet welds on material of unlimited thickness.

Fig.3
Fig.3

T>3.2mm*
2t
T-Unlimited
OD 610m
m T 2t OD
610m
mTest piece
Dia.& above
25mm &
above
73mm &
above

All
All
All
All
All
All
All

F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below
F4 &
Below

Remarks

Refer
Fig. 1,3
Refer
Fig. 1,3

NOTES:
1.

For P grouping refer Chapter II.

2.

For F grouping refer Chapter III.

3.

Base material limitation:

a.

Where test coupons belong to P1 thro P15F, welder is qualified for base
materials P1 thro P15F.( ASME Sec IX QW 423, Alternate base material
for welder qualification)
It means, if a welder is qualified with carbon steel material, he is also qualified for
alloy steel and vice versa.

b.
4.

Use appropriate F group electrodes.

Qualification in one F number, qualifies for that F-number only, except as stated
below in A, B, C & D.
A.

Qualification in F4 qualifies for F4 and below.

B.

Qualification in F5 qualifies for F5 only.

C.

Qualification in any of F41 thro F45 qualifies for F41 thro F45.

D.

For non-ferrous materials, the base materials shall be typical of production

material and appropriate filler materials shall be selected. Qualification is
limited to the base material, process and filler F group. Diameter and
thickness limitations apply as per Table A4.1
OD = outer diameter, t = thickness of test coupon; T = thickness qualified.

5.

Where qualification is for GTAW followed by SMAW, the welder is also

qualified upto 6 mm thickness by GTAW process.

6.

Base material indicated is carbon steel; for other base materials, corresponding
electrodes are to be chosen. Also for GTAW process, the corresponding filler wire
should be chosen.
TACK WELDER QUALIFICATION

WELDER PERFORMANCE

MONITORING

Welder performance evaluation:

For welds dia.

88.9 mm:.

Upto and including 5% defects: Performance is satisfactory else unsatisfactory.

For welds dia. > 88.9 mm and plate welds:
Upto and including 2.5% defects: performance is satisfactory else unsatisfactory.
When a welder gives unsatisfactory performance for a continuous period of 3 months, he shall be
requalified.
WELD FIT-UP INSPECTION:
Maximum permissible mis-alignment at bore
Bore (mm)

Max. Misalignment (mm)

For GTAW

For SMAW

Upto 100 1.0 1.0

Weld area should be protected from drafts and wind, to maintain inert gas shield.

CHECKS DURING WELDING OPERATION:

5.1

Ensure the required minimum preheat temperature is maintained during welding.

5.2

Ensure correct electrode / filler metal is used for welding.

5.3

Tack welds are examined by the welder before they are incorporated in the final weld.

5.4

Ensure proper re-drying / holding of electrodes prior to use.

5.5

Ensure inter pass temperature is not exceeded during welding.

5.6

Ensure proper cleaning of weld between beads.

6.0

CHECKS ON THE COMPLETED WELD:

6.1

No visible cracks, pin-holes or incomplete fusion.

6.2

The weld surface must be sufficiently free of coarse ripples, grooves, overlaps, abrupt
ridges and valleys, visible slag inclusions, porosity and adjacent starts and stops.

6.3

Undercuts not to exceed 0.8 mm or 10% of wall thickness whichever is less.

6.4

Where inside surface is readily accessible, the same shall be inspected for excess
penetration and root concavity. The permissible limits are given below :
Root concavity: max of 2.5 mm or 20% of thickness at weld, whichever is lesser,
provided adequate reinforcement is present.
Excess penetration: up to and including 3.2 mm.

6.5

For plate butt welds, the weld reinforcement should not exceed 3.2 mm.

6.6

For circumferential joints in piping and tubing the maximum weld reinforcements
permitted are given below :
Maximum Permissible Reinforcements ( ASME Sec I PW 35)
Thickness of base metal in mm

6.7

Reinforcement in mm

Upto 3.0

2.5

Over 3 to 5

3.0

Over 5 to 13

4.0

Over 13 to 25

5.0

Over 25 to 50

6.0

Over 50

Max of 6.0 or 1/8 of weld

There shall be no overlaps.

The faces of fillet welds are not excessively convex or concave and the weld legs
are of proper length.

In case of weld joints in pressure parts and joints like ceiling girder, the weld joint must be
suitably identified
Mechanical Properties Test

The amount of deformation which metal can withstand under different modes of force
application
Malleability: Ability of a material to withstand deformation under static compressive loading
without rupture
Ductility: Ability of a material undergo plastic deformation under static tensile loading
without rupture. Measurable elongation and reduction in cross section area
Toughness: Ability of a material to withstand bending or the application of shear stresses by
impact loading without fracture.
Hardness: Measurement of a materials surface resistance to indentation from another material
by static load (Brinell, Rockwell, Vickers)
Tensile Strength: Measurement of the maximum force required to fracture a materials bar of
unit cross-sectional area in tension
Corrosion tests, HIC & SOHIC Tests :Tests for weld quality
TRANSVERSE TENSILE TEST
Reporting Results:
1.
Type of specimen (e.g. reduced section).
2.
Whether excess weld metal is removed or not.
3.
Tensile strength, in Newtons per mm squared, is calculated from maximum load and
original cross sectional area. When excess weld metal is not removed, the cross
sectional area shall be the product of the parent metal thickness and the width of the
specimen
4
Location of fracture - whether in parent plate, heat affected zone or weld metal.
If the fracture is in the parent metal, the distance from the weld zone shall be
stated.
5.
Location and type of any flaws present on the fracture surface.
TENSION TEST :
Tension tests are used to determine the ultimate strength of groove weld joints.
(Transverse Welded Joint, All Weld Metal)
a)

For thickness upto and including 1 inch, a full thickness specimen shall be used for
each required tension test.

b)

For thickness grater then 1 inch, full thickness specimen or multiple specimens may be
used. When multiple specimens are used, the entire thickness shall be mechanically
cut into a minimum number of approximately equal strips of a size that can be tested
in the equipment. Collectively, all of the specimens required to represent the full
thickness of the weld at one location shall comprise a set. Each specimen of the set
shall be tested and meet the acceptance requirements.

c)

For pipe having an outside diameter of 3 inch or less, full pipe may be used for tension
test.

ACCEPTANCE CRITERIA:
The specimen shall have a tensile strength that is not less than-

a)

The minimum tensile strength of the base metal; or

b)

The minimum specified tensile strength of the weaker of the two, if base metal of
different minimum tensile strengths are used; or

c)

The minimum specified tensile strength of the weld metal when the applicable code/
specification provides for the use of weld metal having lower room temp. strength
than the base metal.

d)

If the specimen breaks in the base metal outside of the weld or fusion line, the test
shall be accepted as meeting the requirements provided the strength is not more than
5% below the minimum specified tensile strength of the metal.

NICK BREAK (BEND) TEST

Object: As for fillet weld fracture, used on butt welds.
Reporting Results:
1.
Thickness of material.
2.
Width of specimen.
3.
Location of fracture.
4.
Appearance of joint after fracture.

You are right , root gap is not a essential variable for PQR under ASME Sec. IX , but as far as
root fusion is concern , you have to take care that you will get proper fusion with this much
gap
Bend testing: CTOD (Crack Tip Opening Displacement)
BEND TESTS
Reporting Results:
1.
Thickness of specimen
2.
Direction of bend (root or face)
3.
Angle of bend
4.
Diameter of former
5.
Appearance of joint after bending e.g. type and location of flaws

SIDE BEND TEST

Object:

To determine the soundness of the weld metal and HAZ in a cross section. This
may be preferred to the transverse bend test on thick materials. It is also used
on processes or procedures expecting lack of fusion (e.g. thick plate using
MIG).

Report Results:
1.
Width and thickness of specimen.
2.
Angle of bend.
3.
Diameter of former.
4.
Appearance of joint after bending e.g. type and location of flaws.
GUIDED BEND TESTS:
Guided bend tests are used to determine the degree of soundness and ductility of groove weld
joints.
Bend test specimens shall be prepared by cutting the test plate or pipe to form specimens of
approximately rectangular cross section. The cut surfaces shall be designated the sides of the
specimen. Bend specimens are of five types, depending on whether the axis of the weld is
transverse or parallel to the longitudinal axis of the specimen and which surface (side, face or
root) is on the convex (outer) side of bent specimen.
ACCEPTANCE CRITERIA:
The weld and heat affected zone of a transverse weld-bend specimen shall be completely
within the bent portion of the specimen after testing.
The bend specimens shall have no open defects in the weld or HAZ exceeding 1/8 inch
measured in any direction on the convex surface of the specimen after bending.
FILLET WELD FRACTURE TEST
Object:

To break the joint through the weld to permit examination of the fracture
surfaces for flaws and to check root penetration and fusion.

Reporting Results:
1.
2.
3.
4.
5.

Thickness of parent material.

Throat thickness and leg length.
Location of fracture.
Appearance of joint after fracture.
Depth of penetration / lack of penetration or fusion FILLET WELD TESTS:

Fillet weld tests are used to determine the size, contour, and degree of soundness of fillet
welds. Macro testing: (Fillet weld fracture testing, Butt weld nick-break testing)
The test coupon for plate to plate shall be cut transversely to provide five test specimens, each
approximately 2 inch long. For pipe to plate or pipe to pipe, the test coupon shall be cut
transversely to provide four test specimen sections. The test specimens shall be macro
examined.
MICRO EXAMINATION:
One face of each cross section shall be smoothed and etched with a suitable etched to give a
clear definition to the weld metal and HAZ.
ACCEPTANCE CRITERIA:

a)

Visual examination of the cross section of the weld metal and HAZ shall show
complete fusion and freedom from cracks.

b)

There shall not be more than 1/8 inch difference in the length of the legs of the fillet
NOTCH TOUGHNESS TESTS :

They are used to determine the notch toughness of the weldment.

(Charpy, Izod)
CHARPY V NOTCH IMPACT TEST
Object:

To determine the amount of energy absorbed in fracturing a standardised test

piece at a specified temperature.

The British standard is BS 131: PT 2: 1972.

Reporting Results:
1.
Location and orientation of the notch.
2.
Testing temperature.
3.
Energy absorbed in joules.
4.
Description of fracture appearance.
5.
Location of any defects.

C
F
AC
ACHF
CAV
CO
CO2
DAV

Degree Celsius
Degree Ferried
Alternate Current
Alternate Current High Frequency
Constant Arc Voltage
Carbon Monoxide
Carbon Dioxide
Drooping Arc Voltage

Now let us have look on some essential variables tables.

QW 253 WPS- SMAW
QW 353 WPQ- SMAW
Refer ASME Section IX.
1.
Refer Fig. QW 461.3
2.
Refer Fig. QW 461.4
3.
Refer Fig. QW 461.5
4.
Refer fig. QW 462.2
e)
5.
Refer fig. QW 463.1
f)

Groove Welds in Test Position

Fillet welds in Plates Test Positions.
Fillet Welds in Pipe Test Positions
Method of Taking out the Test Specimen (a, b, c, d &
(Performance Qualification
Method of Taking out the Test Specimen(a, b, c, d,e &

7.

Procedure Qualification Thickness Limits and Test

Performance Qualification and Test Specimens.

Performance Qualification Position and diameter limits
Test Jig dimensions

Qualification)
Refer Table QW 451
Specimens.

8.
9.
10.

Refer Table QW 452

Refer Table QW 461.9
Refer Table QW 461.1

Acceptance Criteria Procedure Qualification

1.
QW 153 Tension Test
2.
QW 163 Bend Test
3.
QW 183 Micro Examination Procedure Specimens
4.
QW 184 Micro Examination Performance Specimens
5.
QW 191 Radiographic Examination
Part QW is divided into 4 articles.
Article I
Welding general requirements
Article II
Welding procedure qualifications
Article III
Welding performance qualifications
Article IV
Welding data
1G or 1F is called flat positions
2G or 2F is called horizontal and circumferential
3G or 3F is called vertical position &
4G or 4F is called overhead position
Position 5G is only in welds in pipes. It is a position when pipe axis is held horizontal and
circumferential seam is welded without rotating. In a way it is combination of 1G, 3G & 4G.
Position 6G is also for the pipes when pipe axis is at 45 deg. to horizontal plate and circumferential
seam is welded without rotating the pipe. It is combination of all positions.
Welding Variables:
Article (IV) gives data about various types of welding variables. It also gives tables for various
welding processes showing essential variables, supplementary essential variables and non-essential
variables for procedures qualification; and essential variables for performance qualification.
Essential variables for procedure are those welding variables whose change will affect the mechanical
properties (other than notch-toughness) of the weldment (ex. Change in P-number, filler metal,
electrode type, preheat post heat etc.)
Supplementary essential variables for procedure are those welding variables for procedure are those
welding variables whose change will after the notch toughness properties of weldment (ex. Uphill or
downhill vertical welding, heat input, preheat or PWHT)
Non-essential variables for performance are those welding variables which will not affect the
mechanical properties of weldment (ex. Joint design, method of back gauging or cleaning etc.)
Essential variables for performance are those welding variables which will affect the ability of welder
to deposit sound weld (e.g. position, deletion of backing F-number etc.
Change in process is essential variable for procedure as well as performance.
Before we proceed let us first understand the term P-number A-number and F-number.
All those materials are divided into various P-numbers depending on their nominal composition and
further divided into groups depending on their nominal composition and further divided into groups
depending on the type of refinement / min. specified UTS etc. QW-422 gives the full details.
Plain carbon steels, C-Si, Cr-Mn & C-Mn-Si are grouped as P-1 materials and austenitic stainless
steel as P-8 material. Ferrous welding consumable are classified under various A-numbers based on
their weld metal chemical composition (table 442) and all welding electrodes and welding rods are

grouped in different F-number depending on their AWS classification which is based on type of flux
and chemical composition (table 432)

There are four steps in the qualification of welding procedure:

# Preparation and welding of suitable samples
# testing of representative specimens
# Evaluation of overall preparation, welding, testing and end results.
# Approval (if the result are favorable)
Code Qualification Requirements :
AWS Structural Welding Code, in paragraph 5.5 sets forth the requirements for qualifying those
welding procedures which do not meet the prequalified status of paragraph 5.1 of that code, or
which must be qualified for other reasons, such as contract requirements. The type and number
of specimens that must be tested to qualify a welding procedure are given in paragraph 5.10.
The test results required are given in paragraph 5.12.
ASME Boiler and Pressure Vessel Code:
The ASME Boiler and Pressure Vessel Code is authoritative about welding procedures. Section IX
is the basic document. It is titled Welding and Brazing Qualifications. All sections of the ASME
Code require welding procedures to be qualified "in accordance with Section IX" in addition
to supplemental requirements of each specific section.
ASME Section III on Nuclear Components for Power Plants, paragraph NB- 2539.2, states. "The
welding procedure ... shall be qualified in accordance with NB-4000 and Section IX of this Code".
Paragraph NC-2539.2 refers to NC-4000 and Section IX. Similarly, NG-2539.2 refers to NG-4000
and IX.
ASME Section VIII, Division I, on Pressure Vessels, paragraph UW 28, requires the qualification
of welding procedures in accordance with Section IX. Paragraph UB 28 requires brazing
procedures to be similarly qualified.
Other procedures in ASME Section III, such as NB-4361 on Specially Designed Seals, are no
exception. "Each Manufacturer or Installer shall prepare a procedure specification. The procedure
shall be qualified as a new procedure and shall be completely re-qualified when any of the essential
variables listed below are changed." Paragraph NB-4381.2 on the requirements for hard surfacing
states. "The procedure shall be qualified as a new procedure and shall be completely re-qualified
when any of the changes listed in NB-4382 are made."
The ASME Code is well summarized in a series of identical paragraphs NB-4321, NC-4321
and so forth-entitled "Procedure Specifications and Qualifications."
Each manufacturer and/or Installer is responsible for the welding done by his organization and shall
establish the procedure and conduct the tests required by this Article and by Section IX of this Code.
Some Common Specifications
SFA 5.1 Covered carbon steel arc welding electrodes
SFA 5.4 Covered corrosion resisting chromium and chromium-nickel electrodes
SFA 5.5 Low Alloy steel covered arc welding electrodes
SFA 5.9 Corrosion resisting chromium and chromium nickel steel bare filler wire
SFA 5.17 Carbon steel electrodes and fluxes for submerged arc welding ( SAW )
SFA 5.18 Carbon steel filler metals for gas shielded arc welding (GTAW / GMAW )
SFA 5.20 Carbon steel electrodes for flux-cored arc welding ( FCAW )

SFA 5.23 Low Alloy steel electrodes & fluxes for SAW
SFA 5.28 Low alloy steel filler metals for gas shielded arc welding (GTAW / GMAW )
SFA 5.29 Low Alloy steel electrodes for Flux-cored arc welding ( FCAW )
AWS Classification of Consumables:
1. Classification of covered Electrodes for SMAW
(Shielded Metal Arc - also known as Manual Metal Arc):
AWS - E - XX - YY - G
E.g. AWS E-7018 or, AWS E 8018 B2
E ..Coated electrode
XX.. Minimum tensile strength in ksi
YYCoating Type & chemistry
G Alloy addition, if any
2. Classification of GTAW / GMAW / PAW Bare Wire Rod
AWS - ER - XX -S - YY
E.g. AWS ER-70-S-G2
ER.. Bare Rod / electrode
XX.. Minimum tensile strength in ksi
S.Solid
YYSpecific chemical composition
3. Classification of SAW Wire and Flux for Carbon Steel
AWS - F - XXX - E - YYY
F.............Flux
1st X......Tensile strength in 10,000 psig
2nd X.......Condition of Heat treatment.
A....as welded
P.... Post heat
3rd X........Impact strength
E..............Electrode wire
YYY..........Classification of
Carbon steel wire, e.g. EL8, EM12K, or EH14.
4. Classification of SAW Wire & Flux for Alloy Steel
AWS - F - XXX - E C- YYY N- ZM
F.............Flux
1st X......Tensile strength in 10,000 psig
2nd X.......Condition of Heat treatment.
A....as welded
P.... Post heat
3rd X........Impact strength
E..............Electrode wire
C..............Composite electrode
YYY..........Classification of alloy steel wire

N..............For special purpose

ZM............Chemical composition of weld metal
Essential Variables are given in comprehensive details in the chapter called "Welding Data".
i. Welding Process, e.g. SMAW, GTAW, SAW etc.
ii. Parent Material, material specifications categorized into P Nos.
Iii. Material Thickness
iv. Welding Consumable, categorized into F No. & A No.
v. Maintenance of Preheat, Interpass & Post heat
Vi. Post Weld Heat Treatment and finally, the supplementary essential requirement of,
vii. Impact Testing to assure notch toughness properties.
Assignment of P Numbers: To rationally reduce the number of Welding Procedure required to be
qualified, base materials have assigned P Numbers, essentially based on comparable material
characteristics, such as chemical composition, mechanical properties and weldability. (Refer QW442)
Assignment of F Numbers : Electrodes and welding rods have been grouped into F Numbers ( Refer
QW-432), essentially on the basis of their usability characteristics, which fundamentally determine
the ability of the Welders to make satisfactory welds, with a given filler metal. This grouping also
reduces the number of welding procedures and performances which required to be qualified, where
it can be logically done.
Assignment of A Numbers: Weld Metal compositions have been classified and grouped Into A
Numbers, essentially on the basis of their weldability characteristics, as reflected by the nominal
chemical composition obtained from their actual weld metal analyses.
GUIDELINES FOR REVIEW OF WPS/PQR.
Checklist for Review of WPS (SMAW Process)
Refer QW 250 for variables. (Supplementary variables not needed)
1)

2)

3)
4)
5)
6)
7)
8)
9)
10)
11)

See identification block showing WPS no.___________, Rev__________ and PQR

no.___________. Also at the end the reviewer shall give his comments. There is signature
of the viewer at the end.
QW 402 gives joint details. QW 403 is indicating Base metals for example if a PQR is
having base metal thk. 25.4mm the WPS supported by it can be from 4.8mm to 5.8mm. So
if these variables are written in QW 403.8 properly in WPS and PQR column then the
column at qualification shall indicate OK which confirms that the variable is within the
requirements and addressed properly.
QW 404 is for filler metals
QW 405 is for positions.
QW 406 is for preheat.
QW 407 is for PWST
QW 409 is for electrical characteristics.
QW 410 is for technique.
Additionally QW 401 says A change in process is an essential variable. This has to be
verified here and documented.
QW 202.2, 3, 4 are mentioned for reminder to the verifier.
This is reminder for QW 200.4 combination of processes.

12)
13)
14)
15)
16)

This is reminder for reviewer for bend and tension test as per QW 451.1
This is reminder for QW 404.5. The basis for assigning A numbers.
This is reminder for QW 170- Notch toughness if required by construction code.
This is to remind if there are any contracts /company/other
requirements to be addressed (QW201)