WELDING PROCEDURES

What is a Welding Procedure?

A welding procedure details all significant items that must be considered when joining two pieces of metal by welding. The procedure may be one document or may be composed of several separate documents which, combined, make up the total. welding procedure. Welding procedures have limits or ranges of variable items, such as kind of welding current, thickness of base metal, type of base metal, etc. A welding procedure is valid only for use within the limits specified on the procedure. If a procedure cannot produce an acceptable weld without being applied outside of the specified variable ranges, then a new welding procedure must be found to take its place. Under most qualification standards, welding procedures must not only be a documentation of the methods and technology required to achieve satisfactory results, but must also be "qualified," which means qualified by test.

What is a Qualified Welding Procedure?

The requirements for welding procedure qualification vary widely from code to code. Welding procedure qualification is the method whereby a particular procedure is proved adequate to produce satisfactory welded joints when a welder or operator produces a sound weld. To be proved adequate, a test weldment must be evaluated with tests and acceptance criteria that are predetermined by the qualification standard being used. When procedures are qualified, a record of qualification, which includes all pertinent data related to how the joint was welded, is required. This document is called a Procedure Qualification Record (PQR).

Why qualify a welding Procedure?

Most products are designed of materials that have known material properties. When these materials are to be joined by welding, the designer must know what the properties of the welded joint will be. Because of the effects of welding heat, it is not sufficient to know only the properties of unjoined base metal and weld metal. We must also know the properties of the complete welded joint base metal, base metal heat-affected zone, and weld metal. Once these properties are proven, the designer has an engineering basis for expecting a particular welded joint to behave in a certain way and he can design accordingly. This is why welding procedures are qualified. In some cases, prequalified procedures are allowed. These are welding procedures for applications where long usage and familiarity with certain steels and welding materials have proven the adequacy of specific procedures based on service over a long period of time.

How is a Procedure Qualified?

The need to perform welding in production work precedes the development of an actual welding procedure. Once the need is identified and judgments are made as to the most suitable welding processes, the actual work of qualifying a procedure can begin. Any weldment must be made with some form of welding procedure. This is also true of procedure qualification test weldments. So, the first thing to be done is to provide a preliminary welding procedure specification that directs how the joint is to be welded. This normally represents engineering and practical judgments as to the welding conditions most likely to produce an acceptable test weldment. If the welding conditions specified in the preliminary procedure are within the scope of a prequalified welding procedure, production welding may be performed without having to "prove" the welding procedure by actual testing, provided the use of prequalified procedures is allowed by the governing document (qualification code or standard).

Where the use of prequalified procedures is not permitted (or for instances where no prequalified procedure fits the production requirement), the preliminary welding procedure specification must be proved adequate through testing and evaluating a test weldment to the requirements in the qualification specification or standard being used. If a procedure qualification test weldment passes all required tests and examinations, the welding conditions, test data, and test results are documented on a Procedure Qualification Record (PQR). The qualification record and the information on the procedure specification used to qualify the procedure then forms the basis for issuing a Welding Procedure Specification (WPS).

The Welding Procedure Specification

The document(s) that tells a welder or welding operator how to weld a joint is called the Welding Procedure Specification (WPS). It tells the welder what filler metal to use with a particular base metal, the range of welding machine settings that are required, the types of weld end preparations that are applicable, etc. In other words, a welder should be able to reference a WPS, and it should contain all the information he needs to weld a specific type joint. Table 7-1 illustrates the number and type of specimens to be removed from procedure qualification test weldments. This table is based on requirements of three common qualification standards and is intended to illustrate the importance of assuring that the specified requirement is the one followed in qualifying a test weldment. Procedure qualification for one code will not normally qualify for another code*

Welding Variables
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Variables are welding conditions that, if changed, will have an effect on the actual welding. For shielded metal arc welding, a change from a rectifier power source to a gas generator would not normally have any effect on the likelihood of producing a satisfactory weld and is thus not considered a variable for SMAW welding. It might, however, be a variable for other welding processes. Some qualification specifications assign all variables the same importance. Others assign different levels of importance (essential variables or nonessential variables) and even use 1variable" to address a specific application such as notch-toughness properties (essentials for toughness). Each qualification standard identifies specific variables applicable to the various welding processes. A common quality control function is to review welding procedures to assure that the variable ranges allowed in a WPS have been qualified by procedure testing. Variables and the changes or ranges allowed for them are key items in performing checks to determine if welding procedure specifications are being properly applied to production work.

Variables thus become an important area of interest for an inspector. A qualified welding procedure specification has specific variables and variable ranges that will result in an acceptable weld if the welder has sufficient skill to produce a sound weld. A change beyond the limits or range shown in a procedure may affect the properties of the weldment even if the welder produces a sound weld. Awareness of the variables, and an understanding of why they exist, will keep the inspector alert to potential changes in production welding that could require a new welding procedure specification and possibly a completely new procedure qualification test.

Who is Responsible for Procedures?

The qualification and utilization of welding procedures is the responsibility of the company performing the production work. Various individuals have specific responsibilities as listed below: Company welding engineer, writes preliminary WPS Company welder, welds test weldment Laboratory, tests procedure specimens Company welding engineer, evaluates and certifies PQR and WPS (5) Company welder, welds production workpieces Inspector, checks welding to assure that it is being done in accordance with the WPS In general, the welding inspector has very limited responsibilities in the actual preparation and approval of welding procedures. He is responsible for assuring that the correct welding procedures are available and being used for production work. It is important that the inspector make himself aware of any supplementary requirements, such as are specified for impact tested materials, and assures that only procedures that are intended for this use are applied in production. (1) (2) (3) (4)

(6)

What is Performance Qualification?

The requirements for welding and welding operator qualification vary widely from code to code. Before a welder or welding operator does any production work, his employer needs some idea of the welder's ability. Finding out that a man is not capable after he has been hired, or ruined production pieces, or welded on pieces where inspection might not find substandard welds is neither economical nor responsible. To assist employers in determining what level of competence they can reasonably expect a welder to maintain when working on production weldments, various tests have been developed to prove a welder or welding operator's skill. These tests are called performance qualification tests. The qualification of welders demonstrates their ability to produce acceptable welds in accordance with a welding procedure specification. The qualification of welding operators demonstrates their ability to operate welding equipment in accordance with a welding procedure specification.

How Do You Qualify Welders?

Regardless of the code or standard being used, all performance tests require the welder or welding operator to make a sample weld which we will call a performance test weldment. During the welding of this test weldment, the welder or welding operator is watched by an inspector to assure that he follows the applicable rules for testing. Performance qualification welding is done in accordance with a WPS. Once completed, the test weldment is examined and tested to determine if it meets the acceptance criteria for performance qualification. These acceptance criteria are predetermined by the qualification code or standard being used. The type of test, test material, examination, and acceptance standards are dictated for the production work to be performed (i.e., if ASME pipe is to be welded, the qualification standard will be Section IX of the ASME code, and it will specify all requirements for the test). The location, number, and type of required tests or examinations will be specifically stated in the qualification standard. Table 7-2 illustrates some of the common requirements specified for evaluating performance qualification test weldments.

What is Qualification Maintenance?

After a welder or operator passes a test and is qualified to weld in production, his qualification remains valid for as long as he works for the same employer, using the welding process for which he is qualified. However, just because a man passes a test this year does not mean he can weld just as well at some later date unless he has "kept his hand in." Qualification maintenance means keeping track of a welder to be sure that he uses the process or processes for which he has been qualified. If he does not engage in welding during specified time limits, then he is required to take another test. The exact requirements for maintaining a qualification are different between qualification standards, so the inspector has to be aware of what is called for by the standard he is working to. The method used to document qualification maintenance is usually not specified, so the inspector must evaluate the particular system being used to determine its accuracy.

How is Performance Qualification Documented?

Each qualification standard contains suggested forms for use in documenting a welder or welding operator's performance qualification. These forms all have in common a listing of the conditions, the variables, and the WPS used to qualify the welder. It is the duty of a welding inspector to verify the required documentation and that the test conditions and statements on the form are correct and in accordance with the applicable qualification standard. Performance documentation is available to an inspector for all welders performing production work. If they are not available, the inspector should ask for them to assure that proper documentation or proof of qualification exists.

Are There Restrictions on Qualifications?

For the purpose of qualification, a performance variable is a condition of welding that, if changed, will require a requalification of the welder or operator. A particular test weldment may qualify the welder or welding operator for other materials, combinations of materials, welding positions, and weld types. Each qualification standard has its own requirements that limit or broaden the scope of an individual qualification. A primary function of the welding inspector is to be familiar with limitations on qualification tests to assure that specified requirements are met, and also to assist the manufacturer in avoiding duplicate testing or other unnecessary expense related to qualifications. A welder or welding operator must be qualified prior to any production work, except that qualification on production weldments is permitted in specific cases by some qualification standards. An employer may withdraw a welder's qualification at any time it becomes apparent that the welder (or operator) is not producing sound welds. This is normally one of the inspector's duties and must be exercised with the understanding that even the best welders can have rejectable defects in their welds. The inspector must therefore exercise judgment.

Who is Responsible for Performance Qualification?

The employer is responsible for assuring that his welders and welding operators are qualified. The welding inspector has the direct responsibility for verifying qualification for the employer. Thus, a welding inspector's responsibility related to performance qualification normally covers all of the steps required to test welders or welding operators. He may be responsible for the following: Assuring that the correct materials used are in accordance with the Welding Procedure Specification used for the test Supervising the actual welding of the test weldment Evaluating the ability of the person being tested at each step of the test. Assuring that requirements related to welding position are strictly adhered to.

Assuring that the test weldment and specimens are identified and traceable to the welder or welding operator being tested. Where test specimens are removed for destructive testing, selecting the locations in accordance with the code or standard governing the test. Evaluating test specimens (or radiographs) for conformance to the acceptance criteria specified in the code or standard governing the test Accepting or rejecting the test Documenting the results of the test, and if the test is acceptable, signing the test record signifying completion of an acceptable test In some cases, an inspector's sole function is quality assurance, wherein his responsibility is to check all welder qualification documentation to assure that only qualified welders are performing production work.

Qualification Requirements
Table 7-3 shows the more common codes, standards, and specifications and the requirements specified for welding qualification. In addition, there are numerous specifications unique to government and industry that require qualification to their own requirements.

Table 7-3 Qualification requirements

End product, code/standard ASME Section I - Power Boilers Section III - Nuclear Components Section VIII - Pressure Vessels ASME B3 1.1 - Power Piping B31.3 - Refinery/Chemical Piping B31.4 - Liquid Petroleum Transportation Piping B31.8 - Gas Transmission Distribution Piping 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 Specifications D14.1 - Industrial and Mill Cranes IX D14.3 - Heavy Equipment for Pipe/Tube D14.4 - Machinery Equipment Specified qualification requirements (may be modified by referencing document) ASME Section IX ASME Section IX ASME Section IX ASME Section IX ASME Section IX API-1 104 or ASME Section IX APIA 104 or ASME IX or Appendix A of

Contained in D 1. 1 Contained in D1.3 Contained in DIA U.S. Navy/U.S. Coast Guard/Bureau of Ships Contained in D14.1 or may use ASME Section Contained in D 14.3 except use AWS D 10. 9 Contained in D14.4

RESPONSIBILITIES The Employer

The responsibility for meeting qualification requirements belongs to the manufacturer who produces production weldments. This responsibility is both legal and practical. If an employer does not use qualified welders or procedures, or both, he may be in violation of his legal responsibility to meet either contract or government requirements, or both. From a practical standpoint, the expense of producing goods today is so high that most manufacturers see the value of qualifications in lowering their rate of rejected products and the cost of producing those products. Properly engineered welding procedures and workmen whose skills are proven can combine to produce adequate welded joint properties at a minimum cost. Poor welding always costs money

The Design Engineer

The design engineer is responsible for specifying the properties and performance expected from a welded joint.

The Welding Engineer

Welding engineers have responsibility for originating, evaluating, and qualifying welding procedures. They are also responsible for specifying where a particular WPS is to be used on production weldments.

The Welding Inspector

It is the responsibility of the welding inspector to assure that all activities related to welding qualification are documented to the extent required by the particular code, standard, or contract document he is working under. Some of the items commonly required to be documented are: (1) (2) (3) Procedure Qualificiation Records (PQR) Performance Qualification Records Welding Procedure Specifications (WPS)

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In addition to the various mandatory documentation requirements, the inspector may also be expected to assure the maintenance and retrievability of various other records or information, including the following: (1) (2A) (3) The range of qualification of all welders employed Record indicating when welders are due for retests or a documented record of qualification maintenance A roster indicating the identification and welder's symbol for all welders.

At a particular job's completion, all required documentation and records must be either retained, disposed of, or turned over to the owner of the plant or component involved. The code, standard, or contract document will normally specify what disposition is to be made of documentation and records. The welding inspector also has active responsibility for assuring that all welding is performed in accordance with the WPS specified for each weldment.

SUMMARY
The practical and legal necessities for qualification requirements and the frequent revisions and changes in such requirements make it important for you, as an inspector, to be able to find and use specified requirements for qualification for each individual project. Accurate documentation is required and a responsibility of the welding inspector. Knowledge of the responsibilities of the employer, the design engineer, and the welding engineer is as essential as the knowledge of one's own responsibilities as welding inspector.

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