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2008.
Preparation WPS
WPS (Welding Procedure Specification) Preparation
WPS is prepared according to ASME Sect. & based on PQR.
There is not required preparing PQR when it is prequalified by AWS.
The completed WPS shall describe all of the essential, nonessential, and , when
required, supplementary essential variables for each welding process used in wps.
1) Applicable Code
Record the applicable code that are ASME , , , , ASME/ANSI B31.1,
AWS D1.1, TRD 201, etc.
2) WPS NO (Specification No )
It is given the serial no according to applicable code, welding process,
material specification.
) A M 0101 001
A : classification of applicable code
- A : ASME(I, III, VIII, ASME/ANSI B31.1) W : AWS (D1.1, D14.1) X : TRD 201
Preparation WPS
M : classification of welding process (ex. TM, TMA ..)
- A : SAW F : FCAW G : GMAW M : SMAW
T : GTAW
S : STUD TF : GTAW + FCAW TM : GTAW + SMAW MA : SMAW + SAW
0101 : given the P-No of combined material (for example : P-No.1 + P-No.1 = 0101)
- ASME, ASME/ANSI: write P-No classified in QW-422
- AWS D1.1: write group no of material classified in Table 3.1.
- Writes Z0Z0 when it doesnt classified in P-No.
001 : serial no
3) Date
Writes its date when WPS is issued with first. (for example : Jul, 06. 1995)
Preparation WPS
5) Date
write its the date when WPS is revised
prepared
other various WPS.(ASME IX QW-200.2 f)
7) Welding Process
Write in a blank of Welding Process
8) Type of joint
Write a Welding Process Type
Manual : GTAW, SMAW
Machine : SAW
Preparation WPS
Joints(QW-402)
9) Joints
Write the type of Joints(for example : Single-V, Double-V, Fillet , etc)
Sketch of joint figure
ASME
- Groove
Write Square-, Single-, Double-, Single Bevel-, Double Bevel-, Single U-,
Double U-, Single J-, Double J-, etc
But various forms of Groove Write - Groove
- Fillet : Write Fillet
- Composition : Grooves & Fillets
AWS
AWS D1.1 Figure 2.4, 2.5 division Butt, T, Corner and addition Joint Designation.
ex) Butt Single bevel Groove (B-U4a)
TRD 201
- Groove : Butt (Square, Single V-) Groove
- Fillet : Fillet
Preparation WPS
10) Root Gap (mm)
Choice the proper size to maintenance the soundness of back bead
(Generally, Max.5mm)
11) Retainer
it is frame that progressed Back Bead.
Write None or Yes
12) Backing
When backing is used, it shall describe information in detail.
(for example : Base Metal, Weld Metal, Ceramic Bar, etc)
Preparation WPS
Preparation WPS
Fillet : UNLIMITED
- AWS : apply D1.1 Prequalified Joint thick range.
If it is accomplished PQ Test, Apply Table 5.1, 5.2, 5.3
- TRD 201 : Annex 3.3.1, 3.3.2
- ASME : Apply IX QW403.6 ~ 14 or QW451
If it is not operated PWHT, Apply thick restriction depend on exemption PWHT
specified for
exempt heat treatment in ASME (PW-39), ASME (UCS-56), and ASME/ANSI
B31.1
(TABLE 132).
AWS : write Unlimited (have no limitation).
Preparation WPS
Position (QW-405)
19) Position
ASME - Write as All because position is non-essential variable in QW-405.1
AWS D1.1 - Prequalified Joint: Applied the position specified in Figure 3.3, and 3.4.
- Qualified Joint: Applied Table 4.1
Groove welding required toughness
Vertical-Up All Position Cover
Stringer Bead - Weave Bead not Cover
OVERLAY position
PQR
WPS
PQR
WPS
V(UP)
F, V
H, V, OH
ALL
F, H
5G
F, V, OH
OH
F, OH
6G
ALL
Preparation WPS
20) Progression of vertical Position
When welded with vertical position: Write either UP or DOWN.
When welded without vertical position: Write N/A.
When welded with Orbital welding: write both UP and DOWN.
Preheat (QW-406)
Selected the proper temperature according to the requirement of code like follows
and
contract.
- ASME : Appendix A-100 and PW-39
- ASME : Appendix R, Table UCS-56
- ASME/ANSI B31.1: Para. 131.4, Table 132
- AWS D1.1: Table 3.2
Preparation WPS
21) Interpass Temp Max.
Max temperature of deposited weld metal before next layer welding when operated
multi
pass welding.
Generally apply below for your reference but when special situation apply code and the
terms of contract desired.
Interpass Temp Max()
C/S & LOW ALLOY
STEEL
350
AUSTENITIC SUS
177
HIGH-Ni, Cu-ALLOY
150
Allowance Temperature :
In ASME . Temp of
Allowance PQR addition 56
A turn around from welding start point is 1Pass. Second pass start point doesnt over
350 .
Preparation WPS
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Preparation WPS
Gas (QW-408)
25) Gas
Write with the chemical symbol that is including chemical composition and flow rate.
(Refer to below table)
Process
GTAW
FCAW
GMAW
Material
Carbon,
Low alloy
S/S
Gas
Composition
Flow rate
Flow rate of
backing gas
Ar, Ar+He
8 ~ 15 L/M
4 ~ 8 L/M
9 ~ 13mm
CO2, Ar+CO2
20 ~ 25 L/M
12 ~ 20mm
CO2, Ar+CO2
20 ~ 25 L/M
12 ~ 20mm
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Preparation WPS
Ingradients : Welding Grade 99.99 % or more
Use
Shielding Gas : Shielding for arc when welding. prevent O, N, H
Backing Gas : Use the other side of base metal. Because prevent oxidation.
Trailing Gas : Active Metal(Zr, Ti, etc.) welding.
There are shielding weld metal from the air after solidification.
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Preparation WPS
Technique (QW-410)
Process
Material
GTAW
FCAW
GMAW
Carbon,
Low alloy
S/S
Gas
Composition
Flow rate
Flow rate of
backing gas
Ar, Ar+He
8 ~ 15 L/M
4 ~ 8 L/M
9 ~ 13mm
CO2, Ar+CO2
20 ~ 25 L/M
12 ~ 20mm
CO2, Ar+CO2
20 ~ 25 L/M
12 ~ 20mm
26) Orifice gas cup size : Applied to GTAW, GMAW, and FCAW Process
(Refer to above table)
27) Contact tube to work distance : Applied to GMAW, FCAW, and SAW process
(Refer to below table)
Welding Process
GMAW
FCAW
13 ~ 25
SAW
25 ~ 38
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Preparation WPS
28) Oscillation
Written the frequency and amplitude (Auto-GTAW, GMAW, FCAW, SAW,ESW
process)
29) Stringer or Weave Bead: Limited except from manual, semi-auto welding.
Stringer Bead
Weave Bead
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Preparation WPS
31) Single or Multi. Electrode
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Preparation WPS
33) Multi or Single Pass (per side)
Hammering process
Be used to decrease transformation. Root pass / Layer or the last layer
dont use
(but, PWHT - use)
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Preparation WPS
Preparation WPS
36) Tungsten Electrode Type and Size
generally, used the EWTh-2, 2.4mm.
- EWTh-2 : Th 2% is included in Tungsten Electrode
- EWP : Pure Tungsten Electrode
- EWZr : Zirconium is included in Tungsten Electrode
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Preparation WPS
40) F-No.
The purpose of classified F-No is to reduce the number of welding procedure
qualification
and welding performance qualification.
- ASME : According to QW-432, AWS D1.1 : N/A
F-No.1 :
F-No.2 :
F-No.3 :
F-No.4 :
48
F-No.5 : Austenite, Two kind SUS steel. Exxx15, 16, 17
F-No.6 : Solid, Flux-cored, Composition ferrous electrode
P-No. : Base metal
F-No. : Welding materials
A-No. : Deposited weld metal
AWS : N/A
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Preparation WPS
41) A-No.
Assign according to chemical composition in deposited weld metal.
- ASME : Described in QW-422
- AWS D1.1 : Described in Table 3.1
42) SFA-NO.
ASME : Described in part C of ASME
AWS D1.1 : N/A
44) Current/Polarity
Record AC, DCRP, DCSP
- SAW : AC or DCRP
- GTAW : DCSP (but Aluminum - AC)
- FCAW, GMAW : DCRP
- SMAW : AC or DCRP
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Preparation WPS
45) Amp. Range, Volt. Range, Speed. Range)
Process
Material
Dia.
Current
2.6
50 - 85
3.2
80 - 130
4.0
110 - 180
5.0
150 - 240
2.6
45 - 85
3.2
65 - 115
4.0
85 - 145
5.0
135 - 180
Carbon &
Low alloy
2.4/2.5
100 190
S/S
2.4/2.5
90 - 190
Carbon &
Low alloy
steel
SMAW
S/S
GTAW
Volt
Trv. speed
22 - 28
6 - 25
22 - 28
6 - 15
10 - 15
8 - 15
FCAW
Carbon &
Low alloy
1.6
210 - 350
22 - 30
30 - 60
SAW
Carbon &
Low alloy
2.4
300 - 350
27 - 34
40 - 60
4.0
500 - 550
28 35
40 - 80
Remark
Can be
changed
according to
recommenda
tion of mill
maker or
test result
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Preparation WPS
46) The others
generally, written the brand name of filler metal, etc
47) Notes
- ASME: Written about heat treatment and other needed instruction, etc
- AWS : Written about Technical Requirement.
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