Welding Procedure Specification

ASME SEC IX

Purpose of WPS Qualification

To determine that the weldment is capable of providing the required properties for the intended application. WPS establishes the properties of the weldment and not the skill of the welder.

Welding Procedure Specification

It is a written document that provides direction to the welder for making production welds in accordance with code requirements. WPS specifies the conditions (ranges) under which welding must be performed called variables. WPS addresses essential, supplementary essential and non essential variables Any WPS must be qualified by the manufacturer.

Procedure Qualification
When two or more procedures (diff processes or other essential variables) are used in one joint, the applicable range of thickness of weld metal qualified is also specified. One or more processes from a combination may be deleted provided remaining metal meets the requirements.

Procedure Qualification
Several WPSs may be prepared from one PQR.

Example. 1G plate PQR may support WPSs in 2G, 3G, 4G, pipe 5G, 6G etc provided other parameters are kept same. A single WPS may cover several PQRs
Example. A single WPS may cover 1.6 mm to 32 mm thickness if PQRs for 1.6 to 4.8 mm and 4.8 mm to 32 mm thickness ranges are available.

Considerations for establishing WPS

Material Thickness Configuration Detailed drawing of weldment Process Code of construction

Preheat/Postheat/ PWHT requirements Skill of welder Good welding m/c with accessories

WPS preparation
WPS Welding Procedure Specification
is prepared based on the PQR Procedure Qualification Record

Procedure Qualification Record

It documents what occurred during welding the test coupon and the results of the test coupon. PQR documents the essential variables and other specific information and the results of the required testing. In addition, when notch toughness is required for procedure qualification, the applicable supplementary essential variables shall be recorded.

Procedure Qualification
PQR is a record of welding data used to weld a test coupon. It also contains test results. Completed PQR shall document all essential variables including ranges. PQR to be certified accurate and shall not be subcontracted. If more than one process is involved then weld deposit thickness for each process and filler metal to be recorded.

Variables

Base metal Welding Process Filler metal Shielding medium Joint design Backing material Preheat PWHT Back gauging

Essential
Non-essential Supplemental essential

Variables

Essential
Changes in which are considered to affect the mechanical properties of the weldment

Supplementary essential
Required for meeting notch toughness requirements

Non-essential
Changes can be made with out requalification

WPS for SMAW

Essential variables
Change in qualified Thickness Change in P no Change in F no of filler metal Change in A no of filler metal Change in deposited metal thickness Decrease of more than 55C in preheat Change in PWHT

WPS for SMAW

Supplementary Essential variables
Change in Group no of base metal
Change in T limits for impact test Change in dia of filler metal > 6 mm Change in AWS class of filler metal Change in welding position Increase of more than 55 C in preheat Change in PWHT Time and temp range Change in current or polarity

WPS for SMAW

Non Essential variables
Change in Groove design, backing, root spacing, retainers etc Change in dia. of filler metal Change in AWS class of filler metal Change in welding position Change in preheat maintenance Change in current or polarity Change in string/weave, cleaning, back gouging, peening, manual/automatic

WPS for GTAW

Essential variables
Change in qualified Thickness Change in P no Change in F no & A no of filler metal Addition/deletion of filler metal Change in size of filler metal, product form Decrease of more than 55 C in preheat Change in PWHT

WPS for GTAW

Essential variables (cond)
Change in single, mixture % gas Deletion of backing gas Change in shielding / trailing gas Change in Closed to out chamber technique

WPS for GTAW

Supplementary Essential variables
Change in Group no of base metal Change in T limits Change in AWS class of filler metal Change in welding position Increase of more than 100 F in preheat Change in PWHT Time and temp range Change in current/polarity, incr. in heat input Change in multi to single pass, electrodes

Procedure Qualification Thickness limits

T mm <1.6 Range
of T
T - 2T 1.5 to 10 1.5 - 2T 10 to <19 5 - 2T 19 to 38 5 - 2T >38

Max t
Weld

Tests
(transverse bend)

2t 2t 2t 2t if 2Tif 38 to 200 2t if 8 if

2Tr Ten,2 FB,2 RB -do-dot<19 2Tr Ten, 4 SB t>19 t<19 -dot>19

Weld positions & orientation

Weld Positions
Plate groove positions 1G, 2G, 3G, 4G Pipe groove positions 1G, 2G, 5G, 6G Plate fillet positions 1F, 2F, 3F, 4F Pipe fillet positions 1F, 2F, 2FR, 4F, 5F

Weld orientations
1F - 0 to 30 2F - +15 -10 wrt 45 4F - 0 - 125 3F - 125 - 235

Base Metal Classification

P nos depend on composition, weldability & mechanical properties. Group nos classify metals within P nos for procedure qualification where notch toughness requirements are specified. But base metals can not be indiscriminately substituted.

Base Metal P Numbers

P1 - P11 P21 - P25 P31 - P35 P41 - P47 P51 - P53 P61 - P62 Steel Al alloys Cu alloys Ni alloys Ti alloys Zr alloys

Base Metal P Numbers

Examples of P nos for steel
P1 P3 P4 P5A P6 P7 P8 P9A P10A P11 C Steel 1/2 Mo steels 1 Cr 1/2 Mo steels 2 1/4 Cr 1 Mo steels 13 Cr steel 17 Cr steel ASS 2 1/2 Ni steels Mn - 1/2 Ni - V steels 9 Ni steels

Base Metal for WPS

Material combinations qualified
Test Coupon Px Px Px Py P3 - P3 P4 - P4 P5A - P5A P5A (P4 / P3 / P1) P4 (P3 / P1) Base Metals qualified Px Px - Py P3 ( P3 / P1) P4 ( P4 / P3 / P1) P5A ( P5A / P4 / P3 / P1) P5A (P4 / P3 / P1) P4 (P3 / P1)

Filler Metal F Numbers

Based on usability characteristics i.e ability of welders to make satisfactory welds with given filler

F1 F2 F3 F4 F5 F6

E XX20 E XX12, E XX13 E XX10, E XX11 E XX18 ASS, Duplex SS Bare rods

Weld Metal A Numbers

Based on chemical composition A1 Mild steel A2 C - Mo steel A3 Cr - Mo steel (Cr 0.4 - 2%) A4 Cr - Mo steel (Cr 2 - 6%) A5 Cr - Mo steel (Cr 6 - 10.5%) A6 Cr Martensitic A7 Cr Ferritic A8 Cr Ni steels (Cr 14.5 - 30% Ni 7.5 - 15%) A9 Cr Ni steels (Cr 19 - 30% Ni 15 - 37%) A10 Ni steels (Ni 0.8 - 4%) A11 Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%) A12 Ni Cr Mo steels (Cr 1.5% Mo 0.25-0.8%
Ni 1.25 -2.8%)

Procedure Qualification Thickness limits

T Range of T Max t
of weld

Tests
(longitudinal bend)

1.6 T - 2T 1.6 to 19 1.6 - 2T 19 1.6 - 2T

2t 2t 2t

2T, 2 FB, 2 RB -do-do-