WELDING PROCEDURE QUALIFICATION SEQUENCE

PQR/WPS/WQT QUALIFICATION

DRAFT WPS Preparation

Following take from approved drawings

Base material

-Piping: Design code/ P number/Group/sub group/design temperature/fittings/flanges/supports

-Structural: Max Specified yield strength for structural/requirement of CTOD/CVN temperature

-Maximum and minimum diameters

-Maximum and minimum thickness

-TKY joints for structural members (for qualification of 6GR position)

Based above details prepare draft wps for PQR qualification

-Select suitable welding process and combination of process (Low thickness GTAW, Higher thickness
GTAW+SMAW, Big pipe/flange with high thick go for GTAW+SMAW+SAW, minor works FCAW like
handrail welding and deck plate support welding

Selection Filler Metal/Flux

Filler metal for piping ref ASME SFA data sheet for comparison of base metal

Selection of filler wire based on the process and base material chemical composition. Best suitable filler
metal will be select from the supplier filler material data book Ex: SANDVIK, KOBELCO

Selection of Backing and Torch Gas /flow rate for GTAW process based on recommended by supplier
filler data sheet.

Selection of Electrical Parameters

All filler material Electrical parameters select form process based on recommended by supplier filler
metal data sheet.

Filler metal data mill certificate/ corrosion test report / mechanical test report can get from
manufacturer/supplier

Requirements of Preheat

Based on base material grade preheat will be select AWS D1.1 for Structural
ASME 31.3 for Piping

Requirements of PWHT

Structural Not Required unless specified drawing

Piping as per ASME 31.3 20mm and above need PWHT so pqr specimen need pwht after welding

Grove design

Structural based on the prequalified wps AWS D1.1 section 3.3 (normally Single/ Double V)

Groove weld qualification covers fillet welds all size thickness

Groove weld thickness up to <25mm will be qualify double thick, 25mm and above cover all thickness

Diameter limits qualified and above, all qualification cover above 600mm diameter pipe welding

Piping ASME based ASME 31.3 on pipe delivery condition (normally single V groove)

Groove weld covers Fillet weld all thickness,

Diameter limits qualified and above.

Thickness and diameter qualified all as per ASME section 9

Root gap, root face, groove angle all will be get from code. AWS/ASME 31.3

Position:

Position requirement as per site assembly and based on code requirements

Structural AWS D1.1 6G cover all position (include 6GR welder qualification for TKY joints)

Piping ASME Section 9 - 6G cover all position

Welding parameters

Conduct the test, record all the welding parameters (electrical/weld sequence)

In testing

-Clamp meter (calibrated by lab) used to find volt and current range

-calculate Heat input H=VI60/Travel distance x1000 (V=volt, I current, 60=seconds, distance in mm)
Ex : 11V, 120A, Per minute time taken 50mm weld distance

H=11x120x60/50000 = 1.584 KJ/mm (Can’t be more 2.5KJ/mm, If more need to change speed)

-Temperature of preheat and Interpass heat recorded by use temp stick or calibrated laser temperature
measure

- Inter pass temp (before start next pass temp on weld) cant more 250oC or recommended by material
certificate

-welding not allowed to stop long time without complete 1/3rd thickness complete

-Use grinding wheel and wire brush as applicable parent material

-SMAW welding bead width not more 2.5 times of rod (if 2.6mm rod, max width 2.6x2.5=6.5mm)

-GTAW rod width maximum 8mm

- Welding sequence is controlled, not start same area every time, in pipe opposite weld and front side
weld change to avoid weld specimen to bend distortion over heat one place

-Backing gas /Torch gas flow rate must check to conform the flow rate 15-20 litter per minute.

After weld completed need to do following:-

1. Visual Inspection

2. NDT (UT/RT/MPT or both)

3. PWHT (If required)

4. Ferrite check weldment

If all the tests ok, cut the welding as per the code reqirements go to the mechanical tests following

Structural follow by AWS D1.1

Piping followed by ASME 9

1. Tensile test (2 specimen) –to find out the tensile strength same or above the base metal
2. Charpy V notch toughness test at required temperature (-29oC/-46oC based on base metal req)
3. Guide bend test (4 specimen) or Root bent 2nos, Face bend 2nos for below 12mm thick
4. Macro etch test weldment (find out the weld sequence)
5. Hardness survey for weld metal fusion line/base metal/heat affect zone HAZ
6. CTOD test for structural If required

The entire test witnessed by client /third party in the testing Laboratory (Setsco/DNV/PTS labs in
Singapore)
If everything satisfactory, the draft wps adjusted with recorded parameters will get approved the wps.

WELDER QUALIFICATION/WELDING OPERTOR QUALIFICATION

Based on the approved wps welder will be qualified based on welder qualification each code

Structural – AWS D1.1 section 4 welder qualification

Piping – ASME 9, welder performance qualifications

The welder qualifications specimen size mentioned by each code.

After WQT Visual inspection ok and RT will be conform the passing requirements

Upon passed welder qualification issue of welder ID card (contains welder name, IC, material P number,
tested parameter and qualified range)

Welder list will be maintain entire project

Welder not welding for 6 months will be conduct retest for again welding

Welder continuously produced defect weld, will be disqualify by welding engineer.

In piping same process different P number material can allowed welding within the thickness and
diameter range.