TECHNOLOGY

Welding Inspection
Weld Procedures
Course Reference WIS 5
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TECHNOLOGY Welding Procedures

What is a Procedure

A systematic method of producing an aim

Therefore, a welding procedure is a

systematic method of producing a sound
weld

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 Stages in welding procedure and welder approval

Development
Application standard
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of procedure
Contract
Project Specification
p WPS
Drawings

EN Approval of
288,ASMEIX,AWS procedure
D1,1

WPAR
Welder approval Finalisation of
certificate procedure

Welding procedure specification

6 months
prolongation
Release for
production
2 years
prolongation
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 Procedure approval
Do all welding procedures need to be written?
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Most production welding procedure are formatted on

written documents or computer spreadsheet, but they
need not be written and may be a product of experience
Do all welding procedures need to be
approved?
•Most procedures are approved, but not all

•An approved welding procedure is one

that has been tested to ensure that the
procedures carried out, produces a weld
satisfies a minimum level of quality for
the mechanical, physical or chemical
properties desired
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TECHNOLOGY Approval of Welding Procedure

Once the weld has been completed it is usually visually

inspected, then radiography or ultrasonic testing is usually applied
Finally, and most important, mechanical tests are performed to
ensure that the desired level of mechanical properties have been
met
If a desired properties have been met, then a procedure
qualification record (PQR or WPAR) is completed with all the test
results, and the procedure then becomes qualified
From this data, a workable document for production welding is
prepared and called a Welding Procedure Specification (WPS)

A CSWIP 3.2 Senior Welding Inspector is normally

responsible for the testing and approval of welding
procedures
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TECHNOLOGY Welding procedure approval terms

Definitions

Essential variables : variable which influence the

mechanical and metallurgical properties

Range of approvals : the extent of approvals for an

essential variable

Examining body : organisation who verifies

compliance

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 TW
I
TECHNOLOGY Welding procedure approval terms

Example of extent of approval include :

•Diameter of pipe or thickness of plate

•Welding position, amperage range or number of
runs
•Welding process ( on multi process procedures
only)
•Change of consumable to one of the same
classification (only if the class is given in the
original procedure )
•Heat input range

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TECHNOLOGY

Welding Procedures
(BS EN 288)

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TECHNOLOGY Welding procedure approval

Specification used for procedure approval :

• EN 288 : Specification and approval of welding
procedures for metallic materials
• EN 288 (Part 1 ): General rules
• EN 288 (Part 2 ): Welding Procedure Specifications
• EN 288 (Part 3 ): Welding Approval Test ( steel )
• EN 288 (Part 4 ): Welding Approval Test ( Aluminium)
• EN 288 (Part 5 ): Approved welding consumables
• EN 288 (Part 6): Previous welding experience
• EN 288 (Part 7 ): Standard welding procedure
• EN 288 (Part 8 ): Pre production welding test
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 Welding Procedures
Producing a welding procedure involves:
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 Planning the tasks

 Collecting the data
 Writing a procedure for use of for trial
 Making a test welds
 Evaluating the results
 Approving the procedure
 Preparing the documentation
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 Welding Procedures
Approving the procedure:
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 When the data has been collected, the procedure must

be validated by producing a test weld, weld procedure
test (WPT).
 A number of standards provides information with
regards to approving a procedure, but normally this will
require the WPT to be tested by NDT and mechanical
testing.
 The locations and tests required will be given in the
applicable code or standard
 Most codes and standards provide a report format to
record the results
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 Welding Procedures
Once the welding procedure has been approved, If any
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essential variable is changed during production the WPS may

require re-approval. Most codes/procedures dealing with
procedure qualifications provide a list of what is an essential
or non-essential variable.

Object of a welding procedure test

To give maximum confidence that the welds mechanical and
metallurgical properties meet the requirements of the
applicable code/specification.
Each welding procedure will show a range to which the
procedure is approved (extent of approval)
If a customer queries the approval evidence can be supplied
to prove its validity
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 Welding Procedures
Components of a welding procedure
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Parent material
• Type (Grouping)
• Thickness
• Diameter (Pipes)
• Surface condition)

 Welding process
• Type of process (MMA, MAG, TIG, SAW etc)
• Equipment parameters
• Amps, Volts, Travel speed

 Welding Consumables
• Type of consumable/diameter of consumable
• Brand/classification
• Heat treatments/ storage
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 Welding Procedures
 Joint design
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• Edge preparation
• Root gap, root face
• Jigging and tacking
• Type of baking
 Welding Position
• Location, shop or site
• Welding position e.g. 1G, 2G, 3G etc
• Any weather precaution
 Welding Variables
• Run sequences
• Back gouging
• Interpass temperatures
 Thermal heat treatments
• Preheat, temps
• Post weld heat treatments e.g. stress relieving
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 WELDING PROCEDURE SPECIFICATION
TECHNOLOGY

• A DOCUMENT PROVIDING IN
DETAIL THE REQUIRED
VARIABLES FOR A SPECIFIC
APPLICATION TO ENSURE
REPEATABILITY.

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 PROCEDURE QUALIFICATION RECORD
TECHNOLOGY

• A RECORD COMPRISING ALL RELEVANT

DATA FROM THE WELDING OF A TEST
PIECE NEEDED FOR APPROVAL OF A
WELDING PROCEDURE SPECIFICATIONS
AS WELL AS ALL RESULTS FROM THE
TESTING OF THE WELD TEST

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 Welding Procedures
Examination and testing requirements of a WPT for
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procedure approval (BS EN 288)

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 WELDING VARIABLES
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• ESSENTIAL VARIABLES
• - ESSENTIAL VARIABLES ARE
THOSE IN WHICH A CHANGE, AS
DESCRIBED IN THE SPECIFIC
VARIABLES, IS CONSIDERED TO
AFFECT THE MECHANICAL
PROPERTIES OF THE WELDMENT

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TECHNOLOGY WELDING VARIABLES

• NON ESSENTIAL VARIABLES

• - NON ESSENTIAL VARIABLES ARE THOSE
IN WHICH A CHANGE, AS DESCRIBED IN
THE SPECIFIC VARIABLES, MAY BE MADE
IN THE WPS WITHOUT REQUALIFICATION

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TECHNOLOGY WELDING VARIABLES

• SUPPLIMENTARY ESSENTIAL VARIABLES

• VARIABLES ARE REQUIRED FOR METALS
FOR WHICH OTHER SECTION SPECIFY
NOTCH - TOUGHNESS TESTS ARE IN
ADDITION TO THE ESSENTIAL VARIABLES
FOR EACH WELDING PROCESS

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 SHALL
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A MANDATORY PRACTICE WHICH WILL

REQUIRED CHANGE OF WPS IF NOT FOLLOWED

SHOULD
A RECOMMENDED PRACTICE

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TECHNOLOGY

Example:

Welding Procedure

Specification (WPS)

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TECHNOLOGY

Welder Approvals
(BS EN 287)

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TECHNOLOGY Welder Approval

Once the procedure has been approved it is then

important to test each welder,to ensure that he has
the skill to reach the minimum level of quality in
the weld,as laid down in the application standard
There is no need to carry out the mechanical tests
of the procedure, although bend tests are often
used to ensure good sidewall fusion
Normally; visual,x ray,bends,fracture and macro
are used in welder approval tests

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TECHNOLOGY Welder approval standards

EN 287 for welder approval

• Part 1 : Steels
• Part 2 : Aluminium and its alloys

• Defines essential variables :

• range of approval
• Testing requirements
• Acceptance requirements
• re tests
• period of validity

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 Welder Approval
Numerous codes and standards deal with welder
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qualification, e.g. BS EN 287.

Once the content of the procedure is approved the next
stage is to approve the welders to the approved procedure. A
welders test know as a Welders Qualification Test (WQT).

Object of a welding qualification test

. To give maximum confidence that the welder meets the
requirements of the approved procedure (WPS).
 The test weld should be carried out on the same material
and same conditions as for the site welds
 The welder who carries out the procedure qualification weld
automatically qualify when the procedure qualifies
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 WELDER QUALIFICATION TEST
TECHNOLOGY

• TO DETERMINE THE WELDER’S

ABILITY TO DEPOSIT SOUND WELD
METAL.
• THE PURPOSE OF THE QUALIFICATION
TEST FOR THE WELDING OPERATOR IS
TO DETERMINE THE WELDING
OPERATOR’S MECHANICAL ABILITY TO
OPERATE THE WELDING EQUIPMENT.

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TECHNOLOGY Welder approval

When supervising a welder test the welding

supervisor should :
• Check the welding process, condition of
equipment and test area for suitability
• Check the extraction system, goggles and all
safety equipment are available
•Check materials to be welded are correct and
stamped correctly for the test
•Check grinders, chipping hammers, wire brush and
all hand tools are available
• Check welding consumables
specification,diameter,and treatment with WPS

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TECHNOLOGY Welder approval

•Check the welders name and stamp details are

correct
• Check that the joint has been correctly prepared
and tacked, or jigged
• Check that the joint and seam is in the correct
position for the test
•Explain the nature of the test and check that the
welder understands the WPS
•Check that the welder carries out the root run,fill and
cap as per WPS
• Ensure welders indentity and stop start location are
clearly marked

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 Welder Approval
Information that should be included on a welders test
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certificate are:
1. Welders name and identification number
2. Date of test
3. Standard/code e.g. BS EN 287
4. Test piece details
5. Welding process, welding parameters, amps, volts
6. Welding parameters, amps, volts
7. Consumables, flux type and filler classification details
8. Sketch of run sequence, welding positions
9. Joint configuration details
10. Material type qualified, pipe diameter etc
11. Test results, remarks
12. Test location and witnessed by
13. Extent (range) of approval
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 Welder Approval
The inspection of a welders qualification test.
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 It is normal for a qualified inspectors usually from an

independent body to witness the welding.
 Under normal circumstances only one test weld per welder
is permitted
 If the welder fails the test weld and the failure is not the fault
of the welder e.g. faulty welding equipment then a re-test
would be permitted.
 The testing of the test weld is done in accordance with the
applicable code, but it is not normal to carry out test that test
for the mechanical properties of welds e.g. tensile, charpy
and hardness tests.

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TECHNOLOGY Range of approval according to electrode flux type

BS EN 287
Range of approval
according material
groups

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TECHNOLOGY

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 Welder Approval
Tests methods required for welder qualification
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(BS EN 287)

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TECHNOLOGY

Example:

Welder Approval

Qualification

Certification

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TECHNOLOGY

Any
Any Questions?
Questions?

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TECHNOLOGY Questions
QU 1. State six essential variables in a welding procedure.

QU 2. What do you understand by the term extent of approval and

give four examples.

QU 3. Describe what you understand by a welding procedure

specification, A welding procedure approval record and a welder
certificate

QU 4. What is the reason for approving a welding procedure and

a welder

QU 5. Give three reasons why a welder may require re-

qualification.

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