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Transcript of WIS5 WPS 05
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8/13/2019 WIS5 WPS 05
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Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
Weld Procedures
Welding Inspection
Course notes section reference 5
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Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
Welding Procedures
Example Code: BS EN 288
Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
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8/13/2019 WIS5 WPS 05
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Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
Producing a welding procedure involves:
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
Welding Procedures
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Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
In most codes reference is made to how the procedure are to bedevised and whether approval of these procedures is required.The approach used for procedure approval depends on the code:
Example codes:
AWS D.1.1: Structural Steel Welding Code
BS 2633: Class 1 welding of Steel Pipe Work
API 1104: Welding of Pipelines
BS 4515: Welding of Pipelines over 7 Bar
Other codes may not specifically deal with the requirement of aprocedure but may contain information that may be used in writinga weld procedure
EN 1011Process of Arc Welding Steels
Welding Procedures
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Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
Parent material
Type (Grouping)ThicknessDiameter (Pipes)Surface condition)
Welding processType of process (MMA, MAG, TIG, SAW etc)Equipment parametersAmps, Volts, Travel speed
Welding ConsumablesType of consumable/diameter of consumableBrand/classificationHeat treatments/ storage
Components of a welding procedure
Welding Procedures
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Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
Joint design
Edge preparation
Root gap, root faceJigging and tacking
Type of baking
Welding Position
Location, shop or siteWelding position e.g. 1G, 2G, 3G etc
Any weather precaution
Welding Variables
Run sequences
Back gougingInterpass temperatures
Thermal heat treatments
Preheat, temps
Post weld heat treatments e.g. stress relieving
Welding Procedures
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WI 3.1
M.Rogers
When the data has been collected, the procedure mustbe validated by producing a test weld,weld procedu re
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 theapplicable code or standard
Most codes and standards provide a report format to
record the results
Approving the procedure:
Welding Procedures
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WI 3.1
M.Rogers
Examination and testing requirements of a WPT for
procedure approval (BS EN 288)
Welding Procedures
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WI 3.1
M.Rogers
After the testing is completed and all the relevant results
collated, the results need to be assessed in accordance withthe relevant code/standard. The results are then generally
recorded.
pWPS:Preliminary Welding Procedure Specification
Before procedure approval.
WPS: Welding Procedure Specification
After procedure approval
WPAR (WPQR):Welding Procedure Approval Record
Welding procedure test record
Welding Procedures
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WI 3.1
M.Rogers
Once the welding procedure has been approved, If any
essential variableis changed during production the WPS mayrequire re-approval. Most codes/procedures dealing with
procedure qualifications provide a list of what is an essential
ornon-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
Welding Procedures
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WI 3.1
M.Rogers
Example:
Welding
Procedure
Specification
(WPS)
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WI 3.1
M.Rogers
Welder Approval
Example Code: BS EN 287
Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
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8/13/2019 WIS5 WPS 05
13/22Copyright 2005 TWI Ltd World Centre for Materials Joining Technology
WI 3.1
M.Rogers
Numerous codes and standards deal with welder
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 Quali f ication 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 materialand same conditions as for the site welds
The welder who carries out the procedure qualification weld
would automatically qualify when the procedure qualifies
Welder Approval
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WI 3.1
M.Rogers
Information that should be included on a welders test
certificate are:1. Welders name and identification number
2. Date of test and expiry date of certificate
3. Standard/code e.g. BS EN 287
4. Test piece details
5. Welding process.
6. Welding parameters, amps, volts
7. Consumables, flux type and filler classification details
8. Sketch of run sequence, welding positions
9. Joint configuration details10.Material type qualified, pipe diameter etc
11.Test results, remarks
12.Test location and witnessed by
13.Extent (range) of approval
Welder Approval
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WI 3.1
M.Rogers
BS EN 287
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WI 3.1
M.Rogers
Range of approval according to electrode flux type
Range of approval
according materialgroups
BS EN 287
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WI 3.1
M.Rogers
The inspection of a welders qualification test.
It is normal for a qualified inspectors usually from anindependent 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.
Welder Approval
M R
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M.Rogers
Tests methods required for welder qualification
(BS EN 287)
Welder Approval
M R
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WI 3.1
M.Rogers
Example:
Welder Approval
Qualification
Certification
M Rogers
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WI 3.1
M.Rogers
pWPS
Stages in Welding and Welder Approval
DEVELOPMENT
OF PROCEDURE
Application standardContract
Project specifications
APPROVAL
OF PROCEDURE
BE 288ASTM IX
AWS D1.1
WPAR/WPQR
WELDER APPROVAL
CERTIFICATE
6 MONTHS +PROLONGATION
FINALISATION OF
PROCEDURE
RELEASE WPS FOR
PRODUCTION
Welding Procedure Specification
WORK INSTRUCTIONS
M Rogers
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WI 3.1
M.Rogers
Any Questions
M Rogers
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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 procedurespecification, 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.
Questions
Welding Procedures