WIS 5 Welding Inspection

Section 05

Welding Procedures and Welder approvals

TWI
Vllfll. THE WELDING INSTITUTE

Welding Procedures:
What is a welding procedure?
A welding procedure is a systematic method that is used to repeatedly produce
sound welds.

The use of welding as a process or method of joining materials in engineering has been
long established, with new techniques and processes being developed from ongoing
research and development on a regular basis. There are over 100 recognised welding or
thermal joining processes of which many are either fully automated or mechanised,
requiring little assistance from the welder/operator and some that require a very high
level of manual input in both skill and dexterity. For each welding process there are a
number of important variable parameters that may be adjusted to suit different
applications, but must also be kept within specified limits to be able to produce welds of
the desired level of quality for a given application. -We generally term these variable
parameters as essential variables. The most basic essential variables of any welding
processes would be very much dependant on the specific nature of the process, we
would need to consider the following:

1) The source of heat and/or method of heat application. (Where applicable)

2) Consumable type and method of delivery. (Where applicable)
3) Shielding of heat source and/or oxidation of materials. (Where applicable)
4) The thermal energy tolerances into the joint area. (Where applicable)
5) Any particular process element not covered by the above.

It is a common thought that the heat source used for most industrial welding applications
is the electric arc, when in fact most welds made within industry utilise the resistance
welding process. The variable parameters for the resistance welding process are very
different to what would normally be expected from an arc welding procedure. For
example welding procedures for the common arc and resistance spot welding of plain
low carbon steels would require a setting of the following very basic essential variables:

Process Pressure
AC/DC
AC/DC
Arc
Amps
ArcAmps/
AmpsTime
Inductance
Travel
Travel
Travel
Flux
Electrode
Voltage
Amps
Voltage
Speed
Tungsten
Speed
Filler
Electrode
Flux Speed
wiretype Gas
Shield
type
Type/0
type/meshtype/0
Polarity type/0 flow
Electrode
Shield
Flux
size gas rate
gasstick
type
type
depth! outflow
Basic
Gas Process
rate Essential
ContactVariables
area/shape
y

It should be noted that these are the very basic process elements for any weld procedure.

Welding Inspection of Steels WIS 5 5.1

Section 05 Welder and Procedure Approvals
TWI WORLD CENTRE FOR
MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY

TWI
VIlDI. _ THE WELDING INSTITUTE

What is the purpose of a welding procedure?

Welding procedures can be utilised for many purposes, which may include:

a) Economic control
b) Quality control

Economic control

This may be exercised over welding operations by stipulating a number of elements that
must be adhered too during manufacture i.e. Control of the welding preparation type is a
major element in the costing of welding, with single sided welds having double the
volume of some double sided welds. The result of no control in this area could be
critical, and thus weld procedures are often used to achieve some control.
The effect of double or single sided preparations on weld volume can be seen below as
in diagram a there are 2 triangles of equal area whilst in diagram b there are 4 triangles
of the same area. This increase surface area or volume would have a major effect on
welding production costs.

a b
~-----------j-----------1----------~

Quality Control:

In the control of quality it is generally perceived in engineering that the main function of
a welding procedure is as a means of achieving and consistently maintaining a minimum
level of required mechanical properties. The specific properties and their critical levels
are generally laid down in the applied application standard. To achieve this, a test weld
is made using a recorded set of variable parameters for the process/joint being used.
After any Visual/NDT requirements have been met the specimens would be cut ready
for mechanical testing. Most application standards specify type/location of specimens to
be cut from the welded test piece, as with a common line pipe example below:

Top of pipe Face or side bend test

Root or side bend test
Tensile test
Nick-break test
Tensile test Root or side bend test
Face or side bend test Nick-break test

Root or side bend test Face or side bend test

Nick-break test
Tensile test
Face or side bend test .~ ~ Tensile
Root testbend
Nick-break
or side test test

Welding Inspection of Steels WlS 5 5.2 TWI WORLD CENTRE FOR

Section 05 Welder and Procedure Approvals MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY

TWI
V/lfll. _ THE WELDING INSTITUTE

Documentation

Should the level of work, and thus the application standard state that a written welding
procedure must be produced, tested and retained then this should be carried out using
the following documentation, with which the welding inspector should be familiar:

pWPS Provisional or Preliminary Welding Procedure Specification.

A provisional welding procedure specification or pWPS is a detailed quality related

document that contains all the preliminary welding data prior to approval. All data
recorded on this document remains as preliminary, or provisional prior to successful
completion of any required testing or examination.

WPAR Welding Procedure Approval Record

(Also known as aPQR Procedure Qualification Record)

A WP AR or WPQR is a quality document that holds precise data for all essential and
non-essential welding variables that were used and recorded for the test weld. It must
also include all subsequent data for any PWHT and results of any mechanical tests
carried out on the weldment. It is normally required that this document be stamped and
signed by the mechanical test house, third party and manufacturers representative and is
recorded and held in the quality file system.

WPS Welding Procedure Specification

A WPS is a working document that is prepared from the WP AR and then is issued to
the welder. It contains all the essential data required by production to complete the weld
successfully, achieving the minimum level of any properties required.

It is also important to note there are numerous applications where acceptable levels of
manufacturing are achieved, where written and/or approved welding procedures are not a
quality requirement, and where the selection of the appropriate welding parameters is
made either by the welder, or welding supervisor, and is based upon their experience.

Extents of approval

An approved WPS may have an "Extent of approval" (Working tolerances) for some
variables, of which the following are possible examples:

Pre-heat
Consumables
Inter-pass
Welding
Thickness
Material oftemperature
Amperage/voltage
Number/sequence
Diameter
1) input
Heat position
type/group
of plate 2)
4)
8)
10)
ofTWI
pipe range
range runs
6)
(kJ/mm) 5.3
WORLD CENTRE FOR
TECHNOLOGY

~~~ NL\TERIALSJO~G
TWI
VflDI. _ THE WELDING INSTITUTE

XYZ Fabrications Ltd

XYZ
Fal1rlcatlrms
44 High St. Weldtown, Australia
ASME IX - Procedure Qualification Record (PQR)
:-_.,,--, Weldspec software by TWI

PQR record number TW~PQR-24 1hiek.

1Sch.
Size
273D5
254.00
21.44
273.05
120 WPS
21.44
Revision
Grp--no.I(mm) Cia.
ASME
record (mm)
254.00 Section
nurnbec IX Sa
Pno. RevisIOn
4

SA-335 {P12)
SA-335 (P11)
~name Dale =002 Wekfing standard

S~ecK:cation (type agrade) Ixvz Fabrications LId

BASE METALS (QW-403)

We1dcd to:

and tesled Iln PW'HT, With hardness

Not ••

POST WELD HEAT TREATMENT (QW-40Tj

Temperature {·C) 71D

Heating rate (&C1hr12Z)
CooCing rate (.~} 2€D
Notes

IJ~

~~z:
Joint design Single-V-groow
Backing: None
Retainers
Groove
Rod: openirg
angle (<leg.)
(mm)
51)

3.2
6
.,
5 '

Rool face (mm) 0-1

~':.
WELDING PROCESSES

GTAW FGAW
Waking process
Man"'" Semi-llutomalic:
Type

,FILLER METALS lQW-4D4

5.28 5.29
SFA specification
AWS classification ERBOS·G E81T1~B2
Filler melal F-number 6 6
Weld metal A-nurrber 3 3
FJ1Ier metall nominal composition
Filler metal trade name TGS-1CM{Kobe) os 8000-82
RlIer metal size (rom} 24 24 1.2 12 12
Doposlted thicknc:ss {mm) 13
Maximum p2SS Ihdmess (mm)
Weld depcait chemistry
None
Supplemental fiUer mer:al
(mm~, None
Supplemental fiEer metal vol
'POSITION
('C)
Position a
g.-cove
(QW-4051

Not us~d
-- 2'
8-151.B
15-20 eo 2'
1.53
1SO
17
120
15-20
String&randWsaw
2.4 6G
8-15150
DCSP 6G

=1
(mm)
{kJlmm} Weld 16 progression
150
(llmin)(IImln)
{i/mm)
{mm)1 None DCSPSFA5.12 300EWTh-2
NotNo.
used
Not 5-8
BrushinglChjpping'IGrindino
applica!:JIe Argon 99.99%

I
Multiple passes
('C]
(mm)
(mmlnnn)I
PREHEAT

Preheat
fQW-406'

tempemlufC
. Argon 99.99%
150

Maxiroom interpass temperature

300

GAS (QW-408}
Shielding gas: Type C02
Flow ",Ia 10-15 10-15 10-15
None
Trailinggas: Type
FkJw rate
None
Backinggas· Type
Flow rate

ES-C- -409}
Finer metal size 1.2 1.2 12
~
Votts
,so
23
190
25
170
24
180-220 11\1-200 210-21\1
Travel speed
Max1mt.m heal input 1.13-1.55 1.43-1.68 O.91~1_17

Tungsten size
Tungsten type
Current/polarity DCRP DCRP DCRP
DC pulsing current
Wrre feed speed
Ate transfer mode Spray

~~-410)
StJingorW&a"o'e Stringerand W~ve
Nc..12·2Q
OtificaJ9a~ cup s~e
C.TW.D
Multi/Single pass per side Multiple passes
Peening NoI:used
InitiaVintarpass cleaning BrushinglChipping./Grinding

Back goLging method Not applicable

Welds.~.t 20#'34 {c} C~9h1 :xJQ4 C-SP'1'c>'1'WiSOf1!.\/ara All rights ~SarVOO W!:Illdwide
Catalog n· POROV010 Page 1 01 ~

Welding Inspection of Steels WIS 5 5.4

Section 05 Welder and Procedure Approvals
TWI WORLD CENTRE FOR
MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY

TWI
V!ll. _ THE WELDING INSTITUTE

:-y=
_1
) WPS (
Utrmate
PQHOCo{110 SA-335 rI
236.262see-ASME
kx:9tion
2008I2002
19.0
Weld
19.0
389.50
20.5 Ama
21<4,255
sae-A$f\.4Etx
Thickness
total
(rnm)
224.228
TWi-PQR-24
Ductlle-BM
235.270
Distance
Dudile-..BM
231.251
244.246
225.237
ASME
391.40
20.6
HAZ
232.241
192.227
f9COfd
(MPo1) Sse
fra'n
HAZ
12(mm'
S!anp tx
load
unit
Section
Accoptable
IOimonsions-9.5
SA-335
(P12)
nl.ll'Tb9t" """""" TIIIN ASME169,166
Corrrnents
Common'"
Result
Result.
Report
stress
IDNLn1bI!Ir
surfa;:e
(P11)- No_ xName 538.6
aW-142'3,Q\N-3Q4'5
Revisfon
tx_QW...451.1
M02-08-QO
Jones
Signature
Signarure 537.5
Acceptance
22.6, 9.5x227,
I I
XYZ Fabrications
Labatalay
cri1eria
9.5 Canpany
x 227, Revision
QW-1912
QW·1G3
name
9.5 Ltd - Test lest
QAnurrber
Good
Acoeptabkl
x aN-4f32,1{c)
22.6. Bend-1BOdog, Managor
rv••••
ndreJ1-2,
diarT\!Xer-38rr.m Ie) 413 Sofr.\rare_ Page
All 2 01 Reduced
2
reserved secli:on
worldwide

~xyz
UJttmate
(mm"J
(NJ Roport
reduced
1ypeottailumand
Accept.able Nos- RT-PQT-S-'.
sedicn lension
Dale lests
Acceptance PT-PQT-5-01
per CftN-1512
criteria - RadIOgraph
and Nos -WP-BC..o3, 0--1. 2-3. 3-4. 4-0 COPyrigtl1 2OGo1 C-SpE!O'TWJ figh1S.

Pre a (}3WBBs
Mechanical testing by
74.183
4.193
sDNESS
RFICA.TION
rnTESTS EST
thIS. (OCCIrd
Test
Testsfile
Twedl:8sl
are cortp.el and ws:red
number
cond\ded
Type I~z
'WeIde;'~bynarTU!l
(&ale)
44 High S~ Weldtown,DNV,
In accordance with Typedlest
Fabricationslld
lR al\d BV Rules,
Australia
Signature
IX - Procedure Qualification Record
Weldspec software (PQR)
by TWI results (PWHT)

I:
Welding s1.andard

Welding Inspection of Steels WIS 5

Section 05 Welder and Procedure Approvals
5.5
TWI WORLD CENTRE FOR
MA TERlALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY

TWI
VIllll. _ THE WELDING INSTITUTE

Welder Approval:
A welder approval test is used to test of the level of skill attained by the welder.

Once a welding procedure has been approved it is important to ensure that all welders
employed in production can meet the level of quality set down in the application
standard. Welder approvals are carried-out, where the welders are directed to an
approved WPS by the welding inspector who also acts as the witness. Upon completion
of the test plate, or pipe it is generally tested for internal/external quality using visual
examination, then NDT generally using Radiography or Ultra-sonic Testing then
followed by some basic Qualitative mechanical/destructive tests, in that order, with the
amount of testing being dependent on the level of skill demanded from the welder by the
application standard.

It should also be noted that welder approval tests are possible when using unapproved
welding procedures, as with BS 4872 "Welder Approval When Procedural Approval Is
Not Required" Whilst the welding procedure remains unapproved it must in this instance
be written. (Page 5:8 shows an example BS 4872 Welder Approval Certificate) The
mechanical tests in a welder approval could include some of the following:

a) Bend tests (Side Face or Root) b) Fillet weld fracture tests

c) Nick break tests d) Macrograph assessment tests

When supervising a welder test the welding inspector should:

1) Check that extraction systems, goggles and all safety equipment are available
2) Check the welding process, condition of equipment and test area for suitability
3) Check grinders, chipping hammers, wire brush and all hand tools are available
4) Check materials to be welded are correct and stamped correctly for the test
5) Check consumables specification, diameter, and any baking pre-treatments
6) Check the welder's name and identification details are correct
7) Ensure any specified preheat has been applied, and is measured correctly
8) Check that the joint has been correctly prepared and tacked, or jigged
9) Check that the joint and seam is in the correct position for the test
10) Explain the nature of the test and check that the welder understands the WPS
11) Check that the welder completes the root run, fill and cap as per the WPS
12) Ensure welders identity and stop start location are clearly marked
13) Supervise or carry out the required tests and submit results to Q/C department.

Examples of typical Welder Peiformance/Approval Qualification/Certificates to ASME

IX and BS 4872 are shown below on pages 5.7 and 5.8 respectively:
Welding Inspection of Steels WIS 5 5.6 TWI WORLD CENTRE FOR
Section 05 Welder and Procedure Approvals MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWl Ltd VOl TECHNOLOGY

TWI
Vllfll. _ THE WELDING INSTITUTE

---------1 XYZ Fabrications Ltd

XYZ i 44 High St. Weldtown. Australia
iFabrlcatiuns ! AS ME Section IX - Welder Performance Qualification (WPQ)
=:Y-
- _---=-'_J ! Welderqual software by TWI Ltd

BASE
Wek:1ers.

10 NulTt>or
Date or birth

DivislOO

Woloodto:

""",,,,,,,
METALS
n:l!!lm8

s..m" n••••.••••
~ny •.••••.••

(OW-403)
Stephen Jenkins
113
7-10-1971
1003215-81
XYZ Fab~tions
Weklng

Product form

Pipe
Pipe

'Groow
shop
Ltd

Specification (type orgrade)

SM06
SM06
(6)
(B)
k
~
Test date
WPQ record
Standan:l test
INPS raGOf'd number
QualflCBtion

Pno
nl.l'J1b.er

nun"bcr

code

Grp-no
D7f11J2002

1WJ·wp~17
NA
NA
ASME Section tX

Size
101,80
101.60
Sch

Standard
Standard
Thd;"

6.02
6.02
Rev
Rev

(mm) 011i11

"4.30
"4.30
jmm)

VARiA8cES Actual values RANGE OUAUFIED

~ W•••
3P1
Fillet
Overlay

TypedwcktjOirt 6.02 &X.", i 6.02

11.4.30
5.18
6G
BareER70S-66 Nane
fot.anuaJ
(solid) toPt
GTAW
Pipe-Groc:we AclUalvaJucs
P-noJS.no_
Groove and Filet welds
1 thru ,,. 34. 41 It1ru47
8a~fTW)tal

BASE "'ETAL THICKNESS """"" ~ Oll'Broay

,
Platethiclmess
no limit nolimil:
normit noliml
PipeAube thdrness
Pipe diameter
73 min no Iim!

PROCESS VARlABLES ~F1ED

, GTAW
Welcfmg process
Manual
Typo
WiIh
B_ng
5""
FIDer melal speclcahon
FIler rne:t1Il classiflCZltlOl"l Any
Fil1erITllHaI F.."Uf'l"ber 6
FGler metal Vo!nety (OW-4Q4,23) Sefid, me1af cored

Consumable Il'IIioert
Wi1hout

NulT'ber of layers. ~pcs4ed

Weld deposit trockOC!l$ 101m. 12..04max
Weld pos..1ion ,ActuAl'JO~iltOIll"';'1Gd,
(jfOCn/;:1 ~~ t. p.1e > G10mm All

C,ooWJ MIX< '3Jnm 10 G10rnm All

Gr:XWi> ~ P\rJo'O 1;11'''11

All

rIliol P'ta:c l. Pipe '" G10mm All

rillal Pip(' 1:,mtt: '0 G10mm All

nlo: Pipe ';':;mm<I:

All

Progrosslon Up Up

Backrng gas Without Wlth,without

DCSP DCSP
GT AW WOId#19 CUrTOntJpOIar'ity

~STS
Acceptance criteria Resuk Conrnen<s
Typecliesl.

2 transWlf!loface bends perOW·1612 BndQW-4623(a) aW-163 Ac:;epta~ see - ASME lX-QW-4521 (a) Note(1)

:2 transv9rse rtX'I bonds par Q\N..1S1.3 and QY\1-462.3\a} aW-163 A=>ptob1. 988 - ASME tX _ QIN-452 1 (a) Note (1)

Visual oxamination porOW"...J-:l24 QW-194 Accepteble see-ASME DC.-QW-452.1 (a) Note(2)

Notes

CERTlFICA TION
.
Noonan Smith Labor.itay test number ADBC 432-,104
Tes$ c:ondudcd by
MechanlClJ: tcsts by ABC Testing Ltd Testfilonul'Ttter

WI!' ceilrly t!lut Ihe IIh!l\e1T1811tti In tru!;. Tf'CUrtI are coned mKJ ti1B~ IIle test we1c!s \"l8fe prepared. we1ded and \esled '" ac::ortlance \.•'111lilt> TeQUlI"l!'I'neots of Sed!Dn I); 01 !lIe ASME:. Code

Welding Engineer Production Manager

Name Name

SYS
Da'"
Dale
<Fred (j3foOBs
'---
QA
ZW'12OO4

Signature

t= I
We-/d\;Irqual " 2.005 Ie) Copyrighl ~ _,:::~o""TWI Sotlware All tigh1~ rMoerved wnrIdwidl?
C8~1o;J n" WPQOOO33 Page 1 01 1

Welding Inspection of Steels WIS 5 5.7 TWI WORLD CENTRE FOR

Section 05 Welder and Procedure Approvals MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd mOl TECHNOLOGY

TWI
Vllfll. _ THE WELDING INSTITUTE
·300mm
...............
:.................
. ·. .............. Welding Position:

et type:
material:
&
umables:type)
. Root
.Butt. .Nick
Fillet
Side .BendI
.............
·Organization's
X.?
Contour:
9th September
. .break
I II.II I. . Penetration
fracture
BendI
lIeeeltaJle
tVut
tVut
: ·APFlfO:V$c{
VerticalMacro
accordance
lWfail'U!
1Wf","I'U!
. . .Rutile
Fixed
5mm
ESAB
N/A
2.5
Axiso
75
l50mm
Surface
All -(BS
Single
. : . : . : . : . : Symbol
lWfail'U!
down.
Visual Inspection: 2005with
OJtee OJtd toe ilel(d. Manufacturers Representative:
.:.:.:
the
10
-defects
Ferritic
E
AWS
MMA8018
Butt except
Overhead. 111
VCSWIP
OKsteel.
steels.
inclined
mm.
Basic.
steel
A5.l-8l
welds
Extent
(No
lIeeeltaJle
lIee"ltaJle 4872:
(with
butt.
1.5
It____
:::::~r::i:<;:~~~~~::::
& 55.00-45
inbacking)
Welders
0:
Vertical
lIee"ltaJle
lIeeeltaJle
Materials
tVut
Thickness
Pipe outside
Joint
Logo:
requirements
types:
Welding
3:1·uo-123·:
2Mr.
of Issue
321
Test
Mr.
up.
ABC
Part
backing)
e Pt"I(~
Welder
mm
o/'llieaJle
Range:
range:U.
name No
record
001 N.
11982) & Weld
No
D'Cutt.
Identity
I Inspection
C
approval: Plenty
approval
TestedlWitnessed
Inspecting
Date: 9th September
Process:
of t~~
BS 4872: Part
2005
1.5 - 2 mm
11982.
&
Ltd.
test
authority,
plate by: orNo Date
preparation
certificate
Stamp
pipe. test
123 of(dimensioned
house: test sketch)

~60~
The statements in this certificate are correct. The test weld was prepared in

Welding Inspection of Steels WIS 5 5.8 TWI WORLD CENTRE FOR

Section 05 Welder and Procedure Approvals MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY

TWI
Vllfll. THE WELDING INSTITUTE

WIS 5 Section 5 Exercise:

1) List 7 other possible Extents of Approval of an Approved Welding Procedure?

1. Material tvpe/2roup

2. _
3. _

4. _
5. -----------------------
6.

7. -----------------------
8.

2) List 3 destructive tests that may be used after the stages of initial visual
inspection & NDT have been carried out, during any welder approval test?

1. Visual Inspection
2. NDT
3. -----------------------
4.

5. _

3) List 4 other documents used in welding procedure or welder approval testing?

1. Provisional Weldin2 Procedure Specification (pWPS)

2.

3.

4. _

5. -----------------------
Welding Inspection of Steels WIS 5 5.9
Section 05 Welder and Procedure Approvals
TWI WORLD CENTRE FOR
MA TERlALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY