Guidance to Prepare WPS-PQR for Welding

WPS ‐ PQR Procedure, in written format, by the Fabricator/Manufacturer, Fabricator/Manufacturer, giving 1 WPS-Welding Procedure is the Procedure, e a s a ou ase me a , we ng groove, er me a s an ns ruc ons a are o owe welding, to make good and quality welding, Code: ASME Sec IX, AWS D.1.1, API1104 2 Welding is done, following the Procedure(WPS)

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3 The welded piece(originally, in the form of plate or pipe) is cut into test speciments/test coupens. 4 PQR-These test specimens are tested in the Lab(for mechanical and metallurgical tests, visual test) and

the welding parameters (during (during actual welding, PWHT etc ) and test results are recorded. Reason to have many WPS: One WPS is made to meet a set of specific welding parameters. If we change the parameters, then we check, whether whether the parameter is essential essential or non essential variable. variable. If it is essential variable, then new WPS WPS is prepared. Each WPS should have their specimen tested and PQR is made for that WPS. So, each WPS has its own PQR. If it is non essential, variable, then , no need to make a new WPS and qualifica tion(somet ime, WPS alone, need amended). ASME Sec IX, gives the QW-XXX reference numbers, on the sample WPS-PQR, so that we can find whether the data is essential variable or not.

If the PQR meets the test acceptance criteria, then the WPS is said , as, WPS is qualified. Steps to make WPS: Study the P.O., Product References & Approval Codes to prepare WPS & PQR:

Prepare Prepare WPS (before welding)

 ASME Sec IX (most common)  AWS D1.1 (for Structures) Structures)

Welding

Prepare additional Coupens & test . Or  change the weld parameters in WPS and retest.

Cut the test piece piece into into Test Specimen/ Test coupen

Lab Testing

 API 1104 (for Country Pipelines) Pipelines) Test is not ok. WPS Rejected

Prepare PQR . Evaluate the results.

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 Aim: To have good and quality weld To pass the test and to get WPS qualified. Preparation for WPS: 1 Reporting Forms: Select the code for approval & select the sample form from the Code WPS and from other people who had already approved WPS 3 Vendors are also preparing detailed step by step WPS, with good practices to produce quality welds.

Welding

Results are satisfactory & Test is Ok and WPS is qualified

List/ record the parameters during welding, PWHT etc and record the test results

results and certify whether the test had passed and if so, declare WPS is qualified

4 Collect Collect welding parameter parameter details: details: Base metal: Plate or Pipe(for testing), from rolled/ for ed/ cast/ cast/ extrud extruded ed form form & its s ec.. Weld metal: Welding Process(SMAW/GTAW/SAW etc) /Filler/welding practices Welder: Already has some basic welding experience & some qualification

Prepared by: Annamalai-JGC