How to Write a Preliminary Welding Procedure Specification (pWPS)

How How to make a preliminary welding procedure specification to ASME IX A product of Engineering Pulse Limited, UK Logos, name es used within this his document are copyrighted co by Eng ngineering Pulse © 2013 Any unautho horized use is illega gal and strictly proh ohibited.

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How to make a preliminary welding procedure

First Words

Preliminary welding procedure means a welding procedure which has not been qualified yet and needs to be qualified. Making of a preliminary welding procedure is not a requirement of ASME IX. Directly a PQR can be made without developing developing a preliminary welding procedure specification. However, it is recommended to make a preliminary welding procedure specification and and then get that qualified through PQR requirements. requirements Very often, manufacturers and contractors need to get the welding g procedures qualified and to make preliminary in those cases makes things easier rather than directly moving to PQR development. It also adds one more review point in finalizing a welding procedure. Moreover, moving directly to PQR includes shared responsibility responsibility of manufacturer /contractor and the 3rd party laboratory. And it is to be noted that 3rd party laboratory would only be doing the required tests as told by the manufacturer. Therefore, if there would be anything missing in communication, qualified procedure may not stand valid for a particular job. This guide helps a welding professional to know exactly what needs to be considered while developing pWPS and how WeldPulse helps in making it right to ASME IX with ASME materials. materials Focus has been given to piping and equipment welding jobs in process industries. Also, welding processes considered in making up this guide are the manual gas tungsten arc welding (GTAW) and shielded metal arc welding (SMAW).

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How to make a preliminary welding procedure

Welding documentation flow

pWPS pWP (preliminary welding procedure specification)

Data collection (Explained next)

Test coupons preparation

PQR (Procedure qualification record)

WPS (Welding procedure qualification)

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Start welding

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How to make a preliminary welding procedure

pWPS (step 1) Data collection

Materials information (casting, forging, ASTM, any final treatment)

Licensor’s guidelines, specifications

Welding job details (thickness, butt/fillet)

Piping part or equipment Applicable construction code

Service requirements (e-g; pwht required) Applicable drawings

Welding process

Data collection needs to be done by the user as this would help in generating an accurate pWPS having high chances of successful qualification.

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How to make a preliminary welding procedure

pWPS (step 2) Materials welding properties Materials propertie The next step is to look look into the material information to find their welding properties like PP-Number, Group Number, chemical composition and mechanical properties (especially minimum yield and tensile strength). P-Number Number and group number information can be found in ASME Sec. II II Part D or ASME Sec. IX. Minimum yield & tensile strength are listed in ASME Sec. II Part D. Chemical compositions can be found in the applicable ASTM or ASME Sec. II Part A (for ferrous metals) or B (for non-ferrous non ferrous metals).

WeldPulse helps you in providing ding all the required materials welding properties at one single platform. Click and enter the material through three different ways to look for the properties. properties

On n the next window, it will show you all the welding properties of a material including the ones as discussed above. You don’t don need to open up a number of references. ences.

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How to make a preliminary welding procedure

pWPS (step 3) Minimum inimum pre-heat pre heat temperature

Applica pplicable construction code

Material PP number & Group number

Iff you know the P-numbe P numberr and the Group number of a certain material to be welded then just look into the applicable design & construction construction code for the requirements. requirements. Almost all ASME design & construction codes provide guidelines on minimum pre-heat pre heat temperature. temperatu In few cases, ca es, you need to look into the mechanical properties (like minimum tensile tensile strength) also to get the result. And there here are some cases when against a P-number P number you won’t won t be able to find the recommended minimum pre-heat pre heat temperatures. In those cases, cases it is recommended to look for the guide books, handbooks, technical technical papers, articles and other printed references on welding. APII recommended guidelines like API 582, ASM and AWS handbooks are really helpful. For dissimilar materials, mater use the one for the material requiring higher prepre heat. WeldPulse Pulse helps you in getting a recommended pre-heat pre heat as per the applicable design & construction code. Data from all the major codes has been pre-loaded. pre loaded. Those codes include ASME Sec. I, Sec. VIII Div. 1 & 2, ASME A B31.3 31.3 and B31.1. B31.1

pWPS (step 4) Appropriate ppropriate consumables Chemical composition

Tensile strength

Welding elding consumables are selected while considering the chemical and mechanical properties of the materials being welded. When hen welding of dissimilar materials materials is involved, consumable suiting to the less alloyed and less strong material should be selected. This This stands true only nly within group, group, means dissimilar welding within carbon & low alloy steel group; group; dissimilar welding within stainless steel group and dissimilar welding within nickel alloy group. group For welding outside outsi these material groups, groups, one need to look into different technicalities like the final weld composition, compatibility compatibility issues leading to defects like cracking etc.

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How to make a preliminary welding procedure

In n order to look for the right consumables, you need to look into ASME Sec. II Part C for their chemical compositions and mechanical mechanical properties. Only then you can make a better decision. However, it is to be noted that ASME Sec. II Part C doesn’t doesn t provide any straight forward forward guide on selecting consumables. It does provide intent of use and other properties. Selecting consumables for similar materials welding is not a difficult task to do as you can can go through ASME Sec. II Part C and find the right one. Selection of consumables for dissimilar materials welding requires more attention.. API API 582 helps in looking for f the right consumables when welding two dissimilar materials. WeldPulse Pulse provides you with the suggested consumables when you input the materials to be welded. These suggestions are based upon study of ASME Sec. II Part C, API 582 and the best welding practices used in the petrochemical industry. Additionally, it also provides you freedom in selecting the appropriate consumables consumables yourself by looking into the materials and filler properties. Click and the window will be opened up showing you to choose the applicable AWS class ss you need to look for. After selecting the AWS class, a list of contained consumables will be opened op up and select the one. Click properties.

A comprehensive report of filler properties will be opened up which would help you in looking more closely into the consumable. It provides description desc (intent of use), F-number, F number, A-number, A welding position (where applicable), polarity, amperage and the chemical composition.

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How to make a preliminary welding procedure

pWPS (step 5) Maximum aximum Interpass temperature Material M Pnumber

Construction C onstruction code

Maximum aximum interpass temperature is not defined for all the P-numbers P numbers in construction codes. However, where interpass temperature temperature is critical for the material being being welded, construction codes provide the maximum temperature. Maximum interpass becomes a critical to quality when welding stainless steels. steel Good reference for maximum interpass temperature is API 582. It provides for the most commonly materials. WeldPulse Pulse provides you with the suggested interpass nterpass temperature based upon the applicable construction code selected. It also takes reference from API 582 when maximum interpass interpass temperature information is not present within the applicable code. This information is present not only for the welding off similar materials but also for dissimilar dissimilar materials.

pWPS (step 6) Post ost weld heat treatment Material Pnumber & Group number er

Applicable ble construction code

Like ike for pre-heat pre heat and interpass temperature, post weld heat treatment can also be obtained if you have the P-number number and Group number and a the knowledge owledge of applicable construction code. Post Post weld heat treatment information includes in temperature and time range with minimum holding time. time WeldPulse Pulse provides you with the suggested post post weld heat treatment including temperature and time ranges along with the minimum holding as recommended by the applicable construction construction code. This information appears as you follow the wizard of making a welding procedure specification with WeldPulse. Pulse.

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How to make a preliminary welding procedure

pWPS (step 7) Other ther details Joint type (groove, fillet) & Joint details This information is normally available within the piping specifications, design documents Root spacing It is set at 2-3 2 mm Backing material & consumable insert This is considered in rare cases Shielding & purging gas (in case of GTAW) Shielding ding in GTAW GTA and where purging is required (for welding of high alloys and stainless steels with higher er Chromium content) is done with Argon Welding current & amperage This information is mentioned mentioned in electrode and filler manufacturers’ manufacturers literature or within ASME Sec. II Part C Welding position Itt is also given in ASME Sec. II Part C or in literature iterature provided by consumables’ consumables manufacturer Size of filler metals This his depends upon the thickness of the materials being welded. A 2.4 mm filler wire with 3.2 mm electrode is used for materials thickness thickness > 10 mm < 22 mm

Of all these miscellaneous details, WeldPulse Pulse provides you with the suggested welding welding current type, amperage (also given in Fillers metal properties module), shielding and purging gas when GTAW is a welding process and typical root spacing. spacing. Most commonly joint details are also listed (with and without dimensions) dimensions).

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How to make a preliminary welding procedure

Using sing WeldPulse Weld Step 1 The he first step would be the material material information. Provide those inputs inputs and move to the next step.

Material designation has to be entered in complete ASTM designation. This can be obtained from the drawings, piping specifications or directly from the design & engineering department. WeldPulse Weld contains 292 ASME acquired materials in Spark Edition and 500+ materials in Arc Edition. In order to look for the material you need to work with, you can go through the list by scrolling it or by start typing material like SA-335 SA 335 and you will narrow down the list to the material you need.

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How to make a preliminary welding procedure Step 2

In n step 2, WeldPulse provides you with the P-number P number and Group Group number of the the materials selected. Thickness range needs to provided by you looking at the design design documents /specifications. Similarly, maximum weld pass thickness if less or greater than 13 mm has to be mentioned as this this information, if yes, is an essential variable. Normally, weld pass thickness is is less than 13 mm. Joint type needs to be specified as groove or fillet.

Step 3

In step 3,, WeldPulse asks sks you the weld joint design (single V set as default), root spacing (normally 2-3 2 mm), m), backing material, weld processes for root root and filling (SMAW set as default for filling /capping), backing and purging gas (with all options as mentioned in ASME Sec. II II Part C).

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How to make a preliminary welding procedure Step 4

In step 4,, WeldPulse provides provides you with the suggested consumables, their SFA, F-number F number and A-number. A number. You need to provide the weld metal thickness range for both the processes to be used. used

Step 5

In n the last step of WPS wizard, WeldPulse provides with the minimum pre-heat pre heat temperature, maximum interpass temperature and the post post weld heat treatment requirements according to the applicable construction code. code You ou need to assess this this for your case when thickness is a condition. In the example above, pre-heat pre iss mandatory for all thicknesses therefore you need to have that as it is. However, PWHT is linked for a condition of thickness or o with Chromium content. Assess that for your case and then apply.

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How to make a preliminary welding procedure

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How to make a preliminary welding procedure

Suggested uggested by WeldPulse Wel

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How to make a preliminary welding procedure

Final nal Words

WeldPulse Pulse helps in making a preliminary welding welding procedure with suggested welding data for most commonly materials used in petrochemicals. petrochemicals. In addition to this, it provides provides a single platform where one can take ake his own decision based upon the material properties, consumable properties and other information.

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