TECHNOLOGY

CSWIP Welder Training

Weld Procedures
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
(BS EN 288)

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
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
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
In most codes reference is made to how the procedure are to be
devised 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 a
procedure but may contain information that may be used in writing
a weld procedure
EN 1011Process of Arc Welding Steels
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M.S.Rogers

TECHNOLOGY

Welding Procedures
Components of a welding procedure
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 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

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
Joint design
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
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
Approving the procedure:
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
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

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

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
After the testing is completed and all the relevant results
collated, the results need to be assessed in accordance with
the 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

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welding Procedures
Once the welding procedure has been approved, If any
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
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Example:
Welding Procedure
Specification (WPS)

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M.S.Rogers

TECHNOLOGY

Welder Approvals
(BS EN 287)

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welder Approval
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 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
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welder Approval
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, 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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M.S.Rogers

TECHNOLOGY
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Range of approval according to electrode flux type

BS EN 287
Range of approval
according material
groups

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Welder Approval
The inspection of a welders qualification test.
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.
Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

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

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Example:
Welder Approval
Qualification
Certification

Copyright 2003 TWI Ltd

M.S.Rogers

TECHNOLOGY

Any
Any Questions?
Questions?

Copyright 2003 TWI Ltd

M.S.Rogers

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 requalification.
Copyright 2003 TWI Ltd

M.S.Rogers