TWI

vo[t

THE \4LDINC NSTN'UTE

SECTION3

TWI

Vr7-/F
l, lllN

THE W:LDI\C I\ST. 1'II

T H EW E L D I N GP R O C E D U R E
The task of col ectingthe data and draftrngthe oocumeniation
is oftenrefei.i-ed
to as w ting a weld procedure.In many ways tnis is an unfofiunate
term as
the writingof documentsts the lasr in a sequenceof tasks.
Producinga weld procedureinvolves:
o
.
.
.
.
.
.

planningthe tasks
collectingihe data
writing a procedurefor use or for trial
makingtest welds
evaluatingthe resultsof the tests
approvingthe procedureof the relevantCode
preparingthe documentation

In each Code referenceis made to how the proceduresare to be devisedand

whether approvalof these proceduresis required. In most Codes approvalis
mandatoryand tests to coniirmthe skill of the welder are specified. Detailsare
also given of acceptancecriteriafor the finishedjoint.
The approachused dependson the Code,for example:
BS 2633 : (Class I arc weldingoi ferritjcsteel pipeworkfor carryingfluids)
pfovroesgeneralcommentson various$pects of a suitableweld
procedure.
AWS D.1.1 (Structural
weldingcode - steel)favoursmore specific
instructionsfor differentjoints and processeswhich are, in effect,pre_
qualifiedprocedures.
Other Codes do not deal specificallywith the detailsof the weld procedure
but referto publisheddocumentation,
e.g. BS 5135 ,processof arc weldinq
carbonand carbonmaneanesesteels,.

? *(s

,r pd.rz-

,t

,^_P_5

"/..VX
Ur-o4!,-.v FTJ
=--1----+-_--+:-j

r,'-\,{

\,r-W

WELDING TECHNOLOGY
I s s u e0 1 9 1

T\MI

7[Or

TIIE \ll-j:)tNc

INSTfijTE

COMPONENTS
OF A WELDPROCEDURE
Items to be includedin the procedurecan be some of the following:
1. Parentmetal
1.1
1.2
1.3
1.4

Type
Thickness(for pipe this includesoutsidediameter)
Surfacecondition
ldentifyingmarks

;-_-2. Welding process

2.1 Type of process(MMA, TlG, MAG etc)
2.2 EouiDment
2.3 Make, brand,type of weldingconsumables
2.4 When appropriatethe temperatureand time adoptedfor
drying and bakingof electrode/consumables
3. Joint design
3.1
3.2
3.3
3.4
3.5
3.6

Weldingposition
Edge preparation
Methodof cleaning,degreasingetc
Fit up of joint
Jiggingor tackingprocedure
Type of backing

4. Weldingposition
4.1 Whethershop or site welding
4.2 Arrangementof runs and weld sequence
4.3 Filler material,compositionand size (diameter)
4.4 Weldingvariables- voltage,currenttravel speed
4.5 Weld srze
4.6 Back gouging
4.7 Any specificfeatures,e.g. heat input control,run-out length
5. Thermal treatment
5.1 Preheatand interpas-s
temperaturesincludingmethod and
control
5.2 Post weld treatmentincludingmethod and control

3.2

WELDING TECHNOLOGY
Issue 0191
i

TWI

THE W LD INC INSTIILITE

APPROVING
THE PROCEDURE
When the data has been co ected, the proceduremust be varidatedby
producingand testinga trial weld.

lf the procedureis to be usedon a fabrication

whichnas beendesiqnedto
meetthe requirements
of a code, the test werdis done underthe s-upervision
of an independent
witness.The detairedarrangements
for the testare subiect
to agreementbetweenthe contracting
parties.
A numberof Britishstandardsmakecrossreference
to anotherstandard
whichcoversapprovaltesting.
OtherCodesof practiceincludetheirown weldprocedureA,velder
aDoroval
information.
In generarthey incrudea standardformatwhichcan be usedto report
the
resultsof an approvaltest.

Exle'rF $

Ayln'.---t

) /o' 4

Y,,l)" \tvl

-/2t""W)
(t'*"c";"
D-"*x4
Q
\ft

3.3

T'wI

7[O{

TlS \!LDINC

INSTTFLFIE

M A N U F A C T U R E RW' SE L D I N G
P R O C E D U RSCP E C I F I C A T I O
NP S )
rw
(so EN 2e-2)

Loc.llon: .......TWI
TFAJNTNG
WOnKSHOp
M:nulrcturr/! Wctdtngproc.durt: .......pwpS
m1/A._.
Rcl.r.nc. Ho: ........{1920...
WPARNo: ........0223........
M:nul:ctrJ.!r : ...-....FnED
BLOGGStNOUSTRIES.
W.lde/.

Errmln.r o. t.3t bo<ba......8.O.1

LTD.....
OEGREASE&
Hotho<tot Prspr.r on .nd CI..nlng:......MACHINE...
Prr!nt t{eterirt Spctftcr on: ..316L STANLESS STEEL
c . c o % c . 1 7 % M n 1 . 5 %M o 2 5 %

Nam.: .-......_A
N OTHER...,..

Ni 1l% Si 0.5% + Resrdualg

welding Proca..; ....-..141C|cROOT)/1
r 1(rt4^ ;t,-l a Copt................... ll.t.rial Thlcknr..
{lnm):.-....15mm
Jolnt Typ.: ........StNG1:
gUT;....-..
VE=
Outsld. Otrm.t.r (lnm):......
155mrn_........-,,._,..............
W.ldlog Poiltlon: ..-...HLO45....,..-...-.,.,................-...-_-.

Wcld Pr!p.r.

on O.trtttJotnt O.3tgn (Sk.tch).

W.ldlng O.t.ltr
ltUn

Procast

t4t

a
10

SE. ot
Rll.? H.trl
AUTOGENEOUS

lll

C{rr?ani

60-70

Voltrg.

l0-t2

Typ. ol
cuftanU
Polr,tty

Wl.. F..d
Sp..d

DCEN

110-120

Traval
Sp..d.

H.at
Inpur

l|o.nnvmn

l.C]|(Ymrn

l{Ornm FIOL

1.o.(yritn

95-l t0

DCEP

l30.nm ROL

1.ol(Yrnm

Ill

70-90

OCEP

tmrnm ROL

l.(}(Yrnrn

70-90

OCEP

t@rnm ROL

LoKYmrn

coanpruoar

Zsftm

Flu.r u.trt ct:3rlttc. on .nd t rd. nrh.:._--.souooMETAL

supEFICROM3l6L to tSO 3581-E19123:t-Rzt....-_..-..._-,_.-.__---._..
anv_sjxclrt 8.r|no o? orytag: ......oRy AT roo.c FoR
2 HOURSOUtyR AT 75.C.......--....___-_-__.
irgFlux: tht.tdtng: .....-Aflcoa.l_ COMMERCLALpURtTy
.-............
Orh.. Inlo.hr on.:...
D.cllng : .--..IAGON - COMMERCTALpURtTy
....,..-.......-.-.-...-...-...
..g.
G.3 Ro- R:t. - sht.tdtng: ._.-.8LITRESA|rNfrfa.....,........._..._...--_:..-.._.:' w.rung (nr,tlmum rtdrh ol .un): _2 x a......
6:ottetton: tmputud., Ir|qq.nca, dw.( Um.: ....!:1requir<l
B.cl|ns: .-.... UTREsa.{'**.......-.......-.....-...........--.-jil.l
-ungslon
Pu|3 w.rdtnc d.trIs ......NoT REoUtRED ....._.--...
El.ctrod. Typ.6ur: ..-...2% THof,tuM
2.5 0................-..-..*.... st nd ott dtstrnc.: .._...NoT REoutREo ._....--._.---...
).lrll.^ot B..l4c.rd.a8.cttng:
...-..BETAJN
Uml nUlr s Or.rw^nO_.
;hr.n. wltdtng d.r.tt* ....-.NOTREOutREo .---.....
Intarpa3iTcmp.rrtura: ......150.CMAX|MUM.................-o3t-W.ld Ho:t T..rtm.nt rn.t/or Ag.tn9: ......NONE..................-..................
l.mpcrrlur.. l{.thod: ......NOTREOU|REO..--...........-.....-...
..r.n.,
H.allng .nct Coo ng R:t..: .-...-ASpROCEDURe..-,..................._...-......:
'nu:ctuilr
Nltna

o:t. .ct3-co-| 99_

Etamrnaaoa ta3t body

N.tn. ,.....1.C.
O:t.
Slgnrtu.a

'ab,.,*ge
? A

WELDINGTECHNOLOGY:
lssue 0191

TWI

VOOT

IHE WELDTNG N.IS?NIN:E ' '

W E L D I N GP R O C E D U RAEP P F O V A LR E C O R OF O R M( w P A R )
TO EN 288
WELDINGPROCEOURE
APPROVAL- TEST CERTIFICATE

H anul.ctursf s W6ldIng Procedu.o

ReterencoNo. _........._.-.................41920/m1/A...................

Errmlnor or test body 8Dl L;0...

R . l o r o n c oN o . . 9 0 17 1 0 O O ? 5
......_.....,..

Manulacturo|:...FREDELOGGSINOUSTRIES
Addre3i ....375 LONDON ROAD. CA 4BRIOGE UK

;od^estlng St.nd.rd:......EN298
-at6 o{ Woldlng:......@-0O-199-

EXTENTOF APPROVAL
weldlng process:...-.l4 t T1GROOT t1l MMA FILL&CAp

Joint Typ: ....^NY EUTTJO|NI tN ptpE OR PLATEF-IET WELOStN ptpApLATE& T BUTTwErts

Par60rmerat(s):....AUsrENt'IIc srAJNLEsssrEELs................

conditionsot ro.npred:
.Nor AppucAaLE...-.-...

Mt:l thlcknGs {mm}: ......t2mm - l6.5mm

Oqt3ld. Dlrmot.r (mm):.....78rnm- 3tOmm
Flllc. llet.l typ.:......3i6L SOUOOME-,ALSUPERCROM
TO tSO EtqtA3:L R 23 ONLY
S hlelding Gt tFlur

.....l,RGON

Typo ol Woldlng Curront ......O|FiECT

CURFTENTt4l

OCEN I l1 rcEp ....___.

tldlng Posltlons: ...,.1LL pOStTIONS EXCEFr p.c. MEFrIIC& mWN)

Oih6r Inlorrn.tlon: ......TACKWELDtNG NOT PERM|TTED UNE Up CLA!,tpS ONLY

c'illll6d thrt te3t ?eld3 p,aPaaad, waldad and tostod satislacto.lly In accordanco *lth tha rcqulrsmnta
ol th. codanoaflng atandard
Indic:ted abovo.

Loc:tlon

Drt. ol lssuo .00-@-199-

El(rmlnor or l6st body

Nrrn6-- El:It EID;

t.c. tTcrNBE

Prg. 1 ol3

WELDINGTECHNOLOGY
lssue 0191

+!.c

T\VI

700t

Tre \I,ELDINCrr-STmJTE

DETAILSOF WELD TEST

Loc:tlon: ......,SHOP- TWt TFAINING WORKSHOP
Menulectur./a Wrtdlng ploc.dur'
Rloroncr No.: ...,._41
920

Ej(rmlner or tsst body.-._..8.D.1.

l_TD....-_

wpanNo:......wpAn
col/A......

;;i;;';;;;;.;;;j;;;;;

;;;.;;;,...;iC i. jiCnerse

ptrent Mater{.|Specific2uon:..316L
STAJNLESS
STE:L

ManuractuEr _.._.
F;iFD Br oc.:c tunr rerorEa

lry.ldln9 S.qu.nc.

ttun

ProcGr

l4t

SE! ot
Flller tlotat

Cunant

AUTOGENEOUS

lll

Volt.g.

Typc ot crJ..!nv
Pohrtty

lt

oceN

WI.! F .d
Sprod

Tr:val
Sp.d.
45mm

115

tO to

' 1

-alnprqton

80

H.rt lnpqt.
Kymtn

21

150mm

0.96

lsornrr

0.84

I lomm

0.96

1lornm

0.96

FIlle. M.trt Ct.3rflc.tjon .nd tnd. n.m.: ....SOUDOMET&

SUpERCAOM 3t6L
Any Specl.t B.ktr|g o. Orytn!:....CRtED AT lm.C _
2 HRS.
/Flux:
q[.ldlng: ....-.8OC AFTGON-..........-........,_.--..........-.-,
G.t
Olhaa Inlormstloni
b.cktng:.-....BOC
AtcON......-..........-.....................
..9. wo.vlng (Ltrxtmurn wtdth ot nrh): .-NONE-.
G:s FlowRat. - Shr.tdtng:.......6
UTFTESA{1N...................._.........:
Osclllatlon:
a.nplttuda, tnquoncyr dw. um.
B.cllng: ......aurREs/MtN....--......--..............................
_
Puls. w.tdlng dtalt( --.NONE_-..-.-.-.-.
TungstonElsct.o{t.Typ.6&.i .--...2%
fHOnrUUZS.^.........-.........'
Stand oft < 3tznc.:..-.NONE....-............
Oot.ll3 oa&cting: _-.-.RFIAINED
UNnL FUN 6--Plrimr weldl.g d.t.lt!: ...NONe-..--_..
Pt!hGat tomp.r.tur.: .......NoNEAppL1ED......................................._...
To.ch .ngt.: .-..ASREOUTREO............
Int.rpasa Tcmp.dtur.: ...-...MAX|MUM
t30.C

Post-W.ld H.et T.strn.nt rnd/o?Ag.|ng:......NONE

I rm., I emprrtur.,l,t.thod:..-.......NONE...-......_----_

Hratlng .nd Coo(ng Brto.i .........NONE-.................

UATIUFACTURER
N.m.: .-.......FREDERlCK
O.t!: .-.-......m-OO-199_ .-.._...

Slgnrtur:

Errmln.. or trst body

Nrmr:..........1
C

qa,ner)

Slgnrtura:
:a n' b ri6)

J.b

P.gr 2 ol 3

WELDINGTECHNOLOdY
- --

I<<t ta n7 01

TWI

voor

TI{E WEI'ING U.]STMUTE

DOCUMENTATION
The objectivesof a procedureor welder approvaltest are:
a) to prove the proceduremeets the necessaryrequirementswith referenceto
feasibiiity,mechanrcalstrengthetc
b) to prove the weldersare competentto work in a particularjob
lf a customerqueriesit, evidencecan and would be suppliedto prove validity,
even though the approvaltests might have been some considerabletime ago.
Approval Test Specifications
call for a paper recordwhich can be know as
either:
procedure/welderapprovalcertificate
procedure/welderapprovalrecord
procedure/welderapprovaireport
The followingrecordsshouldalso be kept:
a) NDT reports
b) records of visual examinationor mechanicaltesting
c) test pieces from destructivetesting
Other recordswhich are equallyimportantare:
a) PROOF of regularemployment
on a job
b) for schedulingre-tests
c) to avoid duplicationon procedureapproval
TEST CERTIFICATE
Should state clearlythat it is a welderapproval;and not a pROCEDURE
approval,and, dependingon the particularStandard,should containthe
following:
a) welder's name and identitynumber- could be his/herclock or payroll
number, or possiblya photograph
b) date of the test
c) Standard of Code in tutt,i.e. BR|TISHSTANDARD4872 pT 1 : 1sB2
d) testpiecedetailsincludingmaterialspecification
e) equipmentand consumabledetails:weldingequipment,type of filler etc
0 e):tent of approval
g) sketch of run sequence,preparationand dimensions

WELDINGTECHNOLOGY
IssueO19l

3l.z

T\VI

vgot

,ITfE WELDiNG
D{STI I'LTrE

h) otherfactors,operatingparameters
etc
i) the test results(visual,NDT,DT etc)
j) remarks
k) witnessed
by
l) testsupervisof
m) locatron
Most Standardsgivean exampleof the test certificate.
SIGNATURES
ON CERTIFICATES
MUSTBE ENDORSED
WITHCOMPANY
STAMP.
STORAGEAND RETRIEVAL
Mostcompaniespreferto storethe recordsin a conventional
filingsystem.
Wth largerccmpaniesit may be usefulto use a computerfilingsystemor
registerwhichcouldautomatically
givean indicationof re-approval.

.]'.(J

WELDINGTECHNOLOGY
Issue0191
i

TWI

wot
r.q.!r.{,!rB.r
iarorrrcr

!0d

//ir.rrt

crr. d

or.r.r:

Eho o,r.

ftisrl.:

arri,nd.

o. rri: 41

A6i.rdN. tur

. . . . . . .p A S S P ' O a r

1r r.lrutrd)

30' iia::3

.. ....

...

Nci aaou R0

.. ..:5 0EcEf.raan i05!BLCCG3 iNOUSTR]ES

iqs rnt srluro

C&i

5b

. ;FD

. . . . 1r C 2 a

5p<.-lor...
.. C::l

rit.r4.

cE'

THE \ILDING L.-ST[T'UTE

FEdLrd

trl.r.ro.Ld)

.r !a.

W E L D E R A P P R O V A LT E S T C E R T I F I C A T E

Ex ?s;

kcoobl.r*<!'d

(o.r.r.

G no!!4l

mG)

STNGLE!E AL|ft

A^IYzuTT OA FIILET WELD

v'OIl,{o?

Frf.. tu@ rtrD.3EMuon

r 5 0 3 5 ! r Ero : r2 l : ! f { 2 1

rOl/1^/O,.1^o I t/

AAOVE PPROVAL IJSING5PCIFISO F|(LER

AAGOfT

^AGC$r EACKING
T.!

pr-.

(.ml

hEr.os

Plp. o@d.

d1a-.16r

5M

(|Ml

AAO GAEATER

GAE IEF T}IAN 0.5 t

aL Posmoa.JsExcPTvEatc
NOr AEOr-/rAaO
&roo.rd

6rolfuu6

r. .d

R:OU|AO o,J oqraLE PneS

.,.Er.E

p@.6d.

,p.chcr0o^ ^lo.:

n d.

dor. sn ,gi!r.

1M6..

o. r.rr r.dy

t@uon

ftobrEdro^
ror h.

,or.ppavil

'Eionrrl

2 yia

sa.r t rkrjr.a

by .rshd
lrlilr

d r.n

b.6i/

ro lO2)

WELDINGTECHNOLOGY
Issue0191

t/ c- -fualte

Lc rTc-aNaE

8cr LID

l\41 lr{^rNrNG \4or\xsfiop

v:Jnrry or !rp@

/\0p.. 3.!srr.

L OO!'N

6ur

Proh.E:!o^ ro. .!pova/

ro. !l. ronorrE

@-e-r99-

by ..rDloFr/@1tu(x
6 donsu (,.i.r ro to:r

T\VI

THE \\'?L-DING bTSTmUTE

OUESTIONS
WELD PROCEDURE
& WELDERAPPROVAL

Q1.

State six (6) essentialvariables

- \ .i ,

i ,

I
\
.
i

meaningof 'extentof ?ppfqv-a]'

and give five (5) examples

Q2.

o4.

Why are proceduresand weldersapproved?

Q5.

Statetwo (2) reasonsfor re-approvalot

a)

A weld procedure- -rr.:,.-.: ,

b)

A welders \.\.j:
_

,'

.-... -

;-c-."-'

k..i^ +

:',

,:i
:

r.Y\'.1 \ar,:'$

t-. ..

'

, ' 4