Navigating the Test Requirements for Weld

Procedure Qualifications

by Franco du Plessis

OVERVIEW

• Welding codes and standards • Procedure documentation • Qualification process flow

• Types of testing • Test requirements

• Conclusion

WELDING CODES AND STANDARDS

PROCEDURE DOCUMENTATION

Qualification requires the formulation of three universally recognized documents:

• pWPS – Preliminary Welding Procedure Specification.

• WPQR – Welding Procedure Qualification Record.

• WPS – Welding Procedure Specification.

OVERVIEW OF THE pWPS

pWPS – Preliminary Welding Procedure Specification. • Produced by the companies welding engineer or responsible welding

coordinator. • A reference document used by the welder to complete the welding

procedure qualification test piece. • Containing key variables of the welding procedure to be qualified.

• Dimensions • Joint configuration • Consumable type • Current • Voltage • Travel speed

• Based on knowledge and / or past experience.

pWPS EXAMPLE

OVERVIEW OF THE WPQR

WPQR – Welding Procedure Qualification Record. • Is a set of documents comprising the WPS detailing:

• The actual welding parameters recorded during the qualification testing as noted on the pWPS.

• Results of any non-destructive and destructive tests. • Material certification for the test piece. • The range of the qualification if all tests are satisfactory. • Based on the range of qualification a single WPQR may be used to

qualify a various number of WPS’. • Essentially the WPQR is a documentary evidence to prove that the

welding parameters used in the qualification test piece do not adversely effect the mechanical properties of the material.

WPQR EXAMPLE

OVERVIEW OF THE WPS

WPS – Welding Procedure Specification. • A single sheet document, WPS is the final link in the chain of

documents required to demonstrate welding process control. • It requires all the information required by the qualified welder to

complete a welded joint. • Unlike the WPS accompanying the WPQR the which contains the

actual welding parameters recorded during the qualification test weld, the final WPS gives a allowable range of welding parameters.

• The WPS must be readily available at the welder’s workplace to be put in practice.

THE QUALIFICATION PROCESS FLOW

Develop a preliminary welding procedure

specification (pWPS)

Complete a welding test procedure

Complete a welding procedure qualification

record (WPQR)

Prepare a welding procedure specification (WPS) based

on the WPQR

Testing based on specification requirements

TYPES OF TESTING

• Destructive testing: • Fillet Weld tests • CTOD (Crack Tip Opening Displacement)

STRESS – STRAIN CURVE

TYPES OF TESTING - continued

• Non-destructive testing (NDT): • Visual and optical testing (VT)

• Penetrant testing (PT) • Magnetic particle testing (PT)

• Radiographic testing (RT) • Ultrasonic testing (UT)

TESTING REQUIRMENTS FOR CODES

• ASME Boiler and Pressure Vessel Code • Section IX – Qualification Standard for Welding and Brazing

Procedures.

• AWS D1.1 – American Welding Society • Structural Welding Code – Steel.

• EEMUA 158 • Construction Specification for Fixed Offshore Structures in the

North Sea.

TENSILE TESTING TEST ASME SECTION IX: PART QW WELDING

(QW 150)

AWS D1.1/D1.1M

(Section 4.8)

EEMUA 158

(Section 4.4.4 a & b) TENSION TESTS

Reduced Section - Plate (QW-151.1) Reduced Section - Pipe (QW-151.2 Turned Specimens (QW-151.3) Full-Section Specimens for Pipe (QW-151.4)

Reduced Section - Plate (4.8.3.4). Fig. 4.14 Reduced Section - Pipe (4.8.3.4). Fig. 4.14 Fig. 4.18 – Turned – All-Weld All-Weld Tension Specimen (4.8.3.6) . Fig. 4.18 ASTM A370 refers.

BS 709 & BS EN 895 refers. BS 709 & BS EN 895 refers. / Fig. 7 in EEMUA.

ASME Section IX

Tensile strength not less than: • the minimum strength of base

metal. • if the specimen breaks in the

base metal outside of the weld metal, the test shall be accepted.

GUIDED BEND TESTING TEST ASME SECTION IX: PART QW WELDING

(QW 160)

AWS D1.1/D1.1M

(Section 4.8)

EEMUA 158

GUIDED BEND TESTS

Transverse Bend Tests: Side Bend (QW-161.1) Face & Root Bends (QW-161.2 & QW-161.3) Sub-size Face & Root Bends (QW-161.4) Longitudinal Bend Tests: Longitudinal Bend Tests (QW 161.5) Face & Root Bends (QW-161.6 & QW-161.7)

Transverse Bend Tests: Face, Root & Side Bends (4.8.3.1). Fig. 4.12 and Fig. 4.13 Longitudinal Bend Tests: Longitudinal Bend Specimen (4.8.3.2). Fig. 4.12

Not applicable.

Failure due to slag deposit in weld metal / fusion line.

Requirement: • No open discontinuity in the

weld or heat affected zone exceeding 3mm.

• No evidence of lack of fusion, slag inclusions or internal discontinuities.

GUIDED BEND TESTING JIGS

Plunger and Die Jig.

Wrap around bend jig.

TOUGHNESS TESTING TEST ASME SECTION IX: PART QW WELDING

(QW 170)

AWS D1.1/D1.1M

(Annex III)

EEMUA 158

(Section 4.4.4 e) NOTCH TOUGHNESS TESTS

“When required by other sections”. Charpy V-Notch (QW-171.1) Requirement: SA-370 referred. Drop Weight (QW-172.1) Requirements: ASTM E208 referred.

Based on contract drawings and specifications. Charpy V-Notch: General (III1) Test Locations (III2) CVN Tests (III3) Requirements (III4) Fig. III-1 Specimen locations. (See III2.1) ASTM E23 & ASTM A370 refers

Section 4.4.4 e Fig. 9a to 9c - Specimen locations

EEMUA 158 • Notch toughness requirement • HAZ notch locations • Specimen locations • Locations in weld

Ductile fracture

Brittle fracture

FILLET WELD TESTING TEST ASME SECTION IX: PART QW WELDING

(QW 180)

AWS D1.1/D1.1M

(Section 4.11)

EEMUA 158

(Section 4.4.4 c)

FILLET WELD TESTS / MACRO EXAMINATION / FRACTURE TESTS

QW-181 Procedure and Performance Qualification Specimens Procedure (QW-181.1) Performance (QW-181.2) Fillet welds in plate – Procedure QW-462.4(a) Fillet welds in plate– Performance QW-462.4(b) Fillet welds in pipe – Performance QW-462.4(c) Fillet welds in pipe – Procedure QW-462.4(d) Fillet welds Fracture Tests Performance QW-182 Macro Examination – Procedure (QW-183) Macro Examination – Procedure (QW-184)

Fillet Weld Test – Section 4.11.2 Fillet welded T-joint for plate – Fig. 4.19 Fillet welded T-joint for pipe – Fig. 4.20 Macroetch Test – Section 4.8.4

Section 4.4.4 c Preparation with 600 grit paper. Requirements – 7.5.4

Macro etch Sample

HARDNESS SURVEY TESTING TEST ASME SECTION IX: PART QW WELDING

(QW 180)

AWS D1.1/D1.1M

(Section 4.11)

EEMUA 158

(Section 4.4.4 c) FILLET WELD TESTS / MACRO EXAMINATION

QW-181 Procedure and Performance Qualification Specimens Procedure (QW-181.1) Performance (QW-181.2) Fillet welds in plate – Procedure QW-462.4(a) Fillet welds in plate– Performance QW-462.4(b) Fillet welds in pipe – Performance QW-462.4(c) Fillet welds in pipe – Procedure QW-462.4(d) Macro Examination – Procedure (QW-183) Macro Examination – Procedure (QW-184)

Fillet Weld Test – Section 4.11.2 Fillet welded T-joint for plate – Fig. 4.19 Fillet welded T-joint for pipe – Fig. 4.20 Macroetch Test – Section 4.8.4

Section 4.4.4 c Preparation with 600 grit paper. Requirements – 7.5.4

HARDNESS SURVEY EXAMPLES

Plate – Single Bevel

Fillet weld

CONCLUSION

• Test requirements vary based on standards and application. • Welding engineers are responsible for testing requirements.

• Laboratory – conduct the testing according to specified standards.

• COMMUNICATION.