Re: Welding Procedure Specification Software Download
Donnell Simon
A Welding Procedure Specification (WPS) is a formal document describing welding procedures. It is an internal document used by welding companies to instruct welders (or welding operators) on how to achieve quality production welds that meet all relevant code requirements. Each company typically develops their own WPS for each material alloy and for each welding type used. Specific codes and/or engineering societies are often the driving force behind the development of a company's WPS. A WPS is supported by a Procedure Qualification Record (PQR or WPQR), a formal record of a test weld performed and rigorously tested to ensure that the procedure will produce a good weld. Individual welders are certified with a qualification test documented in a Welder Qualification Test Record (WQTR) that shows they have the understanding and demonstrated ability to work within the specified WPS.
According to the American Welding Society (AWS), a WPS provides in detail the required welding variables for specific application to assure repeatability by properly trained welders. The AWS defines welding PQR as a record of welding variables used to produce an acceptable test weldment and the results of tests conducted on the weldment to qualify a Welding Procedure Specification. For steel construction (civil engineering structures) AWS D1.1 is a widely used standard. It specifies either a pre-qualification option (chapter 3) or a qualification option (chapter 4) for approval of welding processes.[1]
The American Society of Mechanical Engineers (ASME) similarly defines a WPS as a written document that provides direction to the welder or welding operator for making production welds in accordance with Code requirements.[2] ASME also defines welding PQR as a record of variables recorded during the welding of the test coupon. The record also contains the test results of the tested specimens.
The Canadian Welding Bureau, through CSA Standards W47.1,[3] W47.2[4] and W186,[5] specifies both a WPS and a Welding Procedure Data Sheet (WPDS) to provide direction to the welding supervisor, welders and welding operators. The WPS provides general information on the welding process and material grouping being welded, while the WPDS provides specific welding variables/parameter/conditions for the specific weldment. All WPS and WPDS must be independently reviewed and accepted by the Canadian Welding Bureau prior to use. These CSA standards also define requirements for procedure qualification testing (PQT) to support the acceptance of the WPDS. A record of the procedure qualification test and the results must be documented on a procedure qualification record (PQR). All PQTs are independently witnessed by the Canadian Welding Bureau.
In Europe, the European Committee for Standardization (CEN) has adopted the ISO standards on welding procedure qualification (ISO 15607 to ISO 15614), which replaced the former European standard EN 288. EN ISO 15607 defines a WPS as "A document that has been qualified by one of the methods described in clause 6 and provides the required variables of the welding procedure to ensure repeatability during production welding". The same standard defines a Welding Procedure Qualification Record (WPQR) as "Record comprising all necessary data needed for qualification of a preliminary welding procedure specification".[6] In addition to the standard WPS qualification procedure specified in ISO 15614, the ISO 156xx series of standards provides also for alternative WPS approval methods. These include: Tested welding consumables (ISO 15610), Previous welding experience (ISO 15611), Standard welding procedure (ISO 15612) and Preproduction welding test (ISO 15613).
In the oil and gas pipeline sector, the American Petroleum Institute API 1104 standard is used almost exclusively worldwide. API 1104 accepts the definitions of the American Welding Society code AWS A3.0.[7]
The American Welding Society, acting under ANSI rules for consensus standards, publishes AWS Standard Welding Procedure Specifications (SWPSs) which are initiated by the B2G Subcommittee on Procedure Qualification Records. In initiating SWPSs for consideration as AWS standards, the B2G Subcommittee is guided by the successful service experience in welded construction of the combination of base materials, welding process(es), and welding filler metals covered by the scope of each SWPS. An SWPS must meet the rules for qualification of AWS B2.1, Specification for Welding Procedure and Performance Qualification, and be approved by the AWS B2 Committee on Procedure and Performance Qualification. All SWPSs are supported by procedure qualification records (PQRs) which meet the rules of AWS B2.1 and which in addition are intended to meet the rules of the major codes which govern the intended applications such as AWS Structural Codes (D1.1, D1.2, D1.3, etc.), AWS Sheet Metal Welding Code (D9.1), ASME Boiler and Pressure Vessel Code, Section IX, NAVSEA Technical Publication S9074-AQ-GIB-010/248, Requirements for Welding and Brazing Procedure and Performance Qualification, NAVSEA Technical Publication S9074-AR-GIB-010/278, Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping and Pressure Vessels, MIL-STD-1689, Fabrication, Welding and Inspection of Ships Structure, NAVSEA Technical Publication T9074-AD-GIB-010/688, Requirements for Fabrication Welding, and Inspection of Submarine Structures, and American Bureau of Shipping (ABS) Naval Vessel Rules (NVR).
The data to support a Standard Welding Procedure Specification are derived from procedure qualification records (PQRs) generated by the B2G Subcommittee on Procedure Qualification Records and PQRs received from industry and government agencies. For all committee generated PQRs, the welding, testing, and evaluation are performed under the direct supervision of the B2G Subcommittee.
To be referenced as a supporting document for an SWPS, a PQR received from an industry or government agency must be qualified and documented in accordance with one of the nationally recognized codes or specifications such as AWS D1.1 through AWS D1.6, AWS D15.1, AWS D14.1 through AWS D14.6, ASME Boiler and Pressure Vessel Code, Section IX, NAVSEA Technical Publication S9074-AQ-GIB-010/248, Requirements for Welding and Brazing Procedure and Performance Qualification, or American Bureau of Shipping (ABS) Naval Vessel Rules (NVR). The B2G Subcommittee reviews and validates these PQRs before entering the information contained on them into a data bank.
It is the policy of the AWS B2 Committee that the range of conditions and variables listed for an SWPS be more restrictive than permitted by application of the full range of conditions and variables allowed by the B2.1 document or by other American National Standards (such as AWS D1.1 through AWS D1.6 or ASME Boiler and Pressure Vessel Code, Section IX).
The purpose of this policy is to restrict the WPS to a high probability of successful application by all users. In judging the extent of such restriction, the Committee is guided by the number and scope of the supporting PQRs, including the specific material, thickness and value for each welding variable used for the development of the PQR, and by known fabrication experience. The minimum number of supporting PQRs required by the Committee is two but is usually in the range of two to fifty, the specific minimum number being a Committee decision for each WPS. It is the intent of the AWS B2 Committee to have SWPSs only for commonly welded materials and common manual and semiautomatic welding processes.
A prequalified Welding Procedure Specification (WPS) is a standardized document that provides guidelines for performing a specific WPS welding task. A prequalified WPS means that it has been previously approved by a welding authority, such as the American Welding Society (AWS), without the need for additional testing.
Prequalified WPSs are typically used for relatively simple WPS welding tasks that have been proven to be reliable and effective over time. This can include processes like shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), and gas metal arc welding (GMAW).
The benefit of using a prequalified WPS in WPS welding is that it can save time and resources in the welding process. Central to the WPS is the welding inspection, a key process ensuring procedure compliance and utmost quality in WPS welding. Welders can refer to prequalified WPSs to ensure that they are following the correct procedures and using the appropriate materials and equipment. This can help to ensure that the final welded product is of high quality and meets the necessary standards for safety and performance.
The WPS also specifies the required Welding Procedure Qualification Record (WPQR) and Weld Procedure Qualification Record (PQR) tests to be performed to ensure that the welding process produces quality welds.
WPQR stands for Welding Procedure Qualification Record. It is a document that certifies that a particular welding procedure has been tested and has met the required codes and standards. A WPQR is a necessary requirement for developing a Welding Procedure Specification (WPS).
The WPQR test involves welding a test coupon using the welding procedure specified in the WPS. The test coupon is then subjected to various tests to evaluate the quality and soundness of the weld. These tests may include visual inspection, radiography, ultrasonic testing, or mechanical testing. The results of the tests are recorded in the WPQR document.
The WPQR is closely related to the WPS, as it is used to verify that the welding procedure specified in the WPS produces quality welds that meet the required codes and standards. The WPQR provides evidence that the welding procedure has been tested and has passed the required tests. The WPS, on the other hand, is a document that outlines the welding procedures to be followed for a particular welding job based on the information in the WPQR.
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