Issues related to PQR

[Dương Vinh Quang]

Dear experts, 

I am in the following situation, please ask experts for support and advice. Currently, our company wants to write WPSs from previously available PQRs, but the previous PQRs did not have complete NDT, tensile, hardness, and toughness reports attached, but only one PQR sheet summarizing the That report (of course fully signed by all relevant parties, including third parties). The questions raised are as follows: 

1. Is it wrong if we write WPS since then? Any documents that show this is wrong, please provide me. 

Thank you all!

[Amol Betkar]

Dear Quang,

Writing Welding Procedure Specifications (WPSs) based on previously available Procedure Qualification Records (PQRs) that lack complete Non-Destructive Testing (NDT), tensile, hardness, and toughness reports may not comply with standard practices and regulatory requirements. Here’s a breakdown of the situation and the guidance you need:

Key Points to Consider

1. PQR Completeness:

   • The PQR must be comprehensive and include detailed reports of all required tests (NDT, tensile, hardness, and toughness).
   • The summarized PQR sheet, even if signed by relevant parties, is not a substitute for the complete documentation.

2. Code and Standard Compliance:

   • Standards such as the American Welding Society (AWS) D1.1 and the American Society of Mechanical Engineers (ASME) Section IX specify the requirements for WPS and PQR documentation.
   • These standards mandate complete records of all testing conducted to qualify the welding procedure.

Issues with Incomplete PQRs

• Verification:

  • Complete test records are necessary to verify the qualification of the welding procedure. Without these records, it’s challenging to ensure that the procedure meets the required standards and specifications.

• Audits and Inspections:

  • Incomplete documentation can lead to issues during audits and inspections by regulatory bodies or clients, potentially resulting in non-compliance findings.

Specific Standards and Documentation

• AWS D1.1 (Structural Welding Code – Steel):

  • Section 4.9.3 requires that the PQR include records of all tests conducted to qualify the procedure.
  • A WPS derived from an incomplete PQR would not meet AWS D1.1 requirements.

• ASME Section IX (Welding, Brazing, and Fusing Qualifications):

  • QW-200.2 outlines the requirements for the PQR, including detailed reports of all tests.
  • According to QW-201, a WPS must be based on a PQR that documents all required tests in detail.

Recommendations

1. Complete the PQR Documentation:

   • Ensure that all missing NDT, tensile, hardness, and toughness test reports are attached to the PQR.
   • If necessary, re-perform the tests to obtain the required documentation.

2. Consult Relevant Standards:

   • Review AWS D1.1 and ASME Section IX to ensure full compliance with all documentation requirements.

3. Seek Expert Consultation:

   • Engage with welding engineers or certification bodies to validate the completeness of your PQRs and the adequacy of your WPSs.

Conclusion

Writing a WPS from an incomplete PQR is not compliant with standard practices and regulatory requirements. It is essential to have complete documentation, including all test reports, attached to the PQR. This ensures the validity of the WPS and compliance with standards such as AWS D1.1 and ASME Section IX.

If you need specific documentation references, the following sections from the standards will be useful:

• AWS D1.1: 4.9.3
• ASME Section IX: QW-200.2, QW-201

Ensure that your PQRs are fully documented before proceeding to write WPSs to avoid non-compliance and potential issues during audits or inspections.

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Best regards,

Amol K.B

B.E(Mech), CSWIP 3.2.2, NACE CIP 1 & ASNT LII(4M)