Welder Procedure Specification
Billi Plancarte
A Preliminary-WPS is written by the entity contracted to do the work before welding a Procedure Qualification Record (PQR) test coupon. Welders use the Preliminary-WPS as a starting point when welding PQR test coupons. The PQR weld coupon is formed by two pieces of steel that are cut and beveled to the dimensions specified by the governing code and then welded. Then sections of the welded coupon are cut at code-specified locations and undergo destructive testing to determine the soundness of the welds produced using the parameters of the WPS.
When a fabricator needs to develop a WPS, the person responsible for developing the WPS will review the project specifications, types of metal used, filler metal, types of joints, essential and non-essential variables, and supplementary essential variables (if Charpy V-Notch testing is required), and any additional requirements that the WPS needs to address.
Once the fabricator understands all the project needs, they will fill out a Pre-WPS form based on the welding required for the selected process and the range of the parameters that will provide the best results. The Pre-WPS will provide the welder with a starting point that shows the parameters needed to weld the PQR coupon.
A Prequalified-WPS bases its welding variables on the history of welds and variables used in previous industrial projects. No testing is required if the variables have been maintained within the parameters set forth by the code.
The D.1.1 Structural Steel Code has a clause dedicated to the preparation of a Prequalified WPS. This clause outlines all requirements for base metals, pre-heat and interpass temperatures, filler metals, joint geometry, and essential variables and weld parameters. When the Prequalified WPS adheres to the code, it will produce welds with correct mechanical and metallurgical properties, therefore preparing a PQR is not required.
A Standard-WPS (SWPS) is developed and sold by the American Welding Society (AWS). AWS has a welding procedure committee that examines and develops SWPS from PQRs submitted by industrial and government agencies.
Fabricators can use a SWPS when a prequalified WPS is not acceptable to the code or the process, or if the fabricator does not want (or have time and resources) to develop a WPS through the qualification method. SWPSs are inexpensive and have the testing data required to develop a WPS for a variety of welding processes and applications.
A WPS is a procedure used and created by a fabricator when Prequalified and Standard WPSs do not apply to the project specifications or welding process. When using a WPS, fabricators need to test and develop a PQR to validate and support the WPS data.
If the required code on your project does not allow a Prequalified WPS, there is no SWPS that meets the welding requirements, or the fabricator wants to tailor the WPS to a specific set of parameters, then a WPS is your best option. In any of these instances, the fabricator will run a test coupon, record the testing data in a PQR, and qualify the WPS based on the test results.
Developing and reviewing WPS can be difficult and complicated even in the best circumstances. Our team of CWIs and engineers at Morrison-Maierle is more than willing to assist you during this process. Please contact us to see how we may help with your welding projects.
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.
PQR stands for Procedure Qualification Record. It is a document that certifies that a particular welding procedure has been qualified to meet the required codes and standards. The PQR is an essential element in developing a Welding Procedure Specification (WPS).
The PQR involves welding a test coupon using the proposed welding procedure. 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 PQR document.
The PQR is closely related to the WPS, as it is used to develop the welding procedure specified in the WPS. The PQR provides evidence that the welding procedure has been qualified to meet the required codes and standards. 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 PQR.
WPS, WPQR, and PQR are all related to each other in the context of welding.
They are all important documents that are used to ensure that welding procedures are developed and followed correctly to produce high-quality welded joints.
The Welding Procedure Specification (WPS) is a document that outlines the specific welding procedures that are to be used for a particular welding job. The Procedure Qualification Record (PQR) is a document that certifies that a particular welding procedure has been qualified to meet the required codes and standards.
The Welding Procedure Qualification Record (WPQR) is similar to the PQR in that it involves welding a test coupon using the proposed welding procedure and subjecting it to various tests.
However, the WPQR includes additional information, such as the identity of the welder, the welding equipment used, and any other relevant details that are specific to the welding procedure.
To summarize, WPS (Welding Procedure Specification), WPQR (Welding Procedure Qualification Record), and PQR (Procedure Qualification Record) are interconnected documents that play a critical role in ensuring the proper development and implementation of welding procedures, resulting in high-quality welded joints.
The PQR is utilized to validate a welding procedure, which is then recorded in the WPS. On the other hand, the WPQR is used to confirm that a welding procedure has been qualified and is prepared for deployment in real-world welding assignments.
These meticulously crafted documents serve as roadmaps, detailing the unique characteristics of different metal types and the precise flow rates required.
With WPS, we bring standardization to the welding world, paving the way for precision and excellence.
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]
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