If you buy a copy of AWS D1.1 Structural Welding Code (Steel) expecting to find prequalified welding procedures you are in for a big surprise. CEO at WeldNote, Welding Management Software, 2016 © Weldnote - Welding solutions passes 3 to 6) or if youâre referring to the remaining passes until the capping layer you may use âpasses 3 to Nâ or â3+â. joints, base metals, filler metals, positions, preheat, PWHT, gas etc. Just type in the processes used in the PQR / the ones to be used in production. Weld Tracking, is it really necessary? All the real time data during welding of test coupon and destructive test report data is compiled into one document known as Procedure qualification record (PQR). Example WPS for refer Some definitions you need understand before start it. The detailed description of how each pass should be welded. Now weâve reached into the most important part of the WPS. Introduction - Purpose - requirements: - Welding Procedure Specifications is table work instructions to perform 1 weld of fabrication prescribed. This means you could technically use a WPS for piping and plating / structural work. 2.0 WELDING PROCEDURE 2.1 The Welding shall be done manually using Shielded Metal Arc Welding, SMAW process. are quite important, and you should plan for them ahead of time. There are some additional details that are, nonetheless, relevant to making WPS according to ISO 15609-1 and ISO 15614-1. Nice Information Sir …………………………..can you provide the article regrding Fabrication of Distillation Column, Tanks for this valuable post.now each and everything is cleared for me how to write Wps and which section is followed for that corresponding concern. The rule of thumb is to use a small diameter for the first passes, and raise the diameter as you weld more layers. hello sir, can I get your contact number. Pulse weld details is similar, but only if you are welding with a pulsed transfer mode / current type, and should have the current minimum and maximum peaks, with the period between pulses, etc. Your contribution to knowledge dissemination in the field of welding and allied operations, is a feat that deserves commendation. The. I agree with the comments about seeking out a Welding Engineer, the reason being that the process tables for variables are NOT a “How-To-Guide”. The same goes for the weld type, in which some standards will approve welding fillet welds by performing a butt weld test. WeldProc has ready-to-use welding procedure specifications for SMAW, FCAW, MCAW, GMAW, SAW, SMAW-Roof Deck as well as WPSs required for Stainless Steel and Sheet Steel applications. A welding procedure specification shall contain, as a minimum, the specific essential and nonessential variables that are applicable to the welding process. Nice article. it is very useful article. . First of all we need to identify the welding process which is to be used for example weather it’s a SMAW or GMAW or GTAW or any other welding process or it’s a combination of two or more welding processes. As you already know, PQRs always have approval ranges based on what was welded for the approval of that specific test. Once the welding process is decided then we need to see the corresponding table (QW-252 to QW-257) for the complete list of variables. Welding Procedure Specification’s (WPS) Presented By John Lucas Welding Engineer UTI Corporation. The commercial name for a given filler material is not mandatory as per ISO 15614-1, it is not an essential variable unless you are using the following processes: 111, 114, 12X, 136 and 137, so according to §8.4.5 only the âfluxedâ processes require your WPS to have a filler material commercial designation in them, and even then, itâs only when impact tests are required, even if that is true for most cases. When the referencing Code, standard, or specification requires toughness qualification of the welded joint, then applicable supplementary essential variables shall also be provided in the WPS. This information will probably come in your gas certificate along with the commercial name, which is something that is not at all required to put in your WPS, however, you probably want to put it, especially if you work with more than one gas supplier. 2. Typically, Engineers not schooled in welding metallurgy become “Welding Lawyers” with respect to the Code. You may mention the fact that it could be a single or multi layer weld, but that is not so important, as that information will already be available on the welding passes themselves. The creative license and abuse to the Science of Welding and Metallurgical effects to the cast weld metal and base metal Heat Affected Zones, can only be controlled by an engineer who has studied and experienced these issues. I shall cover ASME IX on a future article. Prepare the WPS and reduce the risk to stray too far from ALL of the variables used. Which you can download in the button right below. Thank you very much sir! You may put a range of layers (e.g. After watching this video you will be able to write a welding procedure specification (WPS) on your own. Preparing a WPS is not as complicated as it seems. Thank you sir. ISO 15614-1 (2017) is out: Changes and Updates, My first experience as an International Welding Engineer (IWE), Writing compliant WPS (and why it's important), 3 Reasons Why You Have To Search for PQR, WPS and WPQ. Amperage has a direct influence on the heat input and also defines how a welder will control his puddle. The joint set up, welding and visual examination of the completed weld should be witnessed by a certified welding inspector such as an AWS certified CWI or an Inspection Body. You wouldnât want an inspector to come to your shop floor and order you to stop using a 15mm WPS because the welder is welding a 15.2mm pipe (which has already happened before). Very well prepared , well compoused and compact info about ASME SECTION ix thanks. The torch angle will directly influence the morphology of the weld bead. Although less important, they should be mentioned. Best regards, Welding symbols and weld sizes clearly specified in drawing and related documents. follow. And a prequalified WPS is not a published document you can buy, it still must be developed. How to write a Welding Procedure Specification (WPS). Dear sir pls also make some articles about storage and pressure vessels APIs thanks. In regards to the diameter or filler material size, according to ISO 15614-1, you can change it, so long as you take into consideration the heat input requirements and, as such, I would recommend you to have 2 to 3 options here (e.g. How prepare welding procedure specification? When the referencing Code, standard, or specification requires toughness qualification of the welded joint, then applicable supplementary essential variables shall also be provided in the WPS. Thanks for sharing. The thermal parameters are usually pretty straightforward, even if they are of the utmost importance (they are straightforward from a WPS standpoint, but if you have to specify a welding procedure before it is qualified it becomes a serious design issue, as it will take into account your companyâs resources and shop areas, as well as material types). Getting into the filler materials or consumables, in my experience there have been some misconceptions on some of the requirements here. This way your welders will know exactly which gas tank they should pick up and avoid any problems with your client about the specified gas for the job at hand. In this case you just have to associate it to the corresponding welding process and pass. I complete the graduation in mechanical engineering from india. In case of a semi-automatic process you will not control the current directly. Privacy Policy | Terms of Service. 1.2 The attached Welding Procedure Data Sheets (WPDS) are an essential part of this WPS. By this, I mean who is responsible for the approval of a WPS. (in this case Iâve named it âSample WPS (ISO)â, but you should use your own designations. A Welding Procedure Specification, or WPS, is a document that serves as a guide for the effective creation of a weld that meets all applicable code requirements and production standards. Of the well over 400 thousand WPSs that I have had to review/comment/approve for the corporation or government entity that I was working for at the time, I typically find a WPSs that try to open up all variables to a level that their welders will not fail an audit. Welding Procedure Specification Number Format. The course will demonstrate how welding coordinators can easily and effectively fulfil the requirements of international standards and … Yes, and hereâs why. Easy to understand for all. higher thickness requiring a higher temperature). NOTE: Like the base materials, in the filler materials you should preferably use ISO specifications and classifications. When similar issue was raised during my senior welding Inspector certification programme in TWI UK, where duties and responsibilities of a senior welding Inspector was being taught, we all criticised it but jokingly concluded at the end, that the job of a welding Inspector as it concerns Welding Procedure Qualification, is not far from that of an errand boy. Click here for instructions on how to enable JavaScript in your browser. As you already know, PQRs always have approval ranges based on what was welded for the approval of that specific test. Because of huge number of variables involved, the knowledge of the welding engineer and the skill of the welder need to be validated by a series of tests. is a written document that provides direction to the welder or welding operator for making production welds in accordance… Well written. X-Y-Z (for a P-number Base Metal Welded to Itself) X1:X2-Y-Z (for Two Different P-number Metals Welded to Each Other) In This Numbering System. Prepare the Welder Performance Test Procedure, and again use the Code as a minimum. Thank u sir it’s a great effort made by u u HV mention all things in very simple way which r easy to understood …. Typically, the more the Welder knows, the lower the Rusk to the company. The safest way to go at it is to put them all in your WPS, as it is approved by the PQR, but the best way to proceed is to define which are the positions to be used in the shop floor, which will mostly be PA, PC and PH. Professionally speaking, a WPS begins with a Preliminary Welding Procedure, that is expected to be written by a Welding Engineer, who thereafter hands over same to an Inspector for qualification/testing. My suggestion would be to use a WPS for small thicknesses and small diameters, and a WPS for bigger thicknesses and bigger diameters (more, if the project has a lot of different pipe or plate sizes). The base material details are also quite straightforward. Can you explain me how to select weld coupon size for both procedure qualification & performance qualification with asme reference code number . Based on the proposed WPS, Test coupon (or coupons) is prepared, and the coupon is welded as per the values (or range) provided in the pWPS. In the case of semi-automatic welding, the voltage is a set value that will remain the same throughout the welding pass, and should be defined, like the current, with previous experience in mind, or with the expertise of an experienced consultant. In this case, the thickness range is exactly the approval range limits of the PQR. Weld maps identify the welding procedure specification (WPS) to be used for specific weld joints. are important, they make the difference between a welder being able to control the torch easily and assuring a sound weld, with no oxidation either on the root or the top side, which means this value should be thought out and based upon previous experience, for both the shielding and backing gases. Thank you for publishing this it is very helpful. The advanced tools of the editor will guide you through the editable PDF template. Just type in the processes used in the PQR / the ones to be used in production. Keep in mind that this is. Let’s break it down into parts. But once again it is not something required. In last line of this paragraph it should QW-253 instead of QW-453. Post weld heat treatment is perhaps one of the most important aspects of your welding, if it is verified to be necessary. I hope this has been helpful, if youâd like to read more, you may follow us on facebook, twitter and linkedin, or subscribe to our newsletter. Preparation methods do not need a lot of details, you should just specify if this welded joint is going to be grinded, machined, etc. Details of back gouging are only relevant if you are performing welding from both sides, and could have some information of the electrode used, how much thickness and width to be gouged, etc. Dimensions detailed and potential for distortion addressed. The joint set up, welding and visual examination of the completed weld should be witnessed by a certified welding inspector such as … You will, however, be able to control the voltage and wire feed speed. Thank you for this article, It’s very helpful for all fresher welding engineer. Although less important, they should be mentioned. On higher layers you can raise the amperage, voltage and travel speed to gain some productivity while maintaining the heat input levels, but for that you also need a larger rod, electrode, or in the case of semi-automatic processes, a higher wire feed speed. This is for a 316 stainless steel and as such Iâve chosen the ER316L for both TIG and MAG processes. This information will probably come in your gas certificate along with the commercial name, which is something that is not at all required to put in your WPS, however, you probably want to put it, especially if you work with more than one gas supplier. How to fill out the Welding procedure specification form on the web: To start the form, use the Fill & Sign Online button or tick the preview image of the blank. Produce a welding procedure specification (WPS) as stated above. for the gas designations in ISO 14175, I1 means 100% Argon and M21 means a mixture of Argon with 15 to 25% CO2. Steel Number = 1.4301 equivalent for 304, Clear and easy to understand. Great work, keep it up. It is very hard to define exactly the number of passes on the weld layer configuration, and as such you should have, at most, a range of the maximum number of layers to be made. In high thicknesses it is mandatory in pretty much every welding code, in Cr-Mo steels as well, in order to prevent the forming of cracks due to three dimensional cooling rates or the high temperability of these Cr-Mo steels. Please click here to download a sample WPS Format. are pretty straightforward. QW-153 Acceptance Criteria-Tension Tests, QW-163 Acceptance Criteria-Guided Bend Tests, QW-172 Toughness Tests-Drop Weight, QW-183 Macro Examination-Procedure Specimens, QW-210 Preparation of Test Coupon, QW-250 Welding Variables (Refer Table-1), QW-401.1 Supplementary Essential Variable (Procedure), QW-407 Post Weld Heat Treatment, QW-409 Electrical Characteristics, QW-420 Base Metal Groupings, Table QW/QB-422 Grouping of Base Metals for Qualification, Table QW-432 Grouping of Electrodes and Welding Rods for Qualification, QW-440 Weld Metal Chemical Composition, Table QW-442 A-Numbers Classification of Ferrous Weld Metal Analysis for Procedure Qualification, Table QW-451.1 Groove-Weld Tension Tests and Transverse-Bend Tests, Table QW-451.2 Groove-Weld Tension Tests and Longitudinal-Bend Tests, Table QW-451.4 Fillet Welds Qualified by Groove-Weld Tests, QW-461.3 Groove Welds in Plate-Test Positions, QW-461.4 Groove Welds in Pipe-Test Positions, QW-461.5 Fillet Welds in Plate-Test Positions, QW-461.6 Fillet Welds in Pipe-Test Positions, QW-462 Test Specimen Table QW-462.1(a) to QW-462.5(e) Fig QW-463.1(a) to QW-469.2, QW-470 Etching — Processes and Reagents. A Welding Procedure Specification (WPS) is the formal written document describing welding procedures, which provides direction to the welder or welding operators for making sound and quality production welds as per the code requirements . which produces castings of valve bodies). Weld a test piece in accordance with the requirements of your specification. They can quote chapter and verse, but do not posses the level of understanding to ensure their company will not inherit a large level of Risk during the life of the product. You may mention the fact that it could be a single or multi layer weld, but that is not so important, as that information will already be available on the welding passes themselves. Which you can download in the button right below This article will be related to ISO 15614-1 and ISO 15609-1. With the help of this video you would able to understand the variables viz. are an essential variable so they are of the utmost importance, but you just need to specify whether the joint will have material, gas or no backing, or if it will be welded in a single side or both sides. A Welding Procedure Specification (WPS) is the formal written document describing welding procedures, which provides direction to the welder or welding operators for making sound and quality production welds as per the code requirements .
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