Preparation of welding procedures (WPS and PQR) based on AWS & ASME

Preparation of Welding Procedures (WPS and PQR) Based on AWS & ASME

The Preparation of Welding Procedures (WPS and PQR) Based on AWS & ASME Course is designed to provide participants with the necessary skills and knowledge to develop and qualify Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) in accordance with industry standards such as AWS (American Welding Society) and ASME (American Society of Mechanical Engineers). This course is crucial for professionals involved in welding, quality control, and fabrication in industries like oil & gas, construction, shipbuilding, and power generation.

Course Overview:

1- Introduction to Welding Procedures

• Welding Procedure Specification (WPS): A document that provides detailed instructions for performing welding operations, including parameters such as materials, joint design, welding process, and techniques.
• Procedure Qualification Record (PQR): A document that records the results of testing a sample weld to verify that the WPS can produce welds that meet specified requirements.

2- Purpose and Importance of WPS & PQR

• Ensures consistency, repeatability, and quality in welding processes.
• Verifies that the welded joints meet applicable codes, standards, and customer requirements.
• Provides a clear guideline for welders to follow during fabrication, helping to prevent defects and ensure safety.
• Necessary for meeting regulatory requirements in industries like oil & gas, construction, and manufacturing.

Key Topics Covered in the Course:

1- Welding Procedure Specification (WPS) Development

• Elements of a WPS:
  • Base materials: Selection of materials to be welded, including their specifications (e.g., steel, aluminum).
  • Joint design: Details of the weld joint, including type, size, and preparation.
  • Filler materials: Specification of welding consumables (e.g., electrodes, filler wire).
  • Welding process: Selection of the appropriate welding method, such as Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW), or Gas Metal Arc Welding (GMAW).
  • Welding parameters: Including current, voltage, travel speed, heat input, preheat, interpass temperature, and post-weld heat treatment.
  • Position and progression: Position of the weld (flat, vertical, overhead, etc.) and the direction of welding progression (uphill or downhill).
• Creating a WPS:
  • Step-by-step approach to filling out a WPS form as per AWS D1.1 or ASME Section IX.
  • Understanding weld codes and standards to ensure the WPS is compliant with specific industry requirements.
  • Example WPS formats based on AWS and ASME codes.

2- Procedure Qualification Record (PQR) Preparation

• Purpose of the PQR: Demonstrates that the welding procedure (WPS) can produce acceptable welds by testing a sample weld.
• Elements of a PQR:
  • Test weld coupon: Preparing a sample welded joint using the WPS parameters.
  • Mechanical testing: Tensile testing, bend testing, impact testing, hardness testing, and other tests to validate the mechanical properties of the weld.
  • Non-destructive testing (NDT): Radiographic testing (RT), ultrasonic testing (UT), and other NDT methods to inspect the weld quality.
  • Recording test results: Documenting all test results and parameters in the PQR form.
• Qualifying a PQR:
  • Performing weld tests in accordance with ASME Section IX or AWS D1.1.
  • Criteria for accepting or rejecting weld test samples based on mechanical properties and weld quality.
  • Developing a PQR based on the tests and recording all essential variables.

3- Welding Codes and Standards

• AWS Standards:
  • AWS D1.1: Structural Welding Code – Steel. This is one of the most widely used standards for welding in structural applications.
  • Other AWS standards: D1.3 (Sheet Steel), D1.6 (Stainless Steel), and D1.2 (Aluminum Welding Code).
• ASME Standards:
  • ASME Section IX: Covers the qualification of welders, welding procedures, and brazing procedures for pressure vessels, boilers, and other components.
  • ASME B31.3: Process Piping Code for welding in piping systems.
  • Other ASME standards: Section VIII for pressure vessels and other specific applications.

4- Essential Variables in Welding Procedures

• Essential variables: Parameters that significantly affect the quality and properties of the weld. Any changes in these variables will require requalification of the WPS.
  • Material groupings: Base metal thickness, grade, and type (e.g., P-Numbers in ASME).
  • Welding process: SMAW, GTAW, GMAW, etc.
  • Welding position: Horizontal, vertical, overhead, etc.
  • Filler material: Type, classification, and composition.
  • Preheat and post-weld heat treatment: Controls to prevent cracking and other defects.
  • Welding speed, current, and voltage: Critical to controlling heat input and avoiding distortion.
• Supplementary and non-essential variables: Variables that don’t necessarily require WPS requalification but must still be controlled.

5- Testing and Qualification of Welding Procedures

• Mechanical testing:
  • Tensile test: Measures the strength of the welded joint.
  • Bend test: Checks for ductility and the absence of surface or internal flaws.
  • Impact test: Measures the toughness of the weld at different temperatures (often required for low-temperature applications).
  • Hardness test: Assesses the hardness of the weld and heat-affected zone (HAZ).
• Non-destructive testing:
  • Radiographic testing (RT): Uses X-rays to detect internal defects in the weld.
  • Ultrasonic testing (UT): Uses high-frequency sound waves to evaluate weld integrity.
  • Visual testing (VT): Inspects the surface of the weld for visual defects such as cracks, porosity, and incomplete fusion.
• Requalification of WPS: When changes to essential variables occur, a new PQR may need to be qualified.

6- Writing and Reviewing WPS and PQR

• How to write clear and effective WPS and PQR documents.
• Reviewing and approving WPS and PQRs for compliance with project and code requirements.
• Understanding the responsibilities of welding engineers and inspectors in reviewing these documents.

7- Welder Performance Qualification (WPQ)

• Welder qualification testing: Ensuring that the welder can produce a weld that meets the WPS criteria.
• Welder qualification records (WQR): Documenting the welder’s ability to follow the WPS and produce acceptable welds.
• ASME and AWS guidelines for qualifying welders.

Course Learning Outcomes:

• Developing WPS: Participants will be able to create a detailed and compliant Welding Procedure Specification (WPS) in accordance with AWS and ASME standards.
• Qualifying PQR: Participants will learn how to perform and record the necessary tests to qualify a Procedure Qualification Record (PQR).
• Understanding essential variables: Participants will gain an understanding of the critical variables that affect the quality of welds and the consequences of modifying these variables.
• Interpreting codes and standards: Participants will be proficient in applying relevant AWS and ASME standards to ensure that welding procedures meet industry requirements.
• Testing and evaluation: Participants will learn how to conduct mechanical and non-destructive tests to verify the quality of welds and how to evaluate test results.

Target Audience:

• Welding Engineers: Professionals responsible for developing and approving welding procedures.
• Welding Inspectors: Individuals involved in inspecting and approving welds and ensuring compliance with codes.
• Quality Control (QC) Personnel: Responsible for ensuring that welding procedures meet project specifications and industry standards.
• Fabrication Supervisors and Foremen: Overseeing welding activities on construction or manufacturing sites.
• NDT Technicians: Involved in the testing and evaluation of welded joints.

Certification:

Upon successful completion of the course, participants may receive certification indicating their ability to develop and qualify WPS and PQR documents as per AWS and ASME standards. This certification demonstrates proficiency in welding procedure development, qualification, and testing.