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WPS PQR WQT WPQ

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 WPS - PQR - WQT / WPQ
WPS – Welding Procedure Specifications
PQR – Procedure Qualification Records, and
WQT / WPQ – Welder Qualification Test / Welder Performance Qualifications.

Prepared by: DSc Dževad Hadžihafizović (DEng)

Sarajevo 2023
The Building Blocks –Some Definitions
 PRELIMINARY (PROPOSED) WELDING PROCEDURE
SPECIFICATIONS (WPS)
• pWPS is essentially a guide for the person that is going to
weld the PQR test coupon and it can also be used as a
document to get in principal approval from the client. You
give the client the change to review what you intend to do,
ie. if I run the test like this and do this testing, will you be
happy with it.
• This is not always required, but it is specified in some
standards. It can save heartache buy ensuring the client is
happy with the WPS at the end.
 WELDING PROCEDURE SPECIFICATIONS (WPS)
• WPS is essentially a welder’s guide that includes applicable code requirements and
production standards. It controls the welding process.
• It has been compared to a recipe for welders. When cooking a roast, the recipe
includes all the ingredients you need, plus the actual steps you will need to make sure
the roast works out right and is repeatable.
• A WPS is very similar. It includes details on what you will need and the welding
processes to follow that will create a sound weld. However, instead of listing type of
meat, barbeque temperature, time you should for, a WPS lists information such as base
metal grade, amps, volts and travel speed along with many other details.
• The WPS is a proven process of welding and is important to ensure welding operators
in the field are maintaining the same, required standards across the board. The
mechanical properties of a weld cannot be verified in production welds after welding
so control of the welding process using a WPS is critical.
• If either a novice or experienced welder follow the WPS, they should be able to
produce welds with similar mechanical properties. This helps new welders grow to the
same level as experienced welders. It ensures clients are receiving serviceable welds
that are the strength, toughness and soundness required by the design.
• A WPS always has ranges to allow for joint and operator technique variation, it is
unlikely every joint is the same or every welder uses the same technique. These ranges
are different for every standard. The ranges are based on what is known as essential
variables. Things which if changed require you to requalify the WPS.
 PROCEDURE QUALIFICATION RECORDS (PQR)
All WPSs start with a PQR. It is a record of the test. It DOES NOT have any ranges. It lists the actual
values recorded during the welding of a test piece. It proves the welding process.
Then using the essential variables (ranges) from the relevant code/standard a WPS can be
generated from this record of actual values.
PQR is essentially the ‘actual’ method that is used to create and test the welds to ensure they meet
all applicable requirements.
The test procedures and final results are documented in the PQR. If the PQR meets the set
standards of the welding world, then it will serve as the foundation on which one or more WPSs are
drafted.
Even though a PQR eventually leads to a WPS, it is important for welders to have knowledge of
both documents. In critical applications and in mechanised and automatic welds welders can refer
to the PQR and replicate the actual values used in the test weld, this removes all the variation.
On face value, these documents look very similar but serve completely different purposes.
The best way to think of it is;
PQR is an office document
WPS is a workshop document

Both are necessary in most cases. The PQR supports the WPS as evidence of qualification.
 WELDER QUALIFICATION TEST / WELDER PERFORMANCE
QUALIFICATIONS (WQT/WPQ)
• While WPS and PQR are used to define and prove the welding process.
• WQT/WPQ is used to test the actual welder. Is the welder able to produce a sound weld;
• With a particular welding process ie. GMAW or GTAW
• In a given position Horizontal, Vertical or Overhead
• On a particular joint configuration Butt weld or Fillet weld.
•
• A WQT does not test the mechanical properties, it looks at weld soundness only in most cases.
• A Welder Qualification Test is recorded on documentation known as a test certificate that details the ranges that
welder is qualified. Ranges or essential variables for WQT are not always the same as those for a WPS. An example
would be that is a welder can weld in the overhead position (more difficult) it is logical they be qualified in the flat
position (less difficult).
• The welder completes a test coupon under supervision following a WPS. The weld is then tested using the method
prescribed in the relevant standard.
• The testing always includes as a minimum visual examination but may also require;
• Bend tests – root/face or sides
• Macro test – cross section view of weld
• Fillet weld break test
• Nick Break
• Radiographic examination
• Ultrasonic examination
The type and number of tests required are detailed in the relevant standard. The most common
standards are for WQT are;
AS/NZS 1554
AS/NZS 2980
AS NZS ISO 9606
AS/NZS 3992
AWS D1.1
ASME IX
Some of these standards like AS/NZS 2980 and ISO 9606 have an optional knowledge which can be
used to help understand the level of your welders knowledge. Being able to weld and understanding
welding are two different things. Someone that has a proven ability to understand what affects the
outcome will always be a better option.
If you are looking to hire a welder, you can ask about previous WQT before hiring them. Generally
companies pay for the WQT so it remains the companies property not the welders, So welders will
not always have them. Certain standards do not allow the transfer of the qualifications. If you are
looking for some assistance there are a number of providers that can assist with WQT online that
will help you develop your welding management system.
It should be noted that qualification and certification are different things, the differences between
the two will be explained in a different blog.
If the welding world confuses you, hopefully this has gone some way to demystifying it.
The terms may seem overwhelming, but the documents these acronyms represent are extremely
important to the welding industry.
[Link]
 Guide to understanding (WPS), (PQR), (WPQR)
Introduction
Welding requires skill. Determining “how to weld” requires knowledge regarding the materialsbeing welded and welding process, among
numerous other factors. Because of huge numberof variables involved, the knowledge of the welding engineer and the skill of the welder
needto be validated by a series of tests. All this information is documented on Welding ProcedureSpecification (WPS), Procedure Qualification
Record (PQR), Welding ProcedureQualification Record (WPQR), and associated Test Reports.

What is Welding Procedure

Specification (WPS)? A WPS is a document that describes how welding is to be carried out in production. Itspurpose is to aid the planning and
quality control of the welding operation. They arerecommended for all welding operations and most application codes and standards
makethem [Link] is Procedure Qualification Record (PQR)? A PQR is required when it is necessary to demonstrate that
your company has the ability toproduce welds possessing the correct mechanical and metallurgical properties. A welding procedure must be
qualified in accordance with the requirements of an appropriatewelding procedure standard, such as ASME Sec IX, as follows:1. Produce
a welding procedure specification (WPS) as stated above.2. Weld a test piece in accordance with the requirements of your specification. The
jointset up, welding and visual examination of the completed weld should be witnessed bya certified welding inspector such as an AWS
certified CWI or an Inspection [Link] details of the test such as the welding current, pre-heat etc., must be recordedduring the test.3. Once
the welding is complete the test piece must be subject to destructive and nondestructive examination such as radiography and mechanical
tests as defined by thewelding procedure standard. This work must be carried out in a qualified laboratorybut the Inspection Body may
require witnessing the tests and viewing anyradiographs.4. If the test is successful you or the test body completes the appropriate
documentswhich the test body’s surveyor signs and endorses.
 What information should they include?
Sufficient details to enable any competent person to apply the information and produce a weld of acceptable quality. The amount of detail and level of

controls specified on a WPS is dependant on the application and criticality of the joint to be welded. For most applications the information required is

generally similar to that recorded on a Procedure Qualification Record (PQR), except that ranges are usually permitted on thicknesses, diameters, welding

current, materials, joint types etc. If a WPS is used in conjunction with an approved procedure qualification record (PQR) then the ranges stated should be

in accordance with the approval ranges permitted by the PQR. However careful consideration should be given to the ranges specified to ensure they are

achievable, so that these ranges represent good welding practice. What is a Prequalified WPS? Some codes, such as AWS D1.1, allow “Prequalified WPS”,

whereby it is established that the WPS written per code will produce welds with correct mechanical and metallurgical properties. It is not necessary to

prepare a PQR in such cases. However, the pre-qualified WPS have a specified range of parameters under which the weld must be produced. When

welding variables fall outside these ranges, a WPS with supporting PQR must be prepared.

What are SWPSs?

In an effort to standardize and harmonize the process of WPS approvals, AWS started writing “Standard Welding Procedure Specifications (SWPSs)” with

input from the pioneers and experts in the welding industry. An extensive testing program was undertaken whereby; these SWPSs were then supported

by numerous PQRs. When the use of SWPSs is permitted by referencing code section, your company does not

have to perform one or more procedure qualification tests. You can simply purchase the

applicable SWPS for unlimited intra-company use from the American Welding Society

([Link]).
 What is Welder Performance Qualification Record (WPQR)?
Once the procedure is approved it is necessary to demonstrate that all your welders working to it have the required knowledge and skill to put
down a clean sound weld. If the welder has satisfactorily completed the procedure test then he is automatically approved but each additional
welder must be approved by completing an approval test to an appropriate standard such as ASME Sec IX as follows:
1. Complete a weld test as stated above. The test should simulate production conditions and the welding position should be the position that
the production welds are to be made in or one more severe.
2. For maximum positional approval a pipe inclined at 45 degrees (referred to as the 6G position) approves all positions except vertical down.
3. Test the completed weld in accordance with the relevant standard to ensure that the weld is clean and fully fused.
4. For a butt weld this is normally a visual examination followed by radiography or bend tests.
5. Once the test is completed the necessary forms have to be completed by you or the test body and signed by the test body’s surveyor.
6. Note that any changes that require a new welding procedure (WPS) may also apply to the welders approval, refer to the referencing code/
standard for precise details
Acceptance Standards
In general welds must show a neat workman like appearance. The root must be fully fused along the entire length of the weld, the profile of
the cap should blend in smoothly with the parent material and the weld should be significantly free from imperfections. Reference should be
made to the acceptance standard for precise details.
Documentation
The necessary documents for a successful Welding Program are as follows:
1. Welding Procedure Specification (WPS), Procedure Qualification Record (PQR), Independent Laboratory Test Report for the PQR, Welder
Performance Qualification Record (WPQR), and Independent Laboratory Test Report for the WPQR; OR
2. Pre-qualified Welding Procedure Specification (Applicable to some Codes only), Welder Performance Qualification Record (WPQR), and
Independent Laboratory Test Report for the WPQR; OR

3. Code adopted Standard Welding Procedure Specification (SWPS), Welder Performance Qualification Record (WPQR), and Independent
Laboratory Test Report for the WPQR
 PQR/ WPQR Testing
The following tests by Independent Test Laboratory may be required on your PQR and WPQR Coupons:

- Weld Visual Examination by a AWS Certified Welding Inspector

- Bend Test

- Hardness Test

- Transverse Tensile Test

- All Weld Metal Tensile Test

- Charpy Impact Test

- Weld Metal Chemical Analysis

- Macroetch Test

- Torque Test

- Peel Test

- Nick Break Test

- Radiography Test

- Ultrasonic Test

Weld Inspection and Testing

In addition to the above, you may require independent inspection of the welds by the following qualified personnel:

- Visual Inspection by AWS Certified Welding Inspector (CWI)

- Radiographic Testing by Level II personnel certified as per SNT-TC-1A

- Ultrasonic Testing by Level II personnel certified as per SNT-TC-1A

- Magnetic Particle Testing by Level II personnel certified as per SNT-TC-1A

- Penetrant Testing by Level II personnel certified as per SNT-TC-1A

AEIS can perform the above tests at your facility or at our laboratory.

[Link]
The Building Blocks –The Goal
 The Building Blocks –WPS’s

The basic requirement of welding management is having a qualified welding procedure and qualified welders to AS1554 or
AS3992.
When starting a project, it is important to understand what the project requires, or you may get caught out. As a minimum, the
purchase order will specify AS1554 or AS4041 for example. On face value, companies do not always realise what this means.
It can be difficult to navigate them and there is a lot of details to understand. The scope of work or purchase might be less
discrete and specifically ask for certain quality documentation.
Some of the acronyms you need to keep in mind are;
•pWPS
•WPS
•PQR
•WQT or WPQ
If you’re unfamiliar with welding, those jumbles of letters probably look like a confusing bowl of alphabet soup. Here’s the
translation.
•WPS – Welding Procedure Specifications
•PQR – Procedure Qualification Records, and
•WQT / WPQ – Welder Qualification Test / Welder Performance Qualifications.
These all have a different purpose. This blog attempts to demystify welding documentation.
The Building Blocks –PQR Sample Form
The Building Blocks –WPS Sample Form
The Building Blocks –WQ Sample Form
The Building Blocks –WPS’s
The Building Blocks -Part A WPS Qualification
The Building Blocks –Heat Input Qualifications
The Building Blocks –Maximum Heat Input Qualifications
The Building Blocks –Maximum Heat Input Qualifications
The Building Blocks –Maximum Heat Input Qualifications
The Building Blocks –Maximum/Minimum Heat Input
Qualifications
The Building Blocks –Maximum/Minimum Heat Input
Qualifications
The Building Blocks –Production Procedure
Qualifications
The Building Blocks –Procedure Qualifications
The Building Blocks –Test Requirements
The Building Blocks -Part A WPS Qualification
The Building Blocks -Part A WPS Qualification
The Building Blocks -Part A WPS Qualification
The Building Blocks -Part A WPS Qualification
The Building Blocks -Part A WPS Qualification
The Building Blocks -Part A WPS Qualification
The Building Blocks –What about Fillet Welds?
The Building Blocks –I am not smart enough to
remember all that
The Building Blocks –Welder Qualifications Part B
The Building Blocks –Welder Qualifications Part B
The Building Blocks –Welder Qualifications Part B
The Building Blocks –Welder Qualifications Part B
The Building Blocks –Welder Qualifications Part B
The Building Blocks –Welder Qualifications Part B
The Building Blocks –Welder Qualifications Part B
Summary
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