General

guide lines for procedure and

performance qualification
Referenced

by

all

ASME

code

of

construction

Covers welding as well as Brazing

operations

WPS:

It is a written procedure prepared to provide welding

parameters for making welds as per code requirement.
Can be used on production only after successful
qualification of supporting PQR(s).
A WPS can be supported by one or multiple PQR(s).

PQR:

Record of the actual welding data used to weld a test

coupon.
Also contains test results (Mechanical, Chemical & Non
Destructive Test) of the test coupon.

One PQR can support one or multiple WPS(es).

Code of
construction
Detailed
drawing of
weldment
Material
Thickness
Configuration
Process

Contract/Customer/
Code/TPI
Preheat/Postheat/
PWHT
requirements
Skilled welder
Good welding m/c
with accessories
Application

Variables are defined for each process in QW-250

through QW-280

Each variable shall be addressed with facts, e.g.

yes, no, none or any other meaningful definition

 A PQR is a record of welding data used to weld a test coupon

It is a record of actual variables recorded during the welding
of the test coupons
PQR shall document all essential and, when required, all
supplementary essential variables for each welding process
Nonessential variables may be recorded (optional)
All variables are actual values used during welding of the test
coupon
Changes to a PQR are not permitted as it is a record of what
happened during a particular welding test, except for
editorial corrections and addenda

All changes except editorial and those invoked by an

Preheat

PWHT
Joint design
Backing material
P Number
Welding Process
Filler metal

Electrode
Method of back
gauging

Essential
Nonessential
Supplement
al essential

Essential variable:
A change in welding condition which will affect the mechanical
properties other than toughness of weldment
Any change in this variable calls for re-qualification of PQR

Supplementary essential variable:

A Change in welding condition which will affect impact

toughness of weldment
Change in this variable calls for re-qualification of PQR in case
there is requirement of impact toughness for the vessel

Non - essential variable:

No change in mechanical properties is expected

A WPS shall record all essential, supplementary

essential & non essential variables

QW 402: Joints
Non essential variables
Groove design,
Backing,
Root gap,
Retainers

QW 403:
Essential variables

P No,
Thickness of base material qualified,
Thickness of each pass beyond 13 mm for
multipass welding

Supplementary

essential variables

Group no for base material

Minimum thickness of base material qualified

Base Metal P Numbers

P1 - P11
P21 - P25
P31 - P35
P41 - P47
P51 - P53
P61 - P62

Steel
Al alloys
Cu alloys
Ni alloys
Ti alloys
Zr alloys

Base Metal P Numbers

Examples of P nos
P1
P3
P4
P5A
P6
P7
P8
P9A
P10A
P11

C Steel
1/2 Mo steels
1 Cr 1/2 Mo steels
2 1/4 Cr 1 Mo steels
13 Cr steel
17 Cr steel
ASS
2 1/2 Ni steels
Mn - 1/2 Ni - V steels
9 Ni steels

Base Metal for WPS

Test Coupon
qualified
Px - Px
Px - Py
P3 - P3
P4 - P4
P5A - P5A
P3,
P4 - P3, P4 - P1
P5A - P4, P5A - P3}
P5A - P1

Base Metal
Px
Px to Py
P3 - P3, P3 - P1
P4 - P4, P4 - P3, P4 - P1
P5A - P5A, P4 - P4, P4 P4 - P1
P4 - P3, P4 - P1
P5A - P4, P5A - P3
}
P5A - P1

Tensile Specimens
CTOD Specimens

Impact Specimens

Non Destructive Exam

Visual- DPI- MPI- RT- UT

Bend Tests

Fillet Weld Fracture

QW 404:
Essential variables -

F no,
A no,
Thickness of deposited weld metal
Flux / wire class,
Alloy addition through flux (SAW),
Re-crushed slag (SAW)

Supplementary essential variables Electrode Diameter > 6 mm for SMAW

Non essential Variables

Change of Electrode Diameter for SAW

F - NUMBERS

F-Number grouping of electrodes &

welding rods is based essentially on their
usability characteristics to reduce the
number of tests required to qualify
procedures and welders.

A - NUMBERS

Used to describe the weld deposit chemistry

and is applicable only to the ferrous metals
for the qualification of a welding procedure.

F
Number

Description

Heavy Rutile Coated Iron Powder

Electrode

Most Rutile Coated Iron Powder

Electrode

Cellulosic Electrodes

Basic Coated Electrodes

High Alloy austenitic stainless steel &

Duplex Stainless steel Electrodes

Any Steel or coated Wire (with flux or

Metal)

2X

Aluminum & Its Alloys Electrodes

3X

Copper & Its Alloys Electrodes

4X

Nickel & Its Alloys Electrodes

5X

Titanium & Its Alloys Electrodes

F Number

ASME
Specification

AWS
Classification

SFA 5.1

E7018, E7018-1

SFA 5.18, 5.28, 5.29,

5.30

All classification

43

SFA 5.11

ENiCrFe-2,
ENiCrFe-3

43

SFA 5.14

ERNiCr-3

71

SFA 5.13

ECoCr-A, ECoCr-B
ECoCr-C, ECoCr-E

Weld Metal Analysis, % [Single values shown are maximum ]

ANo
.

Types of Weld Deposit

Cr

Mo

Ni

Mn

Si

Mild Steel

0.20

1.60

1.00

Carbon-Molybdenum

0.15

0.50

0.40-0.65

1.60

1.00

Chrome (0.4% to 2%)Molybdenum

0.15

0.40-2.00

0.40-0.65

1.60

1.00

Chrome (2% to 6%)Molybdenum

0.15

2.00-6.00

0.40-1.50

1.60

2.00

Chrome (6% to
10.5%)-Molybdenum

0.15

6.0010.50

0.40-1.50

1.20

2.00

Chrome-Martensitic

0.15

11.0015.00

0.70

2.00

1.00

Chrome-Ferritic

0.15

11.0030.00

1.00

1.00

3.00

Chromium-Nickel

0.15

14.5030.00

4.00

7.5015.00

2.50

1.00

Chromium-Nickel

0.30

19.0030.00

6.00

15.0037.00

2.50

1.00

10

Nickel to 4%

0.15

0.55

0.80-4.00

1.70

1.00

11

ManganeseMolybdenum

0.17

0.25-0.75

0.85

1.25-2.25

1.00

12

Nickel-ChromeMolybdenum

0.15

1.50

0.25-0.80

1.25-2.80

0.75-2.25

1.00

QW 405:
Supplementary essential variables -

Change from any position to vertical uphill progression for

SMAW.

Non essential variables

Change in position.

QW 406:
Essential variables -

Decrease of more than 55C in the preheat temperature

qualified.

Supplementary essential variables -

Increase of more than 55C in the interpass temperature

qualified.

Non essential variables

Change of preheat maintenance

Treatment (DHT) etc.

i.e. Dehydrogenation

QW 407:
Essential variables -

Any change in the following conditions:

No PWHT,
PWHT below lower transformation temperature,
PWHT above upper transformation temperature,
PWHT between upper & lower transformation temperature.

Supplementary essential variables

Increase in job PWHT soaking time beyond 20% of

the soaking time qualified in PQR.

QW 408

Essential variables

Single shielding gas to mixture of gasses,

Different types of mixed gasses,
Percentage composition of gasses for GMAW, FCAW,
GTAW process

Non essential variables

Flow rate,
Backing gas flow rate
Backing gas composition

QW 409:
Supplementary essential variables Increase in heat input ,
Change in current type ( AC / DC),
Change in Polarity (DCEN / DCEP)

Non essential variables

Change in current range,
Change in range of voltage (except SMAW & GTAW)

QW 410:
Supplementary essential variables-

Change in multiple to single pass per side .

Change of Single to multi electrode for SAW

Non essential variables

Change of Stringer bead to Weave bead technique or

vice versa,
Method of cleaning,
Method of back gouging,

Purpose

To validate the capability of an welder to deposit sound

weld metal following a qualified welding Procedure
Establish the range of qualification to minimize the
number of qualification
Guide line for renewal of qualification

Welder

Person performing welding by manipulating arc by hand

Welding Operator

Person performing welding by controlling the manipulation

A change in welding condition which will affect

the ability of welder to deposit sound weld metal
Any change in this variable calls for requalification
Essential Variables
Change in welding Process
Change from direct to remote visual control
Deletion of Auto joint tracking
Addition of welding position not qualified
Deletion of consumable inserts
Deletion of backing
Single pass per side to multi pass per side

OD of Test coupon,mm

Minimum OD Qualified, mm

Less than 25 mm

Size welded

25 to 73,mm

25 mm

Over 73 mm

73 mm

Welding Performance Qualification

Test coupon More than 2 welders different procedure can do a single test
coupon. Failure then both are failed.

Retest - 2 consecutive test coupons to pass

1.
2.
3.
4.
5.
6.
7.

Renewal if no welding for 6 months. Single test coupon plate/pipe, any thickness,
material, position. If passed then complete previous qualification is restored.

Welding Performance Qualification

Variables for SMAW
Removal of backing
Change in Pipe diameter
Change in P number
Change in F Number
Change in thickness of weld deposit
Change in welding position

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Variables for GTAW

Removal of backing
Change in Pipe diameter
Addition / deletion of filler metal
Addition / deletion of insert
Change in P number
Change in F Number
Change in solid filler to flux cored filler metal
Change in thickness of weld deposit
Change in welding position
Removal of inert gas backing
Change in current or polarity

Radiography

No crack or LOP or LOF

Any elongated slag
1/3 t for t = 3/8 - 2 1/4

>1/8 for t <3/8

3/4 for t > 2 1/4

Any group of slag in a line with aggregate length t in

12 t
unless separated by 6L

Max permissible dimension for rounded indication

smaller of 20% of t or 1/8
For thickness<1/8, max no of accepted rounded
indication
12 in 6 length
For thickness>1/8,
charts for max acceptable types of rounded indication

PLATE QUALIFICATION

Visual examination
Radiography
2 no of Tensile test
2 no each of Bend test - face and root bend
( 3t for both C steel and alloy steel 180 deg
bend)
1 no Micro examination
1 no Macro examination
PIPE QUALIFICATION
Visual examination
Macro examination
2 no each of Bend test - face and root bend ( 3t for C
steel and 4t for alloy steel 90 deg bend)

PLATE QUALIFICATION
Radiography
1 no each of Bend test - face and root bend

PIPE QUALIFICATION
1 no each of bend test - face and root bend
Macro examination