How to Prepare a WPQR: Step-by-Step Welding Procedure Qualification Guide

Step 1: Set Up the Right Standard

Before you start the qualification test, you need to decide which standard applies to your welding work.

There are several standards that can be used depending on the application, such as:

– EN ISO 15614-1 – Record for welding procedure qualification
– EN ISO 15609 – Standards for welding procedures
– EN ISO 3834 – Quality standards for fusion welding
– EN ISO 9606 – Testing welders
– EN 15085 – Welding for railway vehicles
– EN 1090 – Execution of steel and aluminum parts
– ISO 9712 – Training and certification for non-destructive testing (NDT) personnel
– PED (2014/68/EU) – Pressure equipment directive
– SPVD (2014/29/EU) – Simple pressure vessels directive

At this stage, you should also set up the material specifications, drawings, joint design, client requirements, and acceptance criteria.

Step 2: Create the pWPS

A preliminary Welding Procedure Specification (pWPS) is a plan for the welding parameters you will use during the qualification test.

The pWPS usually includes these details:

– The welding process used
– The type of base metal and its group
– The thickness of the material
– The type of joint
– The welding position
– The welding consumable and its size
– Preheat and interpass temperatures
– Welding current and voltage
– Welding speed
– Shielding gas used
– Number of weld passes or layers
– Welding method
– Heat input (if needed)

You should then weld the test coupons according to this pWPS.

Step 3: Pick the Right Test Coupon

You need to choose the test coupon based on the welding range you want to qualify.

Important factors to consider include:

– The parent material
– The material group
– The material thickness
– The type of joint
– Pipe diameter (if used)
– Welding position
– Welding process
– Consumables used

It is very important to track the material being tested back to its material certificate.
The identification of this material should be clear and traceable throughout the entire qualification process.

Step 4: Do the Welding Qualification Test

While performing the welding test, you need to record the actual welding parameters used.
These values should be clearly shown in the final WPQR.

Common values to record include:

– The welding process
– Welding current and voltage
– Welding speed
– Welding position
– Preheat and interpass temperatures
– The type of consumable used
– Diameter of electrode or wire
– Shielding gas
– Number of passes or runs
– Welding technique
– Heat input (if applicable)

Step 5: Do Visual and Non-Destructive Tests

After the welding test is complete, you need to check the test coupon according to the required standards.

Depending on the qualification needs and the setup, the tests might include any of the following:

– Visual Testing (VT)
– Radiographic Testing (RT)
– Ultrasonic Testing (UT)
– Magnetic Particle Testing (MT)
– Penetrant Testing (PT)

You need to make sure that the test results meet the required acceptance criteria before proceeding with the qualification.

Step 6: Carry Out Mechanical Testing

For mechanical testing, you will take samples from the qualified test coupon.

Depending on the qualification requirements, the tests may include:

– Tensile testing
– Bend testing
– Impact testing
– Hardness testing
– Macro examination

All laboratory reports should clearly show which test coupon they are related to and have good traceability to the WPQR.

Step 7: Evaluate the Test Results

The results from the non-destructive and mechanical tests need to be reviewed based on the welding qualification standard.

You need to check if the weld meets the required acceptance criteria.
If the results don’t match the criteria, the qualification is considered not acceptable.

Step 8: Define the Qualification Range

Setting the qualification range is a key part of preparing the WPQR.

Depending on the actual test conditions and the relevant standard, the qualification range may include any or all of the following:

– Material group
– Material thickness
– Pipe diameter
– Welding process
– Welding position
– Joint type
– Consumables used
– Shielding gas
– Heat input
– Preheat and interpass conditions

The qualification range must be based on the actual test conditions and the relevant standard.
You cannot make assumptions or extend the range beyond what was tested.

Step 9: Make the WPQR

The final Welding Procedure Qualification Record (WPQR) should include all the actual welding parameters, details about the test coupon, results from the tests, the standard used, and the qualification range.

It is important to track all the steps in the following way:

Material Certificate → pWPS → Welding Test → Welding Parameters → NDT Reports → Mechanical Test Reports → WPQR → WPS

All the information in these documents should match.
If there are any differences between the pWPS, welding data, test reports, and the WPQR, those differences need to be carefully reviewed.