Welding Procedure Specification - WPS

D.SELVAKUMARAN
SSE/AWTI/ICF
DEFINITIONS
 Welding procedure specification
WPS - provides the required variables/parameters of
the welding
 qualified document (based on tested sample)
To be made before regular production
 to ensure repeatability during production
welding.

Welding Procedure Qualification Record

WPQR - a record of data as noted during welding test
PQR relates to single test sample
Document which qualifies WPS
Range of qualification
Purpose of WPS
To demonstrate that welding is capable of producing
joints having the required mechanical properties
To ensure quality & safety of welded construction.
To give guidance to welders / engineers in production
to choose the parameters
current, voltage, consumable, joint design, welding
conditions etc
So, to be displayed in shops
Reference documents for inspectors to check the
parameters
Variables in welding
welding process
The parent material group
product type (plate or pipe)
material thickness / outside pipe diameter)
type of joint & type of weld
filler material group (based on metal composition or flux)
filler material type (solid wire/strip/tubular)
welding position
Pre heating / post heating
current, volt, travel speed, Wire speed, gas, gas flow, Polarity
weld detail(s) (weaving/stringer, material backing, gas backing, flux
backing, consumable insert, single side welding, both side welding, single
layer, multi-layer, leftward welding, rightward welding)
Welding procedure specification

COMPLIANCE TO EN 15085 &/or ISO 3834

WPS AS PER ISO 15609 (Part – 1 to 5 )

PQR AS PER ISO 15614 (Part – 1 to 13 )

International standards classification
WPS Standards
ISO 15607: general rule for specification and qualification.
Reference to other standards
ISO 15609 : specifies requirements for the content of
welding procedure specifications for arc welding processes
ISO 15614 : - how a preliminary welding procedure
specification is qualified
- conditions for the execution of welding procedure
tests
- the range of qualification for welding
procedures
Standards / codes
Arc welding of steels
TYPE WPS PQR

Indian standard
IS: 7307-1 / 74

American standard
ASME BPVC Sec - IX

AWS standard AWS D1.1

European / EN ISO 15607, EN ISO EN 1SO 15614 -1
International std 15609-1
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs

Prepare a WPS
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs

Prepare a WPS
List of Joints & WPS

Sl. Joint Material 1 Material 2 Joint Position Process, Approved

no description Butt consumable WPS
in the / spec., gas Reference
sidewall/ fillet

thickness
thickness
roof

spec
spec
List of Joints & WPS
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs

Prepare a WPS
Pre-WPS (pWPS)
Based on experience
Literature
Based on WPS developed elsewhere
Trial and error
Not qualified document
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs

Prepare a WPS
ISO 15614 - 2017
Two levels of welding procedure tests are designated by
levels 1 and 2.
Level 1 - ASME Section IX and
level 2 is based on the previous issues of this document.
In level 2, the extent of testing is greater and the ranges
of qualification are more restrictive than in level 1.
Procedure tests carried out to level 2 automatically
qualify for level 1 requirements, but not vice-versa.
When no level is specified in a contract or application
standard, all the requirements of level 2 apply.
Welding procedure test - Preparation of welding samples

150 150

150
350

350

150

To be witnessed by welding coordinator

Record parameters voltage, current, wire feed, time taken
Record of weld test
Record of weld test
Job sheet
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs
Documentation

Prepare a WPS
EXAMINATION & TESTING
Test piece Type of test Extent of test Methods
Visual Examination 100% ISO 17637
RT or UT 100% ISO 17636 / 17640
Surface crack detection 100% ISO 3452-1 / 17638
Butt joint with full
Transverse tensile test 2 Specimens ISO 4136
penetration Transverse Bend test 4 Specimens ISO 5173
Impact test 2 sets ISO 9016
Hardness test required ISO 9015-1
Macroscopic Examination 1 specimen ISO 17639

Tee joint with full Visual Examination 100% Refer above

penetration Surface crack detection 100%
& RT or UT 100%
Hardness test required
Branch joint with
Macroscopic Examination 2 specimens
full penetration
Visual Examination 100% Refer above
Fillet welds Surface crack detection 100%
Hardness test required
Macroscopic Examination 2 specimens

Note: An application std. may specify additional tests.

LOCATION OF TEST SPECIMENS
LOCATION OF TEST SPECIMENS
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs
Documentation

Prepare a WPS
 Documentation
Designation/nomenclature of variables
Material Spec– ISO/TR 15608
Process – ISO 4063
Position – ISO 6947
Gas – ISO 14175
Electrodes – ISO XXXX (or AWS)
Range of Qualification rules
Material Spec
BM thickness
Throat
Welding position
Designation/nomenclature of variables
Material – ISO/TR 15608
Process – ISO 4063
Position – ISO 6947
Gas – ISO 14175
Electrodes – ISO XXXX (or AWS)
 Documentation

Parent Material groups as per ISO 15608

(Group 1 – 11)
Steel (Group 1 – 11)
Group 1:
Steels with C _ 0.25, Si _ 0.60, Mn _ 1.8, etc. with yield strength specified as
below:
Gr 1.1: y.s _ 275 N / mm2
Gr 1.2: 275 N / mm2 _ y.s _ 360 N / mm2
Gr 1.3: Normalised Steels with y.s > 360 N / mm2
Gr 1.4: Steels with improved atmospheric corrosion resistance, with analysis
which may exceed the above specification..
Group 7.1: Ferritic Stainless Steels – SS 409M
Group 8.1: Austenic Stainless Steels, Ni _ 31 % - AISI301, 304  
ISO/TR 15608
Austenitic stainless steels, Ni ≤ 35 %
8 8.1 Austenitic stainless steels with Cr ≤ 19 %
8.2 Austenitic stainless steels with Cr > 19 %
Documentation
Various processes as per ISO 4063
 1 Arc welding
 11 Metal arc welding without gas Protection
 111 Manual metal arc welding (metal arc welding with covered electrode)
 114 Self-shielded tubular cored arc welding
  
  121 - SAW
 13 Gas-shielded metal arc welding (Gas metal arc welding, USA)
 131 MIG welding with solid wire electrode
 135 MAG welding with solid wire electrode
 136 FCAW
  
 14 Gas-shielded arc welding with non-consumable tungsten electrode
 141 TIG welding with solid filler material (wire/rod) Gas tungsten arc welding using
inert gas and solid filler material (wire/rod), USA
 2 Resistance welding
 212 Direct spot welding

 522 Laser welding / Laser beam welding, USA

Documentation

Welding positions -
ISO 6947
Documentation
Shielding gases – ISO 14175
Documentation
Shielding gases – ISO 14175
Documentation
Shielding gases – ISO 14175
Documentation
Shielding gases – ISO 14175
Example
For Argo shield (ACM – Ar 80% + CO 220%)

Designation : ISO 14175 – M21-ArC-20

 Designation/nomenclature of variables - Summary
Material ISO 15608 1.1 - MS
1.4 - Corten
7.1 - SS 409M
8.1 - AISI 301, 304
Process 111 – MMAW
131 – MIG
135 – CO2, Argo shield
136 – FCAW
141 - TIG
212 – Direct Spot welding
211 – Indirect Spot welding
522 – LBW (CO2)

Positions PA, PB, PC, PD, PE, PF, PG etc

Gas CO2 – C1
Ar – I1
ACM - M21-ArC-20
Range of qualification
Range of qualification
Range of qualification

Given in ISO 15614

In order to minimize the number of welding
procedure tests
Changes outside of the ranges specified shall
require a new welding procedure test
Range of qualification

Material Spec
BM thickness
Throat
Welding position
Range of qualification
Parent Material groups as per ISO 15608– as specified in sub
groups of table 3 & 4 of ISO 15614-1.

Steel (Group 1 – 11)

Group 1:
Steels with C _ 0.25, Si _ 0.60, Mn _ 1.8, etc. with yield strength specified as below:
Gr 1.1: y.s _ 275 N / mm2
Gr 1.2: 275 N / mm2 _ y.s _ 360 N / mm2
Gr 1.3: Normalised Steels with y.s > 360 N / mm2
Gr 1.4: Steels with improved atmospheric corrosion resistance, with analysis
which may exceed the above specification.
 
Group 2: Thermo mechanically treated fine grain steels and cast steels
2.1: 360 N / mm2 < y.s. _ 460 N / mm2
2.2: y.s. > 460 N / mm2
 
Group 3: Quenched and Precipitation hardened fine grain steels (except stainless
steels)
RANGE OF QUALIFICATION -
Thickness
Fillet welds (mm)
Thickness of Range of qualification
test piece material thickness Throat thickness
“t” Single run Multi-run

t≤3 0.7 t to 2 t 0.75a to 1.5a No restriction

3 < t < 30 0.5 t (3 min.) to 2 t 0.75a to 1.5a No restriction
t ≥30 ≥5 ** No restriction
a is the throat as used for the test piece
** for special applications only. Each throat thickness has to be proofed separately by a
welding procedure test.
Diameter of the test Range of qualification
piece D *, mm
D ≤ 25 0.5D to 2D
D > 25 ≥ 0.5D (25 mm min)
NOTE: For structural hollow section D is the dimension of the smaller side.
*
D is the outside diameter of the pipe or outside diameter of the branch pipe.
Range of qualification

Material Thickness

For butt welds (mm)

Thickness of test Range of qualification
piece “t” Single run Multi run

t≤3 0.5t to 2t
3 < t ≤ 12 0.5t (3 min.) to 1.3t a 3 to 2ta
12 < t ≤ 100 0.5t to 1.1t 0.5t to 2t
t > 100 Not applicable 50 to 2t
a
when impact requirements are specified the upper limit of
qualification is 12 mm unless impact testing has been performed.
Range of qualification
Welding processes:
valid for only the one used in test
For level 1: The degree of mechanization is not an
essential variable.
For level 2: Each degree of mechanization shall be
qualified independently (manual, partly mechanized,
fully mechanized and automatic).
 When the test piece is welded with more than one
welding process, the procedure is valid only for the
sequence of processes used on the test piece.
Range of qualification
Welding positions: Welding in any one position
qualifies for all positions except for PG & J-L045 (if
impact & hardness properties are required)
—for impact test : highest heat input position: PF & PA
—hardness test : lowest heat input position: PC and PE
To satisfy both hardness and impact requirements,
two test pieces in different welding positions are
required unless a single position qualification is
required
Range of qualification
Filler Material: qualifies other Filler materials
having same mechanical properties, same type of
covering, same nominal composition.
Change in Filler material size is permitted when
heat input is not varied
Current : Qualification is given for the type of
current & polarity used in the test. (For MMAW ,
AC qualifies DC (both polarities) when impact test
is not required)
Range of qualification
Type of Joint:
 Butt welds qualify full and partial penetration butt welds and fillet
welds.
 Fillet welding qualifies fillet welding only.
 T joints butt welded only qualify T joints butt welded and fillet welds
 Welds made from one side without backing qualify welds made
from both sides and welds with backing;
 Welds made with backing qualify welds made from both sides;
 It is not permitted to change a multi-run deposit into a single run (or
single run on each side) or vice versa for a given process.
Range of qualification
Heat Input:

k-factor according to ISO/TR 17671-1

 K factor = 1 for SAW
= 0.8 for MMAW, GMAW, FCAW
= 0.6 for TIG

For Impact requirement : upper limit + 25 % allowed

For Hardness requirement : lower limit - 25 % allowed

If welding procedure test has been performed at both a high and a low
heat input level, then all intermediate heat input levels are also qualified.
Range of qualification
Preheat temp: A decrease of upto 50 °C allowed
Interpass temp: An increase of more upto 50 °C allowed
Post heating for Hydrogen release:
Temperature and duration for PH shall not be reduced. PH cannot
be omitted, but can be added.
 Post-weld heat-treatment - PWHT: Addition or deletion of PWHT
not permitted.
 summary
Designation/nomenclature of variables
Material Spec– ISO/TR 15608
Process – ISO 4063
Position – ISO 6947
Gas – ISO 14175
Electrodes – ISO XXXX (or AWS)
Range of Qualification rules
Material Spec
BM thickness
Throat
Welding position
Procedure Qualification Record - PQR
Welding Procedure Qualification Record form (WPQR) 
Welding procedure qualification - Test certificate
 
Manufacturer’s WPQR No.: Examiner or examining body
 Manufacturer : Reference No. :
 Address :
 Code/Testing Standard :
 Date of Welding :
 Range of qualification
 Welding Process(es) :
 Type of joint and weld:
 Parent material group(s) and sub group(s):
 Parent Material Thickness (mm) :
 Weld Metal Thickness (mm) :
 Throat Thickness (mm)
 Single run/Multi run:
 Outside Pipe Diameter (mm) :
 Filler Material Designation:
 Filler Material Make:
 Filler Material Size
 Designation of Shielding Gas/Flux :
 Designation of Backing Gas:
 Type of Welding Current and Polarity:
 Mode of Metal Transfer:
 Heat Input:
 Welding Positions :
 Preheat Temperature:
 Interpass Temperature:
 Post-Heating :
 Post-Weld Heat-Treatment:
 Other Information (see also 8.5) :
 Certified that test welds prepared, welded and tested satisfactorily in
accordance with the requirements of the code/testing standard indicated
above.
  ......................................................................................................................
 
Location Date of issue Examiner or examining body 
STAGES IN WPS PREPARATION
Drawing > List of joints > List the variables

Development of a pWPS

Complete welding samples &

Welding procedure test
record of weld test (parameters)

Evaluation

Complete a PQRs
Documentation

Prepare a WPS
 T
RW
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p les
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Sa

PS
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WPS consists of
PQR (tow or more better)
Record of weld test
Lab reports
Radiographs, macro etch photos etc
Exercise welding position

Sample 1 (PQR No. 530

Joint Welding Gas Size of Electrode Current Voltage (V) Type of Wire feed time
Process (Dia) & (A) current / speed taken
Specification polarity (m/min) sec
IRS M41 GMAW CO2 1.2 mm dia 120 - 135 22.9 – 23.2 DCEP 4.2 85
6+6 mm (135) 15 lpm ER S70 S 6 as per
AWS A5.18
PQR
Welding Process
Observed :
GMAW (Process 135 as per ISO 4063)
Range qualified:
GMAW (Process 135 as per ISO 4063)
PQR
Type of joint and type of weld
Observed :
T joint ; Filllet weld
Range qualified:
T joint ; Filllet weld
PQR
Parent Material
Observed :
1.4 as per ISO/TR 15608 (IRS M41)
Range qualified:
1.1 - 1.4 as per ISO/TR 15608 (IRS M41) upto given
yield strength 340 MPa
PQR
Parent material Thickness
Observed :
6 mm
Range qualified:
3 – 12 mm (3 – 2t)
PQR
Weld metal thickness
Observed :
N.A.
Range qualified:
N.A.
PQR
Weld Throat
Observed :
4.2 mm
Range qualified:
3 – 8.4 mm (0.7a to 1.5a)
PQR
Single run / Multi run
Observed :
Multi run
Range qualified:
Multi run
PQR
Pipe Dia
Observed :
N.A.
Range qualified:
N.A
PQR
Electrode Designation
Observed :
ER 70 S6 as per AWS A5.18
Range qualified:
ER 70 S6 as per AWS A5.18
PQR
Electrode Size
Observed :
1.2 mm
Range qualified:
1.2 mm (or others if heat input is maintained)
PQR
Filler material Designation & Filler Material size
Observed :
N.A.
Range qualified:
N.A.
PQR
Designation of Shielding gas
Observed :
C1 as per ISO 14175
Range qualified:
C1 as per ISO 14175
PQR
Designation of Backing gas
Observed :
N.A.
Range qualified:
N.A.
PQR
Current & Polarity
Observed :
DCEP
Range qualified:
DCEP
PQR
Mode of metal Transfer
Observed :
Dip transfer
Range qualified:
Dip Transfer (short circuiting transfer qualifies only
short circuiting transfer. )
PQR
Heat Input
Observed :
Q = k VI/S = 0.8 X 22.9 X 120/300/85 = 0.622 KJ/mm
Q = k VI/S = 0.8 X 23.2 X 135/300/85 = 0.719 KJ/mm
Range qualified:
Lower limit -25% = 0.75 X 0.622 =0.467 KJ/mm
Uper limit + 25% = 1.25 X 0.719 = 1.027 KJ/mm
0.467 – 1.027 KJ/mm
PQR
Welding position
Observed :
PB as per ISO 6947
Range qualified:
PB, PA as per ISO 6947 (when impact and Hardness
requirement is not given)
PQR
Preheat temperature.
Interpass temperature
Post heating
Post weld heat treatment

Observed :
N.A.
Range qualified:
N.A.