WELDING PROCEDURES

What is a Welding Procedure?

A welding procedure details all significant items that must be considered when j
oining two pieces of metal by welding. The procedure may be one document or may
be composed of several separate documents which, combined, make up the total. we
lding procedure.
Welding procedures have limits or ranges of variable items, such as kind of weld
ing current, thickness of base metal, type of base metal, etc. A welding procedu
re is valid only for use within the limits specified on the procedure. If a proc
edure cannot produce an acceptable weld without being applied outside of the spe
cified variable ranges, then a new welding procedure must be found to take its p
lace. Under most qualification standards, welding procedures must not only be a
documentation of the methods and technology required to achieve satisfactory res
ults, but must also be "qualified," which means qualified by test.

What is a Qualified Welding Procedure?

The requirements for welding procedure qualification vary widely from code to co
de. Welding procedure qualification is the method whereby a particular procedure
is proved adequate to produce satisfactory welded joints when a welder or opera
tor produces a sound weld. To be proved adequate, a test weldment must be evalua
ted with tests and acceptance criteria that are predetermined by the qualificati
on standard being used. When procedures are qualified, a record of qualification
, which includes all pertinent data related to how the joint was welded, is requ
ired. This document is called a Procedure Qualification Record (PQR).
Why qualify a welding Procedure?
Most products are designed of materials that have known material properties. Whe
n these materials are to be joined by welding, the designer must know what the p
roperties of the welded joint will be. Because of the effects of welding heat, i
t is not sufficient to know only the properties of unjoined base metal and weld
metal. We must also know the properties of the complete welded joint base metal,
base metal heat-affected zone, and weld metal.
Once these properties are proven, the designer has an engineering basis for expe
cting a particular welded joint to behave in a certain way and he can design acc
ordingly. This is why welding procedures are qualified.
In some cases, prequalified procedures are allowed. These are welding procedures
for applications where long usage and familiarity with certain steels and weldi
ng materials have proven the adequacy of specific procedures based on service ov
er a long period of time.

How is a Procedure Qualified?

The need to perform welding in production work precedes the development of an ac
tual welding procedure. Once the need is identified and judgments are made as to

the most suitable welding processes, the actual work of qualifying a procedure
can begin.
Any weldment must be made with some form of welding procedure. This is also true
of procedure qualification test weldments. So, the first thing to be done is to
provide a preliminary welding procedure specification that directs how the join
t is to be welded. This normally represents engineering and practical judgments
as to the welding conditions most likely to produce an acceptable test weldment.
If the welding conditions specified in the preliminary procedure are within the
scope of a prequalified welding procedure, production welding may be performed w
ithout having to "prove" the welding procedure by actual testing, provided the u
se of prequalified procedures is allowed by the governing document (qualificatio
n code or standard).
Where the use of prequalified procedures is not permitted (or for instances wher
e no prequalified procedure fits the production requirement), the preliminary we
lding procedure specification must be proved adequate through testing and evalua
ting a test weldment to the requirements in the qualification specification or s
tandard being used.
If a procedure qualification test weldment passes all required tests and examina
tions, the welding conditions, test data, and test results are documented on a P
rocedure Qualification Record (PQR). The qualification record and the informatio
n on the procedure specification used to qualify the procedure then forms the ba
sis for issuing a Welding Procedure Specification (WPS).
The Welding Procedure Specification
The document(s) that tells a welder or welding operator how to weld a joint is c
alled the Welding Procedure Specification (WPS). It tells the welder what filler
metal to use with a particular base metal, the range of welding machine setting
s that are required, the types of weld end preparations that are applicable, etc
. In other words, a welder should be able to reference a WPS, and it should cont
ain all the information he needs to weld a specific type joint.
Table 7-1 illustrates the number and type of specimens to be removed from proce
dure qualification test weldments. This table is based on requirements of three
common qualification standards and is intended to illustrate the importance of
assuring that the specified requirement is the one followed in qualifying a
test weldment. Procedure qualification for one code will not normally qualify fo
r another code*

Welding Variables
Variables are welding conditions that, if changed, will have an effect on the ac
tual welding. For shielded metal arc welding, a change from a rectifier power so
urce to a gas generator would not normally have any effect on the likelihood of
producing a satisfactory weld and is thus not considered a variable for SMAW wel
ding. It might, however, be a variable for other welding processes.
Some qualification specifications assign all variables the same importance. Othe
rs assign different levels of importance (essential variables or nonessential va
riables) and even use 1variable" to address a specific application such as notch
-toughness properties (essentials for toughness).
Each qualification standard identifies specific variables applicable to the vari
ous welding processes. A common quality control function is to review welding pr
ocedures to assure that the variable ranges allowed in a WPS have been qualified
by procedure testing. Variables and the changes or ranges allowed for them are

key items in performing checks to determine if welding procedure specifications

are being properly applied to production work.

Variables thus become an important area of interest for an inspector. A qualifie

d welding procedure specification has specific variables and variable ranges tha
t will result in an acceptable weld if the welder has sufficient skill to produc
e a sound weld. A change beyond the limits or range shown in a procedure may aff
ect the properties of the weldment even if the welder produces a sound weld.
Awareness of the variables, and an understanding of why they exist, will keep th
e inspector alert to potential changes in production welding that could require
a new welding procedure specification and possibly a completely new procedure qu
alification test.

Who is Responsible for Procedures?

The qualification and utilization of welding procedures is the responsibility of
the company performing the production work. Various individuals have specific r
esponsibilities as listed below:
(1)
Company welding engineer, writes preliminary WPS
(2)
Company welder, welds test weldment
(3)
Laboratory, tests procedure specimens
(4)
Company welding engineer, evaluates and certifies PQR and WPS
(5)
Company welder, welds production workpieces
(6)
Inspector, checks welding to assure that it is being done in accordance
with the WPS
In general, the welding inspector has very limited responsibilities in the actu
al preparation and approval of welding procedures. He is responsible for assur
ing that the correct welding procedures are available and being used for product
ion work.
It is important that the inspector make himself aware of any supplementary requi
rements, such as are specified for impact tested materials, and assures that onl
y procedures that are intended for this use are applied in production.
What is Performance Qualification?
The requirements for welding and welding operator qualification vary widely from
code to code. Before a welder or welding operator does any production work, his
employer needs some idea of the welder's ability. Finding out that a man is not
capable after he has been hired, or ruined production pieces, or welded on piec
es where inspection might not find substandard welds is neither economical nor r
esponsible.
To assist employers in determining what level of competence they can reasonably
expect a welder to maintain when working on production weldments, various tests
have been developed to prove a welder or welding operator's skill. These tests a
re called performance qualification tests. The qualification of welders demonstr
ates their ability to produce acceptable welds in accordance with a welding proc
edure specification. The qualification of welding operators demonstrates their a
bility to operate welding equipment in accordance with a welding procedure speci
fication.

How Do You Qualify Welders?

Regardless of the code or standard being used, all performance tests require the
welder or welding operator to make a sample weld which we will call a performan
ce test weldment. During the welding of this test weldment, the welder or weldin
g operator is watched by an inspector to assure that he follows the applicable r
ules for testing.
Performance qualification welding is done in accordance with a WPS. Once complet
ed, the test weldment is examined and tested to determine if it meets the accept
ance criteria for performance qualification. These acceptance criteria are prede
termined by the qualification code or standard being used.
The type of test, test material, examination, and acceptance standards are dicta
ted for the production work to be performed (i.e., if ASME pipe is to be welded,
the qualification standard will be Section IX of the ASME code, and it will spe
cify all requirements for the test).
The location, number, and type of required tests or examinations will be specifi
cally stated in the qualification standard. Table 7-2 illustrates some of the co
mmon requirements specified for evaluating performance qualification test weldme
nts.
What is Qualification Maintenance?
After a welder or operator passes a test and is qualified to weld in production,
his qualification remains valid for as long as he works for the same employer,
using the welding process for which he is qualified. However, just because a man
passes a test this year does not mean he can weld just as well at some later da
te unless he has "kept his hand in."
Qualification maintenance means keeping track of a welder to be sure that he use
s the process or processes for which he has been qualified. If he does not engag
e in welding during specified time limits, then he is required to take another t
est. The exact requirements for maintaining a qualification are different betwee
n qualification standards, so the inspector has to be aware of what is called fo
r by the standard he is working to.
The method used to document qualification maintenance is usually not specified,
so the inspector must evaluate the particular system being used to determine its
accuracy.

How is Performance Qualification Documented?

Each qualification standard contains suggested forms for use in documenting a we
lder or welding operator's performance qualification. These forms all have in co
mmon a listing of the conditions, the variables, and the WPS used to qualify the
welder. It is the duty of a welding inspector to verify the required documentat
ion and that the test conditions and statements on the form are correct and in a
ccordance with the applicable qualification standard. Performance documentation
is available to an inspector for all welders performing production work. If they
are not available, the inspector should ask for them to assure that proper docu
mentation or proof of qualification exists.

Are There Restrictions on Qualifications?

For the purpose of qualification, a performance variable is a condition of weldi
ng that, if changed, will require a requalification of the welder or operator.
A particular test weldment may qualify the welder or welding operator for other

materials, combinations of materials, welding positions, and weld types. Each qu

alification standard has its own requirements that limit or broaden the scope of
an individual qualification. A primary function of the welding inspector is to
be familiar with limitations on qualification tests to assure that specified req
uirements are met, and also to assist the manufacturer in avoiding duplicate tes
ting or other unnecessary expense related to qualifications.
A welder or welding operator must be qualified prior to any production work, exc
ept that qualification on production weldments is permitted in specific cases by
some qualification standards.
An employer may withdraw a welder's qualification at any time it becomes apparen
t that the welder (or operator) is not producing sound welds. This is normally o
ne of the inspector's duties and must be exercised with the understanding that e
ven the best welders can have rejectable defects in their welds. The inspector m
ust therefore exercise judgment.
Who is Responsible for Performance Qualification?
The employer is responsible for assuring that his welders and welding operators
are qualified. The welding inspector has the direct responsibility for verifying
qualification for the employer.
Thus, a welding inspector's responsibility related to performance qualification
normally covers all of the steps required to test welders or welding operators.
He may be responsible for the following:
Assuring that the correct materials used are in accordance with the
ocedure Specification used for the test

Welding Pr

Supervising the actual welding of the test weldment

Evaluating the ability of the person being tested at each step of the test.
Assuring that requirements related to welding position are strictly adhered to.
Assuring that the test weldment and specimens are identified and traceable to th
e welder or welding operator being tested.
Where test specimens are removed for destructive testing, selecting the location
s in accordance with the code or standard governing the test.
Evaluating test specimens (or radiographs) for conformance to the acceptance cri
teria specified in the code or standard governing the test
Accepting or rejecting the test
Documenting the results of the test, and if the test is acceptable, signing the
test record signifying completion of an acceptable test
In some cases, an inspector's sole function is quality assurance, wherein his re
sponsibility is to check all welder qualification documentation to assure that o
nly qualified welders are performing production work.
Qualification Requirements
Table 7-3 shows the more common codes, standards, and specifications and the req
uirements specified for welding qualification. In addition, there are numerous s
pecifications unique to government and industry that require qualification to th

eir own requirements.

Table 7-3
Qualification requirements
Specified qualific
ation requirements
End product, code/standard
rencing document)

(may be modified by refe

ASME
Section I - Power Boilers
ASME Section IX
Section III - Nuclear Components
ASME Section IX
Section VIII - Pressure Vessels ASME Section IX
ASME
B3 1.1 - Power Piping ASME Section IX
B31.3 - Refinery/Chemical Piping
ASME Section IX
B31.4 - Liquid Petroleum Transportation Piping API-1 104 or ASME Sectio
n IX
B31.8 - Gas Transmission Distribution Piping
ppendix A of B31.8API

APIA 104 or ASME IX or A

AWS
D 1. 1 - Structural Code-Steel Contained in D 1. 1
D1.3 - Sheet Steel in Structures
Contained in D1.3
DIA Structural Code- Reinforcing Steel
Contained in DIA
D3.5 - Steel Hull Welding
U.S. Navy/U.S. Coast Guard/Bureau of Shi
ps Specifications
D14.1 - Industrial and Mill Cranes
Contained in D14.1 or may use AS
ME Section IX
D14.3 - Heavy Equipment Contained in D 14.3 except use AWS D 10. 9 for P
ipe/Tube
D14.4 - Machinery Equipment
Contained in D14.4

RESPONSIBILITIES
The Employer
The responsibility for meeting qualification requirements belongs to the manufac
turer who produces production weldments. This responsibility is both legal and p
ractical. If an employer does not use qualified welders or procedures, or both,
he may be in violation of his legal responsibility to meet either contract or go
vernment requirements, or both.
From a practical standpoint, the expense of producing goods today is so high tha
t most manufacturers see the value of qualifications in lowering their rate of r

ejected products and the cost of producing those products. Properly engineered w
elding procedures and workmen whose skills are proven can combine to produce ade
quate welded joint properties at a minimum cost. Poor welding always costs money
The Design Engineer
The design engineer is responsible for specifying the properties and performance
expected from a welded joint.
The Welding Engineer
Welding engineers have responsibility for originating, evaluating, and qualifyin
g welding procedures. They are also responsible for specifying where a particula
r WPS is to be used on production weldments.
The Welding Inspector
It is the responsibility of the welding inspector to assure that all activities
related to welding qualification are documented to the extent required by the pa
rticular code, standard, or contract document he is working under. Some of the i
tems commonly required to be documented are:
(1)
(2)
(3)

Procedure Qualificiation Records (PQR)

Performance Qualification Records
Welding Procedure Specifications (WPS)

In addition to the various mandatory documentation requirements, the inspector m

ay also be expected to assure the maintenance and retrievability of various othe
r records or information, including the following:
(1)

The range of qualification of all welders employed

(2A)

(3)

Record indicating when welders are due for retests or a

documented record of qualification maintenance

A roster indicating the identification and welder's symbol for all

welders.

At a particular job's completion, all required documentation and records must be

either retained, disposed of, or turned over to the owner of the plant or compo
nent involved. The code, standard, or contract document will normally specify wh
at disposition is to be made of documentation and records.
The welding inspector also has active responsibility for assuring that all weldi
ng is performed in accordance with the WPS specified for each weldment.

SUMMARY
The practical and legal necessities for qualification requirements and the frequ
ent revisions and changes in such requirements make it important for you, as an
inspector, to be able to find and use specified requirements for qualification f
or each individual project. Accurate documentation is required and a responsibil
ity of the welding inspector. Knowledge of the responsibilities of the employer,
the design engineer, and the welding engineer is as essential as the knowledge
of one's own responsibilities as welding inspector.