WELDING PROCEDURE

SPECIFICATION
EN ISO 15609
 Variables
2

 Essential

 Non-essential

 Supplementary
essential

Welding Research Institute 6/16/2012

 Essential variables
Essential variables are those in which a change, as described in
specific variables, is considered to affect mechanical properties of
the weldment and shall require requalification of the WPS

Supplementary Essential variables

Supplementary Essential variables are those variables which are
also to be considered essential variables when other sections of the
code call for notch toughness testing

Non Essential variables

Non Essential variables are those in which a change, as described
in specific variables, may be made in the WPS with out
requalification
3 Welding Research Institute 6/16/2012
 Essential Variables

 A change in welding condition which will affect the

mechanical properties of the weldment.

e.g.: A) Change in P Number

B) Filler metal
C) Electrode
D) PWHT, etc.

4 Welding Research Institute 6/16/2012

 Non Essential Variables
 A change in welding condition which will NOT affect the
mechanical properties of the weldment.

e.g. : A) Change in Joint Design

B) Methods of Back gouging
C) Cleaning. etc.

5 Welding Research Institute 6/16/2012

 Supplementary Essential Variables

 A change in welding condition which will affect the

Notch-Toughness (Impact) properties of the weldment.

e.g. : A) Change in Heat input

B) Uphill or Down Vertical welding
C) Diameter of Electrode
D) Position, etc.

6 Welding Research Institute 6/16/2012

7

1. Base Metal (E)

2. Welding process (E)
3. Joint design (NE)
4. Consumables (E)
5. Welding position (SE)
6. Preheat, Inter-pass and preheat maintenance (E)
7. Post-heating for hydrogen release (E)

Welding Research Institute 6/16/2012

8

8. Post weld Heat treatment (E)

9. Shielding Gases (E)
10. Electrical Characteristics (SE)
11. Techniques (NE)
12. Metal Transfer Technique (NE)
13. Heat Input (SE)
14. Backing/Back Gouging (NE)
15. Testing Requirements

Welding Research Institute 6/16/2012

 Base Metal
9

Parent material type

• Designation of the material(s), and reference
standard(s);
• Number(s) of the group(s) as given in CR ISO 15608.
• A WPS may cover a group of materials.
Material dimensions
• Thickness ranges of the joint;
• Outside diameter ranges for pipes.

Welding Research Institute 6/16/2012

10 Welding Research Institute 6/16/2012
11 Welding Research Institute 6/16/2012
 Applicable parent material groups

12 Welding Research Institute 6/16/2012

 Range of qualification for butt welds material thickness and weld deposit thickness

13 Welding Research Institute 6/16/2012

Dimensions in millimeters
 Range of qualification for material thickness and throat thickness of fillet welds

14 Welding Research Institute 6/16/2012

Dimensions in millimeters
 Range of qualification for pipe and branch connection diameters

15 Welding Research Institute 6/16/2012

Dimensions in millimeters
 Range of qualification for the type of
16
welded joints
a) Butt welds qualify full and partial penetration butt welds and fillet
welds. Fillet weld tests shall be required where this is the
predominant form of production welding.
b) Butt joints in pipe also qualify branch connections with an angle ≥
60°;
c) T joints butt welded only qualify T joints butt welded and fillet welds
(see a);
d) Welds made from one side without backing qualify welds made
from both sides and welds with backing;
e) Welds made with backing qualify welds made from both sides;
f) Welds made from both sides without gouging qualify welds made
from both sides with gouging;
g) Fillet welding qualifies fillet welding only;
h) 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.
Welding Research Institute 6/16/2012
 Welding Process
17

 Manual or Mechanized and automatic welding

 Process 11 (Manual metal arc welding)

 Process 12 (Submerged arc welding)
 Process 13 (Gas-shielded metal arc welding)
 Process 14 (Gas-shielded welding with non-
consumable electrode)
 Process 15 (Plasma arc welding)

Welding Research Institute 6/16/2012

 Metal Transfer
18

 Short Circuit
 Globular
 Spray

Welding Research Institute 6/16/2012

 Joint Designs
19

 Joint Design
(V-groove, U-groove, Single-bevel etc.)

 Backing
(YES/NO)

 Backing Material Type

(Metal/Non-fusing Metal/Non-
metallic/Others)

Welding Research Institute 6/16/2012

 Consumables
20

• AWS/ISO • Size of Filler metal

Classification
• Flux trade name
• SFA Number
• F. Number • Consumable insert
• A. Number • Electrode flux class

Welding Research Institute 6/16/2012

 Welding position (EN ISO 6947)
21

 Position of a weld in space, which is defined relative to the slope of the axis
and rotation of the face of the weld relative to the horizontal plane.

Main welding position

 welding position, designated PA, PB, PC, PD, PE, PF or PG
Slope(S)
 Angle of the axis of the weld relative to the main welding position
Rotation (R)
 Angle of the face of the weld relative to the main welding position
Inclined angle (L)
 Angle of the axis of the pipe
Welding Research Institute 6/16/2012
22

Welding Research Institute 6/16/2012

23 Welding Research Institute 6/16/2012
24 Welding Research Institute 6/16/2012
25 Welding Research Institute 6/16/2012
26 Welding Research Institute 6/16/2012
27 Welding Research Institute 6/16/2012
 Note : Welding positions used during welding of a test piece shall not exceed ±5° in
slope and ±10° in rotation from the main welding position.

28 Welding Research Institute 6/16/2012

 5. Preheat, Inter-pass and preheat
29
maintenance (EN ISO 13916)
Preheating temperature (Tp)
 The temperature of the work piece in the weld zone immediately
prior to any welding operation. It is normally expressed as a
minimum and is usually equal to the minimum interpass temperature

Inter-pass temperature (Ti)

 The temperature in a multi-run weld and adjacent parent metal
immediately prior to the application of the next run. It is normally
expressed as a maximum temperature

Preheat maintenance temperature (Tm)

 The minimum temperature in the weld zone which shall be
maintained if welding is interrupted

Welding Research Institute 6/16/2012

 Point of Measurement

30 Welding Research Institute 6/16/2012

 Time of measurement
Inter-pass temperature shall be measured in the weld area
immediately before passage of the arc. If the preheat maintenance
temperature is specified it shall be monitored during the period of
welding interruption.

Test equipment
Equipment used for temperature measurement should be specified in
the welding procedure
specifications, e.g.:
— temperature sensitive materials
(e.g. crayons or paints) (TS);
— contact thermometer (CT);
— thermocouple (TE);
— optical or electrical devices for contactless measurement (TB).
31 Welding Research Institute 6/16/2012
 Post weld Heat Treatment
32

 Temperature Range

 Time Range

 Others

Welding Research Institute 6/16/2012

33

Preheat & PWHT requirement based on

Diameter, Thickness and Composition of
Base Material

Welding Research Institute 6/16/2012

 Gases
34

Gas Mix % Flow

Rate

 Shielding

 Trailing

 Backing

Welding Research Institute 6/16/2012

 Electrical Characteristics & Heat Input
35

 Current (AC/DC)
 Polarity (EP/EN)
 Amps & Volts
 W-Electrode type & size
 Mode of Metal Transfer (GMAW)
 Electrode Wire Feed Speed range

Welding Research Institute 6/16/2012

 Heat Input
36

Welding Research Institute 6/16/2012

 Techniques
37

 Stringer or Weave Bead

 Orifice/Gas Cup Size
 Initial or Inter-pass Cleaning
 Method of Back Gauging
 Oscillation
 Contact Tip to Work Distance
 Multiple or Single Pass (per side)
 Multiple or Single Electrode
 Electrode Spacing
 Peening
 Others
Welding Research Institute 6/16/2012
 Butt Joints
38

Joint preparation and fit-up as detailed in the preliminary Welding Procedure

Specification (pWPS)
a Minimum value 150 mm
b Minimum value 350 mm Welding Research Institute 6/16/2012
t Material thickness
 T – Joint ( Fillet Weld)
39

Joint preparation and fit-up as detailed in the preliminary Welding Procedure Specification
a Minimum value 150 mm
b Minimum value 350 mm
t Material thickness Welding Research Institute 6/16/2012
 Pipe Butt Joint
40

Joint preparation and fit-up as detailed in the preliminary Welding Procedure

Specification
a Minimum value 150 mm
D Outside pipe diameter
t Material thickness
Welding Research Institute 6/16/2012
 Location of test specimens for a butt
41
joint in plate

Welding Research Institute 6/16/2012

 Location of test specimens for a butt
42
joint in pipe

Welding Research Institute 6/16/2012

 Location of test specimens in a T- joint
43

Welding Research Institute 6/16/2012

44 Welding Research Institute 6/16/2012
 Foot Notes
45

Welding Research Institute 6/16/2012

46

THANK YOU

Welding Research Institute 6/16/2012