Chapter 7: Welding Procedures – WPS, PQR, and WPQ

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📘 7.1   is a Welding Procedure Specification (WPS)?

A Welding Procedure Specification (WPS) is a detailed, written document that provides direction to the welder for making a weld according to code requirements.

✅ It ensures repeatability, quality, and compliance.

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🧪 7.2 Procedure Qualification Record (PQR)

A PQR is a record of test results used to verify that a welding procedure (WPS) will produce an acceptable weld.

📌 It contains:

Mechanical test results (tensile, bend, impact)

Visual & NDT reports
Actual welding parameters used during testing

Relationship:
👉 PQR validates the WPS.

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👨‍🏭 7.3 Welder Performance Qualification (WPQ or Welder Qualification Test – WQT)

WPQ proves that a specific welder can deposit sound weld metal using a particular process.

🔎 It's based on:

A visual inspection

NDT (e.g., RT/UT)
Mechanical tests (if required)

🧾 Result: Certificate issued showing the range of qualification (position, diameter, thickness).

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🧰 7.4 WPS Contains the Following Parameters:

Parameter	Examples
Welding Process	SMAW, GTAW, FCAW, SAW
Base Material	ASTM A36, IS2062
Filler Material	E7018, ER70S-6
Position	1G, 3G, 5G, etc.
Preheat & Interpass Temp	100°C, 150°C
Amperage / Voltage	90–120 A / 20–30 V
Travel Speed	mm/min
Shielding Gas	Argon, CO₂

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🔎 7.5 Importance of WPS/PQR/WPQ in QA/QC

1. WPS ensures that welding is performed in a controlled and qualified manner

2. PQR proves that the procedure can make a sound weld

3. WPQ certifies that the welder is skilled

🚨 If any of these are missing, the entire fabrication job may be rejected by the client or third-party inspector (TPI).

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🏭 7.6 Practical Example: Pressure Vessel Fabrication

Project: ASME Section VIII Pressure Vessel

WPS developed and tested by fabricator

PQR performed with bend & tensile test
Welders qualified for 6G SMAW on CS plate
All welds inspected with RT
Final reports submitted for third-party approval

📌 Without WPS/PQR, the job would not be accepted, even if the weld looks fine.

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🔎 7.7 Codes Referenced in WPS/PQR/WPQ

Code	Description
ASME Section IX	Qualification of Welders & Procedures
API 1104	Pipeline welding
AWS D1.1	Structural steel welding
ISO 15614	Welding procedure qualification

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📂 7.8 Traceability

Every weld joint should be traceable to:

Welder ID (from WPQ)

WPS No.
PQR No.
Welding date
Weld map

🧾 All these must be included in QA/QC documentation submitted at the end of the project.

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❌ Common QA/QC Issues in Welding Documentation:

Using unqualified welders

Missing or incorrect WPS
PQR doesn’t match actual job parameters
No documentation for repair welds
Mismatch in filler metal and base material

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📌 7.9 Summary

WPS defines how welding should be done

PQR validates that the procedure works
WPQ ensures welder skill is proven
All are mandatory in most mechanical and piping projects

Quiz: Welding Documentation (WPS/PQR/WPQ)

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Q1. What does WPS stand for?
A) Weld Process Schedule
B) Welding Performance Sheet
C) Welding Procedure Specification
D) Welded Pipe Standard
🟩 Correct Answer: C

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Q2. Which document is used to validate that a welding procedure can produce sound welds?
A) WPQ
B) WPS
C) PQR
D) ISO 9001
🟩 Correct Answer: C

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Q3. WPQ certifies the:
A) Quality of welding rod
B) Qualification of the welding inspector
C) Qualification of the welder
D) Type of base material used
🟩 Correct Answer: C

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Q4. Which ASME section deals with Welding Qualifications?
A) Section V
B) Section VIII
C) Section IX
D) Section II
🟩 Correct Answer: C

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Q5. If a welder is qualified in 6G position, they can weld in:
A) Only flat position
B) Only vertical position
C) All positions
D) Overhead only
🟩 Correct Answer: C

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Q6. Which of the following is NOT included in a typical WPS?
A) Welding process
B) Voltage & current range
C) Welder’s name
D) Preheat temperature
🟩 Correct Answer: C

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Q7. The PQR must include:
A) Welding process and base material only
B) Welder’s opinion
C) Mechanical test results (like tensile & bend tests)
D) Client name only
🟩 Correct Answer: C

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Q8. Why is traceability important in welding QA/QC?
A) To track welder's salary
B) For future promotions
C) To ensure each weld is linked to a qualified person and document
D) For quality of paint
🟩 Correct Answer: C

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Q9. Which code governs structural welding practices?
A) API 1104
B) AWS D1.1
C) ISO 9712
D) ASME B16.5
🟩 Correct Answer: B

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Q10. A project’s welds were rejected because no PQR was submitted. This violates:
A) Safety law
B) Financial law
C) Code compliance
D) All of the above
🟩 Correct Answer: C