11.

QUALITY ASSURANCE IN WELDED FABRICATION &

QUALIFICATION OF WELDERS

11.1 WHAT IS QUALITY?

Quality is the degree of conformity to a certain predetermine standard.

11.2 QUALITY ASSURANCE V/S QUALITY CONTROL

In welding fabrication work, Quality Assurance is concerned with defining & planning all the
operations necessary to manufacture a product which will perform satisfactory in service but
which has been completed in the most economical manner.

Where as

Quality control relates to the system established to monitor each stage of manufacture with a view
to achieving the requirement specified by Quality assurance.

11.3 WELD QUALITY

In production welding, the term “weld quality” is relative. The application determines what is
good or bad. Generally, any weld is a good weld if it meets appearance requirements and will
continue indefinitely to do the job for which it is intended. But a weld can be “too good.” This is
the case when a high degree of quality has been obtained at excessive production cost and the
buyer is getting no discernible value from the extra expenditure. Insisting on any method of
inspection that serves no function is illogical as well as wasteful.

The first step, then, in assuring weld quality is to ascertain the degree required by the application.
A standard should be established based on service needs. Engineering performance will be the
main consideration in arriving at the standard, but appearance may also be important. A safety
factory must of necessity, be built into the standard, but it should be reasonable. Once the standard
has been set, it is the responsibility of everyone concerned with the job to see that it is followed.

On the low side, the predetermined standard of quality should never be compromised. On the high
side, there is no objection to extra quality, providing it has been obtained at no penalty in cost. If
tests repeatedly show that the welds are exhibiting a degree of quality far greater than required by
the standard, a cost reduction through modification of weldment design or procedures is possible.

Frequently, the standards are preset by prevailing specifications or engineering and legal codes.
Sometimes such standards are ultraconservative, but when they apply they must be honored. The
engineer can do his company or the customer a service by pointing out unrealistic specifications
and the opportunities for cost savings, but the specifications must be adhered to rigidly until
revised.

11.4 THE FIVE P’s THAT ASSURE QUALITY

After the quality standard has been established, the most important step towards its achievement is
the selection of the best process and procedures. By giving attention too five “P’s” weld quality
will come about almost automatically, reducing subsequent inspection to a routine checking and
policing activity. The five P’s are:

Process Selection - the process, must be right for the job.

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Preparation - the joint configuration must be right and compatible with the welding process.

Procedures - to assure uniform results the procedures must be spelled out in detail and followed
religiously during welding.

Pretesting - by full-scale mockups or simulated specimens the process and procedures are proved
to give the desired standard of quality.

Personnel - qualified people must be assigned to the job.

11.5 GENERAL FACTORS TO BE CONSIDER FOR WELD QUALITY

11.5.1 Design

Weld quality includes weld-design considerations, which means that each weldment should be:

a) Adequately designed to meet the intended service for the required life.
b) Fabricated with specified materials and in accordance with the design concepts.
c) Handled and maintained properly.

11.5.2 Fabrication

The fabrication procedures and practices should be such that they ensure that the weldment meets
the design specifications.

11.5.3 Inspection

Weld quality is verified by NDT.

11.5.4 Operation and Maintenance

Operating a welded product safely, requires periodic inspection. If failure at a facility would result
in a public hazard or the destruction of property, then inspection should be more frequent and
more rigorous.

11.5.5 Economy

Economy also influence weld quality considerations. Economics requires that a product must be
competitive.

11.6 QUALIFICATION OF WELDING PROCEDURES & WELDERS/ OPERATORS

(SOME GENERAL INFORMATION)

11.6.1 Why Qualification ?

Most fabricating codes and standards require qualification & certification of welding procedures
& welders/operators who perform welding in accordance with these procedures.

11.6.2 Some International Codes/Standards Writing Authorities

 AWS-American Welding Society

 API-American Petroleum Institute

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  ASME-American Society of Mechanical Engineers
 ASTM-American Society for Testing & Materials
 JIS-Japanese Industrial Standards
 BS-British Standards
 GB-Chinese Standards

11.6.3 ASME Boiler & Pressure Vessel Code

12 SECTIONS

6 Manufacturing 1 1 Qualification 2 2
Material Inspection Operation
Specifications

11.6.4 Section IX: ASME Boiler & Pressure Vessel Code

Section IX of the ASME Boiler & Pressure Vessel Code relates to the qualification of welders,
welding operators, brazers, and brazing operators, and the procedures that they employ in welding
and brazing according to the ASME Boiler and Pressure Vessel Code and the ASME B31 Code
for Pressure Piping. It is divided into two parts: Part QW gives requirements for welding and Part
QB contains requirements for brazing.

11.7 WELDING PROCEDURE QUALIFICATION

11.7.1 Welding Procedure Specification (WPS)

A WPS is a document that provides in detail required welding conditions for a specific application
to assess repeatability by properly trained welders or welding operators.

Or

A WPS is a written welding procedure prepared to provide direction for making production welds
to code requirements.

The completed WPS shall describe all of the essential, non-essential, and supplementary essential
(when required) variables for each welding process used in the WPS.

11.7.2 Welding Variables

[Link] Essential Variables

A change in a welding condition which will affect the mechanical properties of the weldment,
e.g., change in base material, welding process, filler metal, electrode, preheat or postweld heat
treatment, etc.

[Link] Supplementary Essential Variables

A change in a welding condition which will affect the notch-toughness properties of a weldment,
e.g., change in welding process, heat input, pre heat or PWHT, etc.
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[Link] Non Essential Variables

A change in a welding condition which will not affect the mechanical properties of a weldment
e.g., joint design, method of cleaning, etc.

11.7.3 Procedure Qualification Record (PQR)

A PQR is a document in which the actual welding conditions used to produce an acceptable test
joint and the results of the qualification tests are recorded.

Or

A PQR is a record of the welding data used to weld a test coupon. The PQR is a record of
variables recorded during the welding of the test coupons. It also contains the test results of the
tested specimens.

Recorded variables normally fall within a small range of the actual variables that will be used in
production welding.

[Link] Aim/Purpose

The purpose of the WPS & PQR is to determine that the weldment proposed for construction is
capable of providing the required properties for its intended application.

IN SHORT

WPS is intended to provide direction for the welder &

The PQR lists what was used in qualifying the WPS & the test results.

11.7.4 Types & Purposes of Tests

[Link] Mechanical Tests

[Link].1 Tension Tests

PURPOSE

Tension tests are used to determine the ultimate strength of groove-weld joints.

ACCEPTANCE CRITERIA

In order to pass the tension test, the specimen shall have a tensile strength that is not less than:

a) The minimum specified tensile strength of the base metal; or

b) The minimum specified tensile strength of the weaker of the two.

c) The minimum specified tensile strength of the weld metal when the applicable Section
provides for the use of weld metal having lower room temperature strength than the base
metal;

d) If the specimen breaks in the base metal outside of the weld or fusion line, the test shall be
accepted as meeting the requirements, provided the strength is not more than 5% below
the minimum specified tensile strength of the base metal.

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[Link].2 Guided Bend Tests

PURPOSE

Guided bend tests are used to determine the degree of soundness and ductility of groove-weld
joints.

ACCEPTANCE CRITERIA

The weld and heat affected zone of a transverse weld-bend specimen shall be completely within
the bent portion of the specimen after testing.

The guided-bend specimens shall have no open defects in the weld or heat affected zone
exceeding 1/8 in., measured in any direction on the convex surface of the specimen after bending.
Open defects occurring on the corners of the specimen during testing shall not be considered
unless there is definite evidence that they result from lack of fusion, slag inclusions, or other
internal defects. For corrosion-resistant weld overlay cladding, no open defect exceeding 1/16 in.,
measured in any direction, shall be permitted in the cladding, and no open defects exceeding 1/8
in., shall be permitted in the bond line.

[Link].3 Notch Toughness Tests

PURPOSE

Notch Toughness Tests are used to determine the notch toughness of the weldment.

ACCEPTANCE CRITERIA

The acceptance criteria shall be in accordance with that Section specifying impact requirements.

11.8 WELDER/OPERATOR PERFORMANCE QUALIFICATION

11.8.1 Purpose

The basic purpose of welder qualification is to determine the welder’s ability to deposit sound
weld metal. Whereas the purpose of performance qualification test for welding operator is to
determine the operator’s ability to operate welding equipment. In other words, the performance
qualification tests are intended to determine the ability of welders and welding operators to make
sound welds.

11.8.2 WPQ

A WPQ is a document that includes the essential variables, the type of test & test results, and the
ranges qualified for each welder/welding operator.

11.8.3 In how many Ways a Welder can be Qualified

1. By preparing a WPS Qualification Test Coupon.

2. On Production Weld.

A) For Welder:

R.T. of 6” length of the first production weld.

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 B) For Operator:

R.T. of 3’ length of the first production weld.

3. By preparing a WPQ Test Coupon

11.8.4 Type Of Tests Required

[Link] Visual Examination

Performance test coupons shall show complete joint penetration with complete fusion of weld
metal & base metal.

[Link] Mechanical Tests

A) Thickness < 3/4” 1 Face Bend, 1 Root Bend

B) Thickness > 3/4” & 2 Side Bend

alternate for 3/8” to < 3/4”

OR

Radiographic Examination

If plates: 6” min. Length

For pipes: Full circumference for big dia pipes.
For small dia pipes: Multiple coupons, Max. 4 coupons, Consecutively welded.

11.8.5 Retest & Renewal of Qualification

[Link] Retest

[Link].1 Immediate Retest Using Visual Examination

 If fails in visual examination

* Two consecutive test coupons
* Both shall pass V.E.
* Any one can be used for Mech. Testing.

[Link].2 Immediate Retest Using Mechanical Testing

 When test coupon fails in Mechanical Testing.

* The Welder/Operator shall make two consecutive test coupons.

* Both test coupons shall have to pass the required mechanical test.

[Link].3 Immediate Retest Using Radiography

A). If test coupon fails radiography on plates

The welder/Operator shall make 2 test coupons on plates (Min. Length = 6”)

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B) If test coupon on pipes fails in radiography, the welder/operator shall make 2 coupons on
pipes for a Min. Length of 12” to be radiographed. For small diameter pipe the total
number of consecutively made test coupons need not exceed eight (8)

C) If a welder fails on production weld for 6” length, additional 12” length of the same
production weld shall be radiographed.

D) If operator fails on production weld for 3’ length, additional 6’ length of the same
production weld shall be radiographed.

[Link] Expiration of Qualification

A) No welding during a period of six months or more.

B) Within the six months period, prior to expiration.

1) A welder will maintain his qualification for manual or semiautomatic welding.

2) An operator will maintain his qualification for machine or automatic welding.

C) When there is a specific reason to question the ability of a welder/operator to make sound
welds.

[Link] Renewal of Qualification

A) Renewal of qualification expired under (A) above may be made for any process by
welding a single test coupon of either plate or pipe, of any material, thickness or diameter,
in any position.

A successful test renews the welder/operator’s previous qualifications for that process, for
those materials, thickness, diameters, positions, & other variables for which he was
previously qualified.

Renewal of qualification may also be done on production work.

B) Welders/operators whose qualifications have been revoked under (C) above shall
requalify.

11.9 COMBINATION OF WELDING PROCESSES

A welder/operator may also be qualified on a single test coupon using different welding processes

Or

More than one welders/operators may be qualified on a single test coupon using the same or
different welding processes.

Failure of any portion of a combination test in a single test coupon constitutes failure of the entire
combination.

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11-8
11-9
11-10
 ORDER OF REMOVAL OF TEST SPECIMENS FROM TEST COUPEN
PROCEDURE QUALIFICATION

DISCARD THIS PLATE

REDUCED SECTION TENSILE SPECIMEN

ROOT BEND SPECIMEN

FACE BEND SPECIMEN

ROOT BEND SPECIMEN

FACE BEND SPECIMEN

REDUCED SECTION TENSILE SPECIMEN

DISCARD THIS PIECE

Fig. 11.1a: PLATES-LESS THAN 3/4″ THICKNESS

DISCARD THIS PLATE

SIDE BEND SPECIMEN

REDUCED SECTION TENSILE SPECIMEN

SIDE BEND SPECIMEN

SIDE BEND SPECIMEN

REDUCED SECTION TENSILE SPECIMEN

SIDE BEND SPECIMEN

DISCARD THIS PIECE

Fig. 11.1b: PLATES-OVER 3/4″ & ALTERNATE FROM 3/8″ TO 3/4″

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ORDER OF REMOVAL OF TEST SPECIMENS FROM TEST COUPEN
PROCEDURE QUALIFICATION

Fig. 11.2a: PIPES 1/16″ TO 3/4″ THICKNESS

Fig. 11.2b: PIPES OVER 3/4″ & ALTERNATE FROM 3/8″ TO 3/4″

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ORDER OF REMOVAL OF TEST SPECIMENS FROM TEST COUPEN
PROCEDURE QUALIFICATION

DISCARD THIS PIECE

ROOT BEND SPECIMEN

FACE BEND SPECIMEN

DISCARD THIS PIECE

Fig. 11.3a: PLATES-LESS THAN 3/4″ THICKNESS

DISCARD THIS PIECE

SIDE BEND SPECIMEN

SIDE BEND SPECIMEN

DISCARD THIS PIECE

Fig. 11.3b: PLATES-OVER 3/4″ & ALTERNATE FROM 3/8″ TO 3/4″

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ORDER OF REMOVAL OF TEST SPECIMENS FROM TEST COUPEN
PROCEDURE QUALIFICATION

Fig. 11.4a: PIPES 1/16″ TO 3/4″ THICKNESS

Fig. 11.4b: PIPES OVER 3/4″ & ALTERNATE FROM 3/8″ TO 3/4″

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 TABLE 11.1

PROCEDURE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS

GROOVE-WELD TENSION TESTS AND TRANSVERSE-BEND TESTS

Thickness T of Test Range of Thickness T of Thickness t of Deposited Type and number of Tests required
Coupon Welded, in Base Metal Qualified, in. Weld Metal Qualified, in. (Tension and Guided-Bend Tests)
Min. Max. Max. Tension Side Bend Face Bend Root Bend

Less than 1/16 T 2T 2t 2 - 2 2

1/16 to 3/8 incl. 1/16 2T 2t 2 - 2 2

Over 3/8 but less than 3/4 3/16 2T 2t 2 - 2 2

3/4 to less than 1½ 3/16 2T 2t when t < ¾ 2 4 - -

3/4 to less than 1½ 3/16 2T 2T when t > ¾ 2 4 - -

1½ and over 3/16 8 2t when t < ¾ 2 4 - -

1½ and over 3/16 8 8 when t > ¾ 2 4 - -

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 TABLE 11.2

PERFORMANCE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS

TRANSVERSE-BEND TESTS

Thickness of weld Type of Number of Examinations and Test Specimens Required

metal, in. (mm) Visual Side bend Face bend Root bend
Examination
Less than 3/8 (10) x … 1 1
¾ (10) to less than ¾ x One face and root bend may be substituted for the two side bends.
(19)
¾ and over x 2 … …

THICKNESS OF WELD METAL QUALIFIED

Thickness, t, of weld metal in the coupon, in. (mm) Thickness of Weld Metal Qualified

All 2t
½ (13) and over with a minimum of three layers Maximum to be welded

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 TABLE 11.3

PERFORMANCNE QUALIFICATIONN - POSITION AND DIAMETER LIMITATIONS

Qualification Test Position and Type of Weld Qualified

Groove Fillet
Plate and Pipe
Weld Position Pipe < 24 in. O.D. Plate and Pipe
Over 24 in. O.D.
Plate - Groove 1G F F F
2G F, H F, H F,H
3G F, V F F, H,V
4G F, O F F, H,O
3G and 4G F,V,O F All
2G, 3G and 4G All F, H All
Special Positions (SP) SP, F SP, F SP, F
Plate - Fillet 1F - - F
2F - - F, H
3F - - F, H, V
4F - - F,H,O
3F and 4F - - All
Special Positions (SP) - - SP, F
Pipe - Groove 1G F F F
2G F, H F,H F,H
5G F,V,O F,V,O All
6G All All All
2G and 5G All All All
Special Position (SP) SP, F SP, F SP, F
Pipe - Fillet 1F - - F
2F - - F, H
2FR - - F, H
4F - - F, H,O
5F - - All
Special Positions (SP) - - SP, F
F = Flat
H = Horizontal
V= Vertical
O= Over Head

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