Specification and qualification of welding procedures for metallic materials —Welding

procedure test- Part 1: Arc and gas welding of steels and Arc welding of nickel and nickel
alloys

ISO 15614-1
“In Brief”

PRESENTING BY

RAM KORADA (Welding Engineer)

M.E; IWE; [Link]., CSWIP3.1, ISO 3834 Auditor
**General Rule: Stages in qualification of Welding Procedure & Welder Approval
▪ Applicable standard/ code
▪ Technical Requirements from
Costumer Requirements contract
▪ Drawing
▪ Project Specifications
▪ Consumable compatibility
Applicable WPS available Yes
No
Development of pWPS
(ISO 15609)

Qualification WPQR
of (ISO 15614)

Welder Approval Finalization & Approval

(ISO 9606) of WPS (ISO 15609)

6 Months Conformity Release for Production

“The welder or welding

3 Years 2 Years Unlimited operator who undertakes the
Re-qualification Re-Validation Conformity WPQR is qualified according
to the relevant international
standard provided that the
Examiner/Examining Body relevant testing requirements
Manufacturer of that standard are met”
**Reference: ISO 15607:2019 Annex B & C As per Cl.5 ISO 15614-1.
Introduction
Current Issue : ISO 15614-1:2017 + Amd 1:2019 or DIN EN ISO 15614-1:2020-05
Amendment's ▪ Sub clause [Link] has been deleted and replaced by new text.
▪ The standard has been editorially revised
▪ Key Marks in figure 6
Purpose ▪ How a pWPS is qualified by Welding Procedure Tests.
▪ Produced joints in construction having the required mechanical properties for the
intended application.
Application 1. Production 2. Repair 3. Build up
Levels Level 1 Level 2
(ASME Section IX ) (ISO 15614-1)
Process 111 114 12 13 14 15 311
Fusion by Arc Welding Gas Welding
Material CS, SS & Ni and its alloys CS & SS
Conditions ▪ Procedure tests carried out to level 2 automatically qualify for level 1
requirements, but not vice-versa.
▪ Document does not invalidate previous welding procedure tests made to former
national standards or specifications or previous issues of this document
 Test Piece (Cl.6)
The welding and the testing of the test piece shall be verified by the examiner or examining body.
(cl 6.3)
Joint preparation & fit up as per pWPS
Joint preparation & fit up as per pWPS
Welding position
as per ISO 6947
marking is mandatory

min 350mm
Rolling direction

Pipe OD

min 150mm min 150mm

Fig:2 Butt –pipe -full penetration

min 150mm min 150mm t1 & t2 material

Fig:1 Butt –plate-full penetration OD Branch pipe thickness

Thickness of
Branch Branch pipe
angle, min
min 150mm
min 150mm one used in
production
OD main pipe

min 150mm
Joint preparation & fit up
(set-in/on/through) min 150mm
as per pWPS Joint preparation & fit up as per pWPS
Thickness of
Fig:4 Branch connection ( fillet / Full penetration) main pipe Fig:3 T-Joint ( fillet / Full penetration)
Examination & Testing (cl.7)
Testing &
Test Piece Type of Test Extent Condition applies Acceptance
Sample preparation
(1,2,3) a. Cracks, LOF & LOP , not permitted
VT (Cl.7.3) 100% ISO 17637-1
as per ISO 5817-Level B
a. < 8mm t , Group 8, 10, 41 to 48 -UT shall not be
(1,2) used b. As per ISO 5817-Level C : Under
RT or ISO 17636-2 (RT) &
(1) 100% b. Shall be delayed for materials that are susceptible cuts, Excess (Weld Metal, convexity,
Butt joint UT (Cl.7.3) ISO 17640 (UT)
HIC Penetration, Weld Toes, Throat)
with full
penetration — c. As per ISO 5817-Level B: Unequal
(1,2,3) a. For Non magnetic materials DPT shall be done
Fig 1 & 2 MPI or ISO 3452-1 (PT) &
100% b. Shall be delayed for materials that are susceptible Leg Length & All other Imperfections
DPT (Cl.7.3) ISO 17638 (MPI)
to HIC - (Cl.7.5; table 4)
(1) a. For pipes >50 mm OD the Reinforcement shall be
Transverse
removed on both faces Shall not be less than min of parent
Tensile Test 2 Samples ISO 4136
(2) b. For pipes ≤ 50 mm OD the Reinforcement may be material value.
T- joint with (Cl. 7.4.1)
left undressed at inside.
full (1)
Transverse a. < 12mm (2 RB +2 FB);
penetration — Shall not reveal any imperfection >3
Bend Test 4 Samples b. ≥12mm (4 SB); ISO 5173
Fig 3 and mm in any direction.
(Cl. 7.4.2) c. For Dissimilar (1 RB + 1 FB)
Branch
a. If not Specified : Shall meet min of
connection with a. 1 set (W)+ 1 set (HAZ) for ≥12mm & for < 12mm
base requirements.
full penetration ref applicable standard.
(1) b. Avg of 3 samples shall meet the
— Fig 4 Impact Test b. For t >50mm 1 set (W)+ 1 set (HAZ) additional at
2 Sets ISO 9016 specific requirements.
(Cl. 7.4.4) Root area
c. Each Individual absorbed energy
c. For Multi Process 1 set (W)+ 1 set (HAZ) additional
shall not be less than 70% of the AVG
form each process
(3) value.
Fillet weld —
Fig 3 & 4 (1,2,3) a. Not Req for sub group 1.1 ,8 and 41 to 48. Req for
Hardness
1.1 to 8
Test Required ISO 9015-1 Shall Meet Table 3 of ISO 15614-1.
b. WELD-HAZ (Both sides)-BASE (Both sides)-Each
(Cl 7.4.5)
Row 3 Values
(1,2,3)
Macroscopic (1) Clearly shall reveal , Un affected
1-Specimen
Examination (2,3) a. Surface finishing + Etched ISO 17639 parent metal, the fusion line, the HAZ
2-Specimen
(Cl.7.4.3) and the build-up of the runs.

Retesting (Cl.7.6)- If any specimen fails following applies, If retesting fails WPQR gets cancelled
NDT Tensile & Bend Impact Hardness Macro
One further test coupon 2 Extra Samples If any Individual or Average value Any Single value fails one extra 2 Extra Samples
shall be welded. fails one extra set shall be retested row of indentation shall be taken. from same test coupon.
Location and taking of test specimens (Cl.7.2)
Start of Weld
Discard 1 Macro &
End of Weld 1 Hardness (shall take at Start)

1 Tensile + Bend 1 Tensile + Bend

1 Tensile+ Bend

Welding Direction
Impact & Add test

Impact & Add test

Impact & Add test

1 Tensile + Bend
1 Tensile + Bend
1 Tensile + Bend
Start of Weld End of Weld
Macro & Hardness Discard 1 Macro &
1 Hardness (shall take at Start)
Fig: 5 Butt Joint in Plate
Fig: 6 Butt Joint in Pipe
“ It is acceptable to draw
test specimens by avoiding
areas which have
Discard
acceptable imperfections by
Macro NDT used”.
Branch Angle

Macro & Hardness

Macro

Macro & Hardness

Fig: 7 T-Joint Fig: 8 Branch Connection on Pipe
Range of Qualification (cl.8)
Range of Qualification ( Any Change from ranges specified shall require requalification)
[Link] Essential Variables Range of Qualification
8.2 Manufacturer WPQR Valid to his own workshop
8.3.1 Parent Metal Grouping Steels (Table 5), Nickel alloys & Dissimilar Joints ( Table 6)
8.3.2 Material Thickness If Qualification performed on 30mm or above - No limit for Dissimilar Thickness
Parent material thickness
Deposited weld thickness for each process (s)
Test Piece (t) Single run Multi run
t≤3 0.5t to 2t
3 to ≤ 12 0.5t(3min) to 1.3t 3 to 2t max 2s
Table 7 Butt Welds >12 to ≤ 20
>20 to ≤ 40 0.5t to 1.1t s < 20 max 2s s ≥ 20 max 2t
>40 to ≤ 100 _ 0.5t to 2t s < 20 max 2s s ≥ 20 max 200
>100 to ≤ 150 _ s < 20 max 2s s ≥ 20 max 300
t > 150 _ 50 to 2t s < 20 max 2s s ≥ 20 max 1.33t
Throat Thickness
Test Piece (t) Material Thickness
Single Run Multi Run
t≤3 0.7t to 2t
Table 8 Fillet Welds
>3 to < 30 3 to 2t 0.75 a to 1.5 a No Restriction
t ≤ 30 ≥5
For Different thicknesses, ranges of both shall be calculate separately
Butt Weld for Pipes Qualifies Butt Weld Plates and Vice versa,
8.3.3
Diameter of Pipes & Branch When OD is >500mm or OD >150mm welded in rotated position in PC /PF /PA.
connection Qualification of Diameter of Test Piece Range
Table 9
D ≥ 0.5 D
Qualification of Branch Angle ( α) Range
8.3.4 Angle of Branch connection 60◦ to 90◦ 60◦ ≤ α < 90◦
< 60◦ up to 90◦
a)Each Degree of mechanization shall be qualified independently.
b) Multi process Procedure- Procedure is valid for only on same sequence of process.
8.4.1 Welding Process c) If single process is used from Multi process Procedure- Individual process shall tested.
d) Procedure qualification can be carried out by separate tests of each individual process or single test
as multi process procedure test.
a) If no Impact or Hardness is required, qualification in any position qualifies for any position.
b) If Impact test is done at highest HI & If Hardness test is done at lowest HI covers all position.
8.4.2 Welding Positions c) Vertical Down ( PG, PJ & J-L045) re qualification required.
d)For group 10; Low & High HI positions shall subjected to Impact testing.
e) Butt welds in Plate, PA & PF ( Higher HI) and PC & PE ( Lower HI)
Range of Qualification (cl.8) continue..
[Link] Essential Variables Range of Qualification
Qualification Range
Butt Welds Butt ( Full & Partial ), Fillet & Build up
Fillet weld Required T-Joints (Fillet & Partial Butt ) if predominant in production
Butt Joint ( Full Penetration) Butt ( Full & Partial ) & Fillet
Butt Joint Pipe Branch Connection α ≥ 60◦
T-Joint Butt ( Full Penetration) T-Joint Butt ( Partial Pénétration) & Fillet
Type of Fillet Welds Fillet Welds only
8.4.3 One side welds with out backing Welds from Both sides & welds with backing
Joint/Weld
Welds made with backing Welds made with Both sides
Welds made with Both sides (without root removal) Welds made with Both sides (with root removal)
Welds made with Both sides (with/with out gouging) Welds made from one side with backing
If Impact or Hardness Required Change from Multi run to single run or vice versa;
Not Permitted
Buttering Shall qualify separately
Qualification Condition
Covers other filler material as long as following are same
Filler Material, Filler material i.e. Designation, Mechanical properties, Covering ,
Manufacturer/ chemical composition & Hydrogen content.
8.4.4
trade Name, Trade name is Essential When CVN is required at below -
Designation 20◦C; for Process 111, 114, 12, 136, 132
Manufacturer trade name
Solid wires & Rods, Manufacturer trade name is not
essential variable
8.4.5 Filler Size Change in size is not essential variable when Heat Input is deviated from qualified range.
Qualified for same type of current and polarity
8.4.6 Type of Current
For SMAW, AC Qualifies AC , DCEP & DCEN unless Impact is required
k -factor to be considered (for 111,13 K=0.8; For 12 K= 1, For 141 K= 0.6)
Qualification Range
8.4.7 Heat Input If Test piece require Impact Actual to +25%
If Test piece require Hardness -25% to Actual
If Test piece require Both ± 25% of Actual
8.4.8 Preheating Decrease not more than 50◦C
8.4.9 Inter pass An Increase not more than 50◦C
8.4.10 Post Heating Post heating shall not be omitted but may be added.
8.4.11 Heat treatment Addition or Deletion requires re qualification
Range of Qualification (cl.8) continue..
[Link] Essential Variables Range of Qualification
Each Variant of Process 12 (121 to 126) shall be Qualified Independently
Addition or Deletion of Wires ( Cold or Hot Wire)
Addition or Deletion of no of Wires
8.5.1 Specific to Process (SAW)
A change more than± 10% of the ration of the supplementary filler material
Manufacturer, trade name and Designation for Flux is essential variable.
Use of flux from re-crushed slag is essential variable.
8.5.2 Specific to Process (GMAW)
Designations as per ISO 14175
[Link] Shielding Gas Deviation of Max ±20% of nominal composition of CO2 is allowed
Addition or Deletion of Max 0.1% of any gas is allowed
[Link] Process Variants Restricted to the wire system used (e.g. single-wire or multiple-wire system)
Qualification Range
[Link] Short circuiting Transfer mode
Transfer mode Short circuit Transfer only
Revised (solid & Metal cored wires)
Spray , Pulse or Globular transfer Spray, Pulse & Globular Transfer
8.5.3 Specific to Process (GTAW)
Designations as per ISO 14175
[Link] Shielding Gas Deviation of Max ±10% of nominal composition of Helium (He) is allowed
Addition or Deletion of Max 0.1% of any gas is allowed
[Link] Filler material Welding with filler does not qualify welding with out filler or vice versa
Plasma gas & Shielding gas Change in composition is essential variable
8.5.4 Specific to Process (PAW) Welding with filler does not qualify welding with out filler or vice versa
If Impact requires change in joint preparation (groove) is essential variable
8.5.5 Specific to Process ( Oxy-W) Welding with filler does not qualify welding with out filler or vice versa
WPQR shall signed and dated by Examiner/Examining body
WPS Content shall be as per ISO 15609-1
9 WPQR
WPQR Format ref Annex B, WPS Format Ref Annex A of ISO 15609-1:2019
If required Test Certificate of Base & Consumables shall attached to WPQR
Thank You