INDEX

1. INTRODUCTION TO ASME CODES

2. WPS AND PQR
3. GUIDELINES FOR MAKING WPS AND PQR
4. WELDING VARIABLES
5. SOME IMPORTANT CLAUSES RELATING TO
THE WPS.
Page 1 of 29
1. INTRODUCTION TO ASME CODES:
In industries, a number of equipments like power boilers,
pressure vessels exist which are operational at extreme conditions
such as high pressure, temperature etc. extreme caution has to be
taken to ensure that such equipments work properl and safel in
the required operating conditions. !ence, construction of boilers,
pressure vessels, and other components in a manufacturing plant
is not carried out directl but is done in a methodical fashion
following certain codes and specification.
In order to manufacture, considering safet and optimum cost
of such industrial equipments various codes, standards "
specification are available as reference guidelines. #umbers of
industries have published guidelines to be followed in fabrication
of equipment to obtain best result at maximum safet and
econom. $hese guidelines act as assurances of high standards of
qualit as well as safet in construction and use. %ome of the
sundr of codes established are &%, 'I#, (%)*, I% codes etc.
+ut of these, the (%)* codes are most widel used due to its
winder applicabilit and wealth of experience involves in its
preparation. It is important to note that the codes established onl
serve as guidelines for safet and ease of construction but are not
a compulsion on the manufacturer who has the freedom to out for
a method of his choice or liking.
$he (%)* codes are standard rules established as a result
of setting of a committee of (merican %ociet of )echanical
Page 2 of 29
*ngineering in 1911 for the purpose of formulating standard rules for
the construction of steam boilers and other pressure vessel. (%)*
codes are guidelines covering the safet of design, fabrication, and
inspection during the construction of pressure vessels and boilers.
$he codes serve as guidelines for care and good practice for the ease
and safet of construction onl and the do not limit the freedom of
the manufacturing firm to choose an method or design of
manufacture of its liking.
$he (%)* codes are sub,ected to constant review and are
regularl updated with change in technolog, new researches taking
place and new developments.
(%)* boiler and pressure vessel codes used in
manufacturing of pressure vessels are made up of number of section
relating to various aspects of the fabrication of boilers and vessels.
-ollowing are the section of (%)* code for boiler and pressure
vessels.
%ection I . Power &oilers
%ection II . )aterial specification
Part ( . -errous materials.
Part & . #on ferrous material.
Part / . 0elding 1ods, *lectrodes and -iller )etals.
%ection III . #uclear power plant components.
%ection I2 . !eating &oilers.
%ection 2 . #on3destructive examination.
%ection 2I . /are and operation of heating boilers.
Page 4 of 29
%ection 2II . /are of power boilers.
%ection 2III . Pressure vessel.
'iv. I . 1ules for construction of pressure vessel.
'iv. II . (lternative rules for construction of pressure vessel
%ection I5 . 0elding and bra6ing qualification.
%ection 5 . -iber glass reinforced plastic pressure vessel.
%ection 5I . In service inspection of nuclear reactor coolant
sstem.
(ll these sections of (%)* codes impose control on the
construction of the various production equipment but are mainl
concerned with safet, ease and econom of construction.
Page 7 of 29
2. WPS AND PQR:
2.1 WELDING PROCEDURE SPECIFICATION:
$he purpose of welding procedure specification and procedure
qualification record is to determine that weldment proposed for
construction is capable of having the required properties for its intended
application. It is presupposed that the welder or welding operator
performing the welding procedure qualification test is a skilled
workman. $he welding procedure qualification test establishes the
properties of the weldment, not the skill of the welder or welding
operator. In addition to this general requirement, other section of the
code requires special consideration for notch toughness.
&riefl, a 0P% lists the variables, both essential and non 8
essential, and the acceptable range of these variables when using the
0P%. $he 0P% is like a manual which gives direction for the welding
operator 9 welder.
$he 0P% lists the various parameters of the ,oints required during
welding such as base metal used, filler wire, gas, electrical
characteristics, post weld heat treatment, position, technique, etc.
Page : of 29
2.2 PROCEDURE QUALIFICATION RECORD:
Procedure qualification record lists the parameters used in
qualification of the 0P% and also records the test results. It records the
actual parameters used during the qualification of the test piece. It also
records the results of the various tests such as tensile test, bend test,
toughness tests, etc. depending on the requirements as mentioned in
various clauses of the section I5. It is a proof of the qualit of the
weldment 8 whether it is to the required standard or not.
Page ; of 29
3. GUIDELINES FOR MAKING WPS ! PQR.
3.1 STEPS FOR MAKING A WPS:
%ome guidelines for making a 0P% are as follows. 3
1efer the appropriate P 8 #umber and <roup 8 #umber
and 9 or % 8 #umber of the parent metals to be welded as
given in =0 8 722.
/hoose the appropriate filler metal >wire, electrode, flux,
cored wire etc.? according to the mechanical and
chemical properties required to specifications or section
II part / of (%)* codes for pressure vessels and boilers.
#ote the %-( classification and (0% class of the
required filler metal if given.
$ake reference of the - 8 #umber according to the %-(
classification as given in =0 8 742 >-or ferrous
materials onl?.

-or non 8 ferrous metals the - 8 #umber specifications is
not required.
(ccording to the chemical composition designate the ( 8
#umber according to that given in =0 8 772.
Page @ of 29
#ote down the post weld heat treatment conditions for
the use in production welds in accordance with the
conditions listed in =0 8 7A@.
)ention about the various electrical parameters to be
used in weldment considering the restrictions given in
=0 8 7A9.
*nter the details about the gas >shielding, trailing,
backing? along with its composition and flow rate >for
<$(0 9 -/(0? in accordance with the restrictions of
=0 8 7AB.
*nter the information about the technique used such as
single 9 multiple pass, single 9 multiple electrode,
cleaning required, method of backing gouging, peening
required, etc.
)ention the details of the deposited welded thickness
and thickness range qualified as follows.
a? In case of procedure qualification the thickness qualifies
is according to =0 8 7:A and =0 8 7:1 for groove and
fillet welds.
b? In case of performance qualification the thickness
qualified is according to =0 8 7:2 for groove and fillet
welds.
Page B of 29
c? -or hard 8 facing and corrosion resistant overlas the
qualification is according to =0 8 7:4.
$he details of alternate - 8 #umbers qualified b the
welder for use in production welding is given in =0 8
744.
)ention the details of the process, laer, filler metal,
current, voltage, polarit, travel speed, etc. as used the
weldment in the 0P%.
3.2 STEPS FOR MAKING A PQR:
$he P=1 contains the record of the actual variables used in the
weldment during testing.
)ost of the parameters in P=1 are same as that present
in the 0P%. !owever, some point to be taken care of
while making a P1 are as follows. 3
a? ( detail about the ,oint being welded is a mustC
hence the dimensions of the test coupon must be
mentioned. $he dimensions of the test piece for
procedure qualification shall be according to =0 8
2A2, for 4A2 for performance qualification.
Page 9 of 29
b? $he P=1 must contain the exact parameters such
as current, voltage, filler wire si6e, etc. that has
been used in qualification of the test coupon.
c? It should contain the results of the various tests
carried out in weldment according to the code.
d? In case of procedure qualification the various tests
shall be done in accordance with =0 8 2A2 for
various ,oints like fillets, grooves, etc. while that
for performance qualification the tests will be in
accordance with =0 8 4A2.
Page 1A of 29
4." WELDING VARIABLES:
(s mentioned earlier there are number of parameters which affect
the chemical and mechanical properties of the weldment. (lso the weld
8 ,oint prepared b the welder also is affected b change in the
parameters such as position, etc. hence the various welding variables for
procedure and performance qualification are subdivided into essential
variables, supplementar essential variables, and non 8 essential
variables.
4.1 ESSENTIAL VARIABLES:
*ssential variables are those in which a change, as described
in the specific variables, is considered to affect the mechanical
properties of the weldment, and shall require requalification of the
0P%. It is a change in welding condition, which ma affect the
properties of the weld or ma affect the soundness of the weld deposit
made b the welding operator 9 welder.
*.<. change in P 8 #umber or - 8 #umber, welding process, filler
metal, deletion or addition of backing, change in shielding 9 trailing 9
backing gas etc.
4.2 SUPPLEMENTAR# ESSENTIAL VARIABLES:
( change in weld condition, which will affect the notch
toughness properties of a weldment, is a supplementar essential
variable. It is required for metals for which other section specif notch
Page 11 of 29
toughness tests and are in addition to the essential variables for each
welding process.
*.<. change in welding process, uphill or down vertical welding etc.
4.3 NON $ ESSENTIAL VARIABLES:
( change in a welding condition, which will not affect the
mechanical properties of a weldment, is a non 8 essential variables. (
change in such variables does not requalification of the 0P%.
$he various essential and non 8 essential variables affecting
the 0P% and P=1 for different processes are listed in =0 8 2:A to =0
8 2;7.1 for procedure qualification and =0 8 4:A to =0 8 4B2 for
performance qualification
Page 12 of 29
5. SOME IMPORTANT CLAUSES RELATING TO
THE WPS:

-ollowing are a few details of few clauses which explain the
variables to be considered for specification 9 qualification 9
requalification for a 0P%, 0P= or P=1.
5.1 FILLER METAL % QW $ 4"4 &:
=0 7A7 states about the filler metal used in welding the
,oints. It shows the changes in filler metal characteristics in
the weld ,oint.
It states that.
( change in - 8 number requires re3qualification except as
permitted in =03 744.
(lso a change in %-( specification requires re3
qualification.
0hen a filler metal conforms to an %-( specification
classification, re3 qualification is not required if a change is
made in an one of the following.
Page 14 of 29
a? -rom a filler metal which is designated as moisture3
resistant to one that is not designated as moisture 8
resistant and vice versa e.g. * @A1B1 to *@A1B.
b? -rom one diffusible hdrogen level to another e.g. from
*@A1B3!B to *@A1B3!1;.
c? -or carbon, low allo, and stainless steel filler metals
having the same minimum tensile strength and nominal
chemical composition, a change from one low hdrogen
coating tpe to another low hdrogen coating tpe e.g.
*551:, 1; or *5551:, 1; or 1@ classification.
d? -rom one position3usabilit designation to another for
flux cored electrodes e.g. * @A$31 to * @1$31 or vice
versa.
e? -rom a classification which requires impact testing to
the same classification which has a suffix which
indicates that impact testing was performed at a lower
temperature or exhibited greater toughness at the
required temperature or both, as compared to the
classification which was used during procedure
qualification e.g. * @A1B to * @A1B31.
Page 17 of 29
f? -rom the classification qualified to another filler metal
within the same %-( specification when the weld metal
is exempt from impact testing.
'esignation of the nominal composition ma be given
b reference to (0% classification or (3number
designation.
( change in weld deposit made beond the range
qualified again requires re3qualification.
NOTE: =03744 lists the qualification range for -3
number during qualification testing.
5.2 'OINTS %QW 4"2 &:
=037A2 states about the variation in the various tpes of
grooves, backing gas9material used and the various other
parameter Ds affecting the characteristics of the welded ,oint.

( change in tpe of groove >2ee3 groove, E 8 groove,
%ingle 8 bevel, 'ouble 8 bevel, etc.?.
$he addition or deletion of a backing.
Page 1: of 29
( change in the nominal composition of the backing.
$he deletion of the backing in single 8 welded groove
welds. 'ouble 8 welded groove welds are considered
welding with backing.
$he addition of a backing or a change in its nominal
composition.
(n increase in the fit 8 up gap, beond that initiall
qualified.
$he addition backing.
( change in nominal si6e or shape of the stud at the
section to be welded.
In stud welding, a change in shielding as a result of
ferrule or flux tpe.
( change in the specified root spacing.
$he addition or deletion of nonmetallic retainers or
nonfusing metal retainers.
Page 1; of 29
$he welding procedure qualification test shall duplicate
the ,oint configuration to be used in production within
the limits listed, except that pipe or tube to or tube ma
be used for qualification of a pipe or tube to other
shapes, and solid round to solid round ma be used for
qualification of a solid round to other shapes.
a? (n change exceeding F93 1A degree. In the angle
measured for the plane of either face to be ,oined, to
the axis of rotationC
b? /hange in cross 8 section area of the weld ,oint
greater than 1AG.
c? /hange in the outside diameter of the clindrical
weld interface of the assembl greater than F931AGC
d? /hange from solid to tubular cross 8 section at the
,oint or vice versa regardless of >b? above.
( change in the ,oint from spot to pro,ection to seam or
vice versa.
( decrease in the center 8 to 8 center distance when the
welds overlap. (n increase or decrease of more than 1AG
Page 1@ of 29
in the spacing of the welds when the are within two
diameters of each other.
( change in the si6e or shape of the pro,ection in
pro,ection welding.
( decrease in the distance between the weld fusion line and
the final surface of the production corrosion 8 resistance or
hard 8 facing weld metal overla below the minimum
thickness qualified as shown in =0 8 7;2.:. $here is no
limit on the maximum thickness for corrosion 8 resistance
or hard 8 facing weld metal overla that ma be used in
production.
(n increase in the thickness of the production spra fuse
hard 8 facing deposit above the thickness deposit on the
procedure qualification test coupon.
5.3 BASE METAL %QW $ 4"3&:
=0 8 7A4 states the requirements of the base metals that
constitute the weldment.
( change from a base metal listed under one P 8 number in
=0 8 722 to a metal listed under another P 8 #umber or to
an other base metal. 0hen ,oints are made between two
Page 1B of 29
base metals that have different P 8 #umbers, a procedure
qualification shall be made for the applicable combination
of P 8 #umbers, even though qualification tests have been
made for each of the two base metals welded to itself.
$he maximum thickness qualified is the thickness of the
test coupon.
0here the measurement of penetration can be made b
visual or mechanical means, re 8 qualification is required
where the base metal thickness differs b 2AG from that of
the test coupon thickness when the test coupon thickness is
1 in. and under, and 1AG when the test coupon thickness is
over 1 in. 0here the measurement of penetration canHt be
made, re 8 qualification is required where the base metal
thickness differ b 1AG from that of the test coupon when
the test coupon thickness is 1 in. and under, and :G when
the test coupon thickness is over 1 in.
0elding procedure qualification shall be made using a base
metal of the same tpe or grade or another base metal listed
in the same group >%ee =0 8 722? as the base metal to be
used in production welding. 0hen ,oints are to be made
between base metals from two different groups, a
procedure qualification must be made for the applicable
combination of base metals, even though procedure
Page 19 of 29
qualification tests have been made for each of the two base
metals welded to itself.
0elding procedure qualification shall be made using a base
metal of the same tpe or grade or another base metal listed
in the same group >%ee =0 8 722? as the base metal to be
used in production welding. 0hen ,oints are to be made
between base metals from two different groups, a
procedure qualification must be made for the applicable
combination of base metals, even though procedure
qualification tests have been made for each of the two base
metals welded to itself.
0elding procedure qualification shall be made using a base
metal of the same tpe or grade or another base metal listed
in the same P 8 #umber and <roup 8 number >%ee =0 8
722? as the base metal to be used in production welding. (
procedure qualification shall be made for each P 8 #umber
and <roup 8 #umber combination of base metals, even
though procedure qualification tests have been made for
each of the two base metals welded to itself. If, however,
the procedure specification for welding the combination of
base metals specifies the same essential variables,
including electrode or filler metal, as both specifications
for welding each base metal to itself, such that base metals
is the onl change, then the procedure specification for
Page 2A of 29
welding the combination of base metals is also qualified. In
addition, when base metal s of two different P 8 #umber
and <roup #umber combinations are qualified using a
single test coupon, that coupon qualifies the welding of
those two P 8 #umber to themselves as well as to each
other using the variables qualified. $his variable does not
appl when impact testing of the heat3affected 6one is not
required b other section.
NOTE: =0 8 722 lists the P 8 #umbers and % 8 #umbers
of ferrous and non3ferrous base metals for qualification.
$he minimum base metal thickness qualified is the
thickness of the test coupon $ or :9B in., whichever is less.
!owever, where $ is less than I in., the minimum
thickness qualified is J $. this limitation does not appl
when a 0P% is qualified with a P0!$ above the upper
transformation temperature or when an austenitic material
is solution annealed after welding.
-or the multipasss processes of shielded metal 8 arc,
submerged 8 arc, gas tungsten 8 arc, and gas metal 8 arc,
the maximum thickness qualified for 1192 in. and over
thickness $ of the test coupon of =0 8 7:1.1 shall be B in.
for the conditions shown in =0 8 7:1.1. -or thickness
greater than B in. the procedure test coupon thickness of the
Page 21 of 29
,oint to be welded in production divided b 1.44 and the
maximum thickness of base metal and deposited weld
metal qualified is 1.44$ or 1.44t, as applicable.
NOTE: =0 8 7:1 specifies the procedure qualification
thickness limits and test specimens.
( change in base metal thickness beond the range
qualified b =0 8 7:1, except as otherwise permitted b
=0 3 2A2.7 >b?.
5.4 POSITIONS %QW $ 4"5 &:
=0 8 7A: enumerates the requirements in the positions used
during welding ,oints.
=ualification in hori6ontal, vertical or overhead position
shall also qualif for flat position.
=ualification in hori6ontal fixed position, :< shall qualif
for flat, vertical and overhead position.
=ualification in inclined fixed position ;< shall qualif for
all position.
Page 22 of 29
$he angular deviations permitted in the inclination of weld
axis and rotation of weld face are as defined in =0 8 7;1.1.
( test specimen shall be taken from the test coupon for
qualification in each special orientation.
( change in progression of travel from uphill to downhill, or
vice versa in vertical position requires no re3 qualification.
$he various positions put to use during welding are as shown
below.
5.5 PREHEAT %QW $ 4"(&:
It describes the preheat requirements.
)inimum temperature for preheat shall be specified in the
0P%.
$he minimum temperature for welding shall also be
specified in the 0P%.
Page 24 of 29
(n increase of more than 1AA - in maximum interpass
temperature recorded on P=1 requires requalification. $his
need not be true in case of P0!$ above the upper
transformation temperature or when as austenitic material is
solution annealed after welding.
5.( POSTWELD HEAT TREATMENT %QW $ 4")&:
It states about the requirements of post weld heat treatment.
-or P 8 #o. 1, P 8 #o. 7, P 8 #o. :, P 8 #o. ;, P 8 #o. 9, P
8 #o. 1A, and P 8 #o. 11 materials, the following post weld
heat treatment conditions appl.
a? #o P0!$.
b? P0!$ below the lower transformation temperature.
c? P0!$ above the upper transformation temperature
e.g. normali6ing.
d? P0!$ above upper transformation followed b heat
treatment below the lower transformation temperature
e.g. quenching followed b tempering.
e? P0!$ between the upper and lower transformation
temperature.
Page 27 of 29
-or all other materials, the following P0!$ conditions
appl.
a? #o P0!$.
b? P0!$ within a specified temperature range.
( change in P0!$ conditions requires a new P=1 to be
raised.
$he procedure qualification test shall be done in accordance
with the post weld heat treatment conditions encountered in
the fabrication of production weld.
-or a change of more than 1AG in number of post heating
ccles following the welding intervals a new P=1 has to be
raised.
( new P=1 has to be raised if heat treatment is performed
separatel from the welding operation.
( change in post weld heat condition of 2:G in the total
time at post weld heat treating temperature requires a new
P=1 to be made.
5.) GAS %QW $ 4"*&:
=0 8 7AB states the requirements of the gases
>trailing, backing, shielding? used in the welding the
,oints.
Page 2: of 29
( separate P=1 is required for each of the following
condition. 3
a? ( change from one shielding gas to another.
b? ( change from single shielding gas to a mixture of
gases.
c? ( change in percentage composition of the mixture of
shielding gas.
d? $he addition or omission of shielding gas.
( change in oxgen or fuel gas pressure beond the range
qualified requires requalification.
( change of more than :G in the flow rate of the plasma 8
arc gas or powdered gas or powdered metal feed gas
recorded on the P=1 requires a new P=1.
( change in nominal composition of the powdered feed gas
or >plasma 8 arc spra? plasma gas qualified requires
requalification.
5.* ELECTRICAL CHARACTERISTICS %QW $ 4"+&:
=0 8 7A9 states the requirements of the various electrical
parameters used in welding.
Page 2; of 29
( change in the polarit i.e. *# to *P and vice versa, in
'/ welding or from (/ to '/C requires a change in P=1.
(n increase in heat input or an increase in volume of weld
metal deposited per unit length of weld, over that qualified
requires requalification. $his is not required when the 0P%
is qualified with a P0!$ above the upper transformation
temperature or a solution annealed after welding austenitic
materials.
( change in the power source model requires no separate
P=1s provided the parameter used remain the same.
( change of more than :G in the electrode pressure, the
welding current, or the welding time from that qualified
requires requalification, except that requalification is not
required if there is a change of not more than 1AG in either
the electrode pressure or the welding time ccle, provided
the remaining two variables remain at the values qualified.
( change in beam current of more than :G, voltage of
more than F932G, gun 8 to 8 work distance of more than
F93:G, or a change in oscillation length or width of more
than F932AG from those qualified requires requalification.
Page 2@ of 29
( change of more than 1AG in the range of amperage or
voltage qualified requires requalification.
5.+ TECHNIQUE %QW $ 41"&:
=0 8 71A states the technique to be used during welding.
( change from multipass per side to single pass per side
requires requalification. $his limitation does not appl when
a 0P% is qualified with a P0!$ above upper transformation
or when an austenitic material is solution annealed after
welding.
1equalification is required for a change from single
electrode to multiple electrodes, or vice versa, for machine or
automatic welding onl. $his limitation does not appl when
a 0P% is qualified with a P0!$ above the upper
transformation temperature or when an austenitic material is
solution annealed after welding.
(ddition or deletion of peening requires requalification.
( change from manual to automatic and vice versa raises a
need for requalification.
Page 2B of 29
0hen there is addition or deletion of an electrode3cooling
medium a new P=1 must be raised.
( change of more than 1:G in the travel speed range
recorded on the P=1 require requalification.
( change of more than 1:G in spra 8 torch to workpiece
distance qualified requires a new P=1.
( change of more than 1AG in oscillation motion as
recorded on the P=1 requires a new P=1.

Page 29 of 29