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Welding Procedure Qualification
Welding performed in accordance with any Australian or International Standard requires the completion and approval of a Welding Procedure Qualification Record (WPQR/PQR/WQR). This involves the welding of a specific size/type of coupon or test piece under welding supervision and the performance of the necessary examinations and mechanical tests to be undertaken.
Upon satisfactory results, the essential variables recorded throughout the supervision process are incorporated in a Welding Procedure Qualification Record which serves as proof that a satisfactory and compliant weld was produced under recorded conditions.
What constitutes an essential variable, and tests required for qualification are nominated in the application specification. Typical qualification standards include AS/NZS 1554 (all parts), AS 3992, ASME IX, ISO 15614-1 and a variety of others.
Welding Procedure Specification
After successful completion of a Welding Procedure Qualification Record, the application standard will nominate what constitutes an essential variable - this normally falls in line with the material type and/or product specification and is appropriate for the intended purpose for which the procedure will be utilised. These essential variables are prescribed with nominal ranges which may be employed for use in production welding without the mechanical or metallurgical properties of the weldment being adversely affected with regard to its intended purpose.
A Welding Procedure Specification is the document which employs all the allowable essential variable ranges as defined in the application standard and serves as welding instruction to be followed on the shop floor or site location. Typical common examples for essential variables may be but are not limited to Material types/grades, material or deposited thickness/es, welding process/es, consumable classifications, Amperage, Voltage and Travel Speed.
Welder Qualification
In addition to Welding Procedures to be qualified, there is also a requirement for your welding operators to be qualified. Documentary evidence needs to be maintained showing Welders can produce acceptable quality welds for the Welding Process, Joint types, positions and materials to be welded. Initial qualification is usually performed through the welding of a suitable test piece, and the nominated Non-destructive and Mechanical Tests performed in accordance with the application standard to prove quality or compliance.
Once again, some ranges of qualification can be employed as allowed in the governing standard or specification, and re-validation or requalification requirements as defined in said standards need also apply, often possible through non-destructive techniques on production welds.
Typical Specific Qualification standards include AS/NZS 2980, AS 3992 & ISO 9606-1, however Welder Qualifications may also be covered within the application standards.
Welding Quality Documentation
As with most things these days - the jobs not finished until the paperwork is. The paperwork acts as evidence of product and process compliance. Welding quality documentation is no different, and can also provide traceability, planning and co-ordination of all welding and welder qualification data to ensure that your procedures cover your next project requirements, and you welders continue to hold current qualifications. This can all be easily tracked through use of a Welding Qualification Register, with references to all your Welding Procedure Qualification Records, Welder Qualification Records, Mechanical and Non Destructive Tests and Welding Procedure Specifications
