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    Preparation WPS (Welding Procedure Specification)

    2008.

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    Preparation WPS

    WPS (Welding Procedure Specification) Preparation

    WPS is prepared according to ASME Sect. & based on PQR.There is not required preparing PQR when it is prequalified by AWS.

    The completed WPS shall describe all of the essential, nonessential, and , when

    required, supplementary essential variables for each welding process used in wps.

    1) Applicable Code

    Record the applicable code that are ASME , , , , ASME/ANSI B31.1,AWS D1.1, TRD 201, etc.

    2) WPS NO (Specification No )

    It is given the serial no according to applicable code, welding process,

    material specification.

    ) A

    M

    0101

    001

    A : classification of applicable code

    - A : ASME(I, III, VIII, ASME/ANSI B31.1) W : AWS (D1.1, D14.1) X : TRD 201

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    Preparation WPS

    M : classification of welding process (ex. TM, TMA ..)

    - A : SAW F : FCAW G : GMAW M : SMAW T : GTAW

    S : STUD TF : GTAW + FCAW TM : GTAW + SMAW MA : SMAW + SAW

    0101 : given the P-No of combined material (for example : P-No.1 + P-No.1 = 0101)

    - ASME, ASME/ANSI:write P-No classified in QW-422

    - AWS D1.1: write group no of material classified in Table 3.1.- Writes Z0Z0when it doesnt classified in P-No.

    001 : serial no

    3) Date

    Writes its date when WPS is issued with first. (for example : Jul, 06. 1995)

    4) Rev. No. (Revision No.)

    Write Revision No. of WPS (0,1,2,3,4,5,6,A,B,C,D)

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    Preparation WPS

    5) Date

    write its the date when WPS is revised

    6) Relation number of this PQR (Supporting PQR No.)

    Specified Supporting PQR No.

    If there are satisfied essential variable by a PQRs standard, It is possible that

    prepared

    other various WPS.(ASME IX QW-200.2 f)

    7) Welding Process

    Write in a blank of Welding Process

    8)

    Type of joint

    Write a Welding Process Type

    Manual : GTAW, SMAW Semiautomatic : FCAW, GMAW, STUD

    Auto : Orbital GTAW Machine : SAW

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    Preparation WPS

    Joints QW-402)

    9) Joints

    Write the type of Joints(for example : Single-V, Double-V, Fillet , etc)

    Sketch of joint figure

    ASME

    - Groove

    Write Square-, Single-, Double-, Single Bevel-, Double Bevel-, Single U-,Double U-, Single J-, Double J-, etc

    But various forms of Groove Write - Groove

    - Fillet : Write Fillet- Composition : Grooves & Fillets

    AWS

    AWS D1.1 Figure 2.4, 2.5

    division Butt, T, Corner and addition Joint Designation.ex) Butt Single bevel Groove (B-U4a)

    TRD 201- Groove : Butt (Square, Single V-) Groove- Fillet : Fillet

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    Preparation WPS

    10) Root Gap (mm)

    Choice the proper size to maintenance the soundness of back bead

    (Generally, Max.5mm)

    11) Retainer

    it is frame that progressed Back Bead.

    Write Noneor Yes

    12) Backing

    When backing is used, it shall describe information in detail.

    (for example : Base Metal, Weld Metal, Ceramic Bar, etc)

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    BASE METAL QW-403)

    13) P-NO

    : According to QW-422 in ASME

    To reduce the number of welding procedure qualifications required, base metals have

    been

    assigned P-Numbers. These assignments are based essentially on comparable base

    metal

    characteristics, such as composition, weld ability, and mechanical properties)

    14) Gr-NO : According to QW-422 in ASME

    To reduce the number of welding procedure qualification required, base metals which

    have

    specified impact test requirements, have been assigned group number within P-

    Numbers)

    15) Spec. Grade

    When required, it will be written.

    - generally, write the chemical composition, thickness limitation required in order to

    except

    heat treatment specified in PW-39 of ASME.

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    Preparation WPS

    Fillet : UNLIMITED

    - AWS : apply D1.1 Prequalified Joint thick range.

    If it is accomplished PQ Test, Apply Table 5.1, 5.2, 5.3- TRD 201 : Annex 3.3.1, 3.3.2

    - ASME : Apply IX QW403.6 ~ 14 or QW451

    If it is not operated PWHT, Apply thick restriction depend on exemption PWHT

    by Note of Code of PWHT

    17) Range of pipe (or tube) diameter

    When performed the heat treatment: record with Unlimited

    When didnt perform the heat treatment: write the maximum outside diameter

    specified for

    exempt heat treatment in ASME (PW-39), ASME (UCS-56), and ASME/ANSI

    B31.1

    (TABLE 132).

    AWS : write Unlimited(have no limitation).

    18) Max. Thick per Pass(mm)

    - ASME: Limited as Max. 12.7mm for SMAW, SAW, GMAW, FCAW, FSW, EGW in

    QW-403.9 of ASME .

    - AWS D1.1 : Limited according to Table 3.7 of Chapter 3.

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    Position QW-405)

    19) Position

    ASME - Write as Allbecause position is non-essential variable in QW-405.1

    AWS D1.1 - Prequalified Joint: Applied the position specified in Figure 3.3, and 3.4.

    - Qualified Joint: Applied Table 4.1

    Groove welding required toughness

    Vertical-Up All Position Cover

    Stringer Bead - Weave Bead not Cover

    OVERLAY position

    PQR WPS PQR WPS

    V(UP) F, V H, V, OH ALL

    H F, H 5G F, V, OH

    OH F, OH 6G ALL

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    20) Progression of vertical Position

    When welded with vertical position: Write either UPor DOWN.

    When welded without vertical position: Write N/A.When welded with Orbital welding: write both UPand DOWN.

    Preheat QW-406)

    Selected the proper temperature according to the requirement of code like follows

    and

    contract.- ASME : Appendix A-100 and PW-39- ASME : Appendix R, Table UCS-56- ASME/ANSI B31.1: Para. 131.4, Table 132

    - AWS D1.1: Table 3.2

    21) Preheat Temp. Min.

    - ASME I : PW-39 and Appendix A-100- ASME VIII : Apendix.R, Table UCS-56

    - ASME / ANSI B31.1 : Para.131.4, Table 132

    - AWS D1.1 : Table 4.3- TRD 201 : Matl Spec, Mill Maker Spec

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    21)Interpass Temp Max.

    Max temperature of deposited weld metal before next layer welding when operated

    multi

    pass welding.

    Generally apply below for your reference but when special situation apply code and the

    terms of contract desired.

    A turn around from welding start point is 1Pass. Second pass start point doesn t over350 .

    23) Preheat Maintenance

    If it is required the preheat maintenance, holding temperature and holding time shall be

    recorded on wps.

    Interpass Temp Max()

    C/S LOW ALLOY

    STEEL

    350

    Allowance Temperature :

    In ASME Temp of

    Allowance PQR addition 56

    AUSTENITIC SUS 177

    HIGH-Ni, Cu-ALLOY 150

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    Preparation WPS

    Postweld Heat Treatment QW-407)

    24) Postweld Heat Treatment range of temperature and time.

    Selected the range of temp. and time for PWHT according to applicable code and spec.

    - ASME : According to the PW-39 and PW-39.3.If it is heated for products with heavy wall thickness, it shall be followed for

    rate

    of heating and cooling, and temperature of loading and unloading in

    accordance with the UCS-56 of ASME.- ASME : According to table UCS-56- ASME/ANSI B31.1 : According to table 132

    - AWS D1.1 : According to Para. 5.8

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    Preparation WPS

    Gas QW-408)

    25)

    Gas

    Write with the chemical symbol that is including chemical composition and flow rate.

    (Refer to below table)

    disposition Inactivity gas : Ar, He, etc.

    (There are not caused reaction other element in arc plasma.)

    activity gas : CO, N, etc.

    Ar : Most effective shielding when TIG welding. Well ionization and good

    stableness.

    He : Not apply MIG welding because ionization potential is low.

    Ar + He : 25:70, 30:70 Auto welding of low alloy. 80:20 Apply SUS TIG Welding.

    Ar + CO : 70:30, 95:5 Apply carbon steel or alloy. Arc is stable and low spatter.

    Process

    Material

    Gas

    CompositionFlow rate

    Flow rate of

    backing gasSize of gas cup

    GTAW

    Carbon,

    Low alloy

    S/S

    Ar, Ar+He

    8 ~ 15 L/M

    4 ~ 8 L/M

    9 ~ 13mm

    FCAW

    CO2, Ar+CO2 20 ~ 25 L/M - 12 ~ 20mm

    GMAW CO2, Ar+CO2 20 ~ 25 L/M - 12 ~ 20mm

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    Preparation WPS

    Ingradients : Welding Grade 99.99 % or more

    Use

    Shielding Gas : Shielding for arc when welding. prevent O, N, H

    Backing Gas : Use the other side of base metal. Because prevent oxidation.

    Trailing Gas : Active Metal(Zr, Ti, etc.) welding.

    There are shielding weld metal from the air after solidification.

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    Preparation WPS

    Technique QW-410)

    26) Orifice gas cup size :

    Applied to GTAW, GMAW, and FCAW Process(Refer to above table)

    27) Contact tube to work distance : Applied to GMAW, FCAW, and SAW process

    (Refer to below table)

    Welding Process