CODE, STANDARD,

WELDING PROCEDURE &

WELDER QUALIFICATION
Prof. Dr. Ir. Winarto, M.Sc.
 DEFINISI
 “Standard” adalah kumpulan dokumen-dokumen berisikan
kode (codes), spesifikasi (specification), Saran aplikasi
(recommended practice), klasifikasi, dan petunjuk (guide)
yang telah dipersiapkan oleh suatu institusi organisasi dan di
sahkan (approved) sesuai dengan prosedur yang ada
(berlaku).

 “Codes” adalah suatu standard yang berisikan kondisi dan

persyaratan yang berhubungan dengan bidang khusus (a
particularly subject) dan mengindikasikan bahwa prosedur
yg digunakan telah sesuai dengan persyaratannya. Codes ini
HARUS diikuti (mandatory) karena menyangkut
kepentingan umum yang merefer kepada kebijakan otoritas
pemerintahan. (Codes is a body of laws arranged
systimatically for easy reference)
 DEFINISI
 “Specification” (spesifikasi) adalah suatu
standard yang berisikan penjelasan yang rinci
dan akurat tentang persyaratan teknis dari
material, produk, sistim atau jasa.
 Contoh Kode :
– Structural Welding Code-Steel (AWS D1.1)
– Boiler & Pressure Vessel Code (ASME)
– Welded Pipeline & Vessel (API)
 Contoh Specification :
– Filler Metal Specification (AWS A5.X)
– Material & Consumable of Welding (ASME sec. IIC)
CONTOH APLIKASI
ASME Sec VIII

ASME
B31.3

AWS D1.1
 CONTOH APLIKASI
API 6A Crismas
Tree / Well Head

Refinery / Kilang/
Processing Plant

Pipe line penyalur

ASME B31.8  Gas

API 1104  Oil
ASME B31.1  Steam (Geotermal)
 AWS – Structural Welding Code

 AWS D l.1, Structural Welding Code—Steel

 AWS D l.2, Structural Welding Code—Aluminum
 AWS D l.3, Structural Welding Code—Sheet Steel
 AWS D l.4, Structural Welding Code—Reinforcing Steel
 AWS D l.5, Bridge Welding Code
 AWS D l.6, Structural Welding Code—Stainless Steel
Welding Code – Steel (AWS D.1.1)
ASME STANDARD
 API - STANDARD
 API 1104, Standard for Welding Pipeline
and Related Facilities
 API 620, Recommended Rules for Design
and Construction of Large Welded Low-
Pressure Storage Tanks
 API 650, Standard for Welded Steel Tank
for Oil Storage
Persyaratan Dasar dalam Menentukan
Kualitas dalam Pengelasan
 Standar Eropa dan Amerika
dalam mendukung Kualitas Lasan

 ASME (American Society of Mechanical

Engineers)
 EN (European Norm) / European Standard
 AWS (American Welding Society )
 ASME Standard untuk Welding

 ASME Sec IX (Qualification Standard for

Welding and Brazing Procedure, Welder,
and Welding & Braze Operator.
 ASME Sec II C Standard for Material and
Consumable of Welding.
STANDARD KUALITAS LAS dari ASME
Basic Construction Code / Standard :
•ASME Sec I, ASME B31.1 , ASME B31.3
•ASME Sec VIII Div I & 2

Examination and Welding Personnel

Testing And Welding
Quality of
• ASME V Welds Procedure
• ASME IX

Welding Material
• ASME II C
European Standard For Welding

 EN 288 (Standard & Qualification Welding

Procedure)
 EN 287 ( Standard & Qualification of
Welder)
 EN 1418 ( Standard & Qualification of
Welding Operator )
STANDARD KUALITAS LAS dari EN
 PROSEDUR LAS - EN 288
 EN 288 - 1 . General rules fusion welding.
 EN 288 - 2. WPS for Arc Welding
 EN 288 - 3. Welding procedure test for Arc welding of
steel.
 EN 288 - 4. Welding Procedure Test for Arc welding
of Aluminum and It’s alloys
 EN 288 - 5. Approval by using approved welding
consumables for arc welding
 EN 288 - 6. Approval related to previous experience
 EN 288 - 7. Approval by a standard welding procedure
for arc welding
 EN 288 - 8. Approval by a pre-production welding test.
 KUALIFIKASI WELDER - EN 287
 EN 287 - 1 . Approval testing of welders – Fusion welding
part 1 : Steels.
 EN 287 - 2. Approval testing of welders – Fusion welding
part 2 : Aluminum and aluminum Alloys.
 EN 287 - 3. Approval testing of welders – Fusion welding
part 3 : Copper and Copper Alloys.
 EN 287 - 4. Approval testing of welders – Fusion welding
part 4 : Nickel and Nickels alloys
 EN 287 - 5. Approval testing of welders – Fusion welding
part 5 : Titanium and Titanium, Zirconium and Zirconium
alloys
 EN 288 - 6. Approval related to previous experience
 EN 288 - 7. Approval by a standard welding procedure for arc
welding
 EN 288 - 8. Approval by a pre-production welding test.
POSISI LAS - ASME IX
POSISI LAS - EN 288
POSISI LAS - AWS
Table 1 Examples of application codes and standards and related welding procedure and welder approval standards

Welding Standard
Application
Application Procedure Welder
code/standard
approval approval
Pressure BS 5500 BS EN 288 BS EN 287
ASME VIII ASME IX ASME IX
Vessels
Process BS 2633 BS EN 288 (Part 3) BS EN 287 (Part 1)
BS 4677 BS EN 288 (Part 4) BS EN 287 (Part 2)
Pipe-work ANSI/ASME B311 ASME IX ASME IX
ANSI/ASME ASME IX ASME IX
B31.3 BS EN 288 (Part 3) BS 4872/BS EN 287
BS 2971 (if required)
Structural AWS D1.1 AWS D1.1 AWS D1.1
AWS D1.2 AWS D1.2 AWS D1.2
Fabrication BS 5135 BS EN 288 (Part 3) BS EN 287
BS 8118 BS EN 288 (Part 4) BS EN 287
BS 4872
Storage BS 2654 BS EN 288 (Parts 3 & 4) BS EN 287
BS 2594 BS EN 288 (Parts 3 & 4) BS EN 287
Tanks API 620/650 ASME IX ASME IX
 Stages in welding procedure and welder approval

Development of
Application standard
procedure
Contract
Project Specification
p WPS
Drawings

EN 288, ASMEIX, Approval of

AWS D1,1 procedure

WPAR
Welder approval Finalisation of
certificate procedure

Welding procedure specification

6 months
prolongation
Release for
production
2 years
prolongation
Work instruction
WPS itu apa ?

 Bahan dasar

 Bumbu

 Cara membuat

RESEP
WPS itu apa ?

 Material

 Elektroda

 Proses
Pengelasan

WPS
WPS itu apa ?

RESEP = WPS
 WPS itu apa ?

Di dalam industri makanan, Resep digunakan

untuk menunjukkan komposisi bahan dasar &
bumbu serta cara memasak agar
menghasilkan kualitas makanan yang
diinginkan.

Di dalam industri pengelasan, Welding

Procedure Specification (WPS) digunakan
untuk menunjukkan kombinasi dari variabel
pengelasan agar menghasilkan kualitas
pengelasan yang diinginkan/disyaratkan.
 WPS itu apa ?

• Minimal variabel yang ada di dalam WPS

adalah :
 Material (A36, A572, dll)
 Proses (SMAW, FCAW, dll)
 Spesifikasi kawat las (AWS A5.1, A5.20, dll)
 Klasifikasi kawat las (E7018, E71T-1)
 Diameter kawat las (2.5, 3.2, 4.0)
 Minimum preheat dan interpass temp.
WPS itu apa ?

 Travel Speed
 Posisi pengelasan (F, H, V, OH)
 Post Weld Heat Treatment
 Shielding gas type & flow rate
 Kuat Arus (ampere)
 Tegangan (volt)
 Model sambungan (Groove, Fillet)
Qualification
&
Certification
 Welding Procedure Specification (WPS)
A document that provides in detail required welding
conditions for a specific application.

Procedure Qualification Record (PQR)

A record of actual welding conditions used to produce an
acceptable test joint and the results of the qualification tests.

Welder Performance Qualification-Certification

A record of a welder’s or welding operator’s ability to produce
welded joints that meet prescribed standards
 Pre-Qualified Procedures
(Some Codes Permit - Example AWS D1.1 Code)
Based on the reliability of certain proven procedures
spelled out by the applicable code or specification

• Use Written Procedures From Code

• All Essential Variable Specified
• Weld Qualification Tests Not Required
• Employer Accepts Responsibility for Use
• Deviations Negate Prequalified Status
Basic Steps in Qualification of a Procedure

1. Prepare a preliminary WPS

2. Prepare and weld a suitable test weldment using WPS
3. Conduct required NDT and Destructive Tests
4. Evaluate Results of prep, welding, testing
5. Document results on PQR
6. Issue approved PQR
7. Issue approved WPS
 PQR - WPS Variables Considered
• Base Metal • Tack Weld/Grind Off?
• Welding Process • Welding Details
• Filler Metal • Electrode Size
• Type of Current/Range • Passes
• Voltage •Weave
• Heat Input • Position *
• Travel Speed • Preheat and Interpass
• Joint Design and Tolerances • Peening
• Joint and Surface Prep • Second Side Prep
• Post Weld Heat Treat
• Records (If Required)

Check Specific Code for List of Essential Variables

(Essential Variable Must Be Included in the WPS)
PQR
Page 1
PQR
Page 2
Tests Commonly Used for PQR’s

Test Evaluation
Fracture Tests Risk of Brittle Fracture at Use
(Charpy, COD, Drop) Temperature
Nick-break Determine Weld Soundness
Free Bend Ductility of Weld Metal
Shear Test Shear Strength of Fillet Welds
Hardness Adequacy of Heat Treatment
All-Weld-Metal Tension Mechanical Prop of WM
Elevated Temp Prop at Elev. Service Temp
Restraint Test Crack Susceptibility
Corrosion Prop. In Aggressive Environ.
NDE Soundness of Weld
Delayed Cracking Resistance to H Cracking
WPS
 Welder Performance Qualification

Variables
• Welding Process
• Filler Metal
• Position
• Joint Details
• Thickness
• Technique
(Qualifying in a more difficult position
may qualify in an easier position)

Duration Of Qualification
Dependent upon Code
(Usually inactivity of 3 to 6 months required requalification)
Performance
Qualification
Record
Welding Procedure and Performance Qualification Variable That May Require Requalification

Procedure Variable Procedure Requalification Welder or Operator

Base Metal (Type, Change in BM, Some Codes
Composition, Process)
Thickness of BM
Joint Design
Pipe Diameter
Type of Current, Polarity
Electrode Classification, Size
Welding Current
Position, Progression
Deposition of Filler Metal
Root Prep , Other Side When Method or Extent Has
Preheat, Interpass Temp
Postheat Temp
May Be Required Requalification
Usually Not Required
List Equivalencies
Change Outside Thickness Change Outside Range
Range
Change in Root, Included Change in Root, Included
Angle, Dimensions Angle, Dimensions
Usually Not Required When Reduced Below Some
Minimum
Usually Not Required Usually Not Required
Change in Electrode Change in Electrode
Classification or size Classification or size
When Outside Range Usually Not Required
Usually not Required, But When Change Exceeds Limits
Desirable
For Marked Changes Usually Not Required
Usually Not Required
Changed
When Outside Range Usually Not Required
When Outside Range Usually Not Required
TWI

Welding Procedures
 The Welding Procedure
• A welding procedure gives the precise details of the
steps by which the welding of certain type of joint or
‘weldment’ is to be carried out.
• It contains the necessary details or range of details
for the control variables used in welding and
specifies the materials and joint design to be used
• The procedure thus controls the quality of the weld
controlling each individual step required to be taken.
 Class of work
• There are many classes of work which require engineering
materials to be joined by welding e.g. pressure vessel, bridges,
oil rigs, earth moving equipment, however, the requirements in
respect to the quality of the joint differ immensely and must be
controlled in respect to the ‘fitness for purpose approached’
• Pressure vessel – withstand stress induced by high temp.
• Bridges – the effect of differing vehicle loads & wind loading
• Oil rigs – to withstand the effect of wave formation
 Class of work
Code or Standard Nr. Class of work
• BS 5500 Unfired fusion welded pressure vessel
• ASME IX Procedure and welding and approvals
• AWS D 1.1 Structural welding code
• BSEN 288 Welding procedure approvals
• BSEN 287 Welder approvals
 The welding Procedures
Items to be included in the procedure are the main contained with the
appropriate standard or code and listed below are the essentials
details :-
• Welding process
• Parent material - S,T, C
• Whether shop or site welding
• Edge preparations
• Method cleaning
• Fit up of joint (sketch)
• Welding position
• etc
 Welding Procedure
Specification (WPS)
 A document providing in detail the required
variables for a specific application to ensure
repeatability.
Procedure Qualification Record
(PQR)

 A record comprising all relevant data

from the welding of A test piece needed
for approval of A welding procedure
specifications as well as all results from
the testing of the weld test
 Welder Qualification Test
(WQT)
 To determine the welder’s ability to deposit
sound weld metal.
 The purpose of the qualification test for the
welding operator is to determine the welding
operator’s mechanical ability to operate the
welding equipment.
TWI

Preliminary Welding Procedure

Specification (pWPS )
 A tentative welding procedure specification,
which is assumed to be adequate by the
manufacturer, but which has not been approved
 Welding Variables

 Essential Variables
- Essential 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 WPS e .g base metal thickness ,P no , F no
etc.
 Welding Variables

 Non Essential Variables

- non essential variables are those in which a
change, as described in the specific variables,
may be made in in the WPS without
requalification e.g change groove design, etc.
 Welding Variables

 Supplementary Essential Variables

 Variables are required for metals for which other
section specify notch - toughness tests are in
addition to the essential variables for each
welding process e.g. change group no, base metal
thickness limit PWHT, preheat temperature etc.
 Range of Approval

 The Extend of Approval for an Essential Variables.

e.g base metal thickness , diameter of pipe welding
position etc
 SHALL
A mandatory practice which will required change of WPS if
not followed

SHOULD
A recommended practice which will not required any
new WPS if not followed
 Sample of WPS
WELDING PROCEDURE SPECIFICATION
SECTION IX, ASME BOILER AND PRESSURE VESSEL

Company name : Doc No :

Date :
WPS No :
Revision No :

Supporting WPQR:
Type ( S ) :
Welding process :

JOINT ( QW - 402 ) JOINT DESIGN

Joint Design :
Backing : Yes No
Backing Material

Metal

Non
Metal
Non Fusing Metal

Other
BASE METAL ( QW - 403 )

P No : Group No : to P No : Group No :

Specification Type and Grade : To

Specification Type and Grade : To

OR
Chemical Analysis and Mechanical Properties :

Chemical Analysis and Mechanical Properties :

THICKENESS RANGE
Base Metal : Fillet :

PIPE DIAMETER RANGE

Groove: Fillet :

Others :
FILLER METAL ( QW - 404)

Spec No ( SFA )
AWS No
A - No
Size of filler Metals

WELD METAL
Thickness : Groove
Fillet

Electrode - Flux ( class )

Flux Trade name
Consumable Insert

Others : Storing & Re-drying

POSITION ( QW - 405 ) POSTWELD HEATREATMENT ( QW - 407 )
Position ( S) of groove :
Temperature Range :
Welding Progression : UP
Down Time Range :
Position of fillet :
PREHEAT ( QW - 409 ) GAS ( QW - 407 )

Preheat temperature : Min Gases % Com/mix Flow

rate
Interpass Temperature :
Shielding :
Preheat Maintenance
Trailing :
( Continue or Special heating where Applicable should
be recorded ) Backing :

ELECTRICAL CHARACTERISTICS ( QW - 409)

Current AC or DC :
Amps ( Range ) : Volts :
( Amps and volts should be recorded for each electrode size,
position and thickness and etc. This information may be
listed in a tubular form similar to that shown below)

Tungsten Electrode Size, Type :

Mode of Transfer :
Electrode wire speed range :
TECHNIQUE ( QW -409 )
String or Weave Bead :
Orifice or gas cup :
Initial and Interpass Cleaning
( brushing , grinding and etc )
Method of back Gouge :
Oscillation :
Contact tube to work distance :
Multiple or Single Electrodes :
Travel Speed ( range) :
Peening :

Filler Metal Current Voltage Travel Speed Heat

Weld Process class Type of Range (cm/min) input
Dia. (mm) Amperage
layer polarity (kj/cm)
 Sample of PQR
PROCEDURE QUALIFICATION RECORDS (PQR)
SECTION IX, ASME BOILER AND PRESSURE VESSEL

Company name : Thermo Industrials Boilers and Vessels Doc No : EPMI /VE/02
Date : 6/06/2002
PQR No :
FW/006/2002 Revision No : 0

WPS NO : FW /006/2002 -1

Welding process : GTAW and SMAW Type ( S ) : Manual

JOINT ( QW - 402 )

4
3
2

1
BASE METAL ( QW - 403 ) POST WELD HEAT TREATMENT( QW - 407 )

Materials specification : SA 106 Temperature : N/A

Other : N/A
Type and Grade : GR B

P No : 1 to P.NO 1
OR
Thickness of test coupon : 5.5 mm

Diameter of test coupon : 88.9 mm

Others :
FILLER METAL ( QW - 404) GAS ( QW - 408)

Spec No ( SFA ) : 5.18 ( G) , 5.5 (S) Gases(es) (Mixture) Flow rate

AWS No : ER 70 S – 6 , E 7018 - G Shielding Argon 99.9% 5-9 L/pm
Filler metal F No : 6 4 Trailing - - -
Weld metal analysis A : 1 1 Backing - - -
ELECTRICAL CHARACTERISTICS (QW – 40)
Size of filler metal : 2.4 mm 2.5 mm
Current : Direct current
Others
Polarity : Straight
Deposited weld metal : 2 mm 3.5 mm
Amps : 85 ( G) , 100 (S) Volts : 17(G) , 25(S)
POSITION (QW – 405)
Tungsten electrode size : 2..4 mm ( G) , 2.5 ( S )
Position of groove: 6G
TECHNIQUE ( QW – 410 )
Weld progression : Uphill
Travel speed : 3.6 mm/min ( G) , 6.5 mm/min ( S)
Others :
String or weave bead : String (G) ,weave ( S)
Oscillation :-
PREHEAT (QW – 406)
Multi-pass or single pass : Single ( G) , Multi (S)
Preheat temperature : 380 C
Single or Multiple Electrodes : Single
Inter-pass temperature : 2000 C
Other :
Others :
 Filler Metal Current Voltage Travel Speed Heat input
Dia. (mm) (cm/min ) (kJ/cm)
Weld Process class Type of Amperage
layer polarity

1 TIG ER 70S – 6 2.4 DCSP 87 37 3.6 35.65 kJ/cm

2 SMAW E 7018 -G 2.5 DCSP 76 40 4.2 43.42 kJ/cm
3 SMAW E 7018 – G 2.5 DCSP 97 51 6.5 45.66 kJ/cm
4 SMAW E 7018 - G 2.5 DCSP 141 25 4.7 45.00 kJ/cm
Tensile Test ( QW – 150)

Specimen Thickness Area Ultimate Ultimate Results

Width
No mm Sq - mm Total Load ( kg) Unit stress ( N/mm2)
T1 ( Top ) 19.22 22..10 424.78 23895 551.70 Ductile broke
at base metal
T1 ( Bottom ) 19.49 21.45 418.06 238805 558.43 Ductile broke
at base metal
T1 ( Top ) 19.26 22..28 429.11 23895 546.10 Ductile broke
at base metal
T1 ( Bottom ) 19.31 22..16 427.91 24240 555.54 Ductile broke
at base metal

Bend Test ( QW – 150)

Type and Specimen No Results

Side bend – S1 No visible defects

Side bend – S1 No visible defects

Side bend – S1
No visible defects

Side bend – S1 No visible defects

 Toughness test ( QW – 150)

Specimen Notch type Test Temperature Impact value Drop breaks

Notch weight (y/s)
No location Joule % Shear Mils
1.2.3 Weld metal (top) V - 20 0 C 30.86.162 - - -

1.2.3 HAZ(top) V - 20 0 C 146.44.158 - - -

1.2.3 Weld metal (center) V - 20 0 C 122.86.168 - - -

1.2.3 HAZ (center) V - 20 0 C 206.192.150 - - -

Comments : Satisfactory
Fillet Welds Test ( QW – 180 ) – N/A
Results satisfactory :__________________ No. __________________ Penetration I nto parent metal : Yes _____ No _______
Macro results : Satisfactory
Type of test : Hardness Test
Deposit Analysis : See attachment documents
Other :______________________________________________________________________

Welder Name : John Bloggs I/C No . 550-727-08-5479 Stamp No . FWW 79

Test conducted by : Thermo Industries Boilers and Vessels Sdn Bhd Laboratory Test No . MAT/3748- 01/2015
We certify that the statements in this records are correct and that the test welds were prepared , welded and tested in accordance with the
requirements of section IX of the ASME code.
Manafacturer : Thermo Industrial Boilers and Vessels Sdn Bhd
Date : 12/2/2015 By :
 Sample of WQT
WELDER / WELDING OPERATOR QUALIFICATIONTEST SECTION IX ASME BOILER AND PRESSURE VESSEL
CODE
Welder’s name : Joe Bloggs

IC No : 680510-08-5553

Stamp NO : FWW 255

Welding process (s) used : SMAW /SAW Type : Manual

Iden tification of WPSFollowed by welder during welding of test coupon : TIBV – 004
Base metal (s) welded SA 516 Gr .70 Thickness : 19.05 mm

Manual or semi automatic variables for each process ( QW – 350 ) Actual Values Range Qualified
Backing ( Metal , weld metal , welded from both side, flux, etc) (QW – 350 without with and without
ASME P.No. 1 To ASME P No ( QW – 403 ) 1 P 1 To P 11
Plate ( ) Pipe ( Enter diameter, if pipe, groove ) Plate OD 24’’ and over
Filler metal specification (SFA) 5.1/5.17 classification ( QW – 402 ) E 7018/EL 12 N/A
Filler metal F- no 4/6 4,3,2,1 / All no 6
Consumable insert for GTAW or PAW N/A N/A
Weld deposit thickness for each welding process ( Groove weld ) 3 mm / 16.05 mm 6 mm / 32.1 mm
Welding progression ( 1G,5G,etc ) ( QW – 405 ) 1G Flat
Progression ( Uphill, Downhill ) N/A N/A
Backing gas for GTAW, PAW or GMAW; fuel gas for OFW ( QW – 408 ) N/A N/A
 Actual Values Range
Qualified
GMAW transfer mode ( QW – 409 ) N/A N/A
1 P 1 To P 11

Machine variables for the process Actual values Range of

qualified
Direct remote visual control N/A N/A
Automatic voltage N/A N/A
Automatic joint tracking N/A N/A
Welding position 1G Flat
Consumables insert N/A N/A
Backing ( Metal,weld metal ,welded from both side,flux ,etc Weld metal with backing

GUIDED BEND TEST RESULTS

WELDING AND JOINING

.
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