pWPS pWPS

Preliminary Preliminary Welding Procedure Specification Welding Procedure Specification Welders approval Welders approval

WAR WAR
Approval of welding procedure Approval of welding procedure

WPAR WPAR
Approved consumables Approved consumables Experience Experience Standard procedure Standard procedure Pre-production tests Pre-production tests

Testwelding Testwelding Testing Testing Reporting Reporting

WPS WPS

Required Required Approvals Approvals Available? Available?

Welding Procedure Specification Welding Procedure Specification Yes Yes

PRODUCTION PRODUCTION

Why a WPS
A weld cannot be checked to the full extent!
strength, ductility and corrosion resistance can only be checked by destructive techniques.
properties can only be guaranteed for the actual product when manufactured to exactly the same written procedure,

and carefully controlled.

P. Loos 99

EN 288

Why a WPS The main objective of a WPS is to make a welding operation

reproducable
P. Loos 99

EN 288-3

Methods of approval
welding procedure tests EN 288 part 3 or 4

approved welding consumables - EN 288 part 5

previous welding experience standard welding procedure pre-production welding tests EN 288 part 6 EN 288 part 7 EN 288 part 8

P. Loos 99

EN 288

Acceptance criteria
EN 25817 level B EN 25817 level C
excess throat thickness excess convexity excess weld metal excessive penetration

P. Loos 99

EN 288-3

Acceptance criteria
Strength
according to parent metal

Impact requirements
(temperature, energy) according to the design requirements (and application standard)

P. Loos 99

EN 288-3

EN 288 - ISO 9956

Specification and approval of welding procedures for metallic materials
Part 1 Part 2 Part 3 Part 4 General rules for fusion welding Welding procedure specification for arc welding Welding proc. tests for the arc welding of steels Welding proc. tests for the arc welding of aluminium and its alloys Part 5 Approval by using approved welding consumables for arc welding
Part 6 Approval related to previous experience Part 7 Appr. by a stardard welding proc. for arc welding Part 8 Approval by pre-production welding test
P. Loos 99

Additional tests
Such tests may include: longitudinal weld tensile test all weld metal bend test Charpy V-notch impact test yield strength or 0,2 % proof stress elongation chemical analysis micro examination delta ferrite determination in austenitic stainless steels
P. Loos 99

EN 288-3

Material groups
The use of particular method of approval of a WPS is often a mandatory requirement of an application standard. In the absence of such a requirement the method of approval shall be agreed between the contracting parties at the enquiry or at the order stage.

P. Loos 99

EN 288

Approval of WPS
Preliminary welding procedure specification ( pWPS ) Approval on the pWPS by a method acc. to EN 288 part 3/4, 5, 6, 7 or 8 Approved welding procedure specification ( WPS )
P. Loos 5/99

EN 288

Welding procedure tests

Tests shall be carried out in accordance

with this standard unless more severe

tests are specified by the relevant

application standard or contract

when these shall apply.

P. Loos 99

EN 288-3

Welding procedure tests

All new

welding procedure approvals

are to be in accordance with this

standard from the date of its issue

(first issue april 1992)

P. Loos 5/99

EN 288-3

Welders approval
The welder who undertakes the welding procedure test satisfactory,

is approved for the appropriate

range of approval given in the

relevant part of EN 287

P. Loos 5/99

EN 288-3

Re - testing
If the test piece fails to comply with any of the requirements for visual examinaton or NDE, one further test piece shall be welded and subjected to the same examination. If this additional test piece does not comply with the relevant requirements, the pWPS shall be regarded as not capable of complying with the requirements of this standard without modification.

P. Loos 5/99

EN 288-3

Re - testing
If any test specimen fails to comply with the relevant requirements only due to geometric weld imperfections, two further test specimens shall be obtained for each one that failed. These can be taken from the same test piece if there is sufficient material available or from a news test piece, and shall be subjected to the same test.

P. Loos 5/99

EN 288-3

Re - testing
If either of these additional test specimens

does not comply with the relevant requirements, the pWPS shall be regarded as

not capable of complying with the requirements of this standard without modification.

P. Loos 5/99

EN 288-3

Range of approval
An approval of a WPS obtained by a

manufacturer is valid for welding in

workshops or sites under the same

technical and quality control of

that manufacturer.

P. Loos 5/99

EN 288-3

Essential variables
Process: 111; 114; 131; 135; 136; 137; 141 Material: group 1, 9 (EN 288-3) group 21, 22a, 22b (EN 288-4) Parent metal thickness: Size of fillet weld: Pipe diameter: 3 - 40 mm 3 mm > 25 mm

P. Loos 99

EN 288-5

Approved welding consumables

Some material do not deteriorate significantly in the heat affected zones, provided heat inputs are kept within specified limits. For such materials, a pWPS shall be considered approved on the condition that the welding consumables are approved and that all essential variables are within the range for which the approval is valid

P. Loos 99

EN 288-5

Previous experience
A manufacturer may have a pWPS approved by referring to previous experience on condition that he can prove by appropiate documentation of an independant nature that he has previously satisfactorily welded the type of joint and materials in question

P. Loos 99

EN 288-6

Previous experience
Previous experience shall involve: Satisfactory documentation of tests (e.g. nondestructive, destructive, leak or pressure tests) in all cases. AND A summary of welding manufacturing of at least one year during an appropriate period (5 years) OR Suitability of welds in service for an appropriate period (5 years)
P. Loos 99

EN 288-6

Standard welding procedure

A standard welding procedure shall be issued as a specification in the format of a WPS or WPAR based on an approval to the relevant part of EN 288 for welding procedure testing. Application of a standard welding procedure is also subject to be satisfied by the user.

P. Loos 99

EN 288-7

Essential variables
Process: 111; 114; 131; 135; 136; 137; 141 Material: group 1, 9 (EN 288-3) group 21, 22a, 22b (EN 288-4) Parent metal thickness: Size of fillet weld: Pipe diameter: 3 - 40 mm 3 mm > 25 mm

P. Loos 99

EN 288-7

Standard welding procedure

The use of a standard welding procedure requires welding coordination in accordance with EN 719. The user has to fullfill quality requirements in accordance with the appropriate part of EN 729.

P. Loos 99

EN 288-7

Pre - production welding tests

At least the following tests are to be performed:

a) visual inspection (100 %) b) surface crack detection c) hardness tests (for Re 275 N/mm) d) macrographic examination

P. Loos 99

EN 288-8

Pre - production welding tests

Pre-production welding test are used where the shape and dimension of standardized test pieces do not adequately represent the joint to be welded. One or more special test pieces shall be made to simulate the production joint in all essential features e.g. dimensions, restraint, heat sink effects.

P. Loos 99

EN 288-8

Content of a WPs
preparation of the components to be welded assembling of components for welding welding process post work of the welded connections (e.g.grinding) heat treatment (during fabrication/finalizing)

P. Loos 99

EN 288-2

Material groups
a procedure test with one steel of a group covers the lower alloyed steels of the same group or the steels with equal or lower specified yield strength of this group as long as the welding consumables used for the test can also be used for the steels of this group group 2 covers group 1

P. Loos 99

EN 288-3

WPAR
Welding Procedure Approval Record

(WPAR)
The welding procedure approval record WPAR) is a statement of results of assessing each test piece including re-tests. It shall be signed by the examiner or test body

P. Loos 99

EN 288-3

Pressure vessel
The welding procedure tests for pressure vessels are detailed in the AD-Merkblatt HP 2/1. Welding and testing must be witnessed by the authorised Inspector. The results of the procedure qualification testing shall be available prior to the production. The qualification is based on

EN 288-3 EN 288-4
P. Loos 99

AD HP 2/1

Pressure vessel
Additional requirements are given for: material groups welding positions amount of testing approval requirements for testing

P. Loos 99

AD HP 2/1

Production tests
The number of the test pieces and the type of destructive and non-destructive testing depends on:

type of joint (round seam, long seam) design stress level of the welded joint
(85 %, 100 %)

the base material number of shell rings post heat treatment (U, W) thickness of base material
P. Loos 99

AD HP 5/2

Qualittskontrolle whrend der Fertigung I und II

Summary

SFI-3 / 4.4-4.5 Seite 1

Which possibilities of approval of welding procedures are available ? What are the limits of these possibilities ? Which important essential variables are included in the WPS ? What type of test pieces are standard types according to EN 288-3 ? Which tests (non destructive or destructive) are necessary for EN 288-3 ?
P. Loos 99

EN 288

Qualittskontrolle whrend der Fertigung I und II

Summary

SFI-3 / 4.4-4.5 Seite 1

What are the acceptance criteria for the welded joint of the production test ? What ease gives the grouping system for steel according to EN 288-3 ? What are the ranges of approval for thickness and diameter ? Which changes to EN 288-3 are made in the German standards and regulations ? What is the sense of a production test ?
P. Loos 99

EN 288

Production tests
The requirements of production tests in the field of steel structures are given in guideline DVS 1702. For aluminium and aluminium alloys the DIBt guideline is applicable
P. Loos 99

Steel structures
Based on the requirements of DIN 18 800 Teil 7, welding procedure tests for steel structures are required if:

a) fully mechanized processes are used b) fine grain steels with a yield strenght (Re) > 360 N/mm2 are used

Welding and testing has to be performed under the witness of a representative of the accredeted inspection authoraty for the comprehensive form of verification.

P. Loos 99

Steel structures
For the fully mechanized processes and for fine grain steels with (Re) > 360 N/mm2 ,the requirements of EN 288-3 are applicable. Exceptions: Fillet welds are not covered by butt welds. Welding and testing of fillet welds has to be done in accordance with Guideline DVS 1702 (cruziform test).

P. Loos 99

Aluminium structures
Welding procedure tests for aluminium structures must be performed in accordance with the guideline of the German Institute of Structural Engineering (DIBt) For butt welds the guideline is based on EN 288-4

P. Loos 99