1
PROCEDURE
1.1
GENERAL
1.1.1 All welder performance qualification testing shall comply with the
referenced code/standard, and any customer-supplied specification.
1.1.2 All steps to be performed during testing shall be documented on the
Welder Performance Qualification Test Instruction (WPQTI) in a
manner that assures both the welder and test supervisor are aware
of all applicable requirements. See Para Ошибка! Источник
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1.2
THE TEST FACILITY
1.2.1 The Test Supervisor will check with the Customer representative for
the test facility readiness and the test facility shall include the
following, as a minimum:
1.2.1.1
Welding and cutting equipment.
1.2.1.2
Grinders and other hand tools.
1.2.1.3
Welding shields and gloves
1.2.1.4
Booths and welding fixtures suitable for the required
tests
1.2.1.5
Electrode storage ovens.
1.2.1.6
Shielding and purging gas, as required
1.2.1.7
Storage facilities for tools, equipment, and test coupons
1.2.1.8
Low-stress stamps, vibro-etching tool, or marking
devices.
1.2.2 Off-site testing may be performed in accordance with this procedure.
The Test supervisor shall be responsible for assuring all
requirements of this procedure are adhered to. In this case, the test
facility is located at the established test location other than the
customer premises and agreed with the customer.
1.3
REVIEW OF TESTING REQUIREMENTS
1.3.1 Upon receipt of the purchase order and subsequent notification(s)
from customer(s) to conduct the welder performance test, the
Operation Manager/ Inspection Coordinator shall check the
availability of the Test Supervisor/ Welding Inspector and confirm to
the Customer’s Representative in writing within 48 hours of the
schedule of the welder’s performance qualification test.
1.3.2 In the notification memorandum, the Test Supervisor /Welding
Inspector shall advise the Customer’s Representative to
acknowledge in writing, the schedule of the planned test including
the preparation and confirmation of the following items as per WQTR
Request (Attachment 1).
1.3.2.1
The files of welders who will take the performance
qualification test – each file should include, as a
minimum, the welder’s photograph, his complete name
and welder Identification.
1.3.2.2
Availability of welder’s record and documentation, i.e.,
certification, performance continuity record/tracking log.
1.3.3 The notification system allows the Test Supervisor / Welding
Inspector and the customer to prepare the welder identification
documents, this system also confirms the welder’s availability at the
test facility.
1.3.4 The Test Supervisor/ Welding Inspector reserves the right to
exercise his authority and cancel or terminate the testing schedule if
the Customer’s Representative does not confirm any of the items
described in paragraph 1.3.2.
1.3.5 The Test Supervisor shall assure that the Welder Qualification
Testing Request (WQTR) has been prepared in accordance with
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responsible for reviewing the requirements for the applicable test
including:
1.3.5.1
Required Qualification Range shall be documented on
the WQTR.
1.3.5.2
Required Test to achieve qualification range including.
1.3.5.3
Base metals including type/grade, dimensions, joint
prep, and thickness.
1.3.5.4
Process and if applicable transfer mode
1.3.5.5
Shielding/Purging Requirements.
1.3.5.6
Backing
1.3.5.7
Position and Progression.
1.3.5.8
Filler Metal Requirements
1.3.5.9
Any additional essential variables in the applicable code
of construction.
1.3.5.10
Suitability of WPS for performing
Performance Qualification Test.
the
Welder
Note: The WPS does not have to meet the
requirements for the desired range of qualifications.
1.4
1.3.5.11
Acceptance Criteria of applicable code/standard.
1.3.5.12
Testing Requirements - Destructive or Non-Destructive.
1.3.5.13
Any Additional requirements implemented outside of
this system and the applicable code. This includes but
is not limited to modified acceptance criteria, positioning
requirements, power tool usage and time limits.
REQUIRED DOCUMENTS PRIOR TO STARTING
1.4.1 For all welder performance qualification tests the following
documents are required to be on hand before commencing the test,
1.5
1.4.1.1
WQTR (Para Ошибка! Источник ссылки не
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не найден.), and WPS (Para Ошибка! Источник
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1.4.1.2
Any customer-supplied supplemental requirements.
1.4.1.3
Photo Identification of the individual being tested.
TEST ASSEMBLY DETAILS
1.5.1 For each test, the test supervisor shall assure that the joint
dimensions for the test are available for the welder and meet the
requirements of the applicable code/standard.
1.5.2 The information may be provided verbally or in writing. A joint that is
incorrectly fit-up does not constitute a “failed” test.
1.5.3 The test supervisor is responsible for assuring the joint design meets
the requirements of the code/standard and WPS.
1.5.4 For all tests, materials specified in the WQTR (Para Ошибка!
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use.
1.6
REQUIRED INSPECTIONS
All tests will have the following inspection points or tasks performed as a
minimum and shall be documented on the WPQTI:
1.6.1 Test coupons shall comply with the relevant codes/standards as
applicable.
1.6.2 Proper material type/grade, thickness, and diameter for the test
being conducted.
1.6.3 MTC number for base metals and filler metals recorded on WPQTI.
1.6.4 Proper joint details in accordance with the WPQTI, code/standard,
and WPS.
1.6.5 Equipment condition and suitability for use (Calibration)
1.6.6 Marking of test assembly with the WPQTI number related to that
specific test.
1.6.7 The below are the minimum hold point inspection.
1.6.7.1
Verification of the test assembly is oriented in the
documented position. Root gap, groove preparation,
the position of the joint axis, and Hi-Lo shall be
inspected after fit-up and positioning of the test coupon.
1.6.7.2
Root pass inspection (check of root penetration and
appearance) including internal surface, if accessible.
1.6.7.3
Visual inspection of final pass/layer.
1.6.8 In-process observation of welding. Intermediate passes are not
required to be inspected but may be at the discretion of the test
supervisor.
1.6.9 Marking and Removal of test assembly from the test position.
1.6.10 If destructive testing is performed see below and Para 1.10.3 and
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1.6.10.1
Verification of review of destructive testing
requirements and specimen marking prior to layout and
removal of bend specimens by reference to the
applicable code.
1.6.10.2
Visual Inspection of destructive testing samples
including verification of WPQTI number.
1.6.11 If NDE is required see below and Para 1.10.1.
1.7
1.6.11.1
Verification of NDE requirements.
1.6.11.2
Review of NDE results for compliance with the
applicable code including verification of WPQTI
number.
REQUIRED OBSERVATION PRIOR TO INITIATING AND DURING THE WQT.
The Test Supervisor shall provide the below information to the welder prior to
initiating the test and observe during the WQT.
1.7.1 Ensure the welder receives site safety, rules of conduct, and the
required PPE provided by the Customer.
1.7.2 Applicable WQT and Welding Technique Sheet (WTS), and an
explanation of their functions.
1.7.3 Orientation in welding procedure requirements (i.e., welding in rain,
weld joint cleaning, undercut requirements).
1.7.4 The position of the test coupon, that fit-up and tack welds are
acceptable.
1.7.5 Once fixed in the test position, the test coupon shall not be moved
until the completion of the test.
1.7.6 Use of proper electrodes.
1.7.7 Achieve and maintenance of preheat and interpass requirements.
1.7.8 File, chipping hammer, wire brush, and power brush are allowed in
cleaning between passes.
1.7.9 Grinders are permitted only for feathering of tacks or with the
inspector’s approval.
1.7.10 Welding repairs are not allowed.
1.7.11 No grinding, back-gouging or welding may be performed on the
reverse side of the root bead or stringer except where specifically
called out as part of the performance qualification test. Where backgouging is required as part of the test, the groove must be inspected
prior to back-welding.
1.7.12 No grinding, filling, or dressing of the cap pass is permitted. Any such
evidence shall be cause for rejection.
1.8
SUPERVISING THE TEST
The Test Supervisor shall oversee qualification tests in accordance with the
following:
1.8.1 Performance qualification tests, either initial or renewal, shall be
conducted in the presence of the Test Supervisor/ Welding Inspector
following the guidelines defined in this procedure and as defined in
relevant codes/standards.
1.8.2 The Test Supervisor shall log the welders' reporting for testing. The
Test Supervisor shall interview applicant welders for previous
experience and knowledge. Based on this evaluation, the Test
Supervisor may require a pretest fillet weld demonstration or may
proceed with the qualification test.
1.8.3 Review of Safety Rules with The Welder - All shop safety rules will
be reviewed prior to the start of the test and the test supervisor shall
verify that the welder has all required safety equipment. This may be
done verbally or with written rules.
1.8.4 Review of the Testing Process with The Welder- The welder shall be
informed verbally or in writing of the requirements for testing
including the use of WPS parameters, removing coupon from the
position, hold/inspection points, Inspector's right to stop the test, time
limits, use of power tools, acceptance criteria, and any other
information related to activities controlled by the welder during
testing (See Para 1.7).
1.8.5 Observe the welder during the set-up of the test coupon and welding
as stated in Para 1.7.
1.8.6 The Test Supervisor/ Welding Inspector may terminate the
qualification test whenever it becomes apparent that the welder does
not have the required ability to produce acceptable results.
1.8.7 Discontinue and initiate a new qualification test if a problem occurs
that is not related to the welder's ability to perform the test correctly
(e.g., accidental loss of shielding or purge gas, welding equipment
malfunction).
1.9
IDENTIFICATION OF TEST COUPON
1.9.1 Each welder shall be assigned an identifying number, letter, or
symbol by the sponsoring organization (contractor or manufacturer)
which shall be used to identify the test coupon of that welder or
welding operator.
1.9.2 This identification character is to be hard stamped on the test coupon
prior to the start of welding for proper verification of the Test Welding
Inspector and for the traceability of the test coupon(s) for subsequent
testing, the Test Supervisor/ Welding Inspector shall also hard stamp
his unique ID on all test coupons prior to welding.
1.9.3 For mechanical testing of coupon, it shall be identified on the test
coupon about the type of test required (i.e., face, root, or side bend),
if applicable.
1.9.4 The Test Supervisor shall check to ensure that the identification is
correctly and legibly applied.
1.10
PHYSICAL TESTING OF TEST COUPON
1.10.1 The Test Supervisor shall determine the method of physical testing
in accordance with the WQT requirements and applicable
codes/standards.
1.10.2 Non-Destructive Testing (NDT)
1.10.2.1
Visual Inspection - The Test Supervisor shall visually
inspect the test coupon in accordance with Attachment
4, Qualification Test Acceptance Criteria
1.10.2.2
When NDT (RT/ UT) is selected, it shall be performed
by SGS as per the techniques stated in the applicable
codes/standards and following the approved SGS NDT
procedures.
1.10.2.3
The SGS RTFI Level II Inspector shall interpret the
radiographs and shall submit an interpretation sheet to
the Test Supervisor who shall perform the final
acceptance of the radiograph in accordance with the
criteria indicated in Attachment 4, Qualification Test
Acceptance Criteria and the results of the certified Level
II Inspector's interpretation. See Attachments 10 and
11.
1.10.2.4
All NDT reports shall include WPQTI number.
1.10.3 Destructive Testing (Mechanical)
1.11
1.10.3.1
When mechanical testing is requested, the specimen
for welders and welding operators shall be removed
from the test coupon, prepared, and tested in
accordance with the relevant codes/standards.
1.10.3.2
The test coupons shall be sent to an approved thirdparty testing laboratory through subcontracting (Refer
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1.10.3.3
The minimum required details as mentioned in the Para
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with third-party testing laboratory.
1.10.3.4
Attachment 9. Side bend test coupon specimens shall
be positioned such that the side with the most visible
defects shall become the convex side.
ACCEPTANCE CRITERIA OF TEST COUPON
1.11.1 Welders who pass the required tests for pipe groove welds shall also
be qualified to make fillet welds in all thicknesses and pipe diameters
of any size within the limits of the welding variables of a specific
Welding Procedure Specification (WPS) or WTS.
Note: - Welding tests for only fillet welds are not permitted unless
otherwise requested by the customer in writing.
1.11.2 Brazing operators who perform qualification tests on 1/16 in. (1.5
mm) wall tube/pipe are qualified to braze on thicknesses of 1/32 in.
(0.8 mm) through 1/8 in. (3 mm).
1.11.3 Welds made in test coupons for performance qualification of welders
and welding operators shall be visually examined prior to any
subsequent testing. Qualification of test specimens shall be in
accordance with the applicable codes/standards.
1.11.4 Test coupons (pass or fail) and radiographs shall be maintained until
requested by the Customer or thirty (30) days from the date of
qualification or requalification, whichever is earlier.
1.11.5 Acceptance of test coupons shall be as per applicable codes/
standards (Refer Attachment XX).
1.12
RECORDS
1.12.1 Passed Tests:
1.12.1.1
All tests that meet the requirements of the applicable
code/standard shall be documented as passed on the
WPQTI. A WPQR will be completed and signed by the
test supervisor. A welder file shall be generated as
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1.12.1.2
The Test Supervisor shall ensure records are created in
the Welding Data Base test log with appropriate
documentation.
1.12.1.3
The subject records shall be maintained by the WTA for
each welder tested. Appropriate documentation shall be
maintained in the Welding Data Base. If radiography is
used for qualification, the film interpretation sheet shall
be maintained with the Welder Performance
Qualification Test Record. The radiographic film may be
discarded after the documentation is completed. If weld
bend tests are used for qualification, the weld bend test
straps may be discarded after the documentation is
completed. See Section 6.3F.
1.12.1.4
The WTA shall assure welder qualification records are
entered and maintained in the welder qualification
database.
1.12.2 Failed Test:
1.12.2.1
All tests that do not meet the requirements of the
applicable code/standard shall be documented as failed
on the WPQTI. No WPQR is required, however, a
welder file shall be generated as described in para
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documents as required.
1.12.2.2
If a test is unsuccessful, the Test Supervisor shall
complete data entry in the Welding Data Base test log
with the appropriate documentation. If radiography is
performed
for
qualification,
the
radiographic
interpretation sheet shall be maintained with the Welder
Performance Qualification Test Record. These records
shall be maintained as per the retention period
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failure.
1.12.2.3
Records of failed WQTs, for welders attempting
qualification as a condition of employment but who were
not hired, are not required.
1.12.2.4
Failed weld bend test coupons or failed x-ray test film
are retained in accordance with Para 1.11.4.
1.12.3 Creating certification records in database and Welder and test
information shall be entered into the test log portion of the Welding
Database.
1.13
RETEST OF WELDERS
1.13.1 At the discretion of the Test Supervisor a welder who has failed a
qualification test may be retested, as follows:
1.13.2 The Test Supervisor shall review the failed WQT test specimens or
radiographs to determine the conditions that contributed to the test
failure.
1.13.3 In circumstances where a welder exhibits the ability to perform sound
welds but fails the test due to personal conditions or technique that
produced nonconformances, and upon request from the customer,
the Test Supervisor may decide to conduct a retest after reviewing
the demonstrated training records which justify a retest. The welder
shall be retested in accordance with the original, failed WQT. Should
the retest fail, the welder's qualification cycle shall be terminated.
1.13.4 Retesting without additional training or practice is not recommended;
however, if this approach is approved and requested by the customer
in writing, then, two consecutive tests shall be performed in
accordance with the failed WQT. The weld test method, bend test, or
radiography shall be the same method used during the failed
qualification attempt. Each test coupon must pass the test
requirements to qualify the welder. This retest may be administered
to the welder up to five (5) working days from the time of failure.
Retest for second-time failures of the same WQT shall not be
permitted without demonstrated training and/or practice.
1.14
RENEWAL / REQUALIFICATION
1.14.1 When a welder has not welded with a process during a period of 6
months or more, the welder's qualifications for that process shall
expire.
1.14.2 Within the six (6) month period prior to the welder’s expiration of
qualification:
1.14.2.1
A welder who welds using a manual or semi-automatic
process will maintain qualification for manual and semiautomatic welding with that process.
1.14.2.2
A welding operator who welds with a machine or
automatic process will maintain qualification for
machine and automatic welding with that process.
1.14.3 It is the Customer Representative's responsibility to maintain the
continuity records and sign the welder qualification certificate
continuity with appropriate NDT records.
1.14.4 When there is a specific reason to question a welder’s ability to make
welds that conform to the welding procedure, the welder’s
qualifications for the process(es) associated with the welding shall
be revoked. Other qualifications not questioned shall remain in
effect.
1.14.5 When a welder's qualification in a specific process has expired,
renewal of that qualification may be made by making one satisfactory
test joint weld (plate or pipe) on any thickness (3/8 in. (10 mm) plate
for AWS D1.1), position, or material with that process. This will
reestablish the welder’s qualification in the specific process for any
previously qualified thickness, position, or material.
1.14.6 Welders who fail the renewal test in a process, or who have their
qualifications revoked, must qualify in accordance with the initial
qualification requirements of this procedure prior to further
production welding with that process.