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TableofContents
MODULE4................................................................................................................................................3 Routestoweldingprocedureapproval.............................................................................................3 Weldingoperatorapproval...............................................................................................................5 WeldingsymbolsaccordingISO22553..............................................................................................11 Typesofbuttwelds.............................................................................................................................12 Typesoffilletwelds............................................................................................................................13 Supplementarysymbols......................................................................................................................14

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Objective:

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KnowhowtoworktoaWPS,knowingtheuseofweldingparameters. HavebasicknowledgeabouttheharmonisedsystemofInternationalStandards. Scope:

WeldingProcedureSpecifications(ISO156091). Weldingparameters,weldingpositions(ISO6947). Typesofweldsandjoints:characteristics,size,surfacefinish. WeldingsymbolsaccordingtoISO2553. QualificationofWPSs Essentialvariables;rangeofqualification;validity;testpiecesandassessmentofthewelder. RoleandoperationofCENandISO;relationshipwithNationalStandardsOrganisations ProductStandardswhichcontainweldingrequirements StandardsforQualityandCoordinationinwelding

Expectedresults:

Readweldingdetailsonadrawingandinterpretweldingsymbols(ISO2553). IdentifytheweldingpositionsperISO6947. Identifythetypesofweldedjoints:T,lap,corner,etc. Identifyinthefilletweld:size,shape,tackweld,andexcessweldmetal. IdentifytheuseofaWPSintheproduction. Describehowtogettherequiredparameters. NamethemostimportantInternationalandnationalstandardsforwelding.

Foragivenapplication,themainwayofensuringadequateweldqualityistospecifytheprocedureandtheskill leveloftheweldingoperator.Here,thealternativeroutesforweldingprocedureapprovalaredescribedtogether withtherequirementsforwelderorweldingoperatorapproval. Routestoweldingprocedureapproval ThekeydocumentistheWeldingProcedureSpecification(WPS)whichdetailstheweldingvariablestobeused toensureaweldedjointwillachievethespecifiedlevelsofweldqualityandmechanicalproperties. TheWPSissupportedbyanumberofdocuments(eg,arecordofhowtheweldwasmade,NDE,mechanical testresults)whichtogethercompriseaweldingapprovalrecordtermedtheWPAR(ISO15614).

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IntheEuropeanstandards,thereareanumberof'essentialvariables'specifiedwhich,ifchanged,mayaffect eitherweldqualityormechanicalproperties.Therefore,achangeinanyoftheessentialswillinvalidatethe weldingprocedureandwillrequireanewapprovaltesttobecarriedout.Theessentialvariablesaredetailedin therelevantspecificationbutincludematerialtype,weldingprocess,thicknessrangeandsometimeswelding position.

Stagesinweldingandwelderapproval

TheroutefollowedtoproduceaWPSinISO15614and theresponsibilitiesofthemanufacturerandthe Examiner/ExaminingBodyareshowninthefigure Themostcommonmethodofgainingapprovalistocarry outanapprovaltestasdescribedinISO156141(steels) and156142(aluminiumanditsalloys).The manufacturerinitiallydraftsapreliminarywelding procedure(pWPS)whichisusedbyoneofthe manufacturer'scompetentwelderstoprovethatitis capableofproducingaweldedjointtothespecified levelsofweldqualityandmechanicalproperties.The weldingprocedureapprovalrecord(WPAR)isarecord ofthisweld.IftheWPARisapprovedbytheExaminer, itisusedtofinaliseoneormoreWPSswhichisthebasis fortheWorkInstructionsgiventothewelder. Itisnoteworthythattheweldercarryingouta satisfactoryweldingprocedureapprovaltestisapproved fortheappropriaterangeofapprovalgiveninthe relevantstandard.

Thefollowingoptionsforprocedureapprovalarealsopossible:

Weldingproceduretest(ISO15614) Approvedweldingconsumable(ISO15610) Previousweldingexperience(ISO15611) Standardweldingprocedure(ISO15612) Preproductionweldingtest(ISO5613)

Theconventionalproceduretest(asspecifiedinISO15614)doesnotalwaysneedtobecarriedouttogain approval.Butalternativemethodshavecertainlimitsofapplicationregarding,forexample,weldingprocesses, materialsandconsumablesasspecifiedintheappropriateapplicationstandardorcontractagreement. TheweldingproceduretestmethodofapprovalisoftenamandatoryrequirementoftheApplicationStandard.If not,thecontractingpartiescanagreetouseoneofthealternativemethods.Forexample,aweldingprocedure

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specificationcanbeapprovedinaccordancewiththerequirementsofISO15611(previousexperience)on conditionthatthemanufacturercanprove,withappropriatedocumentation,thatthetypeofjointhaspreviously beenweldedsatisfactorily. Welderapproval Thewelderapprovaltestiscarriedouttodemonstratethatthewelderhasthenecessaryskilltoproducea satisfactoryweldundertheconditionsusedinproductionasdetailedintheapprovedWPSorWorkInstruction. Asageneralrule,thetestpieceapprovestheweldernotonlyfortheconditionsusedinthetestbutalsoforall jointswhichareconsideredeasiertoweld. Asthewelder'sapprovaltestiscarriedoutonatestpiecewhichisrepresentativeofthejointtobewelded,itis independentofthetypeofconstruction.Thepreciseconditions,called'essentialvariables',mustbespecifiedin theapprovaltest,egmaterialtype,weldingprocess,jointtype,dimensionsandweldingposition.Theextentof approvalisnotnecessarilyrestrictedtotheconditionsusedforthetestbutcoversagroupofsimilarmaterialsor arangeofsituationswhichareconsideredeasiertoweld. ItisimportanttonotethatanumberofAmendmentsandCorrigendahavenowbeenissuedwhichaffectthe rangeofapproval(seelistofRelevantStandards). InEN287/EN9606,thecertificateofapprovaltestingisissuedunderthesoleresponsibilityofthe Examiner/ExaminingBody.Thewelderapprovalcertificateremainsvalidsubjecttotherequirementsofthe applicationstandard.InEN287/EN9606,itcanbeextendedatsixmonthlyintervalsbytheemployerforupto twoyearsprovidedthewelderhasbeensuccessfullyweldingsimilarjoints.Aftertwoyears,prolongationofthe welder'squalificationwillneedapprovaloftheExaminerwhowillrequireproofthathisorherperformancehas beenoftherequiredstandardduringtheperiodofvalidity.AstheExaminerwillnormallyexaminethe company'srecordsonthewelder'sworkandtestsasproofthathehasmaintainedhisskill,itisessentialthat workrecordsaremaintainedbythecompany. ItshouldalsobenotedthatEN287/EN9606requiresrecordsoftests,iehalfyearlydocumentationaboutXray orultrasonicinspectionsortestreportsonfracturetestsmustbemaintainedwiththewelder'sapproval certificate(testsonproductionweldswillsatisfythisrequirement).Failuretocomplywillnecessitatearetest. Americanstandardshavesimilarrequirementsalthoughtheextentofapprovaloftheweldingvariablesare differenttothoseofEN287/EN9606. Weldingoperatorapproval Whenrequiredbythecontractorapplicationstandard,theweldingoperatorsresponsibleforsettingupand/or adjustmentoffullymechanisedandautomaticequipmentmustbeapprovedbutthepersonneloperatingthe equipmentdonotneedapproval.Inclarifyingtheterm'weldingoperator',personnelwhoareusingthe equipment(loadingandunloadingroboticequipmentoroperatingaresistanceweldingmachine)donotrequire approval. AsspecifiedinEN1418,approvalofoperatorsofequipmentforfusionweldingandresistanceweldequipment setterscanbebasedon:

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weldingaproceduretest preproductionweldingtestorproductiontest productionsampletestingorafunctiontest.

Itshouldbenotedthatthemethodsmustbesupplementedbyafunctionaltestappropriatetotheweldingunit. However,atestofknowledgerelatingtoweldingtechnologywhichistheequivalentof'Jobknowledgefor welders'inEN287/EN9606isrecommendedbutnotmandatory. ProlongationoftheweldingoperatorapprovalisgenerallyinaccordancewiththerequirementsofEN287/EN 9606.Theweldingoperator'sapprovalremainsvalidfortwoyearsprovidingtheemployer/weldingcoordinator confirmsthattherehasbeenareasonablecontinuityofweldingwork(periodofinterruptionnolongerthansix months)andthereisnoreasontoquestiontheweldingoperator'sknowledge. Thevalidityofapprovalmaybeprolongedforfurtherperiodsoftwoyearsbytheexaminer/examiningbody providingthereisproofofproductionweldsoftherequiredquality,andappropriatetestrecordsmaintainedwith theoperator'scertificate. Weldingproceduresandinstructions. TheManufacturershallpreparetheWeldingProcedureSpecification(s)(WPS)andshallensurethattheseare usedcorrectlyinproduction. Theweldingproceduresappliedduringproductionshallbeasspecificaspossible,inordertoclearlyidentify actionsandparameterstobeusedfortherequiredjoint.However,iftherelevantWPScontainsdatatoodetailed andnotusefulforthewelder,dedicatedworkinstructionsmaybeuseddirectlyderivedfromsuchaWPS containingonlythenecessarydata.Theseinstructionshavetoreferdirectlytotheweldingprocedure specificationtheyderivedfrom,e.g.byreferringtotherelevantWPSnumber. Consideringthatweldingisaspecialprocessandthatthequalityoftheweldedjointcannotbeproperly controlledonlybyfinaltests,theweldingproceduressignificantforthefinalproductqualityshallbequalified preciselypriortoproduction.Asaconsequence,thoseWeldingProcedureSpecificationsshouldbepreparedin accordancewithaWeldingProcedureApprovalRecord(WPAR).Normativereferencestothespecificationand tothequalificationofweldingproceduresaregiveninthetable.

Welding process

Standard

Material

Scope

Fieldofapplication

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ISO15607 ISO15610 Allfusion welding processes ISO15611 ISO15612 All

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WPS, GeneralRules WPAR Qualificationbasedontestedwelding consumables Qualificationbasedonpreviouswelding experience WPAR Qualificationbyadoptionofastandard weldingprocedure Qualificationbasedonpreproduction weldingtest WPS Compiling Qualificationbasedonweldingprocedure WPAR testSteels WPS WPAR WPAR Compiling Qualificationbasedonweldingprocedure test Qualificationbasedonweldingprocedure test

ISO15613

GasWelding

ISO156092 ISO156141 ISO156091

Steels All

ISO15614 Steelsand Nickelalloys 1 ISO15614 2 Aluminium, Magnesium

ISO15614 Qualificationbasedonweldingprocedure Steelcastings WPAR test 3 Arcwelding ISO15614 4 Aluminium castings WPAR Qualificationbasedonweldingprocedure test

ISO15614 Titaniumand Qualificationbasedonweldingprocedure WPAR zirconium test 5 ISO15614 6 Copper WPAR Qualificationbasedonweldingprocedure test

Qualificationbasedonweldingprocedure ISO15614 Allapplicable WPAR testcorrosionresistanceoverlay, 7 claddingrestoreandhardfacing ISO15614 Qualificationbasedonweldingprocedure Allapplicable WPAR testWeldingoftubestotubeplatejoints 8 ISO15609 3 Electronbeam welding ISO15614 11 All WPS Compiling Qualificationbasedonweldingprocedure test

Allapplicable WPAR

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ISO15609 4 All

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WPS Compiling

LaserWelding

ISO15614 Qualificationbasedonweldingprocedure Allapplicable WPAR 11 test

UnderwaterArc ISO15614 Qualificationbasedonweldingprocedure WeldingWet Allapplicable WPAR 9 test Hyperbaric UnderwaterArc ISO15614 Qualificationbasedonweldingprocedure WeldingDry Allapplicable WPAR 10 test Hyperbaric Standardsforthequalificationofweldingprocedures Differentmethodsforthequalificationofweldingproceduresareavailable: weldingproceduretestthismethodconsistsinweldingastandardisedtestpieceonwhichdestructiveand nondestructivetestsarecarriedoutinordertoverifytheachievementofrequiredproperties; - useofapprovedweldingconsumablesthismethodofapprovalmaybeusediftheweldingconsumables andthebasematerialarenotparticularlyaffectingtheweldingquality,providedthatheatinputsarekept withinspecifiedlimits; - previousweldingexperienceaweldingproceduremaybequalifiedbyreferringtopreviousexperiencesin weldingiftheManufacturerisabletoprove,byappropriateauthenticdocumentationofanindependent nature,thathehaspreviouslysatisfactorilyweldedthesamejointwithreliableresults; - useofastandardweldingprocedureaprocedureisqualifiedifitisissuedasaspecificationintheformat ofaWPSorWPARbasedonappropriatequalification(e.gbasedontherelevantpartofENISO15614),not relatedtotheManufacturerandqualifiedbyanexaminerorexaminingbody; - PreproductionTestthismethodistheonlyreliablemethodofqualificationforthoseweldingprocedures inwhichtheresultingpropertiesoftheweldstronglydependoncertainconditionssuchas:components, specialrestraintconditions,heatsinksetc.,whichcannotbereproducedbystandardisedtestpieces;itis mostlyusedwhentheshapeanddimensionsofstandardisedpiecesdonotadequatelyrepresentthejointto bewelded. Evenifdifferentqualificationmethodsareconsidered,themostcommonlyusedarequalificationbywelding proceduretestandpreproductiontest;howevertheapplicablemethodofqualificationisgenerallyspecifiedin eithermanufacturingcodes,standardsorcontracts. Inordertodemonstratetheachievedqualityoftheweldedproduct,alltheweldingrelateddocumentsshallbe properlycontrolled. Thisinvolvesthepreparationandmaintenanceofaprocedureforthemanagementofsuchdocuments,inorder toidentifyissuanceresponsibilities,distributionmethods,availability,andmethodforwithdrawingobsolete documents.Evenifitisnotanormativerequirement,acommonlyadoptedmethodtocontroldocumentationis theproductionofawrittenprocedure,producedorapprovedbytheweldingcoordinator,tobekeptbythe Manufacturerqualityassurancedepartmentordirectlybytheweldingcoordinatorhimself.

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InthenextpageatypicalWPSformisreported,producedaccordingtoENISO156091.

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WELDING PROCEDURE SPECIFICATION (WPS) b ) b ) WPS n Supp. WPQR c ) c ) Re v. Date

COMPANYNAMEORLOGO Welding process(es) Type(s) a ) a )

JOINTS Joint Type Backing Backing material Weld preparation Method of preparation & Cleaning PARENT METAL Group n Spec. Type & grade To Spec. Type & grade Thickness Outside Diameter Other WELDING CONSUMABLE a) Specification n Designation Size Trade name Manufacturer Flux design. EN Flux Trade name Weld deposit Other WELDING POSITION Position b) c) Plasma Shieldi ng Shieldi ng Trailing Backing a ) b ) To group n

Joint drawiing GAS(ES) Gas(e Mixtu s) re Flow Rate l/mi n l/mi n l/mi n l/mi n l/mi n

Other ELECTRICAL CHARACTERISTIC Current Polarity Mode of Metal Transfer Tungsten Electrode Type & size

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Welding Progression Other PREHEAT Preheat Temperature Interpass Temperature Preheat maintenance Other PWHT and/or AGEING Temperature Range Time Range (hour) Heating rate Cooling rate Other Weldin Run(s) g or Layer( proces s) s Filler metal ENdesignationor tradename.

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Electrode wire feed speed range Other TECHNIQUE String or weave beads Orifice or gas cup size Initial & interpass cleaning Method of back gouging Oscilla tion Amplit ude F req .

Size (mm)

Distance contact tube work piece Multiple, single pass (for side) Single or multiple electrodes Torch angle direction of welding Other Current Travel Volt Heat Speed O Amper age input Type & mm/mi ther age V KJ/mm polarity n A

MANUFACTURER WeldingProcedureSpecification

APPROVED BY

WeldingsymbolsaccordingISO22553 Theweldjointiswheretwoormoremetalpartsarejoinedbywelding.Thefivebasictypesofweldjointsare thebutt,corner,tee,lap,andedge. Specialsymbolsareusedonadrawingtospecifywhereweldsaretobelocated,thetypeofjointtobeused,as

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wellasthesizeandamountofweldmetaltobedepositedinthejoint.

Astandardweldingsymbolconsistsofareferenceline,anarrow,andatail.Thereferencelinebecomesthe foundationoftheweldingsymbol.Itisusedtoapplyweldsymbols,dimensions,andotherdatatotheweld.The arrowsimplyconnectsthereferencelinetothejointorareatobewelded.Thedirectionofthearrowhasno bearingonthesignificanceofthereferenceline.Thetailoftheweldingsymbolisusedonlywhennecessaryto includeaspecification,process,orotherreferenceinformation.

Thetermweldsymbolreferstothesymbolforaspecifictypeofweld:fillet,groove,surfacing,plug,andslotare alltypesofwelds.Someofbasicweldsymbolsareshowninthenextfigures.

Typesofbuttwelds

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SingleVpreparation

DoubleVpreparation

Typesoffilletwelds

Theleglengthofafilletweldislocatedinfrontoftheweldsymbol(triangle).Thedimensionisinmillimeters precededwiththeletterZorbythelettera. Inadditiontobasicweldsymbols,asetofsupplementarysymbolsmaybeaddedtoaweldingsymbol. Someofthemostcommonsupplementarysymbolsareshowninthefollowingfigure.

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Weldthisjointonsite

InspectbyNDT,Weld,Paint,etc.

ISO ISOisanetworkofthenationalstandardsinstitutesof157countries,onthebasisofonememberpercountry, withaCentralSecretariatinGeneva,Switzerland,thatcoordinatesthesystem. ISOisanongovernmentalorganization:itsmembersarenot,asisthecaseintheUnitedNationssystem, delegationsofnationalgovernments.Nevertheless,ISOoccupiesaspecialpositionbetweenthepublicand privatesectors.Thisisbecause,ontheonehand,manyofitsmemberinstitutesarepartofthegovernmental structureoftheircountries,oraremandatedbytheirgovernment.Ontheotherhand,othermembershavetheir rootsuniquelyintheprivatesector,havingbeensetupbynationalpartnershipsofindustryassociations. Therefore,ISOisabletoactasabridgingorganizationinwhichaconsensuscanbereachedonsolutionsthat meetboththerequirementsofbusinessandthebroaderneedsofsociety,suchastheneedsofstakeholdergroups likeconsumersandusers. Thenationaldelegationsofexpertsofatechnicalcommitteemeettodiscuss,debateandargueuntiltheyreach consensusonadraftagreement.ThisisthencirculatedasaDraftInternationalStandard(DIS)toISO's membershipasawholeforcommentandballoting.Manymembershavepublicreviewproceduresformaking draftstandardsknownandavailabletointerestedpartiesandtothegeneralpublic.TheISOmembersthentake accountofanyfeedbacktheyreceiveinformulatingtheirpositiononthedraftstandard.Ifthevotingisin favour,thedocument,witheventualmodifications,iscirculatedtotheISOmembersasaFinalDraft InternationalStandard(FDIS).Ifthatvoteispositive,thedocumentisthenpublishedasanInternational Standard. CEN CEN,theEuropeanCommitteeforStandardization,wasfoundedin1961bythenationalstandardsbodiesinthe EuropeanEconomicCommunityandEFTAcountries. CENsupportsthepoliciesoftheEuropeanUnionandEFTA,inparticularforfreetrade,butalsothesafetyof

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workersandconsumers,interoperabilityofnetworks,environmentalprotection,exploitationofresearchand developmentprogrammes,andpublicprocurement. Standardizationdiminishestradebarriers,promotessafety,allowsinteroperabilityofproducts,systemsand services,andpromotescommontechnicalunderstanding. Allstandardshelpbuildthe'softinfrastructure'ofmodern,innovativeeconomies.Theyprovidecertainty, references,andbenchmarksfordesigners,engineersandserviceproviders. Inaddition,regionalorEuropeanStandardsarenecessaryfortheSingleMarketandsupporttheUnion'spolicies fortechnicalintegration,protectionoftheconsumer,andpromotionofsustainabledevelopment. CEMarkingisthesymbol asshown.Theletters"CE"aretheabbreviationofFrenchphrase"Conformit Europene"whichliterallymeans"EuropeanConformity".Theterminitiallyusedwas"ECMark"anditwas officiallyreplacedby"CEMarking"intheDirective93/68/EECin1993."CEMarking"isnowusedinallEU officialdocuments."CEMark"isalsoinuse,butitisNOTtheofficialterm. 1. CEMarkingonaproductisamanufacturer'sdeclarationthattheproductcomplieswiththeessential requirementsoftherelevantEuropeanhealth,safetyandenvironmentalprotectionlegislations,in practicebymanyofthesocalledProductDirectives.* *ProductDirectivescontainsthe"essentialrequirements"and/or"performancelevels"and "HarmonizedStandards"towhichtheproductsmustconform.HarmonizedStandardsarethe technicalspecifications(EuropeanStandardsorHarmonizationDocuments)whichareestablished byseveralEuropeanstandardsagencies(CEN,CENELEC,etc). CENstandsforEuropeanCommitteeforStandardization. CENELECstandsforEuropeanCommitteeforElectrotechnicalStandardization. 2. CEMarkingonaproductindicatestogovernmentalofficialsthattheproductmaybelegallyplacedon themarketintheircountry. 3. CEMarkingonaproductensuresthefreemovementoftheproductwithintheEFTA&European Union(EU)singlemarket(total28countries),and 4. CEMarkingonaproductpermitsthewithdrawalofthenonconformingproductsbycustomsand enforcement/vigilanceauthorities. Alongwithmoredirectives'becomingeffective,moreandmoreproductsarerequiredtobeartheCEMarking forgainingaccesstotheEFTA&EuropeanUnionmarket.