WELDER PERFORMANCE QUALIFICATION

                          

WELDER PERFORMANCE QUALIFICATION

BASIC

·         WPQ is the welder actual working performance against the pre-qualified WPS and PQR.

·         It is the document which have to prepare for each and every welder in the company.

·         WPQ shows that the welder available in the company are capable to do the welding against the approved or qualified WPS.

·         It gives the required mechanical strength and metallurgical properties as mentioned in standard WPS.

·         Once the welding procedure is approved it is essential to follow it by all the welders to getting adequate knowledge and skill to give sound weld quality.

·         Each additional welder when comes in the company needs to qualify under the conditions of WPS.

·         It’s the responsibility of Quality and production department to qualify each welder and make a PQR for each welder available in the factory before starting welding to a job.

·         If the test coupon of welder is accepted in all testing that are mentioned in appropriate standard like ASME section IX then he is automatically approved and qualified against WPS.

·         WPQ are the largest documents in quantity based in overall documentation of welder qualification.

·         WPQ may be similar for number of welders in the company.

PROCESS OF MAKING WPQ

·         After completion of WPS and PQR needs to prepare test coupon for welding with appropriate dimensions minimum required for testing for qualification of new welder.

·         Test coupon must be neat and cleaned with proper edge preparation as per ASME section IX.

·         Tack weld the test coupon with end plates on both end of the plates with axis of welding.

·         Welding is start in required position of qualification most appropriate approval position is Inclined at an angle 45 degree. All welding positions are described already in another section.

·         Note down the welding parameters during welding that is current, voltage, travel speed, base metal material, filler metal material etc. which are already given into WPS.

·         Welding should be witnessed by the AWS certified welding inspector or an inspection body or he may directly witness the test coupon for testing.

·         Once the welding of test coupon is completed it sent to the Radiography testing (non-destructive testing), in RT weld defects are identified and witnessed by inspection agency or welding inspector.

·         If RT of weld coupon is acceptable then it sent for destructive mechanical testing. (Different mechanical testing already discussed on another section)

·         In destructive testing various testing are carried out like bend test, tensile test, impact test if requires etc.

·         Also metallurgical testing is done in the NABL qualified laboratory.

·         Those reports of all testing, RT films review reports are collected with inspector signature and documented as a supporting to PQR.

·         After completion of all test the surveyor review the reports, values mention in WPS and actual PQR report if matches within tolerance limit then he sign the WPQ with his endorsement.

TESTING OF PQR & WPQ

·         Weld visual examination by AWS certified welding inspector.

·         Bend test at various positions of welding.

·         Hardness test.

·         Tensile test at various positions of welding.

·         Impact test.

·         Metallurgical chemical testing or spectro-chemical.

·         Macro test.

·         Torque testing.

·         Peel testing.

·         Radiography testing.