Welding Procedure Process and Method

🔧 How Do I Qualify a Welding Procedure? (WPS Process  Step by Step)

As a mechanical engineer working in pipe manufacturing, qualifying a welding procedure is not just a technical task — it’s a guarantee of quality and safety.

Here’s how to from a concept to a qualified WPS 👇

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1. Start with a pWPS (Preliminary Welding Procedure Specification):

I prepare a draft based on project specs and the applicable standard (e.g., API 5L or ASME IX).

It includes:

" Welding process: SAW / GMAW / SMAW

" Joint type & groove design

" Base metal grade

" Filler wire & flux

" Preheat & interpass temperatures

" Welding positions and passes

" Voltage, amperage, travel speed

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2. Perform the Welding Trial:

Using the pWPS, we weld a test coupon under controlled conditions.

All parameters are monitored and recorded carefully.

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3. Non-Destructive Testing (NDT):

Before we cut the coupon, we apply:

" Visual Inspection (VT)

" Ultrasonic Testing (UT) or Radiography (RT)

This ensures surface and internal weld soundness.

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4. Destructive Testing (DT):

We cut and test the coupon to verify:

" Tensile strength

" Bend test

" Impact test (for PSL 2 or low-temperature service)

" Macro/micro examination

" Hardness test (if required)

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5. Issue PQR (Procedure Qualification Record):

If all results meet the code and project requirements, we record them in the PQR, which validates the process.

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6. Final WPS Approval:

Based on the PQR, the Welding Procedure Specification (WPS) is issued and approved for production use.

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This cycle ensures that every weld meets performance expectations before it even reaches the field.