Principles & Applications of PQR & WPS

Every production weld on a code-governed job must be made to a qualified welding procedure, and the inspector, engineer and supervisor must all be able to read, verify and apply it. This three-day course explains how welding procedure specifications and procedure qualification records are prepared, qualified and used. Participants compare the structure and terminology of the principal American and international codes, work through essential and nonessential variables, review qualification test requirements and ranges, and draft a WPS from a supporting PQR. The emphasis is on practical, defensible documentation that will survive third-party review.

Who Should Attend

• Welding inspectors and QA/QC personnel
• Welding engineers and welding coordinators
• Fabrication supervisors and production managers
• Engineers who review or approve welding documentation

Learning Outcomes

• Explain the purpose and relationship of the WPS, PQR and welder performance qualification
• Identify essential, supplementary essential and nonessential variables for common processes
• Determine qualification ranges for thickness, base metals, fillers and positions
• Specify the mechanical tests required to qualify a procedure and evaluate their results
• Develop a WPS supported by a valid PQR
• Review existing WPS and PQR documents for code compliance

Course Outline

• Module 1 — Introduction to Welding Standards: scope and structure of AWS D1.1, ASME Section IX and ISO 15614-1.
• Module 2 — Understanding Welding Procedure Specifications: content, format and use on the shop floor.
• Module 3 — Procedure Qualification Record Essentials: test coupons, recorded variables and certification.
• Module 4 — Welding Variables: essential, supplementary essential and nonessential variables by process.
• Module 5 — Qualification Testing: tensile, bend, impact, macro and hardness tests and acceptance.
• Module 6 — Developing a Welding Procedure Specification: drafting a WPS from a PQR.
• Module 7 — Review and Application: prequalified procedures, revisions and common audit findings.

Standards & References

Course content draws on AWS D1.1/D1.1M (Structural Welding Code — Steel); ASME Boiler and Pressure Vessel Code, Section IX (Welding, Brazing and Fusing Qualifications); and ISO 15614-1 (Specification and Qualification of Welding Procedures for Metallic Materials — Welding Procedure Test). Participants are introduced to the scope and application of each document; the current edition should always be consulted for project work.

Assessment & Certification

The program comprises 24 contact hours (3 days) of instruction. Assessment consists of a written examination and a practical exercise in which candidates prepare a WPS from a supplied PQR and review documents for compliance. Successful candidates receive an IIME Certificate of Training bearing a unique verification code, which can be verified online.