Professional Documents
Culture Documents
0.1
Scope: This standard provides instructions for the preparation and writing of welding
procedure specifications (WPS's) to ASME Section IX requirements, with and without a referenced
code of construction. It includes lists of the available forms and standard paragraphs to be used on
the forms for specific limitations or exceptions. The referenced forms and referenced Lotus Notes
WPS Database may also be used for welding/construction codes other than ASME.
0.2
Introduction: A welding procedure specification is a document written for a contract which
defines the materials and their preparation, the electrodes and their use and the customer, code and
CBI requirements, limitations and exceptions.
A welding procedure specification is composed of:
1
Title page (see 1.0)
2
Specific Welding Procedure Specifications for each electrode (see 3.0)
3
General Welding Procedure Specification for each process (see 2.0)
The referenced Procedure Qualification Records (PQR's) will be included in the local welding
manager's copy of the Welding Procedure Specifications package in addition to the copy maintained
by the originating Welding Embedded Engineering Groups (WEE) when WEE prepares the WPS's.
Control of WPS's and PQR's for nuclear work will be handled per the specific contract requirements.
0.3
Computer Generated WPS's: A database "WPS Database" is available in Lotus Notes for
writing, storing, retrieving and printing specific Welding Procedure Specifications (WPS's) including
the title page. It should be used to generate all WPS's except for special circumstances or when
unique contract requirements apply.
1.0
TITLE PAGE
A title page is prepared for all contracts except those involving ASME Section III (Nuclear)
vessels/components. Welding Procedure Specifications for Nuclear Work shall be handled per the
specific contract requirements.
A typical welding procedure specification title page consists of:
1
the title "Welding Procedure Specification"
2
a description of the structure(s)
3
the customer's and final owner's name(s)
4
the final location(s)
5
the CBI contract number(s)
6
an index of attachments including:
a
A listing of the Specific Welding Procedure Specifications (WPS) with revision numbers and
the contract number
b
A listing of the General Welding Procedure Specifications (GWPS)
2.0
GENERAL WELDING PROCEDURE SPECIFICATIONS (GWPS)
See Table 2.0 for a list of all attached GWPS available from Corporate Welding & QA Technology
and and available in the Forms Database in Lotus Notes. See GWPS-SMAW for a typical
GWPS. GWPS used for ASME Section III (Nuclear) vessels/components are available from Corporate
Welding and QA Technology - Plainfield.
A GWPS is a general and standardized document which contains instructions applicable to a specific
welding process. If additional instructions are required for the use of a particular electrode, or if
there are limitations or restrictions to the GWPS, these should be shown on the Specific Welding
Procedure Specifications (see 3.0). The GWPS should not normally be altered.
Table 2.0 General Welding Procedure Specifications
Identification
Title
Form No.
GWPS-SMAW
General Welding
Procedure Specifications
for the Shielded
Metal Arc Process
WL 175A
GWPS-SAW
General Welding
Procedure
Specification for the
Automatic
Submerged Arc Process
WL 175B
GWPS-GMAW
General Welding
Procedure
Specification for the Gas
Metal Arc Process
WL 175C
GWPS-GTAW
General Welding
Procedure
Specifiation for the Gas
Tungsten Arc Process
WL 175D
GWPS-EGW
WL 175E
GWPS-STUD
General Welding
Procedure
Specifications for the
Automatically
Timed Stud Welding
Equipment
WL 175F
completing WL 100 and WL 100A. See 4.7 for completing WL 100S. See 3.3 for a
discussion and list of available standard parameter sheets.
3.1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Form WL 100. The following is a description of each entry required on form WL 100 . The
paragraph numbers correspond to the circled numbers shown on the sample form in FIG. 3.1.
Identification: Enter the AWS-SFA classification of the electrode or an abbreviation of the
trade name of the electrode. See Table 3.3 for typical AWS-SFA classifications and
abbreviations.
If the WPS is for submerged arc welding (SAW), both the AWS-SFA classification of the wire
and the number (I.D.) of the flux should be given. Example: WPS EM 12K/860.
Enter the Contract Number or Standard I.D. for CB&I Standard WPS's.
Product: Give general description for all structures.
Customer: Enter the customer's name.
Page No.: Enter the page number and total number of pages included in the WPS. The total
includes form WL 100, WL 100A, WL100S, and the Standard Parameter Sheet for the
specific electrode(s).
Rev. No.: Enter the revision number.
By: Fill in initials of person making the revision or original.
Date: Enter the date the WPS is written or the date the revision is made.
Enter the initials of all welding process used on the WPS. See Table 2.0 for the GWPS's
available.
Enter the number of the Procedure Qualification Record (PQR) used to qualify the WPS. This
PQR must be reviewed to assure that it complies with ASME Section IX and that it fulfills
customer, code and CBI requirements. More than one PQR may be listed to qualify different
thickness ranges, use of preheat, post weld heat treatment, other position, etc.
If a PQR is used that has been post weld heat treated, enter the PQR number and then the
letters PWHT in parenthesis.
Enter the position(s) welded to qualify each PQR.
Enter the thickness range qualified by each PQR in accordance with ASME Section IX.
Enter the welding positions qualified to be used on the specific contract.
Enter the thickness range the PQR will be used on the specific contract. Code impact, preheat
and post weld heat treatment requirements, as well as CBI requirements, must be complied
with.
Enter the Code Edition and Addenda that the WPS is written for. Example: ASME Section IX,
Winter 82.
Enter the page number(s) of the General Welding Technique page or parameter pages that
joint details are shown on.
Give the type of backing required. This may be a tape, consumable insert, flux, strip or strap,
bar, temporary bar, etc. If no backing is to be used, state "None".
Enter the base material(s) by ASME or ASTM grade and whether they are welded together or
to another material. Also list the ASME group number of the base material(s). If a material
does not have an ASME or ASTM type and grade assigned, use proprietary names and state
that the group number is similar to an ASME material(s).
If several materials are to be welded together or to one another with the same electrode, it is
permissible to list all the base materials and their group numbers and state, "These materials
may be welded together or to one another in any combination."
Identify the filler metal to be used by ASME specification number, classification, analysis
number, and group number. Trade names may be referenced but may not be used alone
unless (a) the electrode does not have an ASME specification and/or classification; or (b) a
specific electrode must be used. Also specify the type of consumable insert or type of
supplemental powdered filler metal to be used. If none will be used state, "None" or "N/A"*
If flux is required, give the trade name with the AWS-SFA Flux-Electrode designation
(Classification) in parenthesis. The AWS-SFA Flux-Electrode designation is only applicable
when it is available from the flux manufacturer or from previous CB&I test to AWS A5.17 or
A5.23 Specifications. Alternatively to the complete Flux-Electrode designation being listed in
parentthesis next to the flux trade name, the complete flux-electrode designation
(classification) can be listed for the complelte ASME Classification: as referenced in paragraph
21
88.LIF
Contracts that have impact requirements must have special instructions. These instructions are to
control welding heat input to the maximum qualified on the welding Procedure Qualifications
Records (PQR's) referenced to support the Welding Procedure Specification (WPS). The welding heat
input control requirements per ASME Section IX, QW-409.1 are listed below. The maximum allowed
heat input in KJ/in or maximum bead size including vertical weld pass/bead size sketch shall be
included, as applicable, on WL100 A See the CB&I heat input control requirements below. Multiple
pages of WL100 A form may be required to include all of the limitation requirements for some
Welding Procedure Specifications.
CB&I controls welding heat input per the following, except when special contract requirements apply:
Welding Heat input shall be controlled per paragraph QW-409.1 "a" (control of Voltage, Amperage
and Travel Speed) for machine/automatic welding processes, such as when the Automatic Girth
Welder (AGW) or Automatic Vert Welder is used.
Welding Heat input shall be controlled per paragraph QW-409.1 "b" (control of Volume of Weld
Metal) for manual and semiautomatic welding processes, such as SMAW, GMAW/FCAW and GTAW.
The Volume of Weld Metal control that CB&I uses is bead size.
QW-409.1 states a change in the type of current or polarity, or an increase in heat input, or an
increase in volume of weld metal deposited per unit length of weld, over that qualified. The increase
may be measured by either of the following:
Voltage x Amperage x 60
Travel Speed (in./min.)
For automatic welding, the maximum heat input allowed on the WPS must have a PQR with that heat
input or greater.
For manual welding the maximum bead size allowed on the WPS must have a PQR with that bead
size or larger.
Form WL 100Q can be used for processes not listed in Table 3.3 or when special instructions are
required for impact work.
For the SAW process, the electrode spacing when multiple electrodes are used is a nonessential
variable and must be specified on the WPS.
3.2
3.3
Form WL 100 A. The entries required on form WL 100 A as shown in Fig. 3.2 are:
thru :
Standard Parameter Sheets available are listed in Table 3.3. These contain amperage and
voltage ranges, travel speeds, burn-off rates and/or other pertinent data. Most of the
parameter sheets have typical joint detail sketches included on the form. WL 100Q is a blank
form to provide special joint details when necessary. All of the parameter pages, WL 100E to
WL100U, provide reference to the specific contract drawings for the applicable joint details
and dimensions for application of the specific WPS.
Form WL 100R is to be used for stud welding. The operating parameters and other essential
variables are to be listed for each size of stud and each position to be welded. Damper setting
and equipment specifications should be stated in the body of the WPS.
Applicable parameter sheets for automatic submerged arc welding are provided in the following Red
Book Standards: 814-2-2 , 814-2-5 ,814-2-6 ,814-3-2 , 814-3-3 . The general
welding parameters (amps, volts and travel speed ranges can be listed on form WL 100Q with
the specific welding parameter provided to the CB&I Welding and QC manager as a separate
attachment. The standard pages are considered proprietary infomramation and should not be
sent to customers when Welding Procedure Specifications are sent for review and approval. In
special cases the parameter sheets can be attached to form WL 100A and state stringer
beads as a general note on each parameter page.
The entries required on Standard Parameter Sheets as shown in Fig. 3.3 are:
as for WL 100 described in paragraph 3.1 above.
thru :same
Where necessary, enter the electrode classification or name. Usually this will be the same as
the classification or name in .
Table 3.3 Standard Parameter Sheets
Form
WL
WL
WL
WL
100A
100B
100C
100D
Description
Typical No.
WL 100E
WPS-E6010
WL 100F
WPS-E6012
WL 100G
WPS-E7018
WL 100H
WPS-NR431
WL 100I
WPS-SA66
WL 100J
WPS-E71T-1
WL 100K
WPS-E308
WL 100L
WPS-E7024-1
WL 100M
Parameters for
ENiCrMo-6 electrodes
WPS-ENiCrMo6
WL 100N
WPS-ER308-GTA
WL 100P
WPS-ER308-GMA
WL 100Q
Standard Parameter
Sheet. (To be used
when other forms listed
do not apply.)
WL 100R
Standard Parameter
Sheet for Stud Welding
WL 100S
Welding Procedure
Specifications Preheat
Chart (Information)
WL 100T
WPS-E70T-1
WL 100U
WPS-E316LT1-4
WPS-STUD
8301.LIF
Limitations to the General Welding Procedure Specification. The following are typical
limitations to the GWPS:
E6010 and E7010 electrodes: "Normally this electrode is for use on materials less than
3/8" thick."
E6012, E6024, and E7024 electrodes: "Limit the use of this electrode to fillet and lap
welds."
AVW welding: "Normally this process is used on materials 3/8" thick and greater."
Low hydrogen type welding of impact tested material in the vertical and overhead
position: Limit bead size to that shown in the appropriate table in 813-1-3 , 813-1-4 ,
813-1-4-1
,813-1-5 , Attach a copy of the appropriate table as another page to the
WPS on form WL 100 A and complete per 3.1.
4.2
1
2
4.3
1
2
3
4
5
6
Exceptions to the General Welding Procedure Specification. The following are typical.
Materials on which no flame burning is allowed: "No flame burning shall be permitted
on______________ material."
Materials where no arc gouging is permitted: "No arc gouging is permitted on
______________material."
Miscellaneous requirements. The following paragraphs may be required in certain
applications.
Where welding shall be performed from one side with a single pass: "All
____________ joints shall be welded from one side with a single bead."
Where joints shall be finished uphill: "All ____________________ joints over
__________________ inch shall be finished uphill."
Where stainless steel brushes must be used: "Use only stainless steel brushes on
______________________ material."
Where all passes are deposited downhill: "All passes shall be deposited downhill."
Where all passes are deposited uphill including the root pass. "All passes shall be
deposited uphill."
For stainless and nickel welding where customer specifications address stress corrosion or
when CBI is concerned about stress corrosion: "Remove all visible traces of anti-spatter
compound after welding and before PWHT."
4.4
Preheat requirements. Refer to Standard 895 for CBI minimum preheat requirements.
Pertinent code and customer preheat requirements must also be addressed.
For standard CBI preheat requirements, use pertinent information directly from 895 tables for the P
and Group numbers of materials,
4.5.1 Form WL 100S The following is a description of each entry required on form WL 100S.
The paragraph numbers correspond to the circled numbers shown on the sample form in Fig. 4.7.
1
List maximum interpass temperature.
2
List P number, Group number, material type, and if material is PWHT. Example: Preheat
requirement for P-1 Gp-1 materials (A36, A283C) PWHT.
3
Use ambient temperature requirement. Example: 32F and above.
4
Use thickness range of materials. Spell out; do not use symbols. Example: Less than or equal
to 1 1/4".
5&6
List preheat temperature and referencing notes, Notes to be used are listed below.
Example: 100F Note-2.
Notes:*
1
Preheat for removing moisture may be used.
2
100F is considered warm to hand. (Use this note whenever 100F is
specified).
3
Preheat within 3" of the point of welding and maintain 3" ahead of arc.
4.5.2 Preheat requirements for various welding processes are given in standard 895. Do not
confuse preheat requirements for different processes.
4.5.3 Normally preheat charts will be used for SMAW, GMAW, and GTAW.
4.5.4 In lieu of tables, preheat statements may be used for limited preheat requirements. Examples
are listed below.
Materials P-1 - Group 1
Maximum t 1 1/4" with or without PWHT: "No preheat is required except as an aid for removing
moisture or unless the ambient temperature falls below 32F. When the ambient temperature
falls below 32F, the plate shall be preheated warm to the hand within 3" of the point of
welding and maintain 3" ahead of arc.
Materials P-1 - Groups 2 and 3 ambient temperature 50F:
Maximum t 1 1/4" with or without PWHT: "No preheat is required except as an aid for removing
moisture."
Materials P-1 - Groups 2 and 3 ambient temperature < 50F:
Maximum t 1 1/8" with or without PWHT: "No preheat is required except as an aid for removing
moisture or unless the ambient temperature falls below 50 F. When the ambient temperature
falls below 50 F, preheat within 3" of the point of welding and maintain 3" ahead of arc.
*
The use of these notes shall be dictated by the notes in Standard 895, code, and the customer
requirements.
93.LIF
5.0
DISTRIBUTION OF THE WELDING PROCEDURE SPECIFICATIONS
See Table 5.0a and 5.0b. In all cases the completed WPS should be checked before distribution to
assure that it complies with code, customer, and/or CBI limitations, exceptions, and/or restrictions
and that it is correct and complete. The checker must initial and date the WPS in space 33 of form
WL 100.
The procedure qualification records (see 831-1 ) must also be checked to assure that they meet
customer, code and CBI requirements and comply with ASME Section IX, but do not provide more
data than necessary. Unless specifically required, impact data, dropweight data, chemistries, or
other special information should not be included.
When hardness data is required, it should be reported on form WL 1 or WL 10, as applicable. Form
WL 120, Hardness Test Report, should not be sent out.
Table 5.0a
Distribution of Welding Procedure
Cover Letter
Title Page
All WPS's
Referenced GWPS
Referenced PQR
RBS Attachments
Special Instructions
CB&I Organization
Local Welding & QC Originating
Manager
Department (1)
Original
1 Copy
Original (2)
1 copy
Original (2)
1 copy
1 copy
On File
1 copy
On File
1 copy
On File
Original (2)
1 copy
Notes:
(1)
(2)
Customer or Owner
Copies as Required
Copies as Required
Copies as Required
Copies as Required
Copies as Required
Not to be Sent
Not to be Sent
Table 5.0b
Distribution of Welding Procedure Specification
for Vessel Built to ASME Section III (Nuclear)
CB&I Organization
Local Welding & QC Originating
Manager
Department (1)
Cover Letter
Title Page
All WPS's
Referenced GWPS
Referenced PQR
RBS Attachments
Special Instructions
Customer or Owner
*******
Chicago Bridge & Iron Company, 2006. All Rights Reserved. For Internal Use Only.
NOTICE: THIS DOCUMENT, AND ALL TEXT, DRAWINGS, DETAILS AND DATA SHOWN HERETO, IS THE SOLE PROPERTY OF
CHICAGO BRIDGE & IRON COMPANY, AND SHALL NOT BE REPRODUCED IN ANY MANNER OR USED FOR ANY PURPOSE
WHATSOEVER EXCEPT BY EXPRESS WRITTEN PERMISSION OF CHICAGO BRIDGE & IRON COMPANY.