Indian Institute of Welding ANB

Refresher Course module 16

Quality Assurance of
Welded Structures

Content
Concept of Quality Assurance & Quality Control
A Brief Discussion on ISO 3834
Inspection of Welds
WPS,PQR & WPQ- A Brief Discussion
Comparison Between ASME Sec. IX and ISO 9606
Weld quality and defects
Limits of weld defects as per ISO 5817
Testing of Welds
Visual Testing
VT- its Criteria as per AWS D 1.1 and BS 5289

Concept of QA & QC
Some Definitions
Quality- The totality of features and characteristics of a
product or service that bear on its ability to satisfy stated
and implied needs.
Quality Management- That aspect of overall management
functions that determines and implement Quality System &
Policy.
Quality System- The organisational structure,
responsibilities, procedures, processes and resources for
implementing Quality Management.
Quality Assurance- All those systematic actions
necessary to provide adequate confidence that a product
or service will satisfy given requirement for quality.

Concept of QA & QC
Some Definitions
Quality Control- The operational techniques and activities
that are used to fulfill requirements for quality.
Quality Document- All necessary papers required to
produce Quality Product/Service duly approved by
respective authorities.
Quality Records- All necessary papers to demonstrate
the achievement of required quality and the effective
operation of the quality system.
Quality Plan- A document setting out specific quality
practices, resources and sequence of activities relevant to
a particular product, service contract or project.



QUALITY ASSURANCE
&
QUALITY CONTROL OF
WELDING
Quality
Fitness for purpose or use.
Conformance to specified requirements.

The totality of features & characteristics
of a product or service that bear on its
ability to satisfy the stated and/or implied
needs.

Degree to which a set of inherent
characteristics fulfils requirements.


Quality New definition
Meeting & anticipating customers
requirements, stated or implied.
At a given time & over a period of
time.
At a price the customer can afford
and is willing to pay.
Introducing new & better product s into
the market faster than competitor.
Continuously bringing down the cost of
manufacturing.


Quality
Quality of a Product (or Service) is
not what you put in to it; it is what
the Customer gets out of it.




Quality

REQUIREMENTS :
Need or expectation that is stated, generally
implied or obligatory.

GRADE :
Category or rank given to different quality
requirements for products, processes, or systems
having the same functional use .



Quality
CUSTOMER SATISFACTION :
Customers perception of the degree to which
the customers requirements have been
fulfilled.
SYSTEM :
Set of interrelated or interacting elements.
MANAGEMENT SYSTEM :
System to establish policy and objectives and to achieve
those objectives.
QUALITY MANAGEMENT SYSTEM :
Management system to direct and control an organization
with regard to quality.




Quality
Assurance: The act of giving
confidence, the state of being
certain or the act of making
certain.

Quality assurance: The
planned and systematic
activities implemented in a
quality system so that quality
requirements for a product or
service will be fulfilled.

Quality
Control: An evaluation to
indicate needed corrective
responses; the act of guiding
a process in which
variability is attributable to a
constant system of chance
causes.

Quality control: The
observation techniques and
activities used to fulfill
requirements for quality.

Quality - Customer focus
Organizations depend on their
customers and therefore shall:

1. Understand customer needs and
expectations Current & future
needs
2. Meet customer requirements

3. Strive to enhance customer
satisfaction
Quality - Defect
Anything that
dissatisfies the
Customer (internal
or external)


Quality - Customer focus
Customer requirements are dynamic

Lower the Defects
1. Lower Cycle time (Delivery in
time)
2. Lower Cost of production
3. Higher Customer Satisfaction
4. Higher People Satisfaction
5. Higher Profits

Quality - Customer focus


Two important questions:
1. Who are the customers?
2. What does it take to satisfy them?

Quality - Sequence of
approach
Inspection Call from shop or fabricator
Ensuring availability of Quality Plan,
Quality Control Procedures, Gauges
(calibration) etc.
Verification of Purchase Orders
Verification of Dimensional Report w.r.t
Purchase Order, Approved Drawing

Quality - Sequence of
approach
Verification of raw material TCs
Performing - Visual Examinations
Ensuring - Job Identification details
Dimensional Check
Conducting LPI, MPI, RT / UT as
applicable.
Confirming 1. LPI, MPI, RT / UT results.
2. Heat Treatment details
3. Verification of Heat
Treatment Charts and job correlation.

Quality - Sequence of approach
Ensuring before External Inspection /
Dispatch
Surface Protection-Painting(DFT)
Work Order Details, Color Code
VCI Pellets, End Capping
Final Clearance by Third Party
Inspection Agency / IBR




Quality - Document
Verification
Firm / Product Approvals
WPS/PQR ,Welder Qualifications
Purchase Order
Quality Plan / Quality Control Procedure
Painting Schedule
Work Order, Drawings, Design Changes
/ Non Conformances Report
Raw material / Pipes Test Certificate



Quality - Document
Verification
Lab Test Reports
NDE (LPI/MPI/RT/UT) Reports
Heat Treatment Reports
List of approved vendors for Electrodes /
Paints / NDE consumables
List of approved service agencies for Lab
Testing, NDT, Heat Treatment
Quality - Prior to Fabrication
Drawings &
Specifications
Selection of Welding
Process
Material Specification &
Inspection
Inspection of
consumables
Welding Procedures
Welding Equipments
Welder Qualifications
Testing Facilities
Quality - During Fabrication
Inspection of prepared
material Edge
Preparation, surface
condition etc.
Assemblies Fit up, Root
gap, position, orientation
etc.
Welding Consumables
E 7018, E 7018-A1 etc.
Operators Qualification,
Position, sequence etc.
WPS Conformance
Quality - After Fabrication
Visual Inspection
a) Surface Defects: Blow
Holes, Porosity, Unfilled
Crater, Un-fused welds
b) Surface Cracks
c) Damaged to parent
metal:
Undercut, Burning,
Overheating
d) Profile Defects:- Overlap,
Excess penetration,
Incomplete penetration
Quality - After Fabrication
e) Incorrect Finish:-
Ripple Mark
Weaving Faults
Chipping & Peening marks
Spatter
Inspection of Weld
Dimensions Fillet, Throat
size.
Mech.Testing:- Test Coupons,
Results.
NDE
Quality - Records
Register
Purchase Order
Material Receipt / Account
Raw material Test Certificates
Welders Log Book
NDE, Heat Treatment
Inspection ( Internal / TPI / IBR )
Audit Reports ( Internal / External )
Quality
Quality is better defined
as
Error free or Defect
free performance.

Do the right things
right the first time and
every time.



Welding Defects

Small imperfections which affects the
property of the weld metal are called
discontinuities


When the discontinuty is large and affect
the function of the joint is termed as defect.

Defects
A. External defects
B. Internal defects
C. Both internal&external defects



External defects
1. Undercut
2. Cracks
3. Blowhole and porosity
4. Slag inclusions
5. Edge of the plate melted off
6. Excessive convexity/oversized
weld/ Excessive Reinforcement
7. Excessive Concavity/Insufficient
Throat thickness/ Insufficient fill
Contd
1. Incomplete Root penetration /Lack
of penetration
2. Excessive Root penetration
3. Overlap
4. Mismatch
5. Uneven/Irregular bead appearance
6. Spatters



Internal defects
1. Cracks
2. Blowhole and porosity
3. Slag Inclusions
4. Lack of fusion
5. Lack of Root penetration
6. Internal stresses or locked-up
stresses (or) Restrained joint
Both External And Internal
Defects
1. Blowhole
2. Slag inclusions
3. Lack of penetration (fillet weld)
4. Cracks
5. porosity
Dimensional defects
Distortion
Incorrect Joint Penetration
Incorrect Weld Size
Incorrect Weld Profile
Structural discontinuties
Porosity
Slag Inclusion
Under cut
Incomplete fusion
Incomplete penetration
Crack
Surface defects
Faulty weld size and profile
BUTT JOINT
Lack of Reinforcement
Excessive Reinforcement
Irregular Profile
FILLET WELD
Insufficient Throat
Insufficient Leg Length
Excessive Convexity(or)Concavity
Unequal Leg Lengths
Irregular Weld Face
Crack
Discontinuty caused by the tearing of
the metal

Hot crack
Cold crack
Crater crack
Crater cracks

Longitudinal Crater crack
(may(or)may not extend to the base
metal)

Transverse Crater crack

Star crater crack

Porosity
Group of gas pores in a weld due to
entrapment of gas during solidification
is termed as porosity.
Porosity: small spherical cavities
either clustered locally (or)scattered
Blow hole: single large cavity
piping (or)warm holes: Elongated (or)
tubular gas cavities

Reason
Contamination of the base metal

Moisture in the electrode

Improper arc length

Excessive current

High travel speed
Slag inclusion
Entrapment of slag or Non- Metallic
inclusion
incomplete deslagging of a previous
pass.
Excessive weaving. (slag solidity at
the sides of the bead)
Improper travel speed
Excessive amount of slag ahead of the
arc.

Remedies

Proper cleaning of slag

Restrict the width of the
weaving(width of slag immediately
behind the weld puddle remains
molten.


Weld spatter
At the conclusion of a weld small
particles (or) globular of metal may
sometime be observed scattered
around the vicinity of the weld.this
is known as spatter.
Reason
Arc blow:(making the Arc
uncontrollable)
1. Too long an arc
2. An excessive
current.
Under cut
Continues or discontinues groove at
the toes of the weld pass and is
located on the base metal.
Excessive current
High travel speed
Improper electrode angle.
Improper electrode size
Incomplete Penetration
Failure of weld metal to reach and fuse the
root of the joint.
Reason :
Less bevel angle
High welding speed
Low current
Large dia electrode
Insufficient Root gap
Improper Electrode angle

Controlling factors
1. Proper travel speed

2. proper parameters
a.current
b.voltage
c.flow rate
3.proper edge preparation
a.Angle
b.Root gap

Contd

4.suitable diameter of electrode

5.Base metal preparation

6.Baking of electrode


Documentation
Manual- Strategic Type,
Top Management Function
Procedure- Tactical Type,
Departmental Function
Work Instruction-
Operational Type,
Supervisory Function
Records- Specific Type,
Related to all Function

QUALITY PLAN FOR MANUFACTURING / INSPECTION ACTIVITY
Importance Type Test Type Agency Column
MA = Major P = Test / Inspection to be performed 1= Customer
CR = Critical W = Test / Inspection to be Witnessed 2 = Organization
MI = Minor V = Verification of Documents/Test Records 3 = Consultant / Inspection Agency

S
l
.
N
o
Item
Description. /
Operation
Characteristics
Checked
Categor
y
Type
Method of
Check
Extend
of
Check
Reference
Document
Acceptance
Norms
Format
of report
Agency
Remarks
P W V
1
.
RAW
MATERIALS
Plate
Rounds
Chemical &
Physical
Properties
Internal Flaws
Chemical
Properties only
M A
M A
M A
Verification
U. T.
Verification
1 / Heat
100%
100%
Order /
Specification
Order /
Specification
Drawing
Drg.Spec.
Drg. Spec.
Drg. Spec.
MTC Lab
Report
Lab
Report
Lab
Report
2
2
2
1
3
1
3
1
3
UT for Plates >12 mm thick
2
.
FORGINGS
Chemical
Properties
Dimensions
M I
M A
Verification
Measure
ment
1 Heat
Size
Order
/Spe
cificatio
n
Drawing
Drawing
Drg.Spec.
Detail Drg.
Lab
Report
I. R.
2
2
1
3
1
3
3
.
FABRI
CATED
ITEMS
Fit up
Welding Quality
N D T
Dimensions
M A
M I
C R
M A
Visual
Visual
Dimension
UT, RT,
MPT LDP
Visual
Measure
ment
100%
100%
Order /
Spe
cificatio
n
100%
Drg. Spec.
Drg. Spec.
Drg. Spec.
Drg. Spec.
Drg.Spec.
Drg.Spec.
Drg.Spec.
Detail Drg.
I. R.
I. R.
UT
Report
I.R.
2
2
2
2
1
3
1
3
1
3
1
3
4
.
PAINTING Paint Thickness
M A
M I
Visual
Film
Thickness
100%
Sample
Drg. Spec.
Drg. /
Specification
.
Drg.Spec.
Drg.Spec.
Painting
Certificat
e
Painting
Certificat
e
2
2
1
1
3
Quality Standards
Basic Standards
Specifying general requirements with basic significance eg.Quality
Management Systems, drawings & tolerances
ISO 9000 ff, EN 4500 ff, ISO 17000 series
Special Basic Standards
Specifying matters for several applications eg. Test procedures,
welding requirements, materials
ISO 3834
Special Standards
Product or application standards eg. Pressure vessels, piping,
railway cars
ISO 16528, EN 1090, ISO/DIS 10721, EN 15085,
Quality Management in Welding
Basic Standard for QMS
ISO 9001 -2000
Manufacturing
ISO 3834, EN 1011, ISO 5817
Personnel
ISO 9606, EN 287, ISO 14731, ISO 14732
Procedures
ISO 15607 15614
Testing and Inspection Personnel
ISO 9712, EN 1289
Materials and Calculation & Design
Application of ISO 3834

Certification of companies in accordance
with ISO 3834 Parts 2, 3 or 4

Certification of personnel in accordance
with ISO 14731
ISO 14731 Requirements for
Welding Co-ordination Personnel
Welding Co-ordination :
- Manufacturing operations for all welding and welding related
activities
- The sole responsibility of the manufacturer
- May be sub-contracted
- May be carried out by more than one person
Welding Co-ordinator
- Responsible and competent person
- Specified tasks and responsibilities
- Qualified for each task
Welding Inspection
- Is part of welding co-ordination

What is ISO 3834?


It is an international standard created by
welding
professionals
ISO 9001 provides the requirements for a
quality management system; it does not
establish requirements for products.
ISO 3834 on the other hand, does provide the
quality requirements for a welded product


It encourages a proactive process orientated
approach to managing and controlling
welding product quality in a workshop or
on site
It is also a Factory Control System to control
activities for the manufacture of the product
2. Why adopt ISO 3834 when we have
ISO 9001?

ISO 9001 is a comprehensive standard that lays
down quality management system requirements for
any organisation
ISO 9001 however, does not prescribe specific
details for special processes.
Welding is regarded as a special process.
ISO 3834 was developed to identify all factors that
could affect the quality of welded product and which
need to be controlled at all stages, before, during and
after welding.
3. What are the benefits of specifying the
ISO 3834 Standard for the purchaser & specifier
More assurance of contract delivery dates
Greater assurance of the quality of welded
products
Greater reliability and performance of plant
Reduction in maintenance costs
Reduction or elimination of third party
inspection costs
More competent suppliers of welded
products
4. What are the benefits of using the
ISO 3834 Standard for the manufacturer?
Less rework
Jobs completed on time
Local and international recognition as a competent
organisation
Meet the welding-related requirements of ISO 9001
More efficient coordination of welding activities
More pro-active and responsible workforce
Increased opportunities and capability to bid on jobs
Cost savings more efficient technology
Reduced surveillance audits and inspections by
purchasers with significant savings
5. What are the benefits of using the
ISO 3834 Standard for the individual
employees?
Helps to do the job more satisfactorily
Greater job security
Higher regard by other people
Professional recognition
Satisfied employer and customer
More rewarding job position
Develops team spirit
6. How important are welding
personnel?
A key feature of ISO 3834 is the requirement to
ensure that people with welding responsibilities are
competent to discharge those responsibilities

This is achieved by incorporation of another
standard, namely, ISO 14731 Welding coordination
Tasks and responsibilities

The specifying of minium requirements for personnel
dealing with welding coordination and welding
inspection personnel
7. What is the definition of a
manufacturer?

ISO 3834 defines a manufacturer as a person or
organization responsible for the welding production.

The Standard uses this term to describe any such
organisation, including manufacturing organisations
supplying welding services, either for new products or
for repair and maintenance, as well as other
organisations where the application of the
requirements of ISO 3834 are relevant

A manufacturer may be involved in manufacture,
fabrication, construction, repair or maintenance.
8. What are the types of manufacturing
organisation that
ISO 3834 can be applied to?
Fabrication companies
Construction companies - on-site work
Repair and maintenance contractors
Manufacturers of products
Welding workshops on sites under the same
technical and quality management
Owners of plant with their own workshop(s)
9. What are the types of other organisation that
ISO 3834 can be applied to?

Those which, though not creating welded product
themselves, are specifying or requiring such work from
others and are thus involved in weld design, contract
development, and review of technical requirements and
competencies of subcontractors namely

Asset owners without own workshops, both private
and government
Project management companies
Design companies
Consultants
Government agencies

10. How many parts does ISO 3834 have?

ISO 3834: 2005 Quality requirements for fusion welding of
metallic materials consists of 6 parts:

ISO 3834-1:2005, Criteria for the selection of the
appropriate level of quality requirements

ISO 3834-2:2005, Comprehensive quality requirements

ISO 3834-3:2005, Standard quality requirements

ISO 3834-4:2005, Elementary quality requirements

ISO 3834-5:2005, Applicable documentation (not full title)

ISO/TR 3834-6:2007, Guidelines on implementing ISO
3834
11. How does ISO 3834 link in with ISO 9001?

ISO 3834 does not replace ISO 9001 as a quality
management system however it contains many
attributes that will be important for a welding
manufacturer, in both workshops and at field
installation sites, seeking ISO 9001 certification

Elements of ISO 9001 should be considered when
implementing ISO 3834 quality requirements and
seeking ISO 3834 certification

The specific complementary elements of ISO 9001
are detailed in ISO 3834

WTIA TGN-3834-06 2007 gives more detailed
information
12. Describe how the flexibility of ISO 3834
can be applied?

ISO 3834 describes the following four situations where ISO
3834 can control welding:
Case 1: To provide specific requirements in specifications
which require the manufacturer to have a quality
management system in accordance with ISO 9001:2000

Case 2: To provide specific requirements in specifications
which require the manufacturer to have a quality
management system other than ISO 9001:2000

Case 3: To provide specific guidance for a manufacturer
developing a quality management system for fusion welding.

Case 4: To provide detailed requirements for specifications,
regulations or product standards that require control of
Fusion welding activites
13. What are the implications to satisfy Case 1: To provide specific
requirements in specifications which require the manufacturer to
have a quality management system in accordance with
ISO 9001:2000

For the purchaser - it implies that they want the
manufacturer
to have a quality management system in accordance with ISO
9001 and want to ensure that the supplier manages the quality
of the product. To achieve this the purchaser must detail the
requirements contained in ISO 3834 into the welding
specification.
For the Manufacturer - it implies that their quality
management system must comply with ISO 9001 and that
they need to meetthe requirements of ISO 3834. . It is
recommended that the supplier incorporates the
requirements of ISO 3834 into their
ISO 9001 quality management system using it as a bolt on
14. What are the implications to satisfy satisfy Case 2: To provide
specific requirements in specifications which require the
manufacturer to have a quality management system other than
ISO 9001:2000

For the purchaser - it implies that they want the manufacturer
to have a quality management system but not necessarily in
accordance with ISO 9001. Additionally the purchaser wants to
ensure that the manufacturer manages the quality of the
product. To achieve this the purchaser must detail the
requirements contained in ISO 3834 into the welding
specification or contract documents.

For the Manufacturer - it implies that they must have a quality
management system and meet the requirements of ISO 3834. It
is recommended that the manufacturer adopts ISO 3834 and
incorporate some elements from ISO 9001 to satisfy this requirement
15. What are the implications to satisfy Case 3: To provide specific
guidance for a manufacturer developing a quality management
system for fusion welding.

For the purchaser - it implies increased confidence in their
supplier for its recognition of the importance of controlling the
quality of the welded product


For the Manufacturer - it implies that they recognise the
importance of managing the quality of the product that they
produce. To achieve this they need to use ISO 3834 as a set of
guidelines to identify the key areas that need to be controlled.

In addition it lists the elements of ISO 9001 that need to be
considered when developing a quality management system
16. What are the implications to satisfy Case 4: To provide detailed
requirements for specifications, regulations or product standards
that require control of fusion welding activities

For the purchaser and the Manufacturer - it implies
that there is an industry-wide recognition of the
benefits that ISO 3834 has on the quality of welded
products.

This ISO 3834 Standard will be specified in
specifications, regulations and product standards
across all industry sectors such as pressure
equipment, mining, building and construction,
pipelines, railway etc. Therefore why not take
Advantage of these benefits now.
17. What are the main welding
requirements covered in ISO 3834 ?

Review of requirements
Technical review
Subcontracting
Welding personnel
Welders and welding operators, Welding coordination
personnel
Inspection & testing personnel
Welding Inspection personnel; Non-destructive
testing personnel
Equipment
Production and testing equipment; Description of
equipment; Suitability of equipment; New
equipment; Equipment maintenance
Welding and related activities
Production planning; Welding procedure
specifications (WPS); Qualification of the welding
procedures; Work instructions; Procedures for
preparation and control of documents
Welding Consumables
Batch testing; Storage and handling
Storage of parent materials
Post-weld heat treatment
Inspection and testing
Inspection & testing before welding; Inspection &
testing during welding; Inspection & testing after
welding; Inspection & test status
Non-conformance and corrective actions
Calibration and validation of measuring,
inspection and testing equipment
Identification & traceability
Quality records
Quality requirements as per
ISO 3834
Selection of Welding Quality
Requirement as per ISO:3834
Contract Welding Requirement Quality Requirement
When quality system
conforming to ISO
9001 is required
When quality system
conforming to ISO
9001 is not
required
Comprehensive quality requirement Use ISO 3834-2 Use ISO 3834-2
Standard quality requirement Use ISO 3834-2 Use ISO 3834-3
Elementary quality requirement Use ISO 3834-2 Use ISO 3834-4
Comparison of Welding quality
requirements with regard to ISO 3834-2,
3834-3 And 3834-4
Elements ISO 3834-2 ISO 3834-3 ISO 3834-4
Contract review Full documented
review
Less extensive review Establish that capability and information is
available
Design review Design for welding to be confirmed
Subcontractor Treat like a main fabricator Shall comply with all requirement
Welders, Operators Approved in accordance with ISO 9606
Welding coordination Welding coordination personnel with appropriate
technical knowledge
Not required but personal responsibility of
manufacturer
Inspection personnel Sufficient and competent personnel to be available Sufficient and competent third parties
access are needed
Production equipment Required to prepare, cut, weld, transport, lift, together
with safety equipment and protective clothes
No specific requirement
Equipment maintenance Shall be carry out,
maintenance
plan
necessary
No specific requirements,
shall be adequate
No requirement
Production plan Necessary Restricted plan necessary No requirement
Welding procedure
specification (WPS)
Instruction to made available to welder No requirement
Welding procedure approval In accordance with the appropriate part of ISO
9956,approved as application standard or
contract demands
No specific requirement
Comparison of Welding quality
requirements with regards to ISO 3834-2,
3834-3 And 3834-4
Elements ISO 3834-2 ISO 3834-3 ISO 3834-4
Work instructions Welding procedure specification (WPS) or dedicated
work instructions to be available
No requirement
Documentation Necessary Not specified No requirement
Batch testing of
consumables
Necessary Not specified No requirement
Storage and handling of
welding consumables
According to suppliers recommended minimum
Storage of parent
materials
Protection required from influences by the
environment, identifications to be maintained
No requirement
Post-weld heat treatment Specification and complete
record necessary
Confirmation to
specification
necessary
No requirement
Inspection before, during
and after welding
As required for specified operations Responsibilities as specified in
contract
Non-conformances Procedures shall be available
Calibration Procedures shall be
available
Not specified
Identification Required when appropriate Required when
necessary
Not specified
Traceability Not specified
Quality records Shall be available to meet the rules for product liability As required by contract
Retained for 5 years minimum
Inspection of Welds
Definition of Inspection as per ISO Std.

Inspection is that quality control action by
means of examination, observation or
measurement to determine the conformance of
material parts, components, system,structures
as well as processes and procedures with
predetermined quality requirements.

Nine Essential Variables of
Welding
1) Joints
2) Base metal
3) Filler metal
4) Position
5) Pre-heat
6) PWHT
7) Shielding Gas
8) Electrical Characteristics
9) Technique

Inspection Before Welding
1) Application Standard
2) WPS,PQR,WPQ
3) Drawings
4) Material Composition
5) Condition of Material
6) Type of edge preparation,method & finish
7) Consumables
8) Welding process
9) Clearance dimensions,Type of backing(if
any)
10) Alignment, Tack welds,Presets etc.
11) Pre-heat (if any)

WPS,PQR and WPQ
WPS


PQR


WPQ

Welding Procedure Specification is a written
document to provide direction for making
production weld to the code requirement.

Procedure Qualification Record is a record of
the welding data used to weld a test coupon. It
is also contains the test results of the test
specimen.
Welding Performance Record determines the
ability of the welder/welding operator to achieve
the minimum requirement specified for an
acceptable weldment.


ASME Code
ASME code widely used in India

WPS Format - QW 482

PQR Format - QW 483

WPQ Format QW 484
WPS Format as per
ASME Section IX
QW-482 Front side
Inspection During Welding
1) Welding Process Parameter
2) Inter pass Temperature
3) Filler metal/Electrode condition
4) Inter pass cleaning
5) Distortion
6) Flux /Shielding gas flow
Inspection After Welding
1) Dimensional accuracy
2) Appearance of the weld
3) Post Weld Heat Treatment (if any)
4) Evaluation of internal and surface defects
with or without the aid of Destructive/Non-
destructive testing.

Comparison Between ASME Sec. IX
and ISO 9606- Scope
As per ASME Sec. IX

The rules in this section
apply to the preparation of
WPS, PQR and qualification
of welders and welding
operators for all types of
manual and machine
welding permitted in this
section.
As per ISO 9606-1:1994

This part of ISO 9606
specifies requirements,
ranges of approval, test
conditions, acceptance
requirements and
certification for approval
testing of welder
performance for the welding
of steels.
Comparison Between ASME Sec. IX
and ISO 9606- Reference
As per ASME Sec. IX

ASME Sec.VIII and ASME
B 31

As per ISO 9606-1:1994

ISO 857,1106-1,1106-2,
1106-3, 2560, 3452, 3580,
3581, 4063, 5173, 5817,
6520,6949, 9956-2 and
9956-3
Comparison Between ASME Sec. IX
and ISO 9606- Definition
As per ASME Sec. IX

As per QW- 492


As per ISO 9606-1:1994

1) Welder
a) Manual &
b) Welding operator
2) Examiner Or Test Body
3) WPS
4) Range of Approval
5) Test Piece
6) Test Specimen
7) Test

Comparison Between ASME Sec. IX
and ISO 9606- Variables
As per ASME Sec. IX

Joints ( QW-402)
Base Metal ( QW-403)
Filler Metal ( QW-404)
Position ( QW-405)
Preheat (QW-406)
Postweld Heat Treatment (QW-
407)
Gas ( QW-408)
Electrical Characteristics ( QW-
409)
Technique (QW-410)
Note- Varies with different welding
processes
As per ISO 9606-1:1994

Welding Processes
Joint Type
Material Group
Filler metal, Shielded gas
and flux
Dimensions
Welding position
Comparison Between ASME Sec. IX
and ISO 9606- Material Grouping
As per ASME Sec. IX

Steel & Steel alloys
Aluminium & Al. base alloys
Copper & Cu. base alloys
Nickel & Ni. base alloys
Titanium & Ti. base alloys
Zirconium & Zr. base alloys
As per ISO 9606-1:1994

Low-carbon unalloyed steels
and/or low alloyed steels (W01)
Cr-Mo and/or Cr Mo V creep
resistant steels (W02)
Fine grained structural steels
normalised,quenched and
tempered as well as
thermomechanically treated steels
and nickel steel with Ni content 2%
to 5%
Ferritic or martensitic stainless
steels with Cr content 12% to 20%.
Stainless ferritic-austenitic and
stainless Cr-Ni steels.

Comparison Between ASME Sec. IX
and ISO 9606- Position-Plate-Butt
As per
ASME
Sec IX




As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Plate-Fillet
As per
ASME
Sec IX




As per
ISO
9606

Comparison Between ASME Sec. IX
and ISO 9606- Position-Pipe-Fillet
As per
ASME
Sec IX




As per
ISO
9606

Comparison Between ASME Sec. IX
and ISO 9606- Position-Pipe-Butt
As per
ASME
Sec IX




As per
ISO
9606

Comparison Between ASME Sec. IX
and ISO 9606- Type of Test
As per ASME Sec. IX

A) For Butt Weld
i) Transverse side bend,
ii) Transverse Face Bend
iii) Transverse Root Bend
B) For Fillet Weld
i) Fracture Test
ii) Macro Examination
C) Visual
D) Radiographic Examination

As per ISO 9606-1:1994

Visual
Radiography
Bend
Fracture
MPI or LPT
Macro (Without Polishing)
Comparison Between ASME Sec. IX and ISO 9606-
Expiry or Renewal of Qualification
As per ASME Sec. IX
When the welder has not welded
with a process during a period of 6
months or more, his qualifications
for that process shall expire;
unless, within the six months period
to his expiration of qualification
a) A welder has welded using a manual
or semiautomatic welding which will
maintain his qualification for manual
and semiautomatic welding with
that process.
b) A welding operator has welded
using a machine or automatic
welding which will maintain his
qualification for machine and
automatic welding with that
process.
There shall be no specific reason to
question the welders skill and
knowledge



As per ISO 9606-1:1994
A welders approval shall remain valid
for a period of 2 years providing that
the relevant certificate is signed at six-
months intervals by employer/co-
ordinator and that all following
conditions at fulfilled
a) The welder shall be engaged with
reasonable continuity on welding work
within the current range of approval.
An interruption for a period no longer
than 6 months is permitted.
b) The welders work shall be in
accordance with the technical
conditions under which the approval
test is carried out.
There shall be no specific reason to
question the welders skill and
knowledge
Weld Quality
Discontinuity
An interruption of the typical structure of a material, such as a
lack of homogeneity in its mechanical, metallurgical, or physical
characteristics.
A discontinuity is not necessarily a defect but all defects are
discontinuities.

Defect
A defect is a rejectable discontinuity, which occurs in an amount
great enough to render a particular object or structure unsuitable
for its intended service based on criteria in the applicable code.

Classification of Defects

Planar defects / Two dimensional defects --
E.g. cracks, lack of fusion, lack of penetration, are
crtical in nature and are not tolerated to any extent.
Voluminar defects / Three dimensional defects --
E.g. slag inclusion, cavities, porosities, etc are
tolerated to a certain extent depending on the
product class and applicable code.
Geometric defects-- E.g. excess reinforcement,
underfill, root suckback, distortion are also permitted
to a certain extent.
Misalignment (hi-lo)
Definition: Amount a joint is out
of alignment at the root
Cause: Carelessness. Also due to joining different
thicknesses (transition thickness)
Prevention: Good Workmanship.
Repair: Grinding. Careful on surface finish and
direction of grind marks.
Undercut
Definition: A groove cut at the toe
of the weld and left unfilled.
Cause: High amperage, electrode
angle, long arc length, rust.
Prevention: Set machine on scrap metal. Clean metal before
welding.
Repair: Weld with smaller electrode, sometimes must be low
hydrogen with preheat. Sometimes must gouge first.
Undercut
Insufficient Fill on the Root Side
(Suck back)
Definition: The weld surface is below the adjacent
surfaces of the base metal at the weld root.
Cause: Typically improper joint preparation or
excessive weld pool heat.
Repair: Back weld to fill. May require removal of weld
section by grinding for access to the joint root.
Suck back
Excessive Concavity or
Convexity
Definition: Concavity or convexity of a fillet weld which
exceeds the specified allowable limits
Cause: Amperage and travel speed
Prevention: Observe proper parameters and techniques.
Repair: Grind off or weld on. Must blend smoothly into the base
metal.
Concavity
Convexity
Reinforcement
Excessive
Insufficient
Improper contour
Face Reinforcement
Root Reinforcement
The amount of a groove weld which extends
beyond the surface of the plate
Excessive Reinforcement

Definition: Specifically defined by the standard.
Typically, Reinforcement should be flush to
1/16(pipe) or flush to 1/8 (plate or structural
shapes).
Cause: Travel speed too slow, amperage too low
Prevention: Set amperage and travel speed on scrap
plate.
Repair: Remove excessive reinforcement and feather
the weld toes to a smooth transition to the base plate.
Excessive reinforcement
Definition: Specifically defined by the standard. Typically,
Underfill may be up to 5% of metal thickness, not to exceed
1/32 as long as the thickness is made up in the opposite
reinforcement. Not applied to fillet welds.
Cause: On root reinforcement - Too little filler metal will cause
thinning of the filler metal. In OH position, too hot or too wide
will cause drooping of the open root puddle.
Prevention: Use proper welding technique. Use backing or
consumable inserts. Use back weld or backing.
Repair: Possibly simply increase the face reinforcement. If back
welding is not possible, must remove and reweld.
Insufficient Reinforcement
Insufficient reinforcement
Burn-through
Definition: When an undesirable open hole has been
completely melted through the base metal. The hole may or
may not be left open.
Cause: Excessive heat input.
Prevention: Reduce heat input by increasing travel speed, use
of a heat sink, or by reducing welding parameters.
Repair: Will be defined by standards. Filling may suffice.
Otherwise, removal and re welding may be required.
Burn-through
Lack Of Penetration
Definition: When the weld metal does not extend to the required
depth into the joint root
Cause: Low amperage, low preheat, tight root opening, fast
travel speed, short arc length.
Prevention: Correct the contributing factor(s).
Repair: Back gouge and back weld or remove and reweld.
Lack Of Penetration
Incomplete Fusion
Definition: Where weld metal does not form a cohesive bond
with the base metal.
Cause: Low amperage, steep electrode angles, fast travel
speed, short arc gap, lack of preheat, electrode too small,
unclean base metal.
Prevention: Eliminate the potential causes.
Repair: remove and reweld, being careful to
completely remove the defective area. This is
sometimes extremely difficult to find.
Incomplete Fusion
Arc Strike
Definition: Arc strikes result when the arc is initiated on the
base metal surface away from the weld joint either
intentionally or accidentally
Cause: Carelessness of welder
Prevention: In difficult areas, adjacent areas can be protected
using fire blankets.
Repair: Where applicable, arc strikes must be grinded smooth
and tested for cracks. If found, they must be remove and
repaired using a qualified repair procedure and inspected as
any other weld.
Definition: Slag entrapped within the weld
Cause: Low amperage, improper technique, Trying to weld in
an area that is too tight. Improper wire brushing / cleaning
between passes.
Prevention: Increase amperage or preheat, grind out tight areas
to gain access to bottom of joint.
Repair: Remove by grinding. Reweld.
Slag Inclusion
Slag inclusion
Definition: A tungsten particle embedded in a weld. (Typically
GTAW only)
Cause: Tungsten electrode too small, amperage too high,
electrode dipped into the weld pool or touched with the fill rod.
Prevention: Thoriated or Zirconiated tungsten electrodes are
used in place of pure tungsten electrodes.
Repair: Grind out and reweld
Tungsten Inclusion
Tungsten inclusion
Spatter
Definition: Small particles of weld metal expelled from the
welding operation which adhere to the base metal surface.
Cause: Long arc length, severe electrode angles, high
amperages.
Prevention: Correct the cause.
Repair: Remove by grinding or sanding.
Spatter
Cracks
Longitudinal
Transverse
Crater
Throat
Toe
Root
Under bead and Heat-affected zone
Hot
Cold or delayed
Cracks
Cracks
Laminations
Base Metal Discontinuity
May require repair prior to welding
Formed during the milling process
Porosity - Types
Porosity is gas pores found in the solidified
weld bead.
Single Pore
Uniformly Scattered
Cluster
Linear

Porosity
Clustered Porosity
Testing
It is defined as the physical performance of
operations to determine quantitative
measure of certain properties of a process
It aim to determine quantity i.e. to
discover facts regardless of the implication
of the result.

Types of Destructive & Non-
destructive Testing
Destructive

Tensile Test
Macro Test
Charpy Test
Fracture Test
Bend Test


Non-destructive

Ultrasonic Test (UT)
Magnetic Particle Test (MPT)
Liquid Penetrant Test (LPT)
Radiography Test (RT)
Visual Test (VT)

Defects and their Limits as per ISO 5817 -2003
Defects and their Limits as per ISO 5817 -2003 contd.


Defects and their Limits as per ISO 5817 -2003 contd.


Defects and their Limits as per ISO 5817 -2003 contd.


Defects and their Limits as per ISO 5817 -2003 contd.
Defects and their Limits as per ISO 5817 -2003 contd.


Surface Cracks- Detectable by VT
Surface Irregularities-Detectable by VT
Contour Defects- Detectable by VT
Root Defects- Detectable by VT
Visual Inspection Acceptance Criteria as per AWS D 1.1
Discontinuity Category
&Inspection Criteria
Static Loaded
(Nontubular)
Dynamic Loaded
(Nontubular)

All Loads
(Tubular)

Underrun-In fillet weld upto 1.6 mm
subject to it does not exceed 10% of the
weld length. No underun is permitted for
web-to-flange welds of girder
Applicable Applicable

Applicable

Undercut-Upto 1 in. not to exceed 1mm.
For an accumulated length of 2inch in any
12 inch for material above 1in. Undercut
above 1.6mm not allowed.
Applicable

Not-Applicable Not-Applicable
Porosity-No porosity in the butt weld
traverse to tensile strength. In other butt
welds and for fillet weld the size of
1mmin linear inch of weld and shall not
exceed 19 mm in 12 in length of weld
Applicable

Not-Applicable

Not-Applicable

Porosity-In fillet weld the frequency of
porosity shall not exceed one in 100mm
of weld length and the maximum diameter
shall not to exceed 2mm.
Not-Applicable Applicable

Applicable

Visual Inspection Acceptance Criteria
Discontinuity Category
&Inspection Criteria
Static Loaded
(Nontubular)
Dynamic Loaded
(Nontubular)

All Loads
(Tubular)

Crack- The weld shall have no crack Applicable Applicable

Applicable

Weld/Base-Metal Fusion-Through fusion shall
exist between weld metal to weld metal and
base metal
Applicable

Applicable

Applicable

Crater- All crater shall be filled up to the full
cross section except for the ends of the
intermittent fillet welds outside the effective
length
Applicable

Applicable

Applicable

Weld Profiles-Weld profiles shall be in
conformance to 5.24
Applicable

Applicable

Applicable

Time of Inspection- Immediately after the
completed weld reaches the ambient temp.For
ASTM A514,A517,A709 not less than 48 Hrs.
Applicable

Applicable

Applicable

Visual Inspection Acceptance Limit-Piping
As per BS 5289
Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module

Mr.A.K.Bose
Mr.N.Sadasivan
R.Banerjee
Thank You