The document outlines the processes and qualifications related to welding engineering, specifically focusing on the development of welding procedures and welder qualifications based on shop requirements. It details various welding processes, essential and supplementary variables, and p-number groupings for different base metals to standardize procedure qualifications. Additionally, it covers welder performance qualifications through specific welding positions and filler metal classifications.

1. WELDING ENGINEERING
BY: WELDING TECHNOLOGY DIVISION

2.  DEVELOPMENT OF NEW WELDING PROCEDURES AS PER PRODUCTION
REQUIREMENT.
 WELDER QUALIFICATION IN DIFFERENT PROCESSES / POSITIONS AS PER SHOP
REQUIREMENT.
Main work area of Welding Engineering

3. Welding processes used in HEEP/Hardwar
 SHIELDED METAL ARC WELDING
 GAS METAL ARC WELDING
 GAS TUNGSTEN ARC WELDING
 SUBMERGED ARC WELDING
 PLASMA TRANSFERRED ARC WELDING
 SPOT WELDING

4. Essential Variable: Essential variable are those in which a change, as
described in the specific variables ,is considered to effect the mechanical
properties of weldment, and shall require requalification of the WPS.
Supplementary Variables: Supplementary Variables are required for
metals for which other sections specify notch-toughness tests and are in
addition to the essential variables for each welding process.
Nonessential Variables: may be made in the WPS without
requalification. Nonessential variables are those in which a change, as
described in the specific variable.
Welding Variables

5.  Joint design (Groove angle, root preparation)
 Welding process.
 Type of current.
 Pre and post weld heat treatment.
 Base material (P No: & Group No: ) or Grade.
 Base metal thickness range.
 Filler metal ‘F No’.
 Preheating temperature and inter-pass temperature.
 Voltage & ampere range.
 Supporting Procedure Qualification Report (PQR)
Important Parameter

6. Welding Variables For Procedure Qualification

7. Welding Variables For Procedure Qualification

8. Welding Variables For Performance Qualification

9. P-Numbers are assigned to base metals for the purpose of reducing
the number of welding procedure qualification required.
Base Metal Grouping
BASE METAL GROUPING
Steel and steel alloys P No 1 through P No 15F
Incl. P No. 5A,5B and 5C
Aluminum and aluminum
alloys
P No 21 through P No 25
Copper and copper alloys P No 31 through P No 35
Nickel and nickel base
alloys
P No 41 through P No 49
Titanium and titanium base
alloys
P No 51 through P No 53

10. P No. EN288 Base Metal Example
1 1 C-Mn Steels AA10119, AA10104, AA10108
3 4 Typically half chrome & half moly HW19578
4 5 Typically one and a quarter chrome, half moly
5A 5 two and a quarter chrome one moly(Forging) HW19576
5B 5 Typically five chrome half moly and nine chrome
one moly
HW19688
5C 6 Chrome moly vanadium &Two quarter chrome
one moly(Casting)
HW19581
6 8 Martensitic Stainless Steels Typically Grade 410 HW10767
7 8 Ferritic Stainless Steels Typically Grade 409 ------
8 9 Austenitic Stainless Steels AA10740, AA10788
15E Nine Chrome one Moly- Vanadium HW 19462
ASME P-Numbers

11. Designation for maual electrode

12. Base metal Thickness range for procedure qualification

13. Test required in procedure qualfiacation

14. Welding Procedure Specification

15. Welding Procedure Specification

16. Procedure Qualification Record

17. Procedure Qualification Record

19. Guided-bend test specimens

20. WELDER PERFORMANCE
QUALIFICATION
(WPQ)

21. Welding Positions in welder Qualification
F: FILLET , G: GROOVE
 FLAT - 1F OR 1G
 HORIZONTAL - 2F OR 2G
VERTICAL - 3F OR 3G
 OVERHEAD - 4F OR 4G
 PIPE - 5G (FLAT+ VERTICAL)
 PIPE - 6G(9ALL POSITION)

22. Welding Positions in welder Qualification

23. Welding Positions in welder Qualification

24. Alternate Base Material for Welder Qualification
WELDER QUALIFIED WITH
BASE METALS
WELDER QUALIFIED TO WELD
BASE METALS
P NO 1 THROUGH P NO 15F,P NO
34 AND P NO 41 THROUGH
P NO 49
P NO 1 THROUGH P NO 15F,P NO 34 AND P
NO 41 THROUGH
P NO 49
P NO 21 THROUGH P NO 25 P NO 21 THROUGH P NO 25
P NO 51 THROUGH P NO 53 P NO 51 THROUGH P NO 53

25. Welder Qualified
With
F-No.1
With
Backing
F-No.1
Without
Backing
F-No.2
With
Backing
F-No.2
Without
Backing
F-No.3
With
Backing
F-No.3
Without
Backing
F-No.4
With
Backing
F-No.4
Without
Backing
F-No.5
With
Backing
F-No.5
Without
Backing
Welder Qualified
to Weld
F-No.1
With Backing √ √ √ √ √ √ √ √ √ √
F-No.1
Without Backing √
F-No.2
With Backing √ √ √ √ √ √
F-No.2
Without Backing √
F-No.3
With Backing √ √ √ √
F-No.3
Without Backing √
F-No.4
With Backing √ √
F-No.4
Without Backing √
F-No.5
With Backing √ √
F-No.5
Without Backing √
Alternate F- Number for Welder Qualification

26. WELDER QUALIFIED WITH WELDER QUALIFIED TO WELD
ANY F-NO. 6 ALL F-NO. 6
ANY F-NO.21 THROUGH F-NO. 25 ALL F-NO.21 THROUGH F-NO. 25
ANY F-NO. 31, 32, 33, 35, 36 OR 37 ONLY THE SAME F-NUMBER AS WAS USED
DURING THE QUALIFICATION TEST
F-NO.34 OR ANY F-NO. 41 THROUGH F-
NO. 46
F-NO.34 AND ALL F-NO. 41 THROUGH F-NO. 46
ANY F-NO.51 THROUGH F-NO. 55 ALL F-NO.51 THROUGH F-NO. 55
ANY F-NO.61 ALL F-NO.61
ANY F-NO.71 THROUGH F-NO.72 ONLY THE SAME F-NUMBER AS WAS USED
DURING THE QUALIFICATION TEST
Alternate F- Number for Welder Qualification

27. F Number General Description
1 Heavy rutile coated iron powder electrodes :- A5.1 : E7024
2 Most rutile consumables such as :- A5.1 : E6013
3 Cellulosic electrodes such as :- A5.1 : E6011
4 Basic coated electrodes such as : A5.1 : E7016 and E7018
5 High alloy austenitic stainless steel and duplex :- A5.4 : E316L-
16
6 Any steel solid or cored wire (with flux or metal)
ASME Filler Code

28. Performance Qualification-Performance & diameter
Limitation( QW-303)

29. Base metal thickness requirement for welder qualification

30. Performance qualification in case of pipe