CWI WPS, PQR, and Welder Qualification Questions and Answers — Questions and Answers
Question 1: A fabricator has a WPS qualified for a groove weld on 1-inch thick carbon steel plate. The WPS specifies a 1/8" E7018 electrode. An engineer wants to use a 5/32" E7018 electrode for increased deposition rate, which is a change in an essential variable according to ASME IX. What must be done before this change can be implemented in production?
- Revise the WPS to reflect the new electrode size and proceed with production.
- Perform a new Welder Performance Qualification Test (WPQ) with the 5/32" electrode.
- Weld a new test coupon using the 5/32" electrode, perform the required testing, and document the results on a new PQR. (Correct answer)
- Submit a formal request to the client to waive the requalification requirement.
Correct answer: Weld a new test coupon using the 5/32" electrode, perform the required testing, and document the results on a new PQR.
A change in an essential variable, such as electrode diameter beyond the qualified range, is considered to affect the mechanical properties of the weld. Therefore, the Welding Procedure Specification (WPS) must be requalified. This requires welding a new test coupon under the new conditions, performing all required mechanical and non-destructive tests, and documenting these actual values and results on a new Procedure Qualification Record (PQR).
Question 2: What is the primary function of a Procedure Qualification Record (PQR)?
- To provide a 'recipe' with allowable ranges for the welder to use in production.
- To record the specific test results for an individual welder's ability.
- To serve as a certified record of the actual variables and test results from a successfully welded test coupon. (Correct answer)
- To list all approved non-essential variables that can be changed without requalification.
Correct answer: To serve as a certified record of the actual variables and test results from a successfully welded test coupon.
The PQR is the foundational document that proves a given set of parameters can produce a sound weld. It records the actual, specific data (e.g., exact amperage, voltage, travel speed) used to weld a test coupon and the results of the subsequent destructive and non-destructive testing. This certified record then provides the data to support writing a WPS, which lists allowable ranges for production welding.
Question 3: A welder successfully completes a performance qualification test for a CJP groove weld on a 1-inch thick plate in the 3G (vertical-up) position per AWS D1.1. For which of the following plate groove weld positions is this welder now also qualified?
- 4G (overhead) only
- 1G (flat), 2G (horizontal), and 3G (vertical) (Correct answer)
- All positions (1G, 2G, 3G, and 4G)
- 3G (vertical) only
Correct answer: 1G (flat), 2G (horizontal), and 3G (vertical)
According to AWS D1.1 qualification rules, successfully passing a groove weld test on plate in the 3G position qualifies the welder for production welding in the 1G (flat), 2G (horizontal), and 3G (vertical) positions. Qualification in the 4G (overhead) position requires a separate test in that position.
Question 4: Which of the following documents is the basis for establishing a Welding Procedure Specification (WPS)?
- The Welder Performance Qualification (WPQ)
- The project's quality control manual
- A pre-approved standard welding procedure (SWPS)
- The Procedure Qualification Record (PQR) (Correct answer)
Correct answer: The Procedure Qualification Record (PQR)
The PQR is created first. It is the record of the successful welding and testing of a test coupon. The data from this PQR is then used as the basis to write the WPS, which provides the approved ranges of variables for production welding. A single PQR can support one or more WPSs.
Question 5: During a review of welding documentation, a CWI notes a PQR was qualified using a 1/2-inch thick test coupon. According to ASME Section IX, Table QW-451.1, what is the qualified range of base metal thickness for a WPS written from this PQR?
- 1/4 inch to 1 inch
- 1/8 inch to unlimited
- 3/16 inch to 1 inch (Correct answer)
- 1/2 inch to 2 inches
Correct answer: 3/16 inch to 1 inch
ASME Section IX, Table QW-451.1 specifies the procedure qualification thickness limits. For a test coupon (T) with a thickness over 3/8 inch but less than 3/4 inch (which includes 1/2 inch), the qualified base metal thickness range is from 3/16 inch up to 2T. In this case, 2T is 2 * 0.5 inches = 1 inch. Therefore, the qualified range is 3/16 inch to 1 inch.
Question 6: A change to which of the following variables on a WPS would be considered 'non-essential' per ASME IX, allowing the WPS to be revised without requiring a new PQR?
- A change in P-Number of the base metal
- The addition of post-weld heat treatment (PWHT) where none was performed before
- A change in the groove design (e.g., from a V-groove to a U-groove) (Correct answer)
- A change from the SMAW process to the GTAW process
Correct answer: A change in the groove design (e.g., from a V-groove to a U-groove)
A change in the joint groove design is typically considered a non-essential variable. This means the WPS must be formally revised to reflect the change, but a new procedure qualification test is not required because this change is not considered to affect the mechanical properties of the weldment. Changes in P-Number, the addition of PWHT, and a change in welding process are all essential variables that would require full requalification with a new PQR.
CWI WPS, PQR, and Welder Qualification Questions and Answers
A fabricator has a WPS qualified for a groove weld on 1-inch thick carbon steel plate.
The WPS specifies a 1/8" E7018 electrode.
An engineer wants to use a 5/32" E7018 electrode for increased deposition rate, which is a change in an essential variable according to ASME IX.
What must be done before this change can be implemented in production?