Welder Certification and Procedure Qualification

Overview

The capability extends to CTOD on welding electrodes at negative 45 degrees Celsius (E7018, E7018-1) and CTOD per ONGC Spec 2009F Rev. 8 with FMA preparation.

Coverage extends to AWS D1.2 for structural aluminium, ASME Section VIII for pressure-vessel fabrication, and API 1104 for pipeline and cross-country pipework welds, with coupon programmes combining visual, mechanical, metallographic, and non-destructive examination.

TCR Engineering Services provides a comprehensive welder certification and welding procedure programme that includes:

• Welder Qualification Testing for performance qualification and certification of welders (a welder / welding operator performances qualification - WQT) to ASME Sec. IX, ASME Sec. VIII, ANSI, AWS D 1.1, AWS D 1.2, API 1104 etc.
• Preparation for Weld Procedure Qualification (WPS) that is relevant for either the project or any client requirements
• Coupon Testing as per Welding Procedure Qualification including visual examination, mechanical testing, metallographic examination, and non-destructive testing
• Documentation of the Procedure Qualification Record (PQR) as per ASME Sec. IX, ASME Sec. VIII, ANSI, AWS D1.1, AWS D1.2, API 1104 etc.
• Detailed weld inspection including review of the qualification e.g. weld procedure specification, welder performance qualification, validity for process materials and consumable items, equipment, setup and other factors including certificates of calibration and/or conformity governing the task
• Ascertain safety of operations for self, welder and other workers in the vicinity, particularly ultraviolet radiation from arc during welding

Welding Procedure Programme

The welding inspector deployed on-site by TCR is responsible for monitoring and verifying conformity of tasks against all the relevant requirements including codes, specifications and/or standards:

• Ascertain the Weld Procedure(S) Employed
• Review Weld Procedure and Welder Qualifications
• Supervise Weld Profile Preparation
• Inspect Joint Fit-Up
• Oversee Filler Metals and Consumable Materials
• Ensure Correct Welding Performance Parameters are Maintained
• Perform Visual Examination Upon Completion Of Welding Monitor
• Specified Pre and Post Weld Heat Treatment
• Monitor the Physical Examination including Non-Destructive Test, Hydrostatic Test, and Mechanical Test Etc.
• Based On the Requirement, the Inspector may Choose to send Test Samples to the TCR Engineering Services' Material Testing Laboratory
• Verify all Necessary Visual Inspections are completed and all other necessary Non-Destructive Examinations are Executed as Specified

Based on the requirements, the inspector may employ equipment to accelerate the process:

• Inspection Mirrors
• Torch or other Electrical Lighting Facilities (permitted by safety codes eg. 24V system etc.)
• Physical Size Measuring Instruments such as Welding Gauge, Rule, Vernier etc.
• Electrical Parameter Measuring Instruments such as an Ammeter, Voltmeter etc.
• Temperature Measuring Instruments (Thermometer)/Aids (Thermo Chalk)
• TCR Engineering dedicated materials testing laboratories in Navi Mumbai and Bhubaneswar undertake mechanical testing and chemical analysis as recommended in ASME Section IX, ASME Section VIII Division-1, AWS D1.1, API 1104 & Customer Specifications. Testing for Electrode qualification as per ASME Section II Part C, IS 814 can also be done in our Laboratories. These tests are done for Welding Procedure Specification (WPS)/ Procedure Qualification Record (PQR), Welder Performance Qualification (WPQ) & Production Weld Coupons.
• The laboratory is NABL accredited to ISO/IEC 17025:2017. Tests done for WPS as per ASME Section IX & API 1104 include All Weld Tensile Test, Transverse Tensile Test (as per API/ISO), Nick Break Test, Bend Test, Macro, Micro, Hardness, Chemical Analysis, Charpy V Notch Impact, and Radiography of weld coupon.
• TCR requires coupon of the following sizes:

• 12” NB = 1 coupon
• 2” NB = 4 coupon for API 1104
• 2” NB = 4 coupon for ASME Sec IX

• TCR Engineering has expert CWI and AWS inspectors who provide consultancy as IIW-IWS (RWC-External) for welders Training & Certification which includes training programmes for staff & welders, guidance for preparation of Quality Manual, Procedures, Work Instructions and Witness/Review of WPS/PQR/WPQ tests.

Standards: ASME Section IX (WPS, PQR, WQT), AWS D1.1 (structural steel), AWS D1.2 (structural aluminium), AWS D1.5 (bridge welding), API 1104 (pipeline welds), IS 7318 (welder qualification), EN ISO 9606 series.