Welding Procedure Qualification – Certification Under the Supervision of a Notified Body

Finspection | helmi 14, 2024

So, what is it about? A welding procedure qualification may become relevant for a pressure equipment manufacturer, for example, as a result of product development or a new order. A new product type, material, or material thickness may lead to the need for qualifying a new procedure.

In pressure equipment manufacturing, permanent joints are often made by welding or brazing. Therefore, welding procedure qualification is sometimes referred to as the qualification of permanent jointing methods.

In practice, welding can be performed manually, mechanized, or fully automated. Regardless of the implementation method, when manufacturing CE-marked pressure equipment in categories II, III, and IV, the involvement of a third party defined by the Pressure Equipment Directive, such as Finspection, is always required to supervise and qualify the welding method. The qualification is manufacturer-specific and, in principle, always valid as long as welding is performed within the qualification range of the procedure test.

Welding affects the mechanical and chemical properties of materials. Since certain welding processes are more effective in specific situations, selecting the correct method is critical. An approved welding procedure qualification, supervised by a Notified Body, not only ensures the high quality and safety of welded joints but also fulfills legislative requirements, enabling the free movement of pressure equipment within the European Union’s internal market.

As part of the welding procedure qualification, it is also possible to perform welder qualification testing from the same test piece, provided this is agreed with us in advance. Depending on the scope and scheduling of the procedure qualification, we can supervise multiple procedure and welder qualifications consecutively on the same day, allowing you to conveniently handle all qualifications at once.

Finspection is an accredited Notified Body that conducts qualifications according to commonly used EN standards, such as the EN 15614 series or EN 15613, as well as more specialized standards like ASME BPVC Section IX. We are well-known for the quality of our work and our flexibility.

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The Pressure Equipment Directive PED 2014/68/EU (Annex 1, section 3.12) defines the approval procedures for methods used to make permanent joints. The directive requires the involvement of a third party in qualifying methods used for permanent joints in equipment classified under categories II–IV.

As a Notified Body, Finspection Oy has the authority to approve the qualifications of methods used for permanent joints. Welding procedure and performance qualification tests are the most common qualifications carried out for welding methods in pressure equipment manufacturing. We also offer qualification services for brazing methods.

You may have called us and booked an appointment for a welding procedure qualification. Over the phone, we have provided you with preliminary instructions. Now, let us explain these in more detail.

We will ask you in advance for information about what will be done during the procedure qualification and to what extent. It is the responsibility of the manufacturer’s welding coordinator to prepare a detailed preliminary welding procedure specification, known as pWPS.

This document contains information about the welding process, welding parameters, materials used, and other essential details. It serves as an initial guideline for the welder when performing the welding procedure qualification.

Preparatory measures are mainly the responsibility of the manufacturer. Before welding the procedure or pre-production test, the manufacturer must ensure and arrange the following:

• Identification of the applicable standard: Determine the requirements, applicable standard, or product standard.
• Arrangement of the test welding site: Ensure the availability of necessary welding equipment and supplies.
• Preparation of the preliminary welding procedure specification (pWPS or similar): This serves as a guideline for welding the test pieces.
• Preparation of test pieces: Follow the applicable standard or other agreed-upon procedure.
• Cutting and edge preparation of test pieces: Include material marking transfers, material and filler material certificates, etc.
• Selection of the welder or welding operator: Ensure they have the skills required to perform the specific joint.

Please also note that a harmonized product standard, customer requirements, or other guidelines may require additional tests to be performed. In such cases, the execution of these tests must follow the specific product standard or other agreed-upon instructions.

The welding coordinator is usually our primary contact at the manufacturer and is responsible for the practical arrangements of the procedure test. However, sometimes these tasks may be handled by another member of the manufacturer’s staff.

We will arrive at the agreed time. The welding procedure qualification is always carried out at the manufacturer’s premises.

We hope that the preparatory measures will be completed by the time we arrive. This ensures efficient supervision of the procedure qualification, avoiding unnecessary delays and idle time on the welding day.

Now we get to the core of the process. Before welding begins, we verify the necessary details and agree on the rules of the welding procedure and the welder’s plan for executing tasks such as preheating, welding sequence, possible root opening, and other relevant steps.

The procedure qualification supervisor records and/or verifies the following aspects in the supervision protocol before or during welding. We conveniently document the variables using the Finspection App.

• Information about the company performing the welding procedure qualification
• Information about the welder performing the procedure qualification
• Verification of procedure test pieces, groove shape, and tack welding

• Material, material markings, and their transfer
• Material certificate according to EN 10204 3.1 or 3.2
• Dimensions
• Marking of test pieces
• Procedure qualification identification and test piece number, if multiple positions are involved
• Welder identification
• Welding filler materials
• Marking
• Classification
• Size
• Test certificate in accordance with at least EN 10204 2.2
• Welding shielding and backing gas
• Marking
• Classification

During welding, it is monitored that the welding of the procedure test piece is carried out in accordance with the pWPS:

• Welding position
• Monitoring of welding parameters for each pass:
• Welding process
• Welding consumables
• Current type
• Working temperature/preheating temperature
• Interpass temperature
• Welding current
• Arc voltage
• Travel speed
• Shielding and backing gas flow rate
• Pass sequence

In addition to the variables mentioned above, process-specific variables are also verified, such as:

• Wire feed speed
• Arc type
• Stick-out length
• Pass length welded with one electrode

These welding variables are verified using the supervisor’s own measuring instruments.

During and after welding, we inspect the quality and success of the weld in accordance with the requirements of the standard and the pWPS.

Once the welding is complete, the welder conducts their own inspection to ensure they are satisfied with the final result.

Next we:

• Perform a visual inspection of the test piece.
• Mark the test piece as supervised by stamping it with the supervisor’s stamp. We also verify that all required markings remain on the piece for traceability.
• Depending on the material and its thickness, the test piece may undergo heat treatment.

After welding the procedure test, we determine the required tests for the test pieces in cooperation with the manufacturer. The tests are divided into:

• Non-destructive testing (NDT)
• UT, RT, PT and MT
• Destructive testing (DT).
• Tensile, bending, impact, and hardness tests, as well as macrostructure examination

As a manufacturer, you can choose to have the test pieces tested by our partner or use your own partner.

If you use your own partner for NDT and/or DT, please ensure their testing organization is approved by us beforehand. When issuing the certificate, we are responsible for the accuracy of the testing process.

Our role during the procedure qualification is to supervise the process. We are also responsible for recording and verifying welding parameters during the welding process.

After the visual inspection and determination of the required testing, we send the supervision protocol via email to the manufacturer’s contact person. This protocol contains all the necessary details about the welding process.

The supervision protocol is then delivered, either by us or the manufacturer, to the testing organization along with the test pieces. The required tests are clearly outlined in the supervision protocol documentation.

Once the welding procedure qualification has been successfully completed, we will send the signed WPQR (Welding Procedure Qualification Record) to your email. The WPQR clearly defines the qualification range of the welding procedure in accordance with the standard.

The annex to the procedure record includes all essential variables of the procedure qualification, documented in detail. It also contains all tests conducted during the qualification, their results, and other necessary recorded information. You can also easily access these documents via the Finspection App, where you can view and manage all welding procedures qualified by Finspection.

Does your company need a welding procedure qualification?

Our inspections and qualifications are always carried out with absolute professionalism and impartiality, but in one aspect, we stand out from other inspection bodies: we use the Finspection App. With this user-friendly application, we have made document management simple. All documentation is digital – when you need information, you can access it immediately without searching.

Our real-time system also eliminates the possibility of human error in granting qualification ranges, so you can always trust the accuracy of the data.

Our professional and independent staff across Finland perform welding procedure qualifications on request. The qualification of welding and brazing procedures is an accredited inspection service in which we have extensive experience.

We can provide a quote for the entire procedure qualification process, including the required testing with our partners. When requesting a quote, please provide all essential information regarding the method or methods in question. If necessary, we will request additional details before sending the offer.

You can schedule inspections and welding qualifications at a time that suits you. Contact us via email at finspection@finspection.fi or call us at +358 10 348 0660 to arrange an inspection!

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