An efficient system to automatically write a qualified WPS?

A customer can ask a manufacturer to write a cahier de soudage presenting – in particular – the WPS used for the assembly. However, in some cases, the welds to be made do not correspond to the pre-existing WPS or to the WPS used beforehand to validate the PQR held by the manufacturer.

Warning: the purpose of this article is to comment on and briefly write about the notions related to the above problem. This article is not intended to be exhaustive and is not a substitute for the advice of a welding expert or certification body.

In other words, the manufacturer must write a new Welding Operations DomainWPS representative of the assembly to comply with the customer’s request. Indeed, one or more WPS can be written on the basis of the Validated Domain (DV) of a Welding Procedure QualificationPQR held by the company.

The implementation of a system for writing and archiving WPS is therefore necessary in an environment pressed by tight production deadlines.

Reminder on the qualification steps of a WPS, on the Domain of Validity (DV) of the PQR

The qualification of a WPS requires a standardized qualification coupon (according to EN ISO 15614-1) or a pre-production assembly (according to EN ISO 15613) to be checked by a third party. In some cases, other standards standardize the qualification of a WPS without a coupon, but we do not cover them here for the sake of simplicity.

This control gives rise to a qualification of a preliminary WPSWPS) in the form of a Qualification of Welding Operation ModePQR) including a Domain of Validity (DV). The latter covers a more or less wide range on the basis of Ø and thicknesses (but, it can also be materials, filler metals and other parameters).

image 1: WPS written in EN ISO format with the SIRFULL welding application

Write the WPS from the Validity Domain (DV) of a PQR

Thus, the coordinator will be able to write a WPS adapted to the assembly based on the Validity Domain of a reference PQR. The term “reference” means that the WPS conforms to the company’s qualified know-how and is able to meet the requirements of one or more assemblies.

image 2 : reference number of PQR

In addition, the range of validity of the PQR gives the particular range in which the WPS can be written (see Figure 1). Beyond that, a new WPS and a new qualification are required.

image 3: example of a DV representation established under the American standard ASME Boiler and Pressure Vessel Code 2019, section IX table QW 451.1. Source : weldingandndt.com

In this example, the DV is represented in a table format where the Coordinator can find the thickness range for which a welding procedure can be qualified. He can thus write his WPS within the framework of this field.

In practice, this task must be put in perspective with the time constraints encountered by the Welding Coordinator in the company.

Problem of drafting the WPS and the tight production deadlines

The manufacturer is experiencing tight deadlines, i.e., producing quickly after the order, which means less time to qualify and prepare the assemblies. This constraint puts significant pressure on the interpretation of the Domain of Validity (DoV) and the drafting of the new WPS.

However, the development of the WPS would not be a problem if it were not so time consuming to write.

How can writing a WPS be tedious?

Everyone’s experiences may vary in the development of the WPS. Nevertheless, a WPS is written by type of process, type of assembly, position, grade, group, thickness etc. Internal coding can also be implemented to help harmonize the company’s WPS library (see examples and testimonials on welders.com).

Indeed, the WPS library is growing with each new customer order.

The questions that arise then are:

• Which tools should you use to write your WPS? Excel to interpret the validation fields and edit the WPS (maybe Word for the layout)?
• Writing your WPS manually? Knowing that many fields of the WPS are redundant (position, group, commercial names of filler metals etc.)?
• Which archiving method should I use? Paper or local server? How will this database be accessible and who will be able to use and update it? Besides, how to trace the updates, verification and approval of these documents?

You will have understood: the issue here is to have an efficient system to quickly find your existing WPS in a solid base.

What is an effective system for quickly writing a WPS that conforms to the Domain of Validity (DoV) of a PQR?

A well-functioning system not only simplifies the drafting of your WPS, but also enhances your know-how and saves you time in the document management of welding procedures.

As seen above, this system is developed over time through the cohabitation of various tools. However, there is a point where you will not move faster and the reality of the field will lead you to documentation errors, delays or ordering “sub-optimized” or “superfluous” PQR (i.e. PQR performed without preliminary testing, at the same time as the shop floor part flow).

A system like SIRFULL Welding allows you to quickly write and archive online WPS in EN ISO, ASME, or custom template format (see video 1)

The functionality shown above demonstrates how the solution automatically writes an initiated WPS based on information from a reference PQR. The selection of the reference PQR by the system is done by comparing the Validity Domain (DV) present in the library and the parameters of the assembly to be realized.

This automatic generation of WPS greatly facilitates the handing over of the cahier de soudage to the customer or to your welders.

Linked to a cahier de soudage or written individuallyWPS), you can edit your WPS in English, French, German and Italian.

How do you get SIRFULL Welding?

SIRFULL Welding is an application available in the cloud without installation and can be quickly deployed (less than a week for any order without customizations and settings).

As editor, integrator and trainer of the solution, the SIRFULL team accompanies you directly in the stages of your project (possible customization of the application, deployment, training, accompaniment and support).

To learn more and see the solution in action, book your demo now.