Welder Qualification Test and Welding Procedure Qualification (WPS, PQR)

What does a welder qualification test at TCR cover?

A welder qualification test proves that a welder can deposit sound weld to a qualified WPS; a procedure qualification proves the WPS itself. At TCR Engineering the coupon is welded under witness, tested at the NABL accredited laboratory in Mahape, Navi Mumbai, and recorded with the qualified range, to ASME Section IX, AWS D1.1, API 1104 or IS 7318.

• Witness: CSWIP or AWS CWI certified welding inspectors, each named with the certificate on the record.
• Tests on the coupon: bend, nick break, macro, tensile and radiography, as the governing code names them.
• Record: the welder performance qualification record stating the range qualified, with the test and NDT reports.
• Identity card: issued by TCR in India, and in Saudi Arabia by TCR Arabia, the group's joint venture in Dammam.
• Endorsement: records endorsed by Sachin Ram Bhadange, IIW-certified International Welding Specialist and IIW-certified welding inspector, who leads TCR's welding inspection service.

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' welder certification and welding procedure programme covers:

• Welder Qualification Testing for performance qualification and certification of welders (welder and welding operator performance qualification, WQT) to ASME Sec. IX, ASME Sec. VIII, ANSI, AWS D 1.1, AWS D 1.2, API 1104 etc.
• Preparation of the Welding Procedure Specification (WPS) for the project or the client's 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 on site: 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 the weld procedure and welder qualifications
• Supervise weld profile preparation
• Inspect joint fit-up
• Oversee filler metals and consumable materials
• Ensure correct welding parameters are maintained
• Perform visual examination on completion of welding
• Monitor specified preheat and post-weld heat treatment
• Monitor physical examination, including non-destructive, hydrostatic and mechanical tests
• Where required, send test samples to the TCR Engineering Services materials testing laboratory
• Verify that all required visual inspections and non-destructive examinations are completed as specified

Based on the requirements, the inspector carries the measuring aids the checks need:

• 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)

In the laboratory, the coupons are tested and the qualification records assembled:

• TCR Engineering's 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. The laboratories also test electrodes for qualification to ASME Section II Part C and IS 814. 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.
• Coupons required: one coupon on 12” NB pipe; four coupons on 2” NB pipe for API 1104, and four for ASME Section IX.
• TCR Engineering's CSWIP and AWS CWI inspectors provide consultancy as IIW-IWS (RWC-External) for welder training and certification, including 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 2023 Edition (WPS, PQR, WQT), AWS D1.1 2025 Edition (structural steel), AWS D1.2 (structural aluminium), AWS D1.5 (bridge welding), API 1104 22nd Edition (2021) (pipeline welds), IS 7318 (welder qualification), EN ISO 9606 series.