Fill Out a Valid Welder Performance Qualification Record Form

Welder Performance Qualification Record - Usage Guide

Filling out the Welder Performance Qualification Record form is a critical step in documenting a welder or welding operator's ability to produce welds meeting specific standards and codes. This documentation is essential for ensuring that all welding work is performed to the highest standards of safety and quality. Follow these steps carefully to complete the form accurately.

1. Start by entering the Welder’s Name at the top of the form.
2. Fill in the ATF No. (Accredited Testing Facility Number) and Test No. to track the test attempt.
3. Provide the Welder’s SS No. (Social Security Number) in the format XXX-XX-XXXX.
4. Record the Date of the welding test.
5. Indicate the Reference WPS No. (Welding Procedure Specification Number) associated with the test.
6. Under the VARIABLE QUALIFICATION TEST DETAIL section, specify the Code or Specification Used.
7. Choose the Welding Process and Type from the options provided (Manual, Semiautomatic, Mechanized, Automatic).
8. Indicate whether Backing was Used or Not Used and if Required, specify the type.
9. Detail the Base Metal Spec/P or M-Number and fill in the Plate/Pipe Thickness for both Groove and Fillet tests as appropriate.
10. Provide the Plate/Pipe Thickness and Pipe/Tubular Outside Diameter, again for both Groove and Fillet.
11. Enter the details for Filler Metal Specification No., Classification No., F No., and Diameter.
12. Specify if a Consumable Insert or Penetration Enhancing Flux was used by marking Yes or No.
13. Record the Deposited Weld Metal Thickness.
14. Fill in Current/Polarity & Current Range including Type/Polarity and Range in Amperes.
15. Identify the Metal Transfer Mode for GMAW or FCAW processes.
16. Specify Torch and Root Shielding Gas Type and Flow.
17. Indicate the Test Position(s) (1G, 2G, etc.) and Qualified Position(s) (F, H, V, O, or All).
18. Note the Vertical Progression as Uphill or Downhill where applicable.
19. Complete the MECHANICAL TEST RESULTS section with Type and Figure No. followed by Results for each category.
20. Enter the details of the NONDESTRUCTIVE EXAMINATION RESULTS, including Radiographic and Visual Inspection results.
21. Ensure the Guided mechanical Testing Conducted By and Radiographic Testing Conducted By sections are completed, including dates.
22. Have the welding witnessed by an authorized individual and include their signature.
23. Confirm and certify the accuracy of all statements within the record, and have the record signed by the authorized signatory.
24. Finally, fill in the Date Qualified, ATF Name and Number, and the signatory's CWI No. (Certified Welding Inspector Number).

Once the form is accurately filled out, reviewed, and signed, it becomes an official record of the welder or welding operator's qualifications. This record serves as proof of the individual's ability to perform welding tasks according to the specified standards and procedures. It is important to keep this document updated and readily available for inspections, job applications, and as part of quality control processes.

What is a Welder Performance Qualification Record?

A Welder Performance Qualification Record (WPQR) is a crucial document in the welding industry that verifies a welder's ability to create welds of acceptable quality following certain welding procedures. It records details about the welder's test, including the welding process used, the materials involved, positions they are qualified to weld in, and the results of mechanical and nondestructive examination tests.

Why is it important to fill out a WPQR form accurately?

Accurately filling out a WPQR form is important because it ensures that every welder working on a project possesses the necessary qualifications and skills, thereby upholding safety and quality standards. It serves as formal proof of a welder's ability to perform specific welding tasks under designated conditions. Additionally, accurate records help in tracking a welder’s qualifications over time and are essential for compliance with various codes and specifications.

What information is required in the WPQR form?

The WPQR form requires detailed information about the welder and the welding test. This includes the welder’s name, social security number, the test date, and reference numbers for the Welding Procedure Specification (WPS) followed during the test. It covers the welding process and type, base metal specifications, filler metal used, and details about the welding procedure like thicknesses, diameters, current, and gas flows. It also necessitates results from mechanical and nondestructive examinations to confirm the quality of the welds.

How does one determine the qualification range on the WPQR form?

The qualification range on the WPQR form is determined based on the variables recorded during the welder’s test. It specifies the limits within which the welder is qualified to weld, such as the types of materials, thicknesses, and welding positions. These ranges are aligned with the codes or specifications used during the performance qualification test. It's essential to understand that any welding performed outside of these specified ranges is not covered by the welder’s qualifications as indicated by this record.

One common mistake people make when filling out the Welder Performance Qualification Record form is neglecting to include the welder’s Social Security Number (SSN) in the designated section. The inclusion of SSN, despite privacy concerns, is vital for identification and records-keeping purposes within many organizations that manage welding qualifications.

Another error involves the incorrect identification of the welding process and type. This form provides options such as manual, semiautomatic, mechanized, and automatic, each affecting the qualification's scope. Misidentifying the process can lead to invalid qualification for the intended welding activities.

The use of backing is an area frequently overlooked. The form differentiates between "Used" and "Not Used," and also "Required if used." This detail speaks to the weld’s integrity and its inspection criteria. Failing to accurately specify backing use can misrepresent the welder’s capability in real-world applications.

Mistakes also occur in the specification of base metal. The form requests details like the Specification and M-Number or P-Number, alongside the Plate/Pipe Thickness for both groove and fillet welds. Incorrectly documented specifications can invalidate the qualification for certain projects which require specific base metals.

Omitting or incorrectly documenting the Filler Metal specifications, including the Specification No., Classification No., and Diameter, undermines the qualification's value. Each filler metal reacts differently under given welding conditions, potentially affecting the weld's quality and suitability for certain applications.

Errors related to the deposition of weld metal thickness are common. Accurately recording this ensures the welder’s proficiency across various thicknesses, directly impacting the types of jobs they can perform under their qualification.

Incorrectly indicating the current/polarity and range can be problematic. This technical detail affects welder performance evaluation, especially concerning penetration depth and bead quality under different welding settings.

Another oversight occurs with the position(s) test and qualified position(s). Positions like 1G, 2G for test positions, or F, H, V, O, or All for qualified positions, indicate the welder’s versatility. Misrecorded information limits the welder’s qualification scope unnecessarily.

Within the mechanical test results and nondestructive examination results sections, failing to accurately enter the results, including the type and figure number, and the results of radiographic testing, reduces the reliability of the qualification record. It’s vital to detail these outcomes correctly for ensuring the welder's work meets or exceeds required standards.

Lastly, a common error is the omission of proper certification and dates, including the authority figures' names and numbers who witnessed the test, certified the record, and the date qualified. This oversight diminishes the document's legitimacy, potentially creating obstacles in the welder's professional advancement or project allocation.

When a welder or welding operator undergoes qualification testing, the Welder Performance Qualification Record is a fundamental document. This form is just one piece of the documentation puzzle required to ensure a comprehensive understanding and demonstration of a welder's abilities. Below is a list of other essential documents and forms often used alongside the Welder Performance Qualification Record to provide a full picture of the welder’s qualifications and capabilities.

• Welding Procedure Specification (WPS): This document provides detailed instructions on executing a welding operation. It includes information such as the welding process, materials, techniques, and other parameters necessary to ensure consistency and quality in welding tasks.
• Procedure Qualification Record (PQR): A record that documents what occurred during the welding of a test coupon, which is then tested to ensure it meets necessary standards. This form backs up the WPS by showing that the procedure can produce a good weld.
• Material Test Reports (MTRs): These reports provide the chemical and, often, the physical properties of the materials used in the welding process. They are essential for ensuring that materials meet the necessary specifications and standards.
• Welding Equipment Calibration Certificates: Documents that prove that the welding equipment used in the qualification test was functioning correctly and was calibrated to standard specifications.
• Safety Data Sheets (SDS) for Welding Consumables: Provide important information on the materials used during welding, including any health and safety hazards. Keeping this information accessible is critical for maintaining workplace safety.
• Continuity Log of Welder’s Performance: A log that records the ongoing work of a welder to ensure they maintain their skill level. This document is crucial for verifying that the welder's qualifications are current and valid.
• Inspector and Witness Statements: Documented statements from those who witnessed the welding test, providing additional verification and assurance concerning the welder’s performance and adherence to the applicable standards.

Together, these documents contribute to a robust framework that supports not only the qualification of the welder but also the integrity and safety of welding operations. Ensuring that all relevant documentation is in order and properly maintained is a critical component of quality control in welding projects.

The Welder Performance Qualification Record form is closely related to the Procedure Qualification Record (PQR) because both documents are foundational in the field of welding certification and qualification. The PQR provides a detailed record of welding variables used during the welding procedure qualification test and the results of this test, ensuring that the procedure can produce a weld meeting specified standards and codes. This similarity lies in their fundamental purpose to ensure and document the capability of welding procedures and personnel to meet specific requirements, promoting safety and quality in welding operations.

A Welding Procedure Specification (WPS) document shares similarities with the Welder Performance Qualification Record in its role of guiding welding operations. While the Welder Performance Qualification Record documents an individual welder’s ability to perform under set conditions, the WPS outlines specific welding methods and processes to be followed to ensure a quality outcome. Both play crucial roles in maintaining welding quality and safety standards by ensuring that welding is performed properly and consistently, according to predefined and tested guidelines.

Certificates of Compliance (CoC) also parallel the Welder Performance Qualification Record in their purpose of certifying that products, materials, or services meet required standards. A CoC provides assurance that a particular item meets the specified requirements, similar to how the Welder Performance Qualification Record confirms a welder's qualifications. Both documents serve as critical evidence of compliance with standards and regulations, safeguarding quality and safety in their respective fields.

The Material Test Report (MTR) is akin to the Welder Performance Qualification Record due to its role in documenting the chemical and mechanical properties of materials used in manufacturing, including welding. While the MTR focuses on the quality and specifications of the material itself, the Welder Performance Qualification Record verifies the skill and ability of the individual performing the weld. Both are integral to ensuring the highest standard of quality and safety in welded products by providing traceable records of the materials and craftsmanship.

Quality Control (QC) checklists resemble the Welder Performance Qualification Record in their shared objective of ensuring quality and adherence to specifications through systematic checks. A QC checklist is used to evaluate different aspects of a product or process against predefined standards, similar to how the Welder Performance Qualification Record assesses a welder’s performance against specified criteria. These documents are instrumental in maintaining consistent quality and safety standards by identifying non-conformities or areas for improvement.

The Non-Destructive Examination (NDE) report, like the Welder Performance Qualification Record, serves as a documented proof of inspection, but focuses on evaluating the integrity of materials or assemblies without causing damage. NDE reports verify the absence of defects in a component post-manufacture, similar to how the Welder Performance Qualification Record verifies a welder's ability pre- or post-welding process. Both types of documentation are critical for ensuring the reliability and safety of the manufacturing and construction processes.

The Safety Inspection Report shares objectives with the Welder Performance Qualification Record by focusing on the identification of risks and compliance with safety standards. While the Safety Inspection Report examines the safety of an environment, equipment, or processes to prevent accidents, the Welder Performance Qualification Record specifically verifies that a welder can safely and proficiently perform welding tasks according to established standards. Together, they contribute to creating a safer workplace by ensuring both personnel and procedures comply with required safety measures.

Finally, the Employee Certification Record is akin to the Welder Performance Qualification Record, as both document the qualifications and certifications of individuals within their respective fields. While the Employee Certification Record may cover a broad range of skills and certifications beyond welding, the Welder Performance Qualification Record is specifically focused on welding capabilities. Both are essential for verifying the competence of personnel, thereby ensuring that only qualified individuals are tasked with specific roles, thereby maintaining high standards of quality and safety.

Completing the Welder Performance Qualification Record form accurately is crucial for welders to verify their skills and competencies. Here are five essential dos and don'ts to keep in mind:

Do:

1. Double-check the welder's information, such as the Welder’s Name, ATF No., and Social Security Number, to ensure accuracy and consistency.
2. Clearly reference the Welding Procedure Specification (WPS) No. that the test is based on, ensuring it matches the specific standards and procedures for the test being conducted.
3. Complete all sections related to the welding process, type, and positions accurately, according to the welder's test performance, including any specifics like backing, base metal specifications, and filler metal specifications.
4. Record precise details of the welding test conditions, such as the welding current, polarity, and gas flow rates, to provide a comprehensive overview of the test setting.
5. Include all test results, both mechanical and nondestructive examination outcomes, and ensure they are signed off by the relevant authorities, verifying the welder's qualification status.

Don't:

• Leave any fields blank that are applicable. If a field is not applicable, mark it as 'NA' for 'Not Applicable' instead of leaving it empty, to demonstrate that it has been intentionally omitted.
• Misclassify the welding process or type. Each detail, such as whether it’s manual or automatic and the specific process used, should mirror the welder's actual performance and capabilities.
• Forget to specify whether backing was used, and if so, provide the required details, as this can significantly impact the validity of the test and the welder's qualifications.
• Omit or inaccurately document the test and qualification ranges, including the base metal specifications and filler metal specifications, which are crucial for establishing the scope of the welder's qualification.
• Submit the form without the appropriate signatures and dates from both the testing authority and the welder, as these are essential for the document's legal and procedural validity.

Understanding the Welder Performance Qualification Record (WPQR) form is crucial for ensuring compliance and maintaining high-quality welding standards. However, several misconceptions can lead to confusion and potential non-compliance. Below are eight common misconceptions about the WPQR form, explained clearly to help dispel any confusion.

• Misconception 1: The WPQR is only a formality and does not need detailed attention.

This is not true. The WPQR is a critical document that demonstrates a welder's ability to create welds that meet specific standards and requirements. It's essential for quality control and compliance with industry standards.

• Misconception 2: Any welder can fill out the WPQR form for another.

Incorrect. The WPQR form must be completed based on the individual welder's performance and verified by qualified personnel. This ensures the accuracy and integrity of the qualification records.

• Misconception 3: The SS number is mandatory on the WPQR form.

While the welder's Social Security number may be requested for identification purposes within certain organizations, it's not a mandatory field on the WPQR form and often, for privacy and security reasons, other identifiers are used.

• Misconception 4: Welding process types are interchangeable on the WPQR.

Each welding process and type (Manual, Semiautomatic, Mechanized, Automatic) must undergo its qualification test. A welder qualified in one process is not automatically qualified in another, as each process requires specific skills and settings.

• Misconception 5: The “Backing” field is optional and can be left blank.

The backing field is crucial as it indicates whether backing was used and if it's required by the code or specification used. This information is vital for understanding the conditions under which the welder is qualified to weld.

• Misconception 6: The test positions (e.g., 1G, 2G) and qualified positions (e.g., F, H, V, O) are the same.

Test positions refer to the positions in which the welder performed during the qualification test, while qualified positions refer to the positions a welder is qualified to weld in based on the test results. They are related but not synonymous.

• Misconception 7: Mechanical test results are optional if the weld looks good.

Mechanical test results provide objective evidence of the weld’s mechanical properties, such as its strength and ductility. A visual inspection, no matter how thorough, cannot replace these results.

• Misconception 8: Once qualified, a welder does not need to requalify.

Welders need to requalify under certain conditions, such as if they haven't welded with a process for a prolonged period (typically six months) or if there are significant changes in the welding procedure specification (WPS). Ongoing qualification ensures welders maintain their skills and adhere to current standards.

Clarifying these misconceptions is essential for the proper administration and understanding of the WPQR, ensuring that welding operations meet the necessary quality and safety standards.

When it comes to understanding and utilizing the Welder Performance Qualification Record (WPQR), several critical points need to be considered to ensure compliance and accuracy. This document is essential for both welders and welding operators, serving as a formal record of a welder's ability to produce welds that meet predetermined standards. Here are some key takeaways:

• Complete Identification Details: Properly fill out the welder's name, ATF number, test number, and Social Security number. These details are crucial for record-keeping and identifying the welder or welding operator.
• Reference Codes and Specifications: Clearly indicate the code or specification used during the welding process. This includes the welding process type (manual, semiautomatic, mechanized, automatic), which is essential for setting the qualification's scope.
• Detail the Welding Process: Specify whether backing was used, the base metal specifications, and other variables like plate or pipe thickness. These variables determine the qualification's range and are necessary for ensuring that the welder meets the required standards.
• Record Welding Parameters: Precisely fill in details such as the filler metal specification, current and polarity, metal transfer mode, and shielding gas type and flow. These parameters affect the weld's quality and are integral to replicating the test conditions in actual welding scenarios.
• Positions and Qualifications: Document the test positions (e.g., 1G, 2G) and the positions for which the welder is qualified (e.g., F, H, V, O, or All). Understanding the positions a welder is qualified for is essential for job assignments and compliance.
• Results of Tests: Include results from both mechanical and nondestructive examination tests. The outcomes of these tests validate the weld's integrity and the welder's proficiency.
• Attestation and Certification: Finally, the record must include certifications by relevant authorities, including the date qualified, ATF name and number, and the signature of a Certified Welding Inspector (CWI). This formal acknowledgment confirms the welder's qualifications and compliance with industry standards.

Understanding how to accurately complete and use the Welder Performance Qualification Record form is pivotal. It not only ensures that welders and welding operators are properly assessed for their skills and abilities but also helps in maintaining safety and quality in welding operations. Always ensure that the form is filled out in detail and in accordance with the specific codes or specifications applicable to the welding activities being undertaken.