CWI WPS, PQR, and Welder Qualification Questions and Answers

Question 1

A fabricator has a WPS qualified for a groove weld on 1-inch thick carbon steel plate.
The WPS specifies a 1/8" E7018 electrode.
An engineer wants to use a 5/32" E7018 electrode for increased deposition rate, which is a change in an essential variable according to ASME IX.
What must be done before this change can be implemented in production?

Accepted Answer

Weld a new test coupon using the 5/32" electrode, perform the required testing, and document the results on a new PQR.

Answer

Revise the WPS to reflect the new electrode size and proceed with production.

Answer

Perform a new Welder Performance Qualification Test (WPQ) with the 5/32" electrode.

Answer

Submit a formal request to the client to waive the requalification requirement.

Question 2

What is the primary function of a Procedure Qualification Record (PQR)?

Accepted Answer

To serve as a certified record of the actual variables and test results from a successfully welded test coupon.

Answer

To provide a 'recipe' with allowable ranges for the welder to use in production.

Answer

To record the specific test results for an individual welder's ability.

Answer

To list all approved non-essential variables that can be changed without requalification.

Question 3

A welder successfully completes a performance qualification test for a CJP groove weld on a 1-inch thick plate in the 3G (vertical-up) position per AWS D1.1. For which of the following plate groove weld positions is this welder now also qualified?

Accepted Answer

1G (flat), 2G (horizontal), and 3G (vertical)

Answer

4G (overhead) only

Answer

All positions (1G, 2G, 3G, and 4G)

Answer

3G (vertical) only

Question 4

Which of the following documents is the basis for establishing a Welding Procedure Specification (WPS)?

Accepted Answer

The Procedure Qualification Record (PQR)

Answer

The Welder Performance Qualification (WPQ)

Answer

The project's quality control manual

Answer

A pre-approved standard welding procedure (SWPS)

Question 5

During a review of welding documentation, a CWI notes a PQR was qualified using a 1/2-inch thick test coupon. According to ASME Section IX, Table QW-451.1, what is the qualified range of base metal thickness for a WPS written from this PQR?

Accepted Answer

3/16 inch to 1 inch

Answer

1/4 inch to 1 inch

Answer

1/8 inch to unlimited

Answer

1/2 inch to 2 inches

Question 6

A change to which of the following variables on a WPS would be considered 'non-essential' per ASME IX, allowing the WPS to be revised without requiring a new PQR?

Accepted Answer

A change in the groove design (e.g., from a V-groove to a U-groove)

Answer

A change in P-Number of the base metal

Answer

The addition of post-weld heat treatment (PWHT) where none was performed before

Answer

A change from the SMAW process to the GTAW process