Clause 6 · Existing record route
WPS from an existing PQR
A complete English production WPS built from the actual qualification records you already have, with each target condition tied to its supporting evidence.
The PQR must support this production weld
The review follows the real qualification path represented by the record. A WPS range is limited by the applicable test method, base metals, joint type, position, recorded variables, contract requirements and supporting results.
| Coverage question | Records checked | Common false shortcut to avoid |
|---|---|---|
| Is this the right qualification basis? | Code edition, qualification method, PQR identity/revision, manufacturer, test coupon and test reports | An old WPS sheet or untraceable summary is not a substitute for the supporting record. |
| Do the base metals and their combination fit? | Both coupon and target material specifications/grades, product form and applicable qualification grouping | Two materials that each appear individually familiar do not automatically prove their combination. |
| Does the test cover the target thickness and weld form? | Coupon thickness, CJP/PJP/fillet/plug/slot test path and the applicable qualification table | Base-metal thickness and each process's deposited weld-metal thickness are separate questions. |
| Are position and joint conditions supported? | Plate/pipe/tubular coupon type, test orientation, diameter where relevant, weld position and detail | A CJP record does not automatically cover every PJP detail, fillet size or tubular connection. |
| Can the required production parameters be traced? | Per-process and per-pass PQR readings, filler, diameter, polarity, transfer, gas, PWHT and waveform data where applicable | Do not fill unrecorded test values with typical manufacturer settings or blend unrelated maxima from different PQRs. |
| Are supplemental conditions demonstrated? | CVN condition and reports, heat input evidence, PWHT cycle and any applicable supplementary variables | A material certificate or filler-metal CVN data does not stand in for a required procedure qualification test result. |
Send the full record set
- Every relevant PQR page and revision, including coupon identification and measured welding variables.
- Qualification test reports and results needed to establish the PQR's outcome, including CVN or NDT records when applicable.
- Supporting material, filler-metal and gas records that clarify the recorded classifications and conditions.
- The proposed WPS scope: project code/edition, target base metals and thicknesses, joint detail, position, process/pass sequence and contract requirements.
- Drawings or an identified joint-detail reference, plus specified temperature, PWHT, heat-input, CVN, seismic or other special conditions.
If a page is missing or illegible, send what is available and identify the gap. No trial result, PQR value, approval or signature is created to fill it.
How the supported range is assembled
- Transcribe facts: preserve each PQR's actual recorded coupon, material, process, pass and measured parameter data with its source.
- Apply the matching qualification branch: use the relevant test type and AWS D1.1 provisions for base-metal combination, thickness, position, weld form and any tubular path.
- Check variable limits: compare recorded values with applicable essential and supplementary variables, including the contract's CVN or PWHT conditions where relevant.
- Set a production WPS range: keep it within the code-supported range, actual record support, parameter source and project requirements. This selected production range may be narrower than the qualification range.
What happens when coverage is not established?
The gap is stated against the target condition and the record that would resolve it. Unknown information does not automatically mean a new qualification is required. If an applicable existing PQR does not support a required condition and qualification testing is necessary, that testing is outside this WPS preparation product.
A WPS prepared from a PQR documents a supported procedure range. It does not certify a welder, approve a project, create a test result or replace the responsible Engineer's or client's acceptance process.
Provide the source record and project conditions for route review.