I'm reading D1.1 2010... it pretty much reads the same. I think your answer is right in the last sentence. The Welding Performance Qualification Record  (WPQR) shall serve as written verification and shall list all of the applicable essential variables of Table 4.12.

I read the first part of the paragraph as pertaining to the WPS that is to be followed for testing.

The welder qualification test record or the welder performance test record, which ever one prefers to call it must list the essential variables listed by the table you noted. That is, the WPTR must list the process, the product type, weld type, with or without backing, F number of the SMAW electrode, etc.

When welding the test coupon, the welder must follow a WPS and work within the parameters of the WPS. In some cases the WPS is written specifically for the welder performance test (my preference) or he must follow a WPS used for production welding. The latter is the least desirable because it may not be specific enough to define the test being taken. For example, the production WPS may be written to include groove details with a minimum groove angle of 20 degrees with a 3/8 root opening up to 75 degrees if the root opening is only 1/16 inch. The production WPS may include both grooves and fillet welds and 1/16 inch electrode up through and including 1/4 inch electrodes. The welding parameters may list the arc voltage as 18 through 32 volts, the amperage of 40 up through 400 amps, the travel speed of 2.5 through 14 ipm. It might list all F1, F2, F3, and F4 electrodes.

The boss hands the welder two plates and a backing bar and says weld these and follow the WPS. The welder looks around and says "WTF!" "What does he want me to do?"

The WPS isn't specific enough to provide the direction he needs to weld the test assembly. That's a failure on the part of management, not the welder.

As Gerald stated, once the welder is qualified, let's say for unlimited thickness using plate, in all positions, using F1 through F4. The WPS to be used for production may be limited to 3/4 inch thick base metal, only F3 electrode in the horizontal position, and only with 5/32 inch diameter electrode. That being the case, the welder must work within the constraints of the WPS. They WPS limits what the welder can weld, but when a different job is assigned to the welder using a different WPS, the constrains are those listed by the new WPS.

The only time the welder would have to be requalified is if the new WPS listed parameters that were not covered by his original welder qualification, i.e., the new work assignment involves welding with a different welding process or a product type that he isn't qualified for (he took a plate test and the job involves welding 2 inch NPS pipe), or an electrode with a different F number, perhaps F5 (austenitic stainless steel pipe). This of course assumes there are no breaks in continuity and the welder's skill isn't in question.

Hope these responses help.

Best regards - Al

If the code says all the essential variables of Table 4.7 apply, then they apply. Specifically, once again, the welder must work within the ranges (constrained by the table) listed by the WPS while taking the test. Once the test is completed, the variables of table 4.12 apply and limit what the welder can weld in production.

Al