I am reviewing a WPS and PQR per AWS D1.1-2015 edition. I'm very green when it comes to reviewing this type of documentation and want to make sure I am thinking correctly.
Section 4.7 states the following:
The manufacturer or Contractor shall prepare a written WPS that specifies all of the applicable essential variables referenced in 4.8. The specific values for these WPS variable shall be obtained from the procedure qualification record (PQR), which shall serve as written confirmation of a successful WPS qualification.
Section 4.8.1 states the following:
Changes beyond the limitations of PQR essential variables for the SMAW, SAW, GMAW, GTAW, and FCAW processes shown in Table 4.5 and Table 4.6 shall require requalification of the WPS.
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The PQR I am reviewing uses A36 base material, GMAW process, single-v CJP, A36 backing material, 0.035 in. ER70S-6 filler, welded in the 1G position, etc. The PQR shows that the weld was performed using six (6) passes with 221-251 amps, 27.8-27.9 volts, 8.5-20.5 in/min travel speed, and gas flow at 45 CFH.
The WPS allows 0.030, 0.035, and 0.045 in. filler. The WPS allows 150-300 amps, 250-550 in/min wire feed speed, 20-35 volts, 6-22 in/min travel speed, and 20-50 CFH gas flow.
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Here's the problems I am seeing with the WPS:
1). Table 4.5(10) states "any increase or decrease" for filler metal. I interpret this as the PQR 0.035 in. diameter filler is all that is allowed.
2). Table 4.5(12) states "> 10% increase or decrease" for amperage. Average amperage from PQR for the six passes is 234.8. This would mean an allowable range of 212-258 amps.
3). Table 4.5(16) states "> 7% increase or decrease" for voltage. Average voltage from PQR for the six passes is 27.9. This would mean an allowable range of 26-29 volts.
4). Table 4.5(18) states "> 25% increase or decrease" for travel speed. Average travel speed from PQR for the six passes is 14.3 in/min. This would mean an allowable range of 11-17 in/min.
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Questions:
A). Am I interpreting the requirements of Table 4.5 correctly?
B). If so, how should the large range of travel speed on the PQR (8.5-20.5 in/min) be addressed?