Pick which code applies, say D1.1.  Then go through the section on WPS's make sure what you have meets those requirements, if not add/ develope till it does.  Check the commentary section in the back for help.
Good Luck
its a big task you have there, could take weeks or months

Hello Aaron;

It sounds like they have thrown you to the wolves.

Welding documentation can flow as follows:

1) Write a preliminary WPS - this is what you are trying to qualify. The welding parameters are your best guess of what the welding variables are relative to arc voltage, welding amperage, wire feed speed (GMAW or FCAW), travel speed etc. You can consult with one of your better welders to gather some useful insight. This is a welding procedure that has not been tested. It simply tells the welder what you want him to do.

2) Procedure Qualification Record - this documents what the welder actually did when he welded the test sample. It is independent verification of the material type, thickness, groove angle, welding process, shielding gas (if used), filler metal, and all the welding parameters used on a pass-by-pass basis. The test piece is then tested as per the applicable code. Typically you will visually examine the weld for unacceptable profile, undercut, etc. If the piece is acceptable you may have to do some NDT such as radiography or ultrasonic examination. If the test piece passes this round of testing it moves on to destructive testing. The destructive tests usually consist of guided bend tests and tensile tests in accordance with the applicable code (bend radius is based on material type, thickness, and tensile strength). The test data is recorded on the PQR after the welding data that was recorded while the plates were being welded. Assuming the nondestructive and destructive tests requirements were acceptable, you are ready to write your production WPS.

3) Welding Procedure Specification - there are different types of WPSs. Which one you use or write is dependent on the welding standard you are using. AWS D1.1 allows for the use of qualified WPSs (those tested as noted above) or prequalified WPSs (those not tested, but meet all the requirements of AWS D1.1 Clause 3 as well as Clauses 1, 2, 5, 6, etc.

Assuming you are qualifying your WPSs by testing as noted in item 2, you write a WPS for production welding based on the welding parameters used to weld the successful test coupon. Welding standards used will provide direction on the permissible ranges for voltage, amperage, travel speed etc. Again, these ranges are based on the actual parameters used to weld the test coupon, hence the necessity to witness the welding of the test coupon and carefully recording the parameters used for each weld pass.

The sample forms found in the annex of AWS D1.1 (or other welding standards) is a simple format to follow if you are not familiar with such documentation. Many of us have abandoned the sample formats once we have become familiar with writing WPS. Still, the supplied samples are a convenient way to get started.

3) Welder Performance Qualification – once the WPS is written it may be necessary to qualify the welders to determine they have the minimum skills needed to deposit a sound weld that meets the requirements of the applicable code. You can use the WPS you just qualified for that purpose. Each welder welds a test sample and it is subjected to visual examination and then radiographic testing or guided bend tests.
Welding procedures for fillet welds can be qualified in a similar fashion if you elect not to qualify the WPS using a groove welded butt joint. However, a procedure that is qualified a a fillet weld is only applicable to fillet welds.

My outline is for general work. Each welding standard has their own twists on the way to qualify the WPS and what data must be recorded. However, I find it best to record as much information as possible while the test coupon is being welded. I would rather have too much information than too little only to discover I have to redo the test because I forgot some required detail.

Consider attending a CWI seminar sponsored by AWS. Even if you don’t need to become a CWI, the information you learn will be very useful in your new position.

Best regards – Al