WPS Template & PDF Guide
WPS는 해당 코드에서 요구하는 필수 변수를 포함합니다. D1.1 표 5.5는 구조용 강철에 대한 21가지 변수를 정의하고, ASME IX QW-250은 압력 장비에 대한 공정별 변수를 나열하며, API 1104 Section 5는 파이프라인 매개변수를 다룹니다. 이 가이드는 세 가지 코드를 모두 비교합니다.
21가지 필수 변수 (표 5.5)
D1.1:2025 Table 5.5는 모든 사전 인증된 용접 절차 사양서에 포함되어야 하는 변수를 나열합니다. 상단 섹션(항목 1–21)은 포함되어야 할 내용을 정의하고, 하단 섹션(항목 22–31)은 허용 오차를 정의합니다. 허용 오차를 벗어나 변수가 변경되면 조항 5.2.1에 따라 새롭거나 수정된 용접 절차 사양서가 필요합니다.
Figure 5.1, Figure 5.2, Figure 5.3 →변수들은 주제별로 나열되어 있습니다. 공식적인 번호 순서는 D1.1:2025 Table 5.5 항목 (1)–(21)을 참조하십시오.
검사에 불합격하는 일반적인 WPS 오류
작업 현장에서 용접 절차 사양서를 검토하는 검사관들은 동일한 오류를 반복적으로 발견합니다. 이러한 오류를 피하는 것이 원활한 감사와 시정 조치 보고서 작성의 차이입니다.
누락되거나 불완전한 필수 변수. 가장 흔한 실패는 단순히 필드를 비워두는 것입니다. Table 5.5의 21가지 변수 각각에는 문서화된 값 또는 범위가 있어야 합니다. "TBD" 또는 비어 있는 전류 범위가 있는 용접 절차 사양서는 Clause 5.2.1에 따라 유효한 작성된 용접 절차 사양서가 아닙니다. 검사관은 즉시 이를 거부할 것입니다.
최소 예열 온도 미달. 용접 절차 사양서는 모재 그룹, 용접 공정 및 두께에 대한 Table 5.11 요구 사항을 충족하거나 초과하는 최소 예열 온도를 나열해야 합니다. 제작자는 코드가 최소 예열 온도를 요구하는 경우 — 특히 특정 두께 이상의 Group II 및 Group III 강철에 대해 — 예열 온도를 "N/A"로 기재하는 경우가 있습니다. 예열 계산기를 사용하여 확인하십시오.
용가재 불일치. Table 5.7은 각 모재 그룹에 어떤 용가재 분류가 일치하는지 정의합니다. Group IV 강철에 E7018을 나열하는 용접 절차 사양서(E8018 이상이 필요할 수 있음)는 확인에 실패할 것입니다. 용접 절차 사양서의 용가재 분류는 특정 모재 그룹 및 용접 공정의 요구 사항과 일치해야 합니다.
Joint detail not prequalified. Fabricators sometimes specify groove angles, root openings, or backing conditions that do not match any prequalified joint detail in Figure 5.1, Figure 5.2, or Figure 5.3. If the joint is not prequalified, the WPS must be qualified per Clause 6 with a PQR — the prequalified path does not apply.
매개변수 범위가 너무 넓음. 모든 가능한 시나리오를 포괄하기 위해 "전류: 50-400A"라고 작성하는 것은 용접 절차 사양서의 목적에 어긋납니다. 검사관은 지정된 전극 직경 및 자세에 대한 실제 용접 관행을 반영하는 합리적인 범위를 기대합니다. 지나치게 넓은 범위는 용접 절차 사양서가 공정을 제어하기보다는 개정을 피하기 위해 작성되었음을 시사합니다.
용접 절차 사양서에 서명 또는 날짜 없음. 용접 절차 사양서에는 제작자의 지정된 대표자의 서명(또는 승인된 서명과 동등한 것)이 있어야 합니다. 서명되지 않은 용접 절차 사양서는 승인된 문서가 아닙니다. 일부 검사 기관은 문서 관리를 추적하기 위해 개정 번호와 날짜를 요구하기도 합니다.
WPS 양식 작성 방법
Step 1 — Identify your 모재. Find the ASTM specification on your mill test report. Look it up in D1.1 Table 5.6 to find the base metal group (I through V). This determines your preheat 범주 and filler metal matching 요구사항.
Step 2 — Determine preheat. Use your base metal group with your 용접 공정 and material 두께 to look up the 최소 preheat and 층간 온도 in Table 5.11. The preheat calculator does this lookup instantly.
Step 3 — Select the joint detail. Choose the applicable prequalified joint detail from Figure 5.1 (CJP groove welds), Figure 5.2 (PJP groove welds), or Figure 5.3 (fillet welds). The figure specifies root opening, groove angle, backing requirements, and 용접 크기. See the prequalified WPS reference for the full set.
Step 4 — Match filler metal. Table 5.7 defines the matching 강도 filler metal for each base metal group and 용접 process. The filler metal classification on your WPS must match.
Step 5 — Document electrical parameters. Record 전류, 전압, and 용접 속도 ranges for each 전극 diameter and pass type. These must stay within the ranges on the WPS during production welding — deviations require a new WPS.
WPS 문서 관리 모범 사례
용접 절차 사양서는 통제된 문서입니다. AISC 인증을 받은 작업장에서는 연간 감사 중에 용접 절차 사양서 프로그램이 검토됩니다. ASME 코드 작업장에서는 품질 보증 매뉴얼이 용접 절차 사양서 통제 절차를 참조합니다. 좋은 관행은 다음과 같습니다:
Unique identification. Each WPS should have a unique number (e.g., WPS-001, WPS-002) that is referenced on the welder’s qualification record and on the weld map or drawing. This creates traceability from the finished weld back to the procedure used to make it.
Revision tracking. When a WPS is revised — to add a new electrode diameter, change a parameter range, or update a preheat value — the revision should be documented (Rev A, Rev B, or Rev 1, Rev 2). The previous revision should be archived, not deleted, so the 검사 record shows which version was used for each weld.
작업 현장 접근성. 현재 용접 절차 사양서는 용접 지점에서 사용할 수 있어야 합니다. 작업장에 인쇄되어 게시되거나, 태블릿에서 사용 가능하거나, 작업장 관리 시스템을 통해 접근 가능하든, 용접사는 용접하는 동안 용접 절차 사양서를 참조할 수 있어야 합니다. QC 사무실에 잠겨 있는 용접 절차 사양서는 아무런 목적이 없습니다.
Supporting PQR linkage. For qualified (non-prequalified) WPSs, the supporting PQR number should be referenced on the WPS. This allows an inspector to quickly 확인 that the procedure has been tested. For prequalified D1.1 WPSs, no PQR reference is needed — but the WPS must explicitly state it is prequalified per Clause 5.
WPS 양식 출처
AWS Annex J (D1.1:2025 page 407) provides sample WPS and PQR forms. These are informative — not mandatory. They serve as a starting point for fabricators who do not have their own standardized forms.
AWS Annex K (D1.1:2025 page 429)는 사전 인증된 용접 절차 사양서가 다루어야 하는 모든 코드 하위 조항의 참조 체크리스트를 조항별로 정리하여 제공합니다. 용접 절차 사양서 작성을 완료한 후 누락된 것이 없는지 확인하는 검증 도구로 사용하십시오.
Most AISC-certified fabrication shops, bridge fabricators, and inspection training programs use their own standardized WPS forms. The format does not matter — only the content. Per Clause 5.2.1, the WPS must be a written document that addresses all applicable variables. Need help filling it in? See our field-by-field WPS form guide.
Flux로 용접 절차 사양서 생성
Tell Flux your joint details, base metal, and process — get a complete WPS draft with all essential variables filled in.
Start with Flux다중 표준 WPS 비교: D1.1 vs. ASME IX vs. API 1104
Every fabrication 코드 requires a written WPS, but the rules differ significantly in scope, qualification path, and essential variable definitions. Understanding these differences is critical when a project crosses code boundaries — for example, a structural support (D1.1) welded to a pressure vessel nozzle (ASME IX), or a pipeline tie-in (API 1104) meeting a structural connection.
인증 경로
D1.1 offers two paths: prequalified (Clause 5, no 시험 required) and qualified (Clause 6, PQR required). If SMAW, SAW, GMAW, or FCAW is used on Table 5.6 steels with Clause 5 joint details, no PQR is needed. This prequalified path exists only in D1.1 — no other major code allows it.
ASME IX requires procedure qualification (PQR with destructive testing) for every WPS. There is no prequalified path. Each WPS must reference a supporting PQR that demonstrates the procedure produces acceptable results. The PQR records actual test parameters and mechanical test results (tension, guided bend, impact when required). 표준 Welding Procedure Specifications (SWPSs) published by AWS may be adopted per QW-500 as an alternative, but the organization must accept responsibility for their use.
API 1104 also requires procedure qualification for every WPS per Section 5. The welder welds a test coupon under the WPS conditions, and the coupon is destructively tested (nick break, tensile, bend, macro). There is no prequalified path, and the testing requirements are specifically designed for pipeline girth welds — including requirements for 방사선 testing of the qualification coupon.
필수 변수 비교
| Variable Category | D1.1:2025 | ASME IX:2025 | API 1104 |
|---|---|---|---|
| Base Metal | Table 5.6 Groups I–V | P-Numbers & Group Numbers (QW/QB-422) | Specified min. yield strength & wall thickness |
| Welding Process | SMAW, SAW, GMAW, FCAW (prequalified); any process (qualified) | Any process per QW-250 through QW-265 | SMAW, SAW, GMAW, FCAW, GTAW, combination |
| Position | 1G, 2G, 3G, 4G, 1F–4F (per Clause 5.4) | 1G–6G, 1F–4F (per QW-461) | Roll, fixed (2G, 5G, 6G, 6GR) |
| Filler Metal | Matching classification per Table 5.7 | F-Number (QW-432) & A-Number (QW-442) | AWS filler metal group designation |
| Preheat | Table 5.11 minimum preheat | QW-406 (decrease >55°C is essential) | Minimum preheat per qualified range |
| PWHT | PWHT per Clause 5.9; procedure requirements per Clause 7.8 | QW-407 (addition, deletion, or range change is essential) | Per project specification and material |
| Electrical Parameters | Amperage, voltage, travel speed ranges (Table 5.5) | Heat input range (QW-409); specific variables per process | Voltage, amperage, travel speed type & range |
| Joint Design | Prequalified per Figure 5.1–Figure 5.3; any design for qualified WPS |
Not directly an essential variable (covered by qualification range) | Joint design type per Section 5.3 |
| Qualification Record | PQR per Clause 6 (not required for prequalified WPS) |
PQR per QW-200 (always required) |
PQR per Section 5 (always required) |
ASME IX WPS 필수 사항
ASME IX organizes essential variables by welding process in Tables QW-252 through QW-265. Each table lists the variables that apply to a specific process (SMAW, SAW, GMAW, GTAW, etc.) and classifies them as essential, supplementary essential (when impact testing is required), or nonessential. A change in an essential variable requires requalification of the WPS — meaning a new PQR with fresh test coupons.
모재 그룹화 시스템은 D1.1과 근본적으로 다릅니다. 예열 범주에 기반한 5개 그룹 대신, ASME IX는 모든 재료 사양에 Table QW/QB-422에서 P-번호 및 그룹 번호를 할당합니다. 한 P-번호 재료에 대해 인증된 용접 절차 사양서는 일반적으로 해당 P-번호 내의 모든 재료를 포괄하며, 충격 테스트가 적용되는 경우 그룹 번호 변경에 대한 일부 예외가 있습니다. 이 시스템은 철 합금, 스테인리스강, 니켈 합금, 알루미늄, 구리, 티타늄 및 지르코늄에 걸쳐 2,000개 이상의 재료 사양을 다룹니다.
용가재는 F-번호 (사용성 그룹화, Table QW-432) 및 A-번호 (용접 금속 화학 성분, Table QW-442)로 분류됩니다. F-번호 변경은 항상 필수적입니다. A-번호 변경은 특정 공정 및 충격 테스트가 필요한 경우 필수적입니다.
API 1104 WPS 필수 사항
API 1104 governs welding of pipelines and related facilities. Its WPS requirements in Section 5 are specifically designed for girth welds on pipe — typically single-V groove joints welded in fixed position. The essential variables include process type, base metal (grouped by specified minimum yield strength), wall thickness range, joint design, filler metal group, electrical characteristics (AC/DC, polarity), position, direction of welding (uphill or downhill for vertical joints), shielding gas composition and flow rate, preheat, and interpass 온도 한계.
A distinguishing feature of API 1104 is the qualification testing requirements: test coupons are subjected to tensile, nick break, and guided bend tests. Radiographic examination of the test weld is also commonly performed. The standard allows qualification on a range of wall thicknesses and pipe diameters — the qualified range depends on the test coupon dimensions.
Unlike D1.1 and ASME IX, API 1104 treats the direction of welding (uphill vs. downhill) as an essential variable. Changing from downhill root pass to uphill root pass, or vice versa, requires requalification. This is critical for pipeline productivity — downhill welding is faster but requires different techniques and parameters.
WPS에 적합한 코드 선택
Structural steel fabrication (buildings, bridges, industrial structures): Use D1.1. The prequalified path eliminates qualification testing costs for common joints on common steels — the most efficient path when the fabricator is using standard processes on Table 5.6 materials.
Pressure vessels and boilers (ASME Boiler and Pressure Vessel Code): Use ASME IX. All WPSs require PQR backing. The P-Number system provides the most comprehensive material classification of any 용접 코드. Required for ASME Code-stamped equipment.
Pipelines and piping systems (cross-country pipelines, gathering lines, facilities): Use API 1104. The qualification testing and essential variables are optimized for the specific challenges of field 배관 용접 — fixed position, varying wall thickness, uphill/downhill progression.
Crossover situations: When a project requires compliance with multiple codes (e.g., pipe rack structural members under D1.1 supporting a piping system under ASME B31.3 referencing ASME IX), each code’s WPS requirements must be met independently. A WPS qualified under ASME IX cannot be used for D1.1 work unless it also meets the D1.1 prequalification rules or has been separately qualified per Clause 6.
"용접 절차 사양서 양식은 단지 컨테이너일 뿐입니다. 중요한 것은 Table 5.5의 모든 필수 변수가 문서화되고, 추적 가능하며, 작업 현장에서 준수되는 것입니다."
— Standard fabrication guidance, consistent with D1.1:2025 Clause 5.2.1
자주 묻는 질문
D1.1:2025 Clause 5.2.1 states that a prequalified WPS may follow any convenient format. There is no mandatory form. AWS Annex J provides sample forms as a starting point, and Annex K provides a reference checklist of code subclauses that a prequalified WPS must address. Most fabricators develop their own WPS forms tailored to their shop operations, as long as all 21 essential variables from Table 5.5 are documented.
D1.1:2025 Table 5.5 lists 21 essential variables that must be included in a written prequalified WPS. These cover the welding process, position, base metal group, filler metal classification, electrode diameter, amperage range, voltage range, travel speed range, shielding gas, transfer mode (for GMAW), preheat and interpass temperatures, joint design, weld type, single or multiple pass, and postweld heat treatment. When any of these variables is changed beyond its permitted tolerance, a new or revised WPS is required.
AWS D1.1:2025 Annex J (informative) provides sample welding procedure specification forms. These are not mandatory forms but reference templates. Most steel fabrication shops, AISC-certified facilities, and welding inspection training programs have their own standardized WPS forms. The form layout does not matter as long as all required variables from Table 5.5 are addressed and the WPS is a written document per Clause 5.2.1.
A WPS template is a blank form with labeled fields for each essential variable — ready to be filled in for a specific weld. A WPS PDF is a completed welding procedure specification saved as a portable document. In practice, fabricators fill in the template for each joint configuration, then distribute the completed WPS as a PDF to the shop floor, the inspector, and the project file. The template is reusable; each completed WPS is job-specific.
A prequalified WPS follows the prescriptive rules in D1.1 Clause 5 without any testing. If the welding process is SMAW, SAW, GMAW, or FCAW, the base metal is in Table 5.6, the joint detail matches Figure 5.1 through Figure 5.3, and all 21 essential variables from Table 5.5 are within limits, no procedure qualification record (PQR) is needed. A qualified WPS requires physical testing per Clause 6 — the fabricator welds a test coupon, destructively tests it (bend, tensile, macro), and documents the results on a PQR. Qualified WPSs are mandatory for processes like ESW/EGW, for base metals not listed in Table 5.6, or whenever a prequalified variable limit is exceeded. ASME IX has no prequalified path — every WPS must be backed by a PQR.
Yes, significantly. D1.1 allows prequalified WPSs with no testing if prescriptive rules are followed. ASME IX requires every WPS to be backed by a procedure qualification record (PQR) with physical test results — there is no prequalified path. D1.1 uses base metal Groups (I through V) from Table 5.6, while ASME IX uses P-Numbers and Group Numbers from Table QW/QB-422. D1.1 essential variables are listed in Table 5.5 with 21 items for prequalified WPSs. ASME IX essential variables are spread across Tables QW-250 through QW-265, organized by welding process. API 1104 adds a third approach focused on pipeline-specific variables like travel speed limitations and uphill vs. downhill progression.
Yes — a single WPS can cover any joint configuration that falls within the ranges documented on that WPS. For example, a D1.1 prequalified WPS for SMAW on Group I steel with a specific filler metal and parameter ranges can be used for every joint on a project that matches those conditions, regardless of whether it is a groove weld, fillet weld, or different plate thickness (within the preheat and parameter limits). The WPS defines the envelope of acceptable parameters. Each joint that falls within that envelope can be welded using the same WPS. If a joint requires a parameter outside the WPS range, either revise the existing WPS or write a new one.
AWS D1.1/D1.1M:2025, ASME BPVC IX:2025 및 API 1104의 참조 데이터. AWS 또는 ASME와 제휴하지 않습니다.