Indian Engineer · WPS Helper 2026
Welding Procedure Validation & Inspection Audit Report
Cross-code engine: ASME IX · AWS D1.1 · API 1104 · BS EN ISO 15614 · IBR
IEW-AUD-0006-20261022
Issued: 22 Oct 2026
QA/QC Controlled Document
| WPS Number / Rev | WPS-IEW-2026-106 · Rev. 1 | Governing Code | AWS D1.1 |
| Title | FCAW girder flange-web fillet welds, shop fabrication (winter shift preheat) | ||
| Fabricator | Tata BlueScope Steel Ltd., Jamshedpur | Domain | Structural Member |
| Prepared By | Er. Priya R. Mahato | Registry Status | NON_COMPLIANT |
1 · Procedure Variables (QW-400 mapping)
| Variable | Declared Value | Variable Class |
|---|---|---|
| Welding process | FCAW | Essential |
| Joint type / design | Fillet (Tee/Lap) — Tee joint, 8 mm continuous fillet both sides | Non-Essential |
| Base metal | IS 2062 E350C | Essential |
| P-Number / Group | P-No. 1 Gr.1 | Essential |
| Qualified thickness range | 10 – 40 mm | Essential |
| PQR coupon thickness | 20 mm | Essential |
| Diameter range | All | Essential |
| Filler spec / class | AWS A5.20 / E71T-1C H8 | Essential |
| F-Number / A-Number | F-No. 6 / A-No. 1 | Essential |
| Preheat minimum | 15 °C | Essential |
| Interpass maximum | 260 °C | Essential |
| PWHT | Not required | Essential |
| Current / polarity | DCEP | Essential |
| Amperage | 220 – 300 A | Non-Essential |
| Voltage | 26 – 32 V | Non-Essential |
| Travel speed | 200 – 350 mm/min | Non-Essential |
| Heat input ceiling | 3.2 kJ/mm | Non-Essential |
| Shielding gas / flow | CO2 100% (C1) / 20 L/min | Essential |
| Backing gas | — | Suppl. Essential |
| Position | 3G | Non-Essential |
| Notch toughness regime | Not invoked | Supplementary |
| Supporting PQR | PQR-AWS-2026-106 | Essential |
2 · Automated Compliance Verdict
FAIL
Non-Compliant
Engine run of 18 Feb 2026, 09:30 pm by p.mahato@tbsl.in evaluated 29 cross-code rules against AWS D1.1 with clause-level evidence for every finding.
Passed: 28 · Warnings: 0 · Failures: 1 · Compliance score: 97 / 100
The procedure shall NOT be released for production welding until all essential and supplementary-essential deviations are dispositioned and the WPS is re-validated.
3 · Clause-Level Findings
| # | Variable / Rule | Class | Clause Ref. | Result | Remarks |
|---|---|---|---|---|---|
| 1 | Minimum preheat temperature | Essential | D1.1 Table 5.8 | FAIL | Declared preheat 15°C below required minimum 65°C for P-No. 1 at thickness > 38 mm. |
| 2 | Supporting PQR referenced | Essential | D1.1 §6.3 | PASS | Qualified by PQR PQR-AWS-2026-106. Traceability established. |
| 3 | Base metal P-Number assigned | Essential | D1.1 Table 5.3 | PASS | Base metal group P-No. 1 Gr.1 — IS 2062 E350C. |
| 4 | Dissimilar-metal weld compatibility | Essential | D1.1 §6.3.2 | PASS | Joint is between identical P-Numbers — no dissimilar-metal restrictions apply. |
| 5 | Thickness qualification range (coupon) | Essential | D1.1 Table 6.3 | PASS | Range 10–40 mm within qualified 1.5–40 mm for 20 mm test coupon. |
| 6 | Thickness range sanity | Non-Essential | D1.1 Table 6.3 | PASS | Commercial range 10–40 mm is within conventional procedure limits. |
| 7 | Small-bore thin-wall root control | Non-Essential | D1.1 §6.10 | PASS | Small-bore root check applicable to piping only. |
| 8 | Interpass temperature ceiling | Essential | D1.1 §5.6 | PASS | Interpass 260°C within 315°C ceiling. |
| 9 | Thermal window logic | Non-Essential | D1.1 §5.6 | PASS | Thermal window 15–260°C is internally coherent. |
| 10 | Mandatory PWHT by thickness/code | Essential | D1.1 §5.8 | PASS | PWHT not invoked — permitted for this material/thickness/code combination. |
| 11 | PWHT cycle parameters | Essential | D1.1 §5.8.1 | PASS | PWHT not required — cycle parameters not applicable. |
| 12 | PWHT soak window & hold adequacy | Suppl. Essential | D1.1 §5.8.2 | PASS | PWHT not required — soak band check not applicable. |
| 13 | F-Number consistent with process | Essential | D1.1 §6.3.3 | PASS | F-No. 6 (E71T-1C H8) is consistent with FCAW. |
| 14 | Shielding gas / medium per process | Essential | D1.1 §6.3.4 | PASS | Shielding medium “CO2 100% (C1)” acceptable for FCAW. |
| 15 | Root backing gas protection | Suppl. Essential | D1.1 §6.3.4 | PASS | FCAW — backing gas not driven by process. |
| 16 | Shielding gas flow rate | Non-Essential | D1.1 §6.3.4 | PASS | Flow 20 L/min within the 10–30 L/min band for FCAW. |
| 17 | Current type & polarity | Essential | D1.1 Table 5.5 | PASS | DCEP polarity consistent with FCAW and E71T-1C H8. |
| 18 | Amperage operating window | Non-Essential | D1.1 Table 5.5 | PASS | Amperage 220–300 A inside the FCAW operating envelope. |
| 19 | Arc voltage operating window | Non-Essential | D1.1 Table 5.5 | PASS | Voltage 26–32 V inside the FCAW operating envelope. |
| 20 | Travel speed control | Non-Essential | D1.1 §6.3.5 | PASS | Travel speed 200–350 mm/min is plausible for FCAW. |
| 21 | Heat input ceiling (toughness) | Suppl. Essential | D1.1 §6.3.5 | PASS | Computed worst-case heat input ≈ 2.88 kJ/mm (declared ceiling 3.2 kJ/mm) — no toughness restriction invoked. |
| 22 | Welding position qualification | Non-Essential | D1.1 §6.6 | PASS | Position 3G is a recognised EN ISO 6947 / QW-461 designation. |
| 23 | GMAW metal-transfer mode | Essential | D1.1 §4.7.1 | PASS | Transfer-mode variable applies to GMAW only (FCAW exempt). |
| 24 | Process admissibility under code | Essential | D1.1 §4.7 | PASS | FCAW is an admissible process under AWS D1_1. |
| 25 | ISO 15614 impact-test mandate | Suppl. Essential | D1.1 §6.6.3 | PASS | Impact regime not invoked for the declared thickness/application. |
| 26 | Storage-tank qualification route | Essential | D1.1 §6 | PASS | Tank-specific routing not applicable. |
| 27 | IBR statutory governance | Essential | D1.1 §6.1 | PASS | IBR statutory route not applicable to this scope. |
| 28 | Administrative data completeness | Non-Essential | D1.1 §6.2 | PASS | Administrative header fields adequately populated for issue. |
| 29 | Group Number under toughness | Suppl. Essential | D1.1 §6.3.2 | PASS | Group-No. split applies only when notch toughness is specified. |
4 · Traceability Excerpt
| Timestamp | Actor | Action | Details | Source IP |
|---|---|---|---|---|
| No audit events recorded for this entity. | ||||
Prepared By
Welding Engineer (IWE)
Er. Priya R. Mahato
Sign & Date
Reviewed By
QA/QC Manager
Sign & Date
Approved By
Client / TPI Inspector
Sign & Date