Procedure Qualification Record (PQR): Definition, Requirements & Review Checklist

A Procedure Qualification Record (PQR) is the foundational document in welding quality assurance. Without a valid PQR, no Welding Procedure Specification (WPS) can be considered qualified, and no production welds made under that WPS are code-compliant.

Quick Answer

---

What Is a PQR?

The PQR is a record — not a procedure. It records what actually happened during a specific test weld, including:

• All welding parameters as measured during the test weld (amperage, voltage, travel speed, heat input)
• The filler metal, shielding gas, and flux actually used
• Preheat and interpass temperatures actually recorded
• All mechanical and NDE test results from specimens cut from the coupon

The PQR differs from a WPS, which specifies the ranges within which production welds shall be made. The WPS is a prescription; the PQR is the evidence that the prescription produces sound welds.

---

The PQR–WPS Relationship

PQR (factual record of test weld)
    └── supports one or more ──▶ WPS (production procedure)

A single PQR can support multiple WPSs, provided each WPS stays within the essential and supplementary essential variables established by the PQR. Conversely, some WPSs require multiple supporting PQRs (e.g., different positions or filler metal classifications).

Important distinction: The PQR is never used directly in the fabrication shop. Welders work to the WPS. The PQR lives in the quality file and is presented to the Authorized Inspector on demand.

---

Governing Codes

ASME Boiler and Pressure Vessel Code, Section IX

ASME IX is the most widely referenced welding qualification code for pressure equipment globally. Key provisions:

• QW-200: General requirements for procedure qualification
• QW-250 through QW-280: Essential, supplementary essential, and nonessential variables by process
• QW-300: Test coupon dimensions and positions
• QW-462: Required mechanical tests and acceptance criteria
• QW-483: Required format for PQR

Essential variables are changes that affect the mechanical properties of the weld and require re-qualification. Supplementary essential variables affect notch toughness and are invoked when Charpy testing is required by the referencing code. Nonessential variables require only a WPS revision.

AWS D1.1 Structural Welding Code — Steel

AWS D1.1 calls the equivalent document a Procedure Qualification Record and governs its use for structural steel welding. Prequalified WPSs under D1.1 do not require a supporting PQR, but non-prequalified procedures do.

ISO 15614-1

The European equivalent. Qualification is by process, material group, filler metal, heat input range, and position. Results recorded on a Welding Procedure Qualification Record (WPQR).

---

Essential Variables: What Triggers Re-Qualification

A change to any essential variable invalidates the existing PQR and requires a new test coupon. Common essential variables under ASME IX for SMAW (QW-253):

---

Required Mechanical Tests (ASME IX)

For a groove weld procedure qualification, ASME IX QW-462 requires:

All test specimens must be cut, machined, and tested by a qualified testing laboratory. Results are reported on the PQR with laboratory identification and calibration references.

---

What to Check When Reviewing a PQR

QA engineers and Authorized Inspectors should verify the following when reviewing a PQR:

1. Completeness: All required fields per QW-483 are filled; no blanks in essential variable columns.
2. Test weld date and location: Must precede the WPS issue date. Test performed at a qualified facility.
3. Signatory: Signed and dated by a CWI (AWS), Authorized Welding Inspector (ASME), or equivalent per the applicable code.
4. Variable ranges recorded: Actual measured values, not ranges. Ranges belong in the WPS.
5. Mechanical test results: All required tests performed; specimens meet acceptance criteria; lab report number referenced.
6. NDE results (if required): RT or UT of the test coupon per QW-142 if impact testing is required by the referencing code.
7. Preheat and PWHT: Actual temperatures recorded for the test weld match the WPS application envelope.
8. P-Numbers and F-Numbers: Correctly assigned to the base metal and filler metal used.
9. Supporting laboratory reports: Tensile, bend, and Charpy reports attached or referenced with traceability to the specific coupon.

---

Common PQR Deficiencies Found During Audits

• WPS is supported by a PQR qualified under ASME IX but production uses a different P-Number base metal not covered
• PQR shows "per WPS" in the recorded-parameter columns rather than actual measured values
• Charpy test results reported without reference to the test temperature or specimen orientation
• Re-qualification not triggered after a change to electrode classification that crossed F-Number boundaries
• PQR signed by a welder supervisor who is not a qualified welding inspector
• Laboratory reports not retained with the PQR (traceability broken)

---

PQR Digital Management

Paper PQRs create audit risk: misfiled documents, illegible scans, and no automatic alert when a change requires re-qualification. Platforms such as TestCert allow quality teams to link PQRs to their supporting WPSs, track essential variable status, and receive alerts when a proposed production change would invalidate the qualification basis.

---