Choosing WPS

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Hi all, new to the forum here.Would really appreciate some feedback on this, all opinions welcome.We are beginning to manufacture conveyor pulleys, so most of the welding will consist of plate to inside of pipe, as per the pic attached.So far, any we jobs we have estimated, the customer has always asked us to "do what we think is right" regarding the welding of these parts. In Ireland, WPS is not a big thing and the customers know very little about it, so we wanted to develop and test our own WPS through ISO 15614-1, and then qualify the welders to it via ISO 9606-1.The drawings we receive from them, and the drawings we make for them, (which they approve), the side plates always have a chamfer, which makes the weld cease to be a fillet weld, and now a partial penetration butt weld, (hope I'm correct).I would be grateful for some feedback from the formum members regarding what type of WPS to aim for given the scope, which I'll list below. And also if I should expand the scope by qualifying a full-pen procedure.Material types: Group 1Welding positions: PA/PBProcess:MAGPipe wall thickness range:6mm-30mm.Plate thickness range:8mm-50mm.Many thanks in advance guys.


Reply:Welding is expensive,, failures are EVEN MORE expensive,,Knowing more about the final use of the roller can result in determining what you need as far as welding.If the roller carries a dozen tissue boxes per day,, will result in a totally different recommendation for welding,, as compared to a roller that carries 15,000 tons of sand per day.(My sisters farm has a conveyer belt that was used to carry 15,000 tons of sand per day,, for many years)So, give us a little more data,,Load expected, Type material to be carried.Rotational speed of the roller assembly  (THIS is VERY important)Duty cycle (hours per day,, etc,,)Environment (dust, temperature, outdoor or indoor,, etc)Depending on the answers,, the roller may need three 10mm welds per side,,orthe roller may need full penetration robotic welds for 100% of the circumference.
Reply:That would be a fairly heavy duty roller, regardless of the type of join. What will it be carrying, and what is the duty cycle? Even when I was working on steel bar conveyors, the rollers weren't that heavy -- they used lighter rollers in greater quantity (spaced closer together).Use a bigger hammer.
Reply:I just looked at the ISO spec. Nothing looks pre-qualified.Any chance you can go AWS, and purchase a SWPS for your simple alloy to test your weldor? Also be more specific on the material thickness range? You might have to purchase more than one SWPS to test your weldor to. And the little chamfer hopefully can be distregarded as it is consumed as part of the fillet pass. The engineer did not do you any favors there.Weld like a "WELDOR", not a wel-"DERR"

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