Werder Certification vs. WPS

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For a construction project (SMAW Welding per AWS D1.1) we submitted to the Owner a WPS, signed by a AWS certified inspector.  Most welding will be just for temporary steel templates for pile driving, things like that.  the WPS includes several prequalified joint detais for grove and pipe welds.  The figures / instructions were as shown in Fugure 3.4 of D1.1, including for example that the base metal thickness is "U" (unlimited), even though in practice we don´t expect to have to weld anything over 3/4" thick.We also submitted three Welder's certificates, which indicate clearly the type of certificaton they have and up to what scope.  of these, two are for Plate, in positions 3G and 4G, up to 3/4" base metal thickness, and one is for pipe, 6G, also up to 3/4" BMT.  These certificates were "approved as noted" by the owner, the note being that the Owner´s welding inspector shall verify the welder´s dexterity by doing some verification tests.The problem is that the Owner's Inspector says that our WPS is not acceptable because it shows parameters that exceed our welder's certificates, in particular that our welders are certified to 3/4" base metal thickness, and the WPS shows a prequalified joint detail to unlimited thickness.  So he wants us to resubmit two new WPS, one for the two welders that are certified for plate, and another for the welder certified for pipe, with the WPS limited to the thicknesses and other parameters that the weoders are certified to.Our interpretation is that a project can have a general WPS that shows types of joint, or variables such as thickness, that may be encountered on the project, independently of the level the welders are qualified to.  You could have a large project with many types of welds, for which you employ many welders with different certification levels, and each can only weld to the level that his own certificate allows; but you only make one WPS that encompases all possible welds you could encounter in a project.  If in the future we encounter a situation where we have to make a weld with more than 3/4" base metal thickness, we'll submit and enroll a corresponding certified welder - but we don't have to make a new WPS!The Inspector's comment / posiiton is that the welder must be certified to make up to the most extreme condition shown in the WPS.  But that would mean we have to prepare different WPS for each welder!  So he won't test the welders and approve production welding until these revised WPSs are submitted.We have read carefully our contract and all of AWS D1.1 and believe our interpretation is correct, as we don't see anything that indicates otherwise.  Our AWS certified inspector (third party) has the same interpretation.  But we could be wrong...I'll appreciate any comments and opinions on what should be the correct interpretation and dependency between the WPS and the welder's certifications.
Reply:Surprised you have structural welders with only limited certs! I'd send them to the test booth for unlimited tests. Strange you need a WPS for templates. For falsework, I could see that.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by CEPSurprised you have structural welders with only limited certs! I'd send them to the test booth for unlimited tests.  Strange you need a WPS for templates. For falsework, I could see that.
Reply:Oh I see now! Done a few of them myself.I'd still send those welders in for unlimited certs, they'll need them sooner or later. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:CEP has been in the game a long time, take his advice! Your welders will cringe, but in the long run it will better the company and keep them ill prepared.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I understand and agree with the advice, and we'll pursue that.  But right now the question is conceptual - is it possible (bu code, specification, etc) to have a project WPS that shows a pre-qualified joint with unlimited thickness, even if in fact the project expects to have joints no more than 3/4", and the welders be certified also to 3/4", or does the WPS have to be modified to match the current certification level of the welders submitted to date?
Reply:I'd say the WPS has to be modified, or re-written. Question is, will the inspector accept it? Monday morning on the way to work, I'd stop by the donut shop, and buy him breakfast. Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Unless I'm missing something, and some days I do, it seems simple to me, write a new WPS or requal the welders. Welder requal is probably the best choice, sub unlimited structural quals are a serious limiting factor, imo.J
Reply:Looks to me like the error was in submitting a WPS that exceeded not only your welders certifications but also exceeded what was  need on the job involved. Why have a WPS include "unlimited if the job never exceeds 3/4"? Anyway, you apparently agreed to have the inspector judge your welders on their ability to perform up to there individual certifications BUT did you also agree to have him review your WPS for the job? Seems to me he is outside what was agreed upon. The owner accepted your WPS and your welders certifications I can't see where the inspector gets to interject himself into it beyond examining performance.Gizzmo