How should deviations from the WPS be managed?

• A. Stop welding, document deviation, obtain authorisation, revise WPS and PQR if necessary, and re-inspect.
• B. Proceed and note deviation on the final report.
• C. Ignore minor deviations unless they cause immediate issues.
• D. Change to a different process without documentation.

Answer: (A)

Deviations from the Welding Procedure Specification must be controlled to preserve weld quality and compliance. If a deviation occurs, stop welding to prevent spreading non-conforming work. Document exactly what happened, so there is a clear record of the deviation. Obtain authorization from the appropriate authority before continuing, ensuring any change is approved and traceable. If the deviation means the WPS or qualification doesn’t cover the condition, revise the WPS and the PQR (Procedure Qualification Record) so there is an approved, qualified procedure for the variation. Finally, re-inspect the weld to verify it meets the required standards. This approach protects safety, traceability, and quality, and keeps the welding program in compliance. Proceeding without authorization, ignoring deviations, or changing processes without documentation can lead to unqualified welds and regulatory non-compliance.