Evaluation of Weld Procedure Qualification Practices in Nigerian Oil Sector Fabrication Under ASME and AWS Codes

This study evaluates weld procedure qualification (WPQ) practices in oil sector fabrication facilities in Nigeria, examining compliance with ASME Section IX and AWS D1.1 procedural qualification requirements and identifying gaps between prescribed and actual practice. Weld procedure qualification is the cornerstone of fabrication quality assurance for pressure-retaining and structural components, and compliance failures carry serious safety implications in the oil and gas sector. A structured questionnaire-based survey is administered to welding engineers, inspectors, and quality managers at twenty fabrication facilities in the South South and South West geopolitical zones. The questionnaire addresses the existence of qualified WPS and PQR documentation, record-keeping practices, the qualifications and independence of the third-party inspection agency involved in qualification tests, and the handling of production variables that require requalification. Supplementary review of selected WPS and PQR documents provided by consenting facilities is conducted. Findings reveal that 14 of 20 facilities possess documented WPS and PQR packages, but independent auditing of these documents reveals deficiencies in essential variable coverage, missing essential test results, and inadequate documentation of heat input records in 40 percent of reviewed packages. The study identifies a gap between formal documentation possession and substantive procedural rigour and recommends mandatory third-party WPS audit by COREN-registered welding engineers. Keywords: weld procedure qualification, ASME, AWS, oil sector fabrication, Nigeria.