WELDING PROCEDURE SPECIFICATION (WPS) (QW-482)
In accordance with QW-200.1, Section IX, ASME BPVC
Company Name WPS No. PQR No. Welding Process
Precision profiles India , Chennai. Rev 0 Date PPI/L&T/WPS/014 6/4/2014 Date PPI/L&T/PQR/014 Type: MANUAL GMAW This procedure applying for fabrication welding/repair welding of P 1 material with PWHT
Scope JOINTS (QW-402) Joint Design Root Space (A) Root land (B) Bevel Angle Backing Backing Material Retainer
Refer Sketch 2mm 2mm 60°±5˚ Yes Weld area Nil
BASE METALS (QW-403)
P.NO 1 Material Specification Chemical Analysis Mechanical Properties
Group No.
2
Base Metal Pipe Diameter Weld pass thickness ≥ 13 mm FILLER METALS (QW-404)
Thickness Range
to P. No. 1(all P .NO 1 material) Grade SA516 As per specification specification As per specification specification 5-200mm Greater than 73mm Yes
2
Group No GR 70
Fillet Fillet
All size All dia
Specification No. (SFA)
A5.18
AWS No. (Classification) (Classification)
E R70S-6
F-No.
6
A-No.
1
Size of Electrode / Filler Metal
Ø1.2mm Dia
Filler Metal Product Form
Wire
Supplemental Filler Metal
NA
Weld Metal Thickness Range
5-200mm
Fillet
Electrode Flux (Classification)
NA
Consumables Brand Name
ESAB MW1
Manufacturer
ESAB INDIA LTD
Consumable Insert
NA
Powder Feed Rate
NA
Diameter > 6 mm (1/4 in.)
NA
Change of Alloy Element
NA
POSITIONS (QW-405)
PREHEAT (QW-406)
All Size
Position
1G
Preheat Temperature, min.
150˚C
Welding Progression
NA
Interpass Temperature, max.
300°C
Position(s) of Fillet
All
Preheat Maintenance
NIL
POST WELD HEAT TREATMENT (QW-407)
Type Holding Temperature
620-640°C
Time Range, min
1 1/2hr min
Time Range, max
2 hrs
Loading / Unloading Temperature, Max
300°C
Rate of Heating Rate of Cooling
Max. Max.
100°C 100°C
WELDING PROCEDURE SPECIFICATION (WPS) (QW-482)
In accordance with QW-200.1, Section IX, ASME BPVC
GAS (QW-408) Gas
Mixture composition (%)
Shielding Gas
CO2
99.99
15-20
Trailing Gas
NA
NA
NA
Backing Gas
NA
NA
NA
FlowRate(litres/minute)
ELECTRICAL CHARACTERISTICS (QW-409) Filler Metal Diameter Classification (mm)
Weld Pass
Process
Root run
GMAW
E R70S-6
Sub sequence layers
GMAW
E R70S-6
Current
Travel Speed (range) (mm/min)
Type
Polarity
Amps (Range)
Volt (Range)
1.2
DC
RP
120-160
20-24
120-180
1.2
DC
RP
150-220
20-30
120-180
Pulsing Current
NA
Heat input (max)
NA
Tungsten Electrode Size & Type
NA
Mode of metal transfer
Globular Transfer
Electrode wire feed speed range
4-6 m/min
TECHNIQUE (QW-410)
String or Weave Bead
Both (Weave not more than 3 times of the electrode)
Oriffice, Nozzle and Gas cup size
NA
Initial and interpass cleaning method
Wire brushing & Chipping
Method of back gouging
Grinding
Oscillation
NA
Multiple or single pass (per side)
Multiple Pass
Multiple or single layer
Multiple
Multiple or single electrode
single
Electrode Spacing
NA
Welding Process
GMAW
Peening
NA
Use of thermal process
NA
Note: The filler metal shall be stored, issued and controlled as per manufacturer's recommendation / Precision Profiles India procedures. PPI
FLOWSERVE
DNV
Name:
Name:
Name:
Signature:
Signature:
Signature:
WELDING PROCEDURE QUALIFICATION RECORD (PQR) (QW-483) In accordance with QW-200.2, Section IX, ASME BPVC Company Name WPS NO PQR No. Welding Process Date of Welding JOINTS (QW-402) Joint Design Root gap / Space Root land Backing Backing Material Retainer Bevel Angle BASE METALS (QW-403) Material Specification Grade
Precision Profiles India,Chennai. REV PPI/L&T/WPS/014 REV PPI/L&T/PQR/014 GMAW Type 29-Oct-13
0 0
Date Date :Manual
10/29/2013
Refer Sketch 2mm 2mm yes weld area nil 60˚±5˚
SA516 GR 70
P.No to 1 Gr. No. 2 Thickness of test coupon Diameter of test coupon Size (l x w x t) (mm) Weld pass thickness <13mm
. P.No 1 Gr. No. 32mm na 300x150x32 Yes
FILLER METALS (QW-404) SFA Specification AWS Classification Filler Metal F-No. Weld Metal Analysis A-No. Filler Metal Product Form Size of Filler metal Weld metal thickness
2
PREHEAT (QW-406) Preheat temperature 150 ˚c Interpass temperature 300 ˚c nil Preheat Maintenance POST WELD HEAT TREATMENT (QW-407) Temperature 620-640 ˚c 1hr Time Rate of Heating 100 ˚c Rate of Cooling 100 ˚c Loading / Unloading Temperature (max.) 400 ˚c
GAS (QW-408) 5.18 ER70S-6 6 1 wire Ø1.2mm
Gas C02
Shielding Gas Trailing Gas Backing Gas
Mixture c omposition(%) 99.99 NA NA
Flow Rate (lpm) 15-20 NA NA
dia
13mm
POSITION (QW-405) 1G
Position
na
Weld Progression .
ELECTRICAL CHARACTERISTICS (QW-409) Filler Metal Weld Pass
Process
Current
Classification
Diameter (mm)
Type
Polarity
Amps (Range)
Root run
GMAW
E R70S-6
1.2
DC
RP
Sub sequence layers
GMAW
E R70S-6
1.2
DC
RP 150-220
TECHNIQUE (QW-410) Travel Speed String or Weave Bead Initial and interpass cleaning Method of back gouging Oscillation Multiple or single pass (per side) Multiple or single layer Multiple or single electrode Welding Process Peening Use of thermal process
Form No: QP-051-R0
120-160
Volt (Range)
Travel Speed (range) (mm/min.)
20-25
120-180
20-30
120-180
120-180mm/min
Both (weave not more than 3 times of the electrode) Wire brushing & Chipping Grinding NA Multiple pass Multiple Single GMAW HT NA
WELDING PROCEDURE QUALIFICATION RECORD (PQR) (QW-483) In accordance with QW-200.2, Section IX, ASME BPVC TENSILE TEST (QW-150) Specimen No.
Width, mm
Thickness, mm
T1 T2
19.08 19.31
31.99 31.85
2
Area, mm 610.37 615.02
Ultimate total load, kN 320.95 319.3
Ultimate unit stress, MPa 525.83 519.17
Type of failure & location BASE BASE
GUIDED-BEND TESTS (QW-160) Specimen Size(mm) Type and Figure No.QW462.3a` Sample ID-SB(1) Sample ID-SB(2) Sample ID-SB(3) Sample ID-SB(4) FILLET-WELD TESTS (QW-180) Results
NA
Penetration into parent metal
NA
Macro - Results
NA
300 x 33 x 10.4 Bend Angle 180 181 182 183
Result No cracks or fissures observed No cracks or fissures observed No cracks or fissures observed No cracks or fissures observed
OTHER TESTS Sl. No
Type of Examination
Result
1
Visual Examination
Free from spatters
2 3
Liquid Penetrant Examination Radiographic Examination
No indication found in weld areas Report no:PPIL 004/13-14
Hardness (HV10) 4
Base Weld HAZ
145 / 164 157 / 191 168 / 194
5
Macro Examination
Specimen did not reveal any cracks or other defects
Welder's Name
P.PANDIYAN
Identification No.
PP
M/s Precision Profiles India Test Conducted by We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Boiler and Pressure Vessel Code.
Form No: QP-051-R0
Prepared by
Reviewed & Approved by
O.Rajesh Quality Assurance
E.X.Xavier Quality Assurance
WELDER PERFORMANCE QUALIFICATION (WPQ) (QW-484A) In accordance with QW-301, Section IX, ASME BPVC WPQ No. Welder's Name Weld Shop
PPI/L&T/WPQ/014 P.Pandiyan M/s Precision Profiles India
TEST DESCRIPTION Identification of WPS followed Test Coupon or Production Weld Material Specification Base Metal Thickness Date of Welding
Date 1/2/2014 Identification No. PP .
PPI/L&T/WPS/014 Test Coupon SA516 Grade 32mm 15-Nov-13
70
TESTING VARIABLES AND QUALIFICATION LIMITS Welding Variables (QW-350) Welding Process(es) Type (i.e.; manual, semi-automatic) used Backing (with / without)
GMAW Manual with backing
Plate or Pipe (enter diameter if pipe or tube)
Plate
Base metal P-Number to P-Number Filler metal or electrode specification(s) (SFA) (info. only) Filler metal or electrode classification(s) (info. only) Filler metal F-Number(s) Consumable insert (GTAW or PAW) Filler Metal Product Form (solid/metal or f lux cored/powder) (GTAW or PAW)
1 to 1 5.18 ER70S-6 6 NA solid wire
Deposit thickness for each proces , mm
2mm
Deposit thickness for each process (3 layers min)
6mm
Position qualified (1G, 6G, 3F, etc.)
1G
Vertical progression (uphill or downhill)
NA
Type of fuel gas (OFW) Inert gas backing (GTAW, PAW, GMAW) RESULTS Visual Examination Results (QW-302.4) Liquid Penetrant Examination results(QW-195.2) Radiographic Examination results (QW-190) Mechanical Test conducted by Hardness Test conducted by Macro Examination conducted by Bend test results (QW-462.2) Type Result Type
CO 2 GMAW
Side Bend
No cracks or fissures observed
-
Report no:PPIL 004/13-14 M/s.MICRO LAB M/s.MICRO LAB M/s.MICRO LAB Result
Type
-
-
Result
Welding qualification conducted by M/s.PrecisionProfiles India We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Boiler and Pressure Vessel Code.
Form No: QP-051-R0
Prepared by
Reviewed & Approved by
O.Rajesh Quality Assurance
E.X.Xavier Quality Assurance
