WPS FOR DIFFERENT MATERAIL BY BHEL

BHARAT HEAVY ELECTRICALS LIMITED WELDING TECHNOLOGY CENTRE Tiruchirappalli-620014

WELDING PROCEDURE SPECIFICATION Page 1 of 2

Form No. 101-401 WPS No.:

1001

Date: 06.11.93

Rev. No.:

00

Date: ---

Welding Process: SMAW

Supporting PQR No.: 007

Type:

Manual (Auto-Semi-Auto-Manual-Machine)

Application: Butt-welding of P1 Gr. 1 & Gr.2 tubes without preheat and without PWHT. JOINTS (QW-402) Joint Design

: Groove as per drawing

Backing (Yes/No)

: As per drg.

Backing Material (type)

: -- do –

Metal/Non fusing metal/ Non metallic/Others BASE METAL (QW-403) P. No.: 1

Group No.: 1 or 2 TO

P. No.: 1

Group No.: 1 or 2

Spec. Type & Grade: N.A. Chem. Analysis & Mech. Prop.: N.A. Thickness Range Base Metal:

Groove: 1.6 to 9.0

Fillet:

N.A.

Weld Metal:

Groove: E6013; 5.0 max. : E7018; Balance Fillet: N.A.

Pipe dia.:

Groove: Unlimited Fillet: N.A.

Others: Nil FILLER METALS (QW-404) AWS No. (Class):

E6013 + E7018

Specn. No. (SFA):

5.1

Size of filler metal: See Table

F. No.:

2,4

Flux Trade Name: N.A.

A. No.: 1

Consumable insert: N.A. Electrode |Flux (Class): NA.

POSITION (QW-405)

PREHEAT (QW-406) Nil (min. 100C)

Position of Groove:

All

Preheat temp. (min.):

Position of fillet:

N.A.

Inter pass temp. (max.): 300 C

Weld Progression: (Up/Down)

Vertical up

Post heat maintenance: Nil

0

Others:

Nil


WELDING PROCEDURE SPECIFICATION Form No. 101-401

Page 2 of 2

WPS No.: 1001

PWHT (QW-407)

GAS (QW-408) Gases

Mix.%

Flow Rt.

Temp. Range:

Nil

Shielding

N.A.

---

---

Time Range:

Nil

Trailing

N.A

---

---

Others:

Nil

Backing

N.A.

---

---

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See Table

Polarity: See Table

Amps. (Range):

Volts: -- do –

-- do --

Tungsten Electrode type and size:

N.A.

Mode of metal transfer for (GMAW):

N.A.

Electrode wire feed speed range:

N.A.

Pulsing current (GTAW):

N.A.

TECHNIQUES (QW-410) String or Weave Bead:

Root & 2G: String; Others: String/Weave (3dia max.)

Orifice or Gas cup size:

N.A.

Initial and inter pass cleaning:

Brushing/Chipping/Grinding

Method of back gouging:

Nil

Oscillation:

N.A.

Contact tube to work distance:

N.A.

Multiple or single pass (per side):

Single or Multiple

Multiple or single electrode:

Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Amps.

Volt Range

Travel speed range

Others (hot wire, torch angle etc.)

DCEP

70-130

N.A.

N.A.

Nil

2.5

DECP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

Current

Weld Layer

Process

Class

Dia.

Type

Root

SMAW

E6013

2.5

Others

SMAW

E7018

- Do -

- Do -

- Do -

Approved by: (V. Ravindran) Manager/WTC Date: 06-11-93

Prepared by: (D.N. Ravishankar) S.W.E./WTC Date: 06-11-93



Page 1 of 2

WPS No.:

1228

Date: 15.12.06

Rev. No

:00

Date: ------

Supporting PQR No: 1258

Welding Process: FCAW (CO2)

Type: Semi Automatic (Auto,Semi-Auto,Manual,Machine)

Application: Groove & fillet welding of IS2062 carbon steel structure up to 50 mm thickness without PWHT. (AS PER AWS D1.1, SIP: NP: 07/01. QCP: 002/02). JOINTS (QW-402) Joint Design

: Groove / Fillet as per drawing.

Backing (Yes/No)

: As per drawing.


: Metal

Metal/Non fusing metal/

:

Non metallic/Others BASE METAL (QW-403) P. No: --

Group No: --

to

Spec. Type & Grade

: IS 2062

Chem. Analysis & Mech. Prop

: --

Thickness Range

P. No: --

Group No: --

:-

Pipe dia range: Others: Nil

Groove: 3.0 mm – 50 mm

Fillet: Unlimited.

Groove: ---

Fillet: ---

FILLER METALS (QW-404) AWS No. (Class):

E 71T-1

Size of filler metal: Refer table

Specn. No. (SFA):

5.20

Flux Trade Names:

N.A

F. No.:

6

Consumable insert:

N.A

A. No.:

1

Electrode |Flux (Class): N.A.

Deposited weld metal thickness range: Groove: 3.0mm-50mm Fillet:

3.0mm-50mm

Others:Nil POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

Flat

Position of fillet:

Flat

Weld Progression:

N.A.

Preheat temp (min):Thickness,T ≤ 38:Nil 38
≤ 63: 100Oc

T> 63: 150oC Inter pass temp. (Max.): 300OC

Others:

Nil

Preheat Others:

:

Nil Nil.



WPS No.: 1228

PWHT (QW-407)

Page 2 of 2

GAS (QW-408) Gases

Mix%

Flow Rt.

Temp. Range:

Nil

Time Range

Nil

Shielding

CO2

Others:

Nil

Trailing

Nil

---

----

Backing

Nil

---

----

100%

16-24 LPM

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): DC

Polarity: EP

Amps. (Range):

Volts : 26-28

180-220


N.A.


Globular


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String; Others: string or weave Orifice or Gas cup size: Max. 3 times dia. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gouging / grinding for second side welding Oscillation: 16/18 Contact tube to work distance: 8-15 mm Multiple or single pass (per side): Multiple Multiple or single electrode: Single Electrode spacing: N.A. Travel speed Range N.A. Peening: N.A. Others:

Nil Filler

Weld Layer

All

Process

FCAW

Prepared by:

(Kinkar P Narzary) Welding Engineer / WTC

Amps.

Volt Range

Travel speed range


180-220

26-28

N.A.

Nil

Current

Class

dia.

Type

E71T-1

1.6

DCEP

Reviewed by:

(Dr.K.P.Dhandapani) DGM / WTC & WCMC

Approved by:

(B.Natarajan) SDGM/ WTC & WCMC



Page 1 of 2

WPS No.:

1227

Date: 17.11.06

Rev. No

:00

Date: ------



Type: Manual (Auto,Semi-Auto,Manual,Machine)

Application: Groove & fillet welding of A588 Gr A components with PWHT. JOINTS (QW-402) Joint Design

: Groove / Fillet as per production drg.

Backing (Yes/No)

: As per production drawing.


: Nil


:

Non metallic/Others BASE METAL (QW-403) P. No: Nil

Group No: Nil

to

P. No: Nil

Group No: Nil

Spec. Type & Grade

: A 588 Gr A or equivalent S3 material.


: Nil.

Thickness Range

:-


Groove: 5.00 to 32 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.

FILLER METALS (QW-404) AWS No. (Class): Specn. No. (SFA):

E 8018-B2


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

Nil

A. No.:

3


Deposited weld metal thickness range: Groove: 32 mm maximum (4 mm maximum per pass) Fillet: Unlimited. (4 mm maximum per pass) POSITION (QW-405)

PREHEAT (QW-406) 150oC

Position of Groove:

All.

Preheat temp (min). :

Position of fillet:

All

Inter pass temp. (Max.): 300OC

Weld Progression: (Up / Down)

Vertical up.

Post heat

Others:

Nil

Other:

:

N.A Nil.


WELDING PROCEDURE SPECIFICATION Form No. 101-401 PWHT (QW-407)

GAS (QW-408) o

Temp. Range: Time Range

Page 2 of 2

WPS No.: 1227

655± 15 C

Gases

2.5 min / mm (Minimum 30 minutes.)

Others:

Nil

Mix%

Flow Rt.

Shielding

N.A.

N.A.

N.A.

Trailing

N.A.

N.A.

N.A.

Backing

N.A.

N.A.

N.A.

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): Refer table Amps. (Range): Refer table Tungsten Electrode type and size: Mode of metal transfer for (GMAW): Electrode wire feed speed range:

Polarity: Refer table Volts : Refer table N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String; Others: string or weave (3 dia. max) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Back grinding for second side welding Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

Amps.

Volt Range

Travel speed range


Current

Class

dia.

Type

Root

SMAW

E 8018-B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

1 to 2 & Back side

SMAW

E 8018-B2

3.15

DCEP

100-130

N.A.

N.A.

Nil

E 8018-B2 4.0 DCEP Reviewed by:

140-180

N.A. N.A. Approved by:

Further SMAW Prepared by:



Nil




Page 1 of 2

WPS No.:

1226

Date: 17.11.06

Rev. No

:00

Date: ------




Application: Groove & fillet welding of A588 Gr A components with out PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)



: Nil


:


Group No: Nil

to

P. No: Nil

Group No: Nil

Spec. Type & Grade

: A 588 Gr A or equivalent S3 material.


: Nil.

Thickness Range

:-



Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 8018-B2


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

Nil

A. No.:

3


Deposited weld metal thickness range: Groove: 16mm maximum (4 mm maximum per pass) Fillet: 13mm maximum (4 mm maximum per pass) POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All



Vertical up.

Post heat

Others:

Nil

Other:

:

N.A Nil.



Page 2 of 2

WPS No.: 1226

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding

N.A.

N.A.

N.A.

Others:

Nil

Trailing

N.A.

N.A.

N.A.

Backing

N.A.

N.A.

N.A.

Gases


Polarity: Refer table Volts : Refer table N.A. N.A. N.A.


N.A.

Mix%

Flow Rt.

TECHNIQUES (QW-410) String or Weave Bead: Root: String; Others: string or weave (3 dia. max) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Back grinding for second side welding Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

Amps.

Volt Range

Travel speed range


Current

Class

dia.

Type

Root

SMAW

E 8018-B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

1 to 2 & Back side

SMAW

E 8018-B2

3.15

DCEP

100-130

N.A.

N.A.

Nil

Further

SMAW

E 8018-B2

4.0

DCEP

140-180

N.A.

N.A.

Nil

Prepared by:


Reviewed by:


Approved by:




Page 1 of 2

WPS No.:

1225

Date: 04.05.06

Rev. No

:00

Date: ------




Application: Groove & fillet welding of IS 2062 attachments to SS attachments without Preheat and PWHT. JOINTS (QW-402) Joint Design

: Groove / Fillet as per drg.

Backing (Yes/No)

: As per drg.


: Metal


:

Non metallic/Others BASE METAL (QW-403) P. No: ---

Group No: --

to

P. No: 8

Group No: 1

Spec. Type & Grade

: IS 2062 + Stainless Steel (18Cr –8Ni)


: N.A.

Thickness Range

:-


Groove: 4.5 to 20.0 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 309

Size of filler metal: See table

Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


Deposited weld metal thickness range: Groove: 20.00 max (Maximum 8 mm per pass) Fillet: Unlimited (Maximum 8 mm per pass) PREHEAT (QW-406)

POSITION (QW-405) Position of Groove:

All.


Position of fillet:

All



Vertical up.

Pre heat maintenance: Nil

Others:

Nil

Other:

Nil

Nil.



WPS No.: 1225

PWHT (QW-407)

Page 2 of 2

GAS (QW-408) Gases

Mix%

Flow Rt.

Temp. Range:

Nil

Time Range

Nil

Shielding

Not required ----

----

Others:

Nil

Trailing

Not required

----

---

Backing

Not required

----

-----

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table Amps. (Range): See table Tungsten Electrode type and size: Mode of metal transfer for (GMAW): Electrode wire feed speed range:

Polarity: See table Volts : See table N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Orifice or Gas cup size: Initial and inter pass cleaning: Method of back Gouging: Oscillation: Contact tube to work distance: Multiple or single pass (per side): Multiple or single electrode: Electrode spacing: Peening:

String N.A. Brushing/Chipping/Grinding Grinding for second side welding N.A. N.A. Single or Multiple Single N.A. Nil.

Others:

Nil Filler

Weld Layer

Process

Current

Class

dia.

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E 309

2.5

DCEP

70-100

N.A.

N.A.

Nil

All

SMAW

E 309

3.15

DCEP

90-130

N.A.

N.A.

Nil

All

SMAW Approved by:

E 309

4.0

DCEP

120-160 N.A. Prepared by:

N.A.

Nil

(S.Ramesh) SDGM/WTC & WCMC

(Dr.K.P.Dhandapani) DGM/ WTC & WCMC



Page 1 of 2

WPS No.:

1224

Date: 27.04.06

Rev. No

:00

Date: ------

Supporting PQR No: 814, 819



Application: Welding butt joints of Galvanized Iron Pipes. JOINTS (QW-402) Joint Design

: Groove as per Drg.

Backing (Yes/No)

: As per drg.


: Metal


:


Group No: Nil

to

P. No: Nil

Group No: Nil

Spec. Type & Grade

: IS 3586 and equivalent Carbon content ≤ 0.25%


: Galvanized pipes

Thickness Range

:-



Fillet: N.A.

Groove: Unlimited.

Fillet: N.A.


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1


Deposited weld metal thickness range: Groove: 12 mm (6 mm per pass max.) Fillet: 12 mm (6 mm per pas max.) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.


Position of fillet:

All



Vertical up.


Others:

Nil

Other:

Nil

Nil.



Page 2 of 2

WPS No.: 1224

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil


Gases

Mix%

Shielding

N.A.

----

Trailing

N.A.

----

Backing

N.A.

Flow Rt.

Polarity: See table Volts : See table N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Orifice or Gas cup size: Initial and inter pass cleaning:

String or weave (3 dia. max) N.A. initial grinding of Galvanic coating at the joint / Chipping & Brushing of slags. Method of back Gouging: N.A. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

Current

Class

dia.

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E 7018

3.15

DCEP

100-140

N.A.

N.A.

N.A.

All

SMAW

E 7018

4.0

DCEP

140-190

N.A.

N.A.

N.A.

All

SMAW E 7018 Approved by:

5.0

DCEP


N.A.

N.A.

(S.Ramesh) SDGM/WTC

(Dr.K.P.Dhandapani) DGM / WTC



Page 1 of 2

WPS No.:

1223

Date: 25.10.2004

Rev. No

:00

Date: ------




Application: Groove welding of IS8500 Fe 540 Structural components like Ceiling girders / Columns / Built up Beams etc. JOINTS (QW-402) Joint Design

: As per production Drg.

Backing (Yes/No)



: Metal


:


Group No: Nil

to

P. No: Nil

Spec. Type & Grade

: IS 8500 Fe 540 or equivalent


: Nil.

Thickness Range

Group No: Nil

:-


Groove: 10 to 200 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 8018-B2


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

3


Deposited weld metal thickness range: Groove: 200mm maximum (maximum 5 mm per pass) Fillet: Unlimited (maximum 5 mm per pass) POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All



Vertical up.


Others:

Nil

Other:

Nil.



WPS No.: 1223

PWHT (QW-407)

Page 2 of 2

GAS (QW-408) O

Temp. Range:

600 –650 c

Time Range

2.5minutes/mm (minimum 120 minutes)

Others:

Nil

Gases

Mix%

Shielding

N.A.

----

Trailing

N.A.

----

Backing

N.A.

Flow Rt.

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): Refer table

Polarity: Refer table

Amps. (Range):

Volts : Refer table

Refer table


N.A.


N.A.


N.A.


N.A.


String or weave (3 dia. max)


N.A.



Method of back Gouging:

Air arc gouging / grinding for second side welding

Oscillation:

N.A.


N.A.


Multiple


Single

Electrode spacing:

N.A.

Peening:

N.A.

Others:

Nil Filler

Weld Layer

Process

Amps.

Volt Range

Travel speed range


Current

Class

dia.

Type

Root

SMAW

E8018B2

3.15

DCEP

100-130

N.A.

N.A.

N.A.

Others

SMAW

E8018B2

4.0

DCEP

140-180

N.A.

N.A.

N.A.

Others

SMAW E8018B2 Approved by:

5.0

DCEP


N.A.

N.A.

(S.Chellaiah) AGM/WTC/WCMC/TE

(R.Rajanarayanan) DM/ WTC




1220

Date: 19.07.01

Rev. No

:00

Date: ------




Application: Fillet welding of AISI 430 components with Preheat & without PWHT. JOINTS (QW-402) Joint Design

: As per drawing.

Backing (Yes/No)

: As per drawing.


: Metal


:

Non metallic/Others BASE METAL (QW-403) P. No: 7

Group No: 2

to

P. No: 7

Spec. Type & Grade

: AISI 430 or equivalent.


: N.A.

Group No: 2

Thickness Range

Pipe Dia. range:

Groove: N.A.

Fillet: 6.0 mm maximum

Groove: N.A.

Fillet: 100 mm maximum


E 309


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

Nil

A. No.:

8


Deposited weld metal thickness range Groove: N.A. Fillet: 6mm maximum (maximum 3 mm per pass) POSITION (QW-405)


Position of Groove:

N.A.


Position of fillet:

All



Vertical up.

Pre heat maintenance: Nil Other:

Nil.


WELDING PROCEDURE SPECIFICATION

Form No. 101-401

WPS No.: 1220

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Gases

Time Range

Nil

Shielding N.A.

Others:

Nil

Trailing

N.A

Backing

N.A.

Mix%

Flow Rt.

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table

Polarity: See table

Amps. (Range):

Volts : N.A.

See table


N.A.


N.A.


N.A.


Nil.


String


N.A.




N.A.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Weld Layer

Process Class

Travel speed range


Current Dia. mm

Type

Amps.

Volt Range

All

SMAW

E 309

2.5

DCEP

70-90

N.A.

N.A.

Nil

All

SMAW

E 310

3.15

DCEP

80-120

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

DGM / WTC

Sr.Welding Engineer / WTC



Page 1 of 2

WPS No.:

1219

Date: 19.07.01

Rev. No

:00

Date: ------




Application: Groove & fillet welding of SA 240 Type 310S components without Preheat & without PWHT. JOINTS (QW-402) Joint Design

: As per drawing.

Backing (Yes/No)

: As per drawing.


: Metal.


:


Group No: 2

to

P. No: 8

Group No: 2

Spec. Type & Grade

: SA 240 Type 310S or equivalent


: N.A.

Thickness Range Pipe Dia range:

Groove: 4.8 mm to 20.0 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 310


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

Nil.

A. No.:

8


Deposited weld metal thickness range Groove: 20.0 mm max. (Max. 4 mm per pass) Fillet: Unlimited (Max.4 mm per pass) POSITION (QW-405)

PREHEAT (QW-406) Nil (10Oc Min)

Position of Groove:

All.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1219

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding N.A

Others:

Nil

Trailing

N.A.

Backing

N.A..

Gases

Mix%

Flow Rt.


Polarity: See table

Amps. (Range):

Volts : N.A.

See table


N.A.


N.A.


N.A.


Nil.


String


N.A.




Nil

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E 310

2.5

DCEP

70-90

N.A.

N.A.

Nil

All

SMAW

E 310

3.15

DCEP

90-120

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

DGM / WTC

Sr. Welding Engineer / WTC



Page 1 of 2

WPS No.:

1218

Date: 18.07.01

Rev. No

:00

Date: ------




Application: Groove & fillet welding of A 588 Gr A components. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per production drg.


: Nil


:


Group No: Nil

to

P. No: Nil

Spec. Type & Grade

: A 588 Gr A or equivalent


: Nil.

Group No: Nil

Thickness Range

Pipe Dia. range: Others: Nil

Groove: 1.6 to 6

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 8018-B2


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

3


Deposited weld metal thickness range Groove: 6mm maximum (maximum 3 mm per pass) Fillet: 6mm maximum (maximum 3 mm per pass) POSITION (QW-405)

PREHEAT (QW-406) Nil (10Oc Min)

Position of Groove:

All.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1218

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts : -do-

-do-


N.A.


N.A.


N.A.


N.A.


Root: String; Others: string or weave (3 Dia. max)


N.A.




Back grinding for second side welding

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

N.A.

Others:

Nil Filler

Weld Layer

Process

All

SMAW -Do-

-Do-

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E 8018-B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

3.15

-do-

100-130

N.A.

N.A.

Nil

Class

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

DGM / WTC

Sr.Welding Engineer / WTC




1217

Date: 14.07.01

Rev. No

:00

Date: ------




Application: Groove & fillet welding of SA 240 Type 304 Stainless Steel components without Preheat & without PWHT. JOINTS (QW-402) Joint Design

: As per drawing

Backing (Yes/No)

: As per drawing.


: Metal


:


Group No: 1

to

P. No: 8

Spec. Type & Grade

: SA 240 Type 304 or equivalent.


: N.A.

Group No: 1

Thickness Range


Groove: 3.0 mm to 12.0 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 308


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


Deposited weld metal thickness Groove: 12.0 mm max (Max. 5mm per pass) Fillet: Unlimited (Max.5mm per pass) POSITION (QW-405)

PREHEAT (QW-406) Nil (10Oc min)

Position of Groove:

All.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1217

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding N.A

Others:

Nil

Trailing

N.A.

Backing

N.A.

Gases

Mix%

Flow Rt.


Polarity: See table

Amps. (Range):

Volts: N.A.

See table


N.A.


N.A.


N.A.


N.A.


String


N.A.




Nil

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

All

Process Class SMAW

E 308

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range

3.15

DCEP

90-120

N.A.

N.A.

Others (hot wire, torch angle etc.) Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

DGM / WTC

Sr.. Welding Engineer / WTC




1216

Date: 29.03.00

Rev. No

:00

Date: ------




Application: Groove & fillet welding of 1Cr .5Mo/ 1.25Cr 0.5Mo Steel attachment to 2.25Cr 1Mo Steel attachment. JOINTS (QW-402) Joint Design


Backing (Yes/No)





:


Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No: 5A

Group No: 1

Thickness Range

Pipe Dia. range:

Groove: 9.00 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.

Others: Nil FILLER METALS (QW-404) AWS No. (Class): Specn. No. (SFA):

E 8018-B2


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

3


Deposited weld metal thickness range Groove: 10.0 mm (Maximum 8 mm per pass) Fillet: 10.0 mm (Maximum 6.0 mm per pass) POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All

Inter pass temp. (Max.): 300 C


Vertical up.


O

Other:

Nil.



Page 2 of 2

WPS No.: 1216

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A.

See table


N.A.


N.A.


N.A.


N.A.


Root: String; Others: string or weave (3 Dia. max)


N.A.




Air arc gauging /Grinding for second side welding

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

N.A.

Others:

Nil Filler


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E 8018B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do-

-Do-

4.0

DCEP

140-190

N.A.

N.A.

Nil

Weld Layer

Process

All

SMAW

-Do-Do-

Current

Class

Approved by:

Prepared by:

(V.Ravindran)

(P.Sivasubramanian)

Sr. Manager / WTC

Welding Engineer / WTC



Page 1 of 2

WPS No.:

1215

Date: 11.10.97

Rev. No

:01

Date: 04.04.06

Supporting PQR No: 790 & 547



Application: Groove & fillet welding of 2.25Cr1Mo Steels attachments for non-pressure parts & Non Load Carrying applications with pre heat and without PWHT. JOINTS (QW-402) Joint Design

: Groove / Fillet as per drg.

Backing (Yes/No)

: With or without.


: Metal.


:

Non metallic/Others BASE METAL (QW-403) P. No: 5A

Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

Thickness Range

:-

P. No: 5A

Groove: 3.0 to 10 mm Pipe Dia. range: Others: Nil

Group No: 1

Fillet: Unlimited.

Unlimited.


E 9018 B3


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

4


POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All



Vertical up.


Nil.



WPS No.: 1215 Rev 01

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts : --do--

---do--


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root& H String; Others: string or Weave (3 Dia. max) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gouging /Grinding for second side welding Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Root Others -Do-

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


SMAW

E 9018-B3

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

--Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do-

-Do-

4.0

DCEP

140-190

N.A.

N.A.

Nil

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM/ WTC & WCMC

DGM / WTC & WCMC



Page 1 of 2

WPS No.:

1214

Date: 11.10.97

Rev. No

:00

Date: ------




Application: Groove & fillet welding of 2.25Cr1Mo Steels to carbon Steels with Preheat & without PWHT for Non- Pressure part applications only. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: With or without.


: Metal.


:


Group No: 1

to

P. No: 1/IS 2062

Spec. Type & Grade

: P5A + P1 / IS 2062 or equivalent.


: N.A.

Group No: 1 or 2

Thickness Range



Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 9018 B3


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

4


Deposited weld metal thickness range: Groove: 10.0 mm (Maximum 8 mm per pass) Fillet

: 10.0 mm (Maximum 8 mm per pass)

POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All



Vertical up.


Nil.



WPS No.: 1214

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A.

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String; Others: string or weave (3 Dia. max) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gauging /Grinding (where second side welding is done) Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


Root

SMAW

E 9018B3

2.50

DCEP

80-100

N.A.

N.A.

Nil

Others

SMAW

E9018B3

3.15

DCEP

100-140

N.A.

N.A.

Nil

Others

SMAW

E9018B3

4.00

DCEP

140-180

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

Sr. Manager / WTC




Page 1 of 2

WPS No.:

1213

Date: 06.10.97

Rev. No

:00

Date: ------

Supporting PQR No: 272, 517 & 700



Application: Groove & fillet welding of Carbon Steel attachments to Carbon steel attachments without PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: With or without.


: Metal.


:


Group No: 1or 2

to

P. No: 1 IS 2062

Spec. Type & Grade

: P1 + P1 / IS 2062


: N.A.

Group No: 1 or 2/--

Thickness Range



Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E7018

Specn. No. (SFA):

5.1


F. No.:

4

Flux Trade Names:

N.A

A. No.:

1

Consumable insert:

N.A.

Electrode |Flux (Class): N.A. Deposited weld metal thickness range Groove: 38.0 mm (maximum 8 mm per pass) Fillet: 38.0 mm (Maximum 8 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Preheat temp (min). : Up to 25 mm: Nil

Position of fillet:

All


Vertical up.

(Min. 10oC) o Above 25: 150 C Inter pass temp. (Max.): 300OC Pre heat maintenance: Nil Other:

Nil.



Page 2 of 2

WPS No.: 1213

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts : N.A.

See table


N.A.


N.A.


N.A.


N.A.


Root: String; Others: String or weave (3 Dia. max.)


N.A.




Air arc gauging/Grinding (where second side welding is done)

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

SMAW

E 7018

2.5

DCEP

60-90

N.A.

N.A.

Nil

All

SMAW

E 7018

3.15

DCEP

100-140

N.A.

N.A.

Nil

All

SMAW

E 7018

4.00

DCEP

140-180

N.A.

N.A.

Nil

Weld Layer

Process

All

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

Sr. Manager / WTC




Page 1 of 2

WPS No.:

1212

Date: 20.08.97

Rev. No

:00

Date: ------




Application: Groove & fillet welding of 2 ¼ Cr 1 Mo steel attachments to Stainless steel attachments and non pressure part applications with preheat and without PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: With or without.


: Metal.


:


Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No: 8

Group No: 1 or 2

Thickness Range

Pipe Dia. range:


Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 309

Specn. No. (SFA):

5.4


F. No.:

5

Flux Trade Names:

N.A

A. No.:

8

Consumable insert:

N.A.

Electrode |Flux (Class): N.A. Deposited weld metal thickness range Groove: 10.0 mm maximum (maximum 6.0 mm per pass) Fillet: 10.0 mm maximum (maximum 6.0 mm per pass) POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up / Down)

All. All Vertical up.

PREHEAT (QW-406) Preheat temp (min). : 150oC (on P5A side only) Inter pass temp. (Max.): 300OC Pre heat maintenance: Nil Other: Nil.



Page 2 of 2

WPS No.: 1212

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

--


Polarity: See table

Amps. (Range):

Volts : N.A.

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Grinding for second side welding. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Process Class

Travel speed range


Current Dia. mm

Type

Amps.

Volt Range

Root

SMAW

E 309

2.5

DCEP

60-90

N.A.

N.A.

Nil

Other layers

SMAW

E 309

3.15

DCEP

70-110

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

Sr. Manager / WTC




Page 1 of 2

WPS No.:

1211

Date: 26.07.97

Rev. No

:00

Date: ------




Application: Groove / Fillet welding pf CS Compounds. To 2 ¼ Cr 1Mo Steel for Non-Pr. Parts and Non IBR items with Preheat and PWHT. JOINTS (QW-402) Joint Design

: Groove / Fillet as per production drawing.

Backing (Yes/No)

: With or with out.


: Metal.


:


Group No: 1 or 2

to

P. No: 5A

Group No: 1

Spec. Type & Grade

: Carbon Steel to 2 ¼ Cr1Mo Steels


: N.A.

Thickness Range

Pipe Dia. range:

Groove: 4.8 – 46.0 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 7018

Specn. No. (SFA):


5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1

Electrode |Flux (Class): Nil.

Deposited weld metal thickness range Groove: 46.0 m max. (Max.6 mm per pass) Fillet: Unlimited (Max . 6 mm per pass) POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1211

PWHT (QW-407)

GAS (QW-408) o

Temp. Range:

650- 680 C

Time Range

1 Hour / 25 mm

Gases

Flow Rt.

Shielding N.A.

(Minimum 1 Hour ) Others:

Mix%

Nil

Trailing

N.A.

Backing

N.A.


Polarity: See table

Amps. (Range):

Volts: N.A.

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String; Others: String or Weave (3dia max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gouging / grinding for second side welding. Oscillation: Nil. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Class

Dia. mm

Type

Amps.

Volt Range

Process

Travel speed range


Current

All

SMAW

E 7018

2.5

DCEP

60-80

N.A.

N.A.

Nil

All

SMAW

E 7018

3.15

DCEP

80-110

N.A.

N.A.

Nil

All

SMAW

E 7018

4.0

DCEP

110-140

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(P.Sivasubramanian)

Sr. Manager / WTC




Page 1 of 2

WPS No.:

1210

Date: 21.07.97

Rev. No

:00

Date: ------




Application: Fillet welding of SS attachment to 2.25 Cr 1 Mo Steel attachments with Preheat and without PWHT. JOINTS (QW-402) Joint Design

: Fillet as per production drawing.

Backing (Yes/No)

: Yes


: Metal.


:


Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No: 8

Group No: 1or 2

Thickness Range

Pipe Dia. range Others: Nil

Groove: N.A.

Fillet: Unlimited.

Groove: N.A.

Fillet: Unlimited.


E 309


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


Deposited weld metal thickness range Groove: N.A. Fillet: 12.5 max. (Max. 6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

N.A.

Preheat temp (min). : 150oC (P5 side only)

Position of fillet:

All



Vertical up.


Nil.



WPS No.: 1210

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A.

See table


N.A.


N.A.


N.A.


N.A.


String N.A. Brushing/Chipping/Grinding Nil Nil. N.A. Single or Multiple Single N.A. Nil.

Others:

Nil Filler

Weld Layer

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E 309

2.5

DCEP

60-80

N.A.

N.A.

Nil

All

SMAW

E 309

3.15

DCEP

80-110

N.A.

N.A.

Nil

All

SMAW

E 309

4.0

DCEP

110-140

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(P.Sivasubramanian)

Sr. Manager / WTC




Page 1 of 2

WPS No.:

1209

Date: 08.11.93

Rev. No

:01

Date: 07.02.95




Application: Groove and Fillet welding of SS components. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: Metal.


:


Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No: 8

Group No: 1

Thickness Range


Groove: 1.6 to 50

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 347


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


Deposited weld metal thickness range Groove: Maximum 50.0 (Max. 6 mm per pass) Fillet: Maximum 50.0 (Max. 6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406) Nil (Min 10oC)

Position of Groove:

All.


Position of fillet:

All



Vertical up.


O

Other:

Nil.




PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: See table

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Grinding for Groove welds where second side welding is done Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: N.A. Others:

Nil Filler

Weld Layer

All -Do-Do-

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


SMAW

E347

2.5

DCEP

60-90

N.A.

N.A.

Nil

-Do

-Do

3.15

-Do-

70-110

N.A.

N.A.

Nil

-Do-

-Do-

4.0

DCEP

110-150

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager / WTC

SWE / WTC



Page 1 of 2

WPS No.:

1208

Date: 08.11.93

Rev. No

:00

Date: ------




Application: Butt and fillet welding of 2 ¼ Cr 1 Mo steel structures with PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: ---do---


:

Non metallic/Others BASE METAL (QW-403) P. No: ---

Group No: ---

to

P. No: ----

Spec. Type & Grade

: 2 ¼ Cr 1 Mo steel


: N.A.

Group No: ---

Thickness Range Base Metal

Groove: 200 max

Fillet: 200 max.

Weld Metal

Groove: 200 Max

Fillet: 200 Max.


Groove: N.A.

Fillet: N.A.


E9018B3


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

4


POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Position of fillet:

All


Vertical up.


o

150 C

Inter pass temp. (Max.): 300OC Pre heat maintenance: Nil Other:

Nil.



WPS No.: 1208

Page 2 of 2

GAS (QW-408)

PWHT (QW-407) o

Temp. Range:

680- 720 C

Time Range

1 Hr / 25 mm

Others:

Nil

Gases Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: --do--

--do---


N.A.


N.A.


N.A.


N.A.


Root: String; Others: String or Weave (3dia max.) N.A. Brushing/Chipping/Grinding Grinding (for second side welds). N.A. N.A. Single or Multiple Single N.A. Nil.

Others:

Nil Filler

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

SMAW

E9018B3

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do

-Do

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do-

-Do-

-Do-

4.0

DCEP

140-190

N.A.

N.A.

Nil

-Do-

-Do-

Do-

5.0

DCEP

200-240

N.A.

N.A.

Nil

Weld Layer

Process

All

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager / WTC

S.W.E./ WTC



Page 1 of 2

WPS No.:

1207

Date: 08.11.93

Rev. No

:02

Date: 06.09.05

Supporting PQR No: 543 & 544



Application: Groove / Fillet welding 1Cr 0.5 Mo / 1.25Cr 0.5Mo steels to 2.25Cr 1 Mo steels with PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)



: Metal.


:


Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No: 5A

Group No: 1

Thickness Range


Groove: 4.8 – 200.0 mm

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 8018-B2

Specn. No. (SFA):


5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

3


Deposited weld metal thickness range Groove: 200 mm max. (Max. 6 mm per pass) Fillet: Unlimited (Max . 6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Position of fillet:

All


Vertical up.

Others:

Nil


t = 13 : Nil t> 13: 150oC


Nil.



Page 2 of 2


PWHT (QW-407)

GAS (QW-408) o

Temp. Range:

695 ± 15 C

Time Range

2.5 min. / mm

Gases

(Minimum 30 minutes) Others:

Nil

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table Amps. (Range): --do--Tungsten Electrode type and size: Mode of metal transfer for (GMAW): Electrode wire feed speed range:

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---

Polarity: See table Volts(range): N.A. N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String; Others: String or Weave (3dia max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gouging / grinding for second side welding. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: Nil. Peening: N.A. Others:

Nil Filler

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

SMAW

E8018B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do

-Do

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do-

-Do-

-Do-

4.0

DCEP

140-190

N.A.

N.A.

Nil

Weld Layer

All

Process

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM / WTC & WCMC



Page 1 of 2

WPS No.:

1206

Date: 08.11.93

Rev. No

:01

Date: 06.09.05




Application: Groove and fillet welding of 1Cr 0.5Mo/ 1.25Cr 0.5Mo steel structure with PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)



: Metal.


:


Group No: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No: 4

Group No: 1

Thickness Range


Groove: 200 mm max.

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.


E 8018-B2

Specn. No. (SFA):

5.5


F. No.:

4

Flux Trade Names:

N.A

A. No.:

3

Consumable insert:

N.A.

Electrode |Flux (Class): N.A Deposited weld metal thickness range Groove: 200 mm max. (max.5 mm/pass) Fillet: Unlimited. POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Position of fillet:

All


Vertical up.


t = 13 mm : Nil t > 13 mm : 125OC


Nil.



Page 2 of 2


PWHT (QW-407)

GAS (QW-408)

Temp. Range:

655 ± 15 C

Time Range

2.5 minutes / mm

o

Others:

Gases Mix%

Flow Rt.

Shielding

N.A.

---

---

(min . 30minutes)

Trailing

N.A.

---

---

Nil

Backing

N.A.

---

---


Polarity: Refer table Volts: Refer table N.A. N.A. N.A.


N.A.


Root: String; Others: String or Weave (3dia max.) N.A. N.A. N.A. N.A. N.A. Single or Multiple Single N.A. N.A.

Others:

N.A. Filler

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E8018-B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

E8018-B2

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do-

-Do-

E8018-B2

4.0

DCEP

140-190

N.A.

N.A.

Nil

-Do-

-Do-

E8018-B2

5.0

DCEP

200-240

N.A.

N.A.

Nil

Weld Layer

Process

All

SMAW

-Do-

Class

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM / WTC & WCMC




1205

Date: 08.11.93

Rev. No

:02

Date: 05.02.01




Application: Butt and fillet welding of 1Cr/1.25Cr 0.25Mo steel structures with Preheat & without PWHT. JOINTS (QW-402) Joint Design

: Groove as per production drawing.

Backing (Yes/No)



: Metal.


:

Non metallic/Others BASE METAL (QW-403) P. No: P4

Group No: 1

to

P. No: 4

Group No: 1

Spec. Type & Grade

: 1Cr / 1.25Cr ½ Mo steel structures.


: Carbon content ≤ 0.15 %

Thickness Range

Pipe Dia. range:

Groove: 1.6 to 12

Fillet: Unlimited.

Groove: Unlimited.

Fillet: Unlimited.

Others: Nil FILLER METALS (QW-404) AWS No. (Class): E 8018-B2 Specn. No. (SFA):

5.5


F. No.:

4

Flux Trade Names:

N.A

A. No.:

3

Consumable insert:

N.A.

Electrode |Flux (Class): Nil. Deposited weld metal thickness range: Groove: 12 max. (6 mm per pass max.) Fillet: 12 max. (6 mm per pass max.) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Position of fillet:

All


Vertical up.


125oC


Nil.



Page 2 of 2


PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

--

--

Trailing

N.A.

--

--

Backing

N.A.

--

--


Polarity: See table

Amps. (Range):

Volts: See table

See table


N.A.


N.A.


N.A.


N.A.


String or Weave (3dia max.)


N.A.




Air arc gouging / grinding for second side welding.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Current

Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

Process


All

SMAW

E8018B2

2.5

DCEP

70-110

N.A.

N.A.

Nil

All

SMAW

E8018B2

3.15

DCEP

100-140

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

DGM / WTC

Sr. Welding Engineer /WTC



Page 1 of 2

WPS No.:

1204

Date: 08.11.93

Rev. No

:02

Date: 05.02.01




Application: Butt and fillet welding of carbon steel structures to 1Cr /1.25Cr 0.5Mo steel structure with preheat and without PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)



: Metal.


:

Non metallic/Others BASE METAL (QW-403) P. No: P1

Group No: 1 or 2

to

P. No: P4

Group No: 1

Spec. Type & Grade

: CS to 1Cr / 1.25Cr 0.5Mo steels.


: Carbon content ≤ 0.15 % for AS Carbon content ≤ 0.25% for CS

Thickness Range Groove: 1.6 to 12 Pipe Dia. range Others: Nil

Groove: Unlimited.

Fillet: Unlimited. Fillet: Unlimited.


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1


Deposited weld metal thickness range: Groove: 12 max. (6 mm per pass) Fillet: 12 max. (6 mm per pass) PREHEAT (QW-406)


N.A.

Position of fillet:

All


Vertical up.


125oC


Nil.




PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases Mix%

Flow Rt.

Shielding

N.A.

--

--

Trailing

N.A.

--

--

Backing

N.A.

--

--


Polarity: See table

Amps. (Range):

Volts: See table

See table


N.A.


N.A.


N.A.


N.A.


String or Weave (3dia max.)


N.A.




Air arc gouging / grinding for second side welding.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E7018

2.5

DCEP

70-110

N.A.

N.A.

Nil

All

SMAW

E7018

3.15

DCEP

100-140

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(R.Rajanarayanan)

DGM / WTC

Sr. Welding Engineer /WTC




1203

Date: 08.11.93

Rev. No

:00

Date: ----




Application: Fillet welding of carbon steel structure (up to 38 mm) without PWHT. JOINTS (QW-402) Joint Design

: Fillet as per drawing.

Backing (Yes/No)

: As per drg.


: --do--


:

Non metallic/Others BASE METAL (QW-403) P. No.: ---

Group No.: ---

to

P. No.: ---

Spec. Type & Grade

: Carbon steel.


: N.A.

Group No.: ---


Groove: N.A.

Fillet: 38 Max.

Weld Metal

Groove: N.A

Fillet: 8 Fillet Max.


Groove: N.A.

Fillet: N.A.


E 6013


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

2

Consumable insert:

N.A.

A. No.:

1


POSITION (QW-405)

PREHEAT (QW-406) Nil (Min 10oC)

Position of Groove:

N.A.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1203

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases Mix%

Flow Rt.

Shielding

N.A.

--

--

Trailing

N.A.

--

--

Backing

N.A.

--

--


Polarity: See table

Amps. (Range):

Volts: --do--

--do--


N.A.


N.A.


N.A.


N.A.


Root: String: Others: String or Weave (3dia max.)


N.A.




N.A.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E6013

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do-

-Do-

4.0

DCEP

140-190

N.A.

N.A.

Nil

Weld Layer

Process

All

SMAW

-Do-DO-

Class

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager / WTC

S.W.E. / WTC




1202

Date: 08.11.93

Rev. No

:01

Date: 06.09.05




Application: Butt and fillet welding of carbon steel structures (above 50mm) and tension members of any thickness with PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:

Non metallic/Others BASE METAL (QW-403) P. No.: ---

Group No.: ---

to

P. No.: ---

Spec. Type & Grade

: Carbon steel.


: N.A.

Group No.: ---


Groove: 200 Max.

Fillet: 200 Max.

Weld Metal

Groove: 200 Max.

Fillet: 200 Max.


Groove: N.A.

Fillet: N.A.


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1


POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

N.A.

Position of fillet:

All


Vertical up.

Others:

Nil


Up to 38: Nil Above: 100oC


Nil.



Page 2 of 2


PWHT (QW-407)

GAS (QW-408) o

Temp. Range:

610±15 C

Time Range

1 Hr / 25 mm

Others:

Nil

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table Amps. (Range): --do-Tungsten Electrode type and size: Mode of metal transfer for (GMAW): Electrode wire feed speed range:

Gases

Mix% Flow Rt.

Shielding

N.A

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---

Polarity: See table Volts: --do-N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String: Others: String or Weave (3dia max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Grinding for double side weld. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E7018

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

-Do

-Do

-Do-

4.0

DCEP

140-190

N.A.

N.A.

Nil

-Do

-Do

-Do-

5.0

DCEP

200-240

N.A.

N.A.

Nil

Weld Layer

Process

All

SMAW

-Do

Class

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM / WTC & WCMC



Page 1 of 2

WPS No.:

1201

Date: 08.11.93

Rev. No

:01

Date: 28.02.96




Application: Butt and fillet welding of carbon steel structures without PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)



: Metal.


:

Non metallic/Others BASE METAL (QW-403) P. No.: --

Group No.: --

to

P. No.: ---

Spec. Type & Grade

: I S 2062 or equivalent


: Carbon content ≤ 0.25 %

Group No.: ---

Thickness Range Groove: 4.8 to 50

Fillet: 4.8 to 50.

Pipe Dia. range Groove: Unlimited Others: Nil

Fillet: Unlimited


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1


Deposited weld metal thickness range Groove: 50 max. (6 mm per pass) Fillet : Unlimited. POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Position of fillet:

All


Vertical up.


Upto 38: Nil above 38: 150oC


Nil.



Page 2 of 2


PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: See table

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String or Weave (3dia max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gouging / grinding for second side welding. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Process

All

Amps.

Volt Range

Travel speed range


Current

Class

Dia. mm

Type

SMAW

E 7018

3.15

DCEP

100-140

N.A.

N.A.

N.A.

All

SMAW

E 7018

4.0

DCEP

140-190

N.A.

N.A.

N.A.

All

SMAW

E 7018

5.0

DCEP

160-210

N.A.

N.A.

N.A.

Approved by:

Prepared by:

(V.Ravindran)

(P.Sivasubramanian)

Manager / WTC

General Foreman/ WTC




1113

Date: 15.07.03

Rev. No

:00

Date: --




Application: Fillet welding of 9Cr 1 Mo 0.25V steel tubes/ pipe with 2.25 Cr 1 Mo attachments with Pre heat. Post heat & PWHT. JOINTS (QW-402) Joint Design

: Groove /Fillet as per drawing.

Backing (Yes/No)

: As per Production drawing.


: Metalic


:

Non metallic/Others BASE METAL (QW-403) P. No.: 5B

Group No.: 2

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 5A

Group No.: 1

Thickness Range Groove: N.A.

Fillet: Unlimited.

Pipe Dia. range Groove: N.A. Others: Nil

Fillet: Unlimited


E 9018-B3


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

4


Deposited weld metal thickness range:Groove: N.A. Fillet: Unlimited (Maximum 3 mm per pass) POSITION (QW-405)


Position of Groove:

All.


Position of fillet:

All



Vertical up.

Pre heat maintenance: Post heat at 220Deg C for 2 hours on completion of welding & on interruptions. Other:

Nil.



Page 2 of 2

WPS No.: 1113

PWHT (QW-407)

GAS (QW-408) o

Temp. Range:

730 – 760 C

Time Range

2.5 minutes / mm

Gases


Nil

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---



Amps. (Range):

Volts: N.A.

Refer table


N.A.


N.A.


N.A.


N.A.


Root: String: Others: String or Weave (3 Dia. max.)


N.A.




N.A.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E9018-B3

2.5

DCEP

70-100

N.A.

N.A.

N.A.

-Do

-Do-

3.15

-Do-

90-120

N.A.

N.A.

N.A.

-Do-

-Do-

4.0

-Do-

140-180

N.A.

N.A.

N.A.

Weld Layer

Process

All

SMAW

All All

Class

Approved by:

Prepared by:

(K.Narasimhan)

(R.Rajanarayanan)

DGM /WTC

DM / WTC




1112

Date: 28.01.02

Rev. No

:01

Date: 31.10.06




Application: Fillet welding of Non-Load carrying SS attachments to 9Cr1 Mo ¼ V Steel tubes and pipes. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per product drg.


: Metal.


:


Group No.: 2

to

P. No.: 8

Spec. Type & Grade

: SA213T91 or equivalent to P8


: Nil.

Group No.: 1/2


Fillet: Unlimited.

Pipe Dia. range Groove: N.A. Others: Nil

Fillet: Unlimited.


E 309


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


Deposited weld metal thickness range Groove: N.A. Fillet: Unlimited POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

N.A.

Position of fillet:

All


Vertical up.

Others:

Nil

Preheat temp (min). : side

200 deg C on T91

Inter pass temp. (Max.): 300OC Pre heat maintenance: 220 deg C for 2 hours during interruptions and on completion of welding. Other:

Nil.




PWHT (QW-407)

Page 2 of 2

GAS (QW-408) Gases

Temp. Range:

730 –760degC

Time Range

1 Hr /25 mm

Shielding N.A.

(min. 30 mts.)

Trailing

N.A.

Nil

Backing

N.A.

Others:

Mix%

Flow Rt.


Polarity: See table

Amps. (Range):

Volts: See table

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Nil. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others: Nil Filler Weld Layer

Process Class

Amps.

Volt Range

Travel speed range


Current Dia. mm

Type

All

SMAW

E309

2.5

DCEP

60-90

N.A.

N.A.

Nil

All

SMAW

E 309

3.15

DCEP

70-110

N.A.

N.A.

Nil

All

SMAW

E 309

4.0

DCEP

110-140

N.A.

N.A.

Nil

Prepared By:

Reviewed By:

Approved by:

(Kinkar.P.Narzary)

(Dr.K.P.Dhandapani)

(B.Natarajan)

Welding Engr / WTC

DGM/ WTC & WCMC

SDGM / WTC & WCMC



Page 1 of 2

WPS No.:

1111

Date: 07.02.95

Rev. No

:01

Date: 06.09.05

Supporting PQR No.: 516, 632



Application: Groove and Fillet welding of Carbon steel attachments to Carbon steel pipe / tubes with PWHT. JOINTS (QW-402) Joint Design

: groove / Fillet as per production drawing.

Backing (Yes/No)



: Metal.


:

Non metallic/Others BASE METAL (QW-403) P. No.: 1

Group No.: 1 or 2

to

P. No.: 1

Spec. Type & Grade

: Carbon Steel.


: N.A.

Group No.: 1 or 2

Thickness Range Groove: 4.8 to 200.

Fillet: Unlimited.

Pipe Dia. range Groove: Unlimited. Others: Nil

Fillet: Unlimited.


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1


Deposited weld metal thickness range Groove: 200 Max. (Maximum 8 mm per pass) Fillet: 200 Max. (Maximum 8 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All.

Position of fillet:

All


Vertical up.


t < 25 mm : Nil > 25 mm: 150oC


Nil



Page 2 of 2


PWHT (QW-407)

GAS (QW-408) o

Temp. Range:

610±15 C

Time Range

1 Hr / 25 mm

Others:

Nil


Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---

Polarity: See table Volts: See table N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String: Others: String or Weave (3dia max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc gouging / grinding wherever. Oscillation: N.A. Contact tube to work distance: N.A. Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Process Class

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

60-90

N.A.

N.A.

Nil

All

SMAW

E7018

2.5

DCEP

All

-Do

-Do-

3.15

-Do-

100-140

N.A.

N.A.

Nil

All

-Do-

-Do-

4.0

-Do-

140-180

N.A.

N.A.

Nil.

All

-Do

-Do

5.0

-Do-

180-220

N.A.

N.A.

Nil.

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM / WTC & WCMC




1110

Date: 08.11.93

Rev. No

:00

Date: --




Application: Welding of P8 tubes to P8 attachments JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:


Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 8

Group No.: 1 or 2


Groove: N.A.

Fillet: 12 Max.

Weld Metal

Groove: N.A.

Fillet: 12 Max.


Groove: N.A.

Fillet: 100 Max.


E 309


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


POSITION (QW-405)

PREHEAT (QW-406) o

Nil (Min 10 C)

Position of Groove:

N.A.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1110

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: --do--

--do--


N.A.


N.A.


N.A.


N.A.




N.A.




Nil.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E309

2.5

DCEP

60-100

N.A.

N.A.

Nil

-Do

-Do

-Do-

3.15

DCEP

90-130

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager / WTC

S.W.E. / WTC



Page 1 of 2

WPS No.:

1109

Date: 08.11.93

Rev. No

:00

Date: --




Application: Welding of P8 Tubes to P4/P5A attachments JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:


Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 4/5A

:Group No.: 1

Thickness Range Wetd Metat:

Groove: N.A.

Fillet: 12 mm Max.

Pipe Dia. range:

N.A.

Fillet: 100 max.


E 309


Specn. No. (SFA):

5.4

Flux Trade Names:

N.A

F. No.:

5

Consumable insert:

N.A.

A. No.:

8


POSITION (QW-405)

PREHEAT (QW-406) o

Nil (Min 10 C)

Position of Groove:

N.A.


Position of fillet:

All



Vertical up.


Nil.



WPS No.: 1109

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: --do--

--do--


N.A.


N.A.


N.A.


N.A.




N.A.




Nil.

Oscillation:

N.A.


N.A.


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process Class

Travel speed range


Current Dia. mm

Type

Amps.

Volt Range

All

SMAW

E309

2.5

DCEP

60-100

N.A.

N.A.

Nil

-Do

-Do

-Do-

3.15

DCEP

90-130

N.A.

N.A.

Nil

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager / WTC

S.W.E. / WTC




1108

Date: 08.11.93

Rev.

:01

Date: 04.04.06




Application: Welding of P5A Tubes / Pipes & P1 / P4 / P5A attachments. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:

Non metallic/Others BASE METAL (QW-403) P. No.: 5A

Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: P1/4/5A: Group No.: 1 or 2


Fillet: 8 mm Max.


Unlimited


E 9018-B3


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

4


POSITION (QW-405)

PREHEAT (QW-406) o

150 C

Position of Groove:

N.A.


Position of fillet:

All



Vertical up.


Nil.




PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table Polarity: See table Amps. (Range): :--do-Volts: --do-Tungsten Electrode type and size: N.A. Mode of metal transfer for (GMAW): N.A. Electrode wire feed speed range: N.A. Pulsing current (GTAW):

N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: String: Others: String or Weave (3 Dia. max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: N.A. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Process

All

SMAW

All

-DO-

Travel speed range


Current Dia. mm

Type

Amps.

Volt Range

E9018-B3

2.5

DCEP

70-100

N.A.

N.A.

Nil

-DO-

3.15

DCEP

100-140

N.A.

N.A.

Nil

Class

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM / WTC & WCMC



Page 1 of 2

WPS No.:

1107

Date: 06.11.93

Rev.

:02

Date: 04.04.06




Application: Welding of 1 ¼ Cr ½ Mo/ 1 Cr ½ Mo Tubes / Pipes & Carbon steel / 1 ¼ Cr ½ Mo /1 Cr ½ Mo/ 2 ¼ Cr 1 Mo attachments with pre heat & without PWHT.. JOINTS (QW-402) Joint Design

: Groove as per Production drg.

Backing (Yes/No)

: As per drg.


: Metal.


:


Group No.: 1

to

P. No.: 1

:Group No.:1 or 2

Spec. Type & Grade

: N.A.

4

:Group No: 1


: N.A.

5A

:Group No: 1


Fillet: 12 mm.


Unlimited


E8018-B2


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

3


Deposited weld metal thickness range Groove : N.A. Fillet : 12 mm max., (Max .4 mm / pass) POSITION (QW-405)

PREHEAT (QW-406) Preheat temp (min). : P4+ P1: 125OC:

Position of Groove:

All

Position of fillet:

All

P4 + P4: 125oC


Vertical up.

P4+ P 5A: 150oC Inter pass temp. (Max.): 300oC Post heat maintenance: Nil Other:

Nil.



Page 2 of 2


PWHT (QW-408)

GAS (QW-408)

Temp. Range

Nil

Time Range

Nil

Shielding N.A

Others:

Nil

Trailing

N.A

Backing

N.A

Gases


Mix%

Flow Rt.

Polarity: Refer table Volts: N.A. N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String / Weave (3 Dia. Max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Air arc Gouging / Grinding. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


All

SMAW

E 8018-B2

2.5

DCEP

70-100

N.A.

N.A.

N.A.

All

SMAW

E 8018-B2 3.15

DCEP

100-140

N.A.

N.A.

N.A.

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM / WTC & WCMC




1106

Date: 08.11.93

Rev.

:00

Date: --------




Application: Welding of P3 (1/2 Mo steel) tubes to P1/P4/ P5A attachments. JOINTS (QW-402) Joint Design

: Fillet as per drawing

Backing (Yes/No)

: As per drg.


: --do--


:


Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 1/4/5A

Group No.: 1 or 2

Thickness Range Base Metal:

Groove: N.A.

Fillet: 12 Max.

Weld Metal:

Groove: N.A.

Fillet : 12 Max.

Pipe Dia. range:

Groove: N.A.

Fillet: 100 Max.


E 7018A1


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

2

Electrode |Flux (Class): N.A. PREHEAT (QW-406)


N.A.

Preheat temp (min). : Nil (Min 10oC)

Position of fillet:

All

Inter pass temp. (Max.): 300oC


Vertical up.


Others:

Nil

Other:

Nil



WPS No.: 1106

PWHT (QW-408)

Page 2 of 2

GAS (QW-408) Gases

Temp. Range:

Nil

Time Range

Nil

Shielding

N.A.

Others:

Nil

Trailing

N.A

Backing

N.A.

Mix%

Flow Rt.


Polarity: See table

Amps. (Range):

Volts: --do--

--do---


N.A.


N.A.


N.A.


N.A.


Root : String, Others : String or Weave(3 dia. max.)


N.A.




Nil.

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process

All

SMAW

-Do-

-Do-

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E 7018A1

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

Class

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager /WTC

SWE / WTC




1105

Date: 08.11.93

Rev.

:02

Date: 04.04.06

Supporting PQR No.: 010 & 548



Application: Welding of Carbon steel Tubes / Pipes to Carbon steel / 1.25 Cr 0.5 Mo(P4) /2.25Cr 1 Mo (P5A) Steel attachments. JOINTS (QW-402) Joint Design

: Groove as per Production drawing.

Backing (Yes/No)

: As per Production drg.


: Metal.


:


Group No.: 1or 2

to

P. No.: P1

Group No.: 1 or 2

Spec. Type & Grade

: N.A.

P4

Group No: 1


: N.A.

P5A

Group No: 1


Fillet: 13 mm Max.


Unlimited.


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1



N.A.

Position of fillet:

All


Vertical up.

Others:

Nil

Preheat temp (min). : P1 + P1: 100Oc when t > 19 mm P1 + P4: 150oC P1 + P5A: 150oC Inter pass temp. (Max.): 300oC Pre heat maintenance: Nil Other:

Nil.




PWHT (QW-408)

Page 2 of 2

GAS (QW-408) Gases

Temp. Range:

Nil

Time Range

Nil

Shielding

N.A.

Others:

Nil

Trailing

N.A

Backing

N.A.

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table Amps. (Range): --do--Tungsten Electrode type and size: Mode of metal transfer for (GMAW): Electrode wire feed speed range:

Mix% Flow Rt.

Polarity: See table Volts: --do-N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Nil. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

SMAW

E 7018

2.5

DCEP

80-100

N.A.

N.A.

Nil

-Do-

-Do-

3.15

DCEP

90-130

N.A.

N.A.

Nil

Weld Layer

Process

All -Do-

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM/ WTC & WCMC




1104

Date: 08.11.93

Rev.

:00

Date: -------

Supporting PQR No.: 650, 651 652, 653



Application: Welding of SS attachments to P1/P3/P4/P5A Tube/Pipe JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:

Non metallic/Others BASE METAL (QW-403) P. No.: 1/3/4/5A

Group No.: 1or 2

Spec. Type & Grade

: N.A.


: N.A.

to P. No.: 8

Group No.: 1 or 2


Fillet: 8mm Max.


Unlimited.


E 7018-A1


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

2



N.A.

Position of fillet:

All


Vertical up.

Others:

Nil

Preheat temp (min). : P1/P3Nil (Min 10oC) P4: 120OC ; P5A: 150oC Inter pass temp. (Max.): 300oC Pre heat maintenance: Nil Other:

Nil.



Page 2 of 2

WPS No.: 1104

PWHT (QW-408)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding

N.A.

----

Others:

Nil

Trailing

N.A.

----

Backing

N.A.

----

Gases

Mix% Flow Rt.


Polarity: See table

Amps. (Range):

Volts: --do--

--do---


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root: - String; Others: - String / weave (3 Dia max) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back Gouging: Nil. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil. Others:

Nil Filler

Weld Layer

All -Do-

Process Class

Travel speed range


Current Dia. mm

Type

Amps.

Volt Range

SMAW

E 7018-A1

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

Approved by:

Prepared by:

(S.Ramesh)

(Dr.K.P.Dhandapani)

SDGM / WTC & WCMC

DGM/ WTC & WCMC




1103

Date: 08.11.93

Rev.

:00

Date: -------




Application: Welding of P5A radiographic plug to P5A pipes. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:


Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 5A

Group No.: 1


Groove: N.A.

Fillet: Unlimited.

Weld Metal

Groove: N.A.

Fillet: 9 max.

Pipe Dia. Range: Others: Nil

Groove: N.A.

Fillet: Unlimited


E 9018B3


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

3


POSITION (QW-405)

150oC

Position of Groove:

N.A.


Position of fillet:

All



Vertical up.


Others:

Nil

Other:

Nil.



Page 2 of 2

WPS No.: 1103

PWHT (QW-408)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding N.A.

Others:

Nil

Trailing

N.A

Backing

N.A.

Gases

Mix%

Flow Rt.


Polarity: See table

Amps. (Range):

Volts: --do--

--do---


N.A.


N.A.


N.A.


N.A.


Root: - String; Others: - String / weave (3 Dia. max)


N.A.




Nil.

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

NA.

Others:

Nil Filler

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

SMAW

E9018B3

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

Weld Layer

Process

All -Do-

Approved by:

Prepared by:

(V.Ravindran) Manager / WTC

(D.N.Ravishankar) S.W.E./ WTC

Date: 08/11/93

Date: 08/11/93




1102

Date: 08.11.93

Rev.

:00

Date: -------




Application: Welding of P4/P5A radiographic plug to P4 pipes. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:


Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 4/5A

Group No.: 1


Groove: N.A.

Fillet: Unlimited.

Weld Metal

Groove: N.A.

Fillet: 9 max.

Pipe Dia. range

Groove: N.A.

Fillet: Unlimited


E 8018B2


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

4

Consumable insert:

N.A.

F. No.: A. No.:

3


POSITION (QW-405)


Position of Groove:

N.A.


Position of fillet:

All



Vertical up.


Nil.



Page 2 of 2

WPS No.: 1102

PWHT (QW-408)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding

N.A.

Others:

Nil

Trailing

N.A.

Backing

N.A.

Gases

Mix%

Flow Rt.


Polarity: See table

Amps. (Range):

Volts: --do--

--do---


N.A.


N.A.


N.A.


N.A.




N.A.




Nil.

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

NA.

Others:

Nil Filler

Weld Layer

All -Do-

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

SMAW

E8018B2

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

Process

Approved by:

Prepared by:

(V.Ravindran) Manager / WTC

(D.N.Ravishankar) S.W.E./ WTC

Date: 08/11/93

Date: 08/11/93




1101

Date: 08.11.93

Rev.

:00

Date: -------




Application: Welding of radiographic plug to carbon steel pipes. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: --do--


:


Group No.: 1 or 2

to

Spec. Type & Grade

: N.A.


: N.A.

Thickness Range

P. No.: 1

Group No.: 1 or 2

:-

Base Metal

Groove: N.A.

Fillet: Unlimited.

Weld Metal

Groove: N.A.

Fillet: 9 max.

Pipe Dia. range:

Groove: N.A.

Fillet: Unlimited


E 7018


Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

4

Consumable insert:

N.A.

F. No.: A. No.:

1



N.A.

Position of fillet:

All


Vertical up.

Others:

Nil

Preheat temp (min). : Up to 25: Nil above 25: 100oC above 75 & Grc: 150oC Inter pass temp. (Max.): 300oC Pre heat maintenance: Nil Other:

Nil.



Page 2 of 2

WPS No.: 1101 GAS (QW-408)

PWHT (QW-408) Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A.

---

---

Backing

N.A.

----

---


Polarity: See table

Amps. (Range):

Volts: --do--

--do---


N.A.


N.A.


N.A.


N.A.




N.A.




Nil.

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

NA.

Others:

Nil Filler

Weld Layer

Process

All

SMAW -Do-

-Do-

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E7018

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

3.15

DCEP

100-140

N.A.

N.A.

Nil

Class

Approved by:

Prepared by:

(V.Ravindran)

(D.N.Ravishankar)

Manager / WTC

S.W.E./ WTC




1050

Date: 30.11.06

Rev.

:01

Date: 07.12.06


Welding Process: GTAW +SMAW


Application: Groove welding of 9Cr 1 Mo 0.25 V (T91/P91) steel Tubes/ Pipes for thickness up to 20.00 mm with pre heat & PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: GTAW: No; SMAW: Yes.


: GATW: Nil; SMAW: Metal.


:


Group No.: 2

to

P. No.: 5B

Spec. Type & Grade

: SA 213 T91 or equivalent.


:

Group No.: 2

Thickness Range Groove: 5.0 to 20.0mm

Fillet: N.A.

Pipe Dia. range: Unlimited Others: Nil FILLER METALS (QW-404) GATW

SMAW

AWS No. (Class):

E 90S-B9

E9018-B9/E9015-B9 Size of filler metal: Refer table

Specn. No. (SFA):

5.28

5.5

Flux Trade Names:

N.A

F. No.:

5

5

Consumable insert:

N.A.

A. No.:

6

4


Deposited weld metal thickness range Groove: 5-20 mm max. GTAW: 4.0 mm max. (Max.2 mm per pass) SMAW: Balance (Max.5 mm / pass) Fillet: Nil.

POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up / Down) Others:

All N.A. Vertical up. Nil

PREHEAT (QW-406) Preheat temp (min). : 220Oc Inter pass temp. (Max.): 350oC Pre heat maintenance: 220Oc (Min) Other: Insulate while cooling to 80-100degc and keep the job dry. Maintain at 80-100deg c for 1 hr. and conduct PWHT immediately.



GAS (QW-408)


760 ± 10oC

Time Range

2.5-mts/ mm (Thickness of weld) (Min.120 Minutes.)

Others:

Page 2 of 2


Rate of heating / cooling above 350oC 110O C/Hr maximum

Gases

Purity% Flow Rt.

Shielding

Argon

99.99

6-14 LPM

Trailing

N.A.

----

----

Backing

Argon

99.99

10-20 LPM

(For root welding)

ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC): See table Amps. (Range): See table Tungsten Electrode type and size: Mode of metal transfer for (GMAW): Electrode wire feed speed range: Pulsing current (GTAW):

Polarity: See table Volts: See table EWTh-2/EWCe-2, Ø 2.4 mm. N.A. N.A. Nil.


String 6/9 Brushing/Chipping/Grinding Nil. N.A N.A Multiple Single N.A. Nil.

Others:

Nil Filler

Current


Class

Dia. mm

Type

Amps.

Volt Range

Travel speed range

GTAW

ER 90S-B9

2.4

DCEN

70-100

N.A.

N.A.

Nil

Others Layers

SMAW

E9018-B9 Or E9015-B9

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

SMAW

-Do-

3.2

DCEP

90-130

N.A.

N.A.

Nil

-Do-

SMAW

-Do-

4.0

DCEP

140-160

N.A.

N.A.

Nil

Weld Layer

Process

Root

Prepared by:

Reviewed by:

Approved by:

(Kankar Narzary)

(Dr K.P.Dhandapani)

(B.Natarajan)


DGM/ WTC & WCMC

SDGM/ WTC & WCMC

Form No. 101 - 401 BHARAT HEAVY ELECTRICALS LIMITED TIRUCHIRAPPALLI-620014 WELDING TECHNOLOGY CENTRE


WPS. No. Rev. No

: 1049 : 01

Welding Process

:

Date Date

: 16/10/2006 : 22/09/2007

Page 1 of 2

Supporting PQR. No

1173

SMAW

Type : Manual (Auto/Semi-Auto/Manual/Machine) Application : Groove / Fillet welding of 9Cr.1Mo. ¼V ( P91 / T91 / F91 / Gr.91 ) steel components like Branches, Stubs , Attachments etc. to P91 steel pipes JOINTS ( QW – 402 ) Joint Design : Groove / Fillet as per drawing Backing ( Yes / No ) : As per drawing. Backing Material Type : Metal. (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 5B Group No. Spec. Type & Grade Chem. Analysis & Mech. Prop. Thickness Range Pipe Diameter Range Others

: 2 to P. No : N.A. : N.A. : Groove : 5.0 to 200.0mm : Groove : Unlimited : Nil

: 5B

Group No. : 2

Fillet : Unlimited Fillet : Unlimited

FILLER METALS ( QW – 404 ) AWS No. ( class ) : E9015 –B9 / 9018 – B9 Spec. No. ( SFA ) : 5.5 F. No. : 4 A. No. : 4 Deposited weld metal thickness range (t) Groove : 200.0mm Max. (Max.6 mm / pass) Fillet : Unlimited. (Max.6 mm / pass) Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : All Weld Progression.(Up/Down): Vertical up Others : Nil

Size of Filler metal : Refer Table Flux trade name : N.A. Electrode-flux (Class ) : N.A.. Consumable insert : N.A.

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 220 0C Interpass Temp. (Max) : 350 0C Preheat Maintenance :Till completion of welding. Postheat Maintenance: 220-280 0C for 2 hrs. on completion of welding. Others : Insulate till PWHT after cooling to room temp. & keep it dry.

BHEL Trichirappalli – 14

WPS. No. : 1049

PWHT ( QW – 407 ) Temp. Range : 760 ± 10 0C Time Range : 2.5minutes/mm (Min.120minutes) ROH / ROC : t upto 50mm : 110 0C / hr max. t 50 – 75mm : 75 0C / hr max. t above 75mm : 55 0C / hr max. Others : To be done within 72 Hrs. of welding completion.

GAS ( QW – 408 ) Gases Shielding : N.A. Trailing : N.A Backing : N.A.

ELECTRICAL CHARACTERISTICS (QW – 409 ) Current (AC / DC ) : Refer Table Amps ( Range ) : Refer Table Tungsten Electrode type & size : N.A. Mode of Metal transfer for GMAW : N.A. Electrode wire feed speed range : N.A. Pulsing current ( GTAW ) : N.A. TECHNIQUES ( QW – 409 ) String or weave bead Orifice or Gas cup size Initial and Interpass cleaning Method of Back Gouging Oscillation Contact tube to work distance Multiple or Single pass per side Multiple or Single Electrode Electrode Spacing Peening Others Weld Layer

Process

SMAW E9015-B9 or E9018-B9 Further SMAW --do---do-SMAW --do--

Polarity Volts

Mix/Purity % -------

Flow.Rt.(lpm ) -------

: Refer Table : Refer Table

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) : N.A. : Chipping / Brushing / Grinding : Grinding for double side welding : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root

Page 2 of 2 Revision : 01

Dia 2.6

3.2 4.0

Approved by (Dr.K.P.Dhandapani) DGM / WTC

Current Type DCEP

DCEP DCEP

Voltage range

Travel speed Range

N.A.

N.A.

Amps 70 - 100

90 - 130 140 - 160

N.A. N.A

N.A. N.A.

Others(Hot wire, Torch angle, ROL ) Nil

Nil Nil

Prepared by (S.Singaravelu) Manager / WTC




1048

Date: 13.10.06

Rev.

:00

Date: -----




Application: Welding of 1Cr ½ Mo / 1 ¼ Cr ½ Mo header to 2 ¼ Cr 1 Mo steel Nipples/Stubs with Pre heat and PWHT at 655 ± 15oC JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per Drawing.


: As per Drawing.


:


Group No.: 1

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 5A

Group No.: 1


Fillet: P4 : All; P5A :13mm Max.

Pipe Dia. range Groove: N.A.

Fillet: P4: All; P5A 102 mm Max.


E 8018-B2


Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

Nil.

A. No.:

3


Deposited weld metal thickness range: Groove: N.A. Fillet: 13 mm Max.

POSITION (QW-405)

PREHEAT (QW-406) 150Oc

Position of Groove:

N.A.


Position of fillet:

All



Vertical up.

Post heat maintenance: Nil.

Others:

Nil

Others

:

Nil.



Page 2 of 2

WPS No.: 1048

PWHT (QW-408)

GAS (QW-408)

Temp. Range:

655 ± 15oC

Time Range

1 Hr / 25mm (Min.1Hr.)

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

------

----

-----

Trailing

------

----

-----

Backing

-----

----

-----

Travel speed range


ELECTRICAL CHARACTERISTICS (QW-409) Current (AC/DC):

Refer table


Amps. (Range):

Refer table

Volts: Refer table


N.A.


N.A.


N.A.


N.A.


String


----




N.A.

Oscillation:

N.A


N.A


Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Current

Weld Layer

Process

All

SMAW

All

SMAW

-do-

All

SMAW

-do-

4.0

Class E 8018-B2

Prepared by:

(Kankar Narzary) Welding Engineer / WTC

Amps.

Volt Range

DCEP

70-100

N.A.

N.A.

Nil

DCEP

100-140

N.A.

N.A.

Nil

DCEP

140-190

N.A.

N.A.

Nil

Dia. mm

Type

2.5 3.15

Reviewed by:

Approved by:

(Dr K.P.Dhandapani)

(B.Natarajan)

DGM/ WTC & WCMC

SDGM/ WTC & WCMC



Form No. 101-401 WPS No.: 516

1047

Date: 20.09.2006

Rev.

:00

Date: -----

Supporting PQR No.: 00:1330



Application: Groove welding of 9Cr 1Mo 0.25 V Steel pipes to Stainless, Steel Thermo well with PWHT.

JOINTS (QW-402) Joint Design

: Groove As per Drawing.

Backing (Yes/No)

: With or without


: Metal


:

Non metallic/Others BASE METAL (QW-403) P. No.: 5 B Group No.: 2

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 8

Group No.: 1

Thickness Range Groove: 5.0 to 22mm

Fillet: Unlimited

Pipe Dia. range Groove: Unlimited

Fillet: Unlimited.

Others: Nil FILLER METALS (QW-404) GTAW

SMAW

AWS No. (Class):

ER Ni Cr-3

E Ni Cr Fe-3

Specn. No. (SFA):

5.14

F. No.:

43

A. No.:

Nil


5.11

Flux Trade Names:

N.A

43

Consumable insert:

Nil.

Nil


Deposited weld metal thickness range: Groove: GTAW: 5 mm Max: Balance: SMAW Fillet: Unlimited POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

F,H


220Oc

Position of fillet:

N.A.

Inter pass temp. (Max.):

350oC


N.A.

Post heat maintenance:

N.A.

Others

N.A.

Others:

Nil

:



Page 2 of 2

WPS No.: 1047

PWHT (QW-408)

GAS (QW-408)

Temp. Range:

745± 15oC

Time Range

2.5minutes/mm (Min.1Hr.)

Others:

Nil

Shielding

Gases

Mix%

Flow Rt.

Argon

99.95

8-14 LPM

---

---

99.95

4-6 LPM

Trailing Backing

Argon


Polarity: Refer table Volts: Refer table EW Ce-2, Ø 2.4 mm N.A. N.A.


N.A.


String 6/9. Brushing/Chipping/Grinding N.A. N.A N.A Multiple Single N.A. Nil.

Others:

Nil Filler

Weld Layer

Class

Dia. mm

Type

Amps.

Volt Range

Process

Travel speed range


Current

Root

GTAW

ERNiCr-3

2.4

DCEN

70-85

N.A.

N.A.

Nil

1 to 2

SMAW

ENiCrFe-3

2.5

DCEP

80-85

N.A.

N.A.

Nil

Further

SMAW

EniCrFe-3

2.5

DCEP

85-90

N.A.

N.A.

Nil

For Fillet weld use SMAW only

Prepared by:

Approved by:

(Dr.K.P.Dhadapani)

(B.Natarajan)

DGM/WCMC& WTC

SDGM/ WCMC & WTC




1046

Date: 30.08.06

Rev. No.:

00

Date: -----

Supporting PQR No.: 503, 883.


516


Application: Welding of Carbon Steel Pipe / Headers with Carbon Steel Nipple / Stubs with PWHT.


: Groove and Fillet as per Production Drg.

Backing (Yes/No)

: Yes


: Base Metal / P1 If removable type


:

Non metallic/Others Retainers

: Permitted P1 only

BASE METAL (QW-403) P. No.: 1

Group No.: 1 or 2

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 1

Group No.: 1 to 2


Fillet: Unlimited

Pipe Dia range Groove: Unlimited

Fillet: Unlimited.

Others: Nil FILLER METALS (QW-404) AWS No. (Class): E 7018-1 Specn. No. (SFA): 5.1 F. No.: 4 A. No.: 1 Deposited weld metal thickness range: -

Size of filler metal: See table Flux Trade Names: N.A Consumable insert: N.A. Electrode |Flux (Class): N.A.

Groove: 200 Max. (Maximum 6 mm per pass) Fillet: Unlimited (Maximum 6 mm per pass) POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up / Down) Others:

All All. Vertical up Nil

PREHEAT (QW-406) Preheat temp (min). :

a) t < or = 25 mm: Nil O (Min. 10 c) b) t > 25 mm and SA 106 Gr C > 19 mm 150oC Inter pass temp. (Max.): 300oC Post heat maintenance: Post heat at 150 for 2 Hrs for SA 106 Gr.C if t > 19 mm Others: : Nil



Page 2 of 2

WPS No.: 1046

PWHT (QW-408)

GAS (QW-408)

Temp. Range:

595 – 650oC

Time Range

2.5minutes/mm (Minimum 30 minutes)

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

--

----

Trailing

---

---

Backing

---

---


Refer table


Amps. (Range):

Refer table

Volts: Refer table


N.A.


N.A.


N.A.


N.A.


Root: String; Others: String or Weave (3dia.max.)


N.A.




Nil.

Oscillation:

N.A


N.A


Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process

All All All

Current Amps.

Volt Range

Travel speed range


DCEP

90-140

N.A.

N.A.

For stub t Less than or = 3.6 mm

DCEP DCEP

90-140 140-190

N.A. N.A.

N.A. N.A.

For stub t grater than 3.6 mm

Class

Dia. mm

Type

SMAW

E 7018-1

3.15

SMAW SMAW

E 7018-1 E 7018 –1

3.15 or 4.0

Approved by: Kinkar Narzary

Approved by (Dr.K.P.Dhandapani)

Welding Engineer/WTC

DGM/WTC/WCMC




1045

Date: 18.08.06

Rev. No.:

00

Date: -----




Application: Buildup of 2.25 Cr 1Mo Steel components with Pre heat, post heat & PWHT..


: Buildup as per requirements..

Backing (Yes/No)

: Yes.


: Metal.


:

Note: Bead overlap 50%.


Group No.: 1

to

P. No.: --

Group No.: --

Spec. Type & Grade

: ASTM A.217 WC9/SA 234 WP 22 CI 1 or equivalent


: N.A.

Thickness Range 5.0 to 200.0 mm Pipe Dia. range

Unlimited

Others: Nil FILLER METALS (QW-404)

AWS No. (Class):

E 9018 –B3

Size of filler metal:

See table

Specn. No. (SFA):

5.5

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

4


Deposited weld metal thickness range Buildup: Maximum 200 mm. (Maximum 6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Overlay:

Flat


200oC

Position of fillet:

N.A.


350oC


N.A.

Others:

Nil

Post heat maintenance: Post heat at 200Oc for 2 Hrs on completion of welding & interruptions. Others:

:

Nil



Page 2 of 2

WPS No.: 1045

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

695 ± 15oC

Time Range

2.5 min/ mm (Minimum 30 minutes)

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

--

----

Trailing

N.A.

---

---

Backing

N.A.

---

---


See table

Polarity: See table

Amps. (Range):

See table

Volts: See table


N.A.


N.A.


N.A.


N.A.


String


N.A.




Nil.

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

Nil.

Others:

Nil Filler

Weld Layer

Process

All

SMAW

-do-

-do-

Welding Engineer/ WTC

Volt Range

Travel speed range


Dia. mm

Type

E9018-B3

3.15

DCEP

100-140

N.A.

N.A.

Nil

E9018-B3

4.0

-do-

140-180

N.A.

N.A.

Nil

Class

Prepared By: (Kinkar Narzary)

Current

Reviewed By: (Dr.K.P.Dhndapani) DGM / WTC

Amps.

Approved By: (B.Natarajan) SDGM / WTC & WCMC




1044

Date: 13.06.2006

Rev. No.:

00

Date: -----




Application:

Groove and Fillet welding of Stainless Steel to Carbon Steel components without Pre heat and without PWHT.


: Groove and Fillet as per Drg.

Backing (Yes/No)

: As per Drg.


: -do-


:


Group No.: 1 or 2

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 8

Group No.: 1

Thickness Range Groove: 5.0 to 12.5 mm

Fillet: 12.5 mm Max.


Fillet: Unlimited.

Others: Nil FILLER METALS (QW-404)

AWS No. (Class):

EniCrFe-3


See table

Specn. No. (SFA):

5.11

Flux Trade Names:

N.A

F. No.:

43

Consumable insert:

N.A.

A. No.:

Nil


Deposited weld metal thickness range Groove: Maximum 12.5 mm (Max.4 mm per pass).

Fillet: Maximum 12.5 mm (Max.4 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

All


Nil

Position of fillet:

All.


300 C


Vertical up

Post heat maintenance:

Nil

Others:

Nil

Others:

Nil

:

o



Page 2 of 2

WPS No.: 1044

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Shielding

N.A.

--

----

Others:

Nil

Trailing

N.A.

---

---

Backing

N.A.

---

---

Gases

Mix%

Flow Rt.


See table

Polarity: See table

Amps. (Range):

See table

Volts: See table


N.A.


N.A.


N.A.


N.A.


String


N.A.



Method of back Grinding:

By Grinding

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

Nil.

Peening:

N.A.

Others:

Nil Filler

Weld Layer

All

Process Class SMAW

EniCrFe-3

Approved by: (S.Ramesh) SDGM / WTC & WCMC

Travel speed range


N.A.

Nil

Current Dia. mm

Type

Amps.

Volt Range

3.15

DCEP

70-110

N.A.

Prepared: (Dr.K.P.Dhandapani)

DGM / WTC & WCMC



WPS. No. Rev. No

: 1043 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 08/04/2006 : 22/09/2007

Page 1 of 2

Supporting PQR. No

1329

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove, Fillet & Socket welding of Carbon steel pipe to 2¼ Cr.1Mo.steel Pipes with preheat & without PWHT.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 1 Group No. Spec. Type & Grade Chem. Analysis & Mech. Prop. Thickness Range Pipe Diameter Range Others

: Groove as per drawing : GTAW : No ; SMAW : Yes. : GTAW : Nil ; SMAW : Metal.

: 1 or 2 to P. No : Carbon steel to 2¼ Cr.1Mo.steels. : N.A. : Groove : 1.5 to 8.0mm : Groove : Max. Ø102mm : Nil

: 5A

Group No. : 1

Fillet : Max. 13mm Fillet : Unlimited

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 12.0mm Max. GTAW : 4.0mm.Max.; SMAW: Balance (Max.5mm / pass) Fillet : Unlimited (Max.5mm / pass) Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All. Position(s) of Fillet : All. Weld Progression.(Up/Down): Vertical up

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 150 0C Interpass Temp. (Max) : 300 0C Preheat Maintenance : Nil

Others

Others

: Nil

: Slow cool


WPS. No. : 1041

PWHT ( QW – 407 )

GAS ( QW – 408 ) Gases Shielding : Argon Trailing : N.A Backing : N.A.

Temp. Range : Nil Time Range :

Nil

Others

Nil

:


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 10 -----

ELECTRICAL CHARACTERISTICS (QW – 409 ) Current (AC / DC ) : Refer Table Polarity : Refer Table Amps ( Range ) : Refer Table Volts : Refer Table Tungsten Electrode type & size : EW Th-2 / EW Ce-2 Ø 2.4mm Mode of Metal transfer for GMAW : N.A. Electrode wire feed speed range : N.A. Pulsing current ( GTAW ) : N.A. TECHNIQUES ( QW – 409 ) String or weave bead Orifice or Gas cup size Initial and Interpass cleaning Method of Back Gouging Oscillation Contact tube to work distance Multiple or Single pass per side Multiple or Single Electrode Electrode Spacing Peening Others Weld Layer

Process

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-1 --do-- SMAW E7018-1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP

Voltage range Amps 60 – 110 N.A. 60 - 100 N.A. 90 - 140 N.A

Travel speed Range N.A N.A N.A

Others(Hot wire, Torch angle, ROL ) Nil Nil Nil

Prepared by (Dr.K.P.Dhandapani) DGM / WTC

(S.Singaravelu) Manager / WTC




1042

Date: 28.12.2005

Rev. No.:

00

Date: -----




Application:

Welding of Carbon Steel Pipes/Headers with Carbon Steel Nipples/ Nozzles etc with PWHT.


: Groove and Fillet as per Drg.

Backing (Yes/No)

: Yes


: Metal


Group No.: 1 or 2

to

Spec. Type & Grade

: N.A.


: N.A.

P. No.: 1

Group No.: 1 to 2


Fillet: Unlimited


Fillet: Unlimited


E7018-1


See table

Specn. No. (SFA):

5.1

Flux Trade Names:

N.A

F. No.:

4

Consumable insert:

N.A.

A. No.:

1


Deposited weld metal thickness range Groove: 49.0 mm (Maximum 6 mm per pass)

Fillet: Unlimited (Maximum 6 mm per pass) POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up / Down) Others:

All N.A. Vertical up Nil

PREHEAT (QW-406) Preheat temp (min). : For thickness < 25 mm: Nil > 25 mm & P1 Gr 2> 19 mm: 150oC Inter pass temp. (Max.): 300oC Post heat maintenance: post heat at 150deg C for P1Gr2>19mm for 2 Hrs. Others: : Nil



WPS No.: 1042

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

610±15deg C

Gases

Mix%

Flow Rt.

Time Range

1 Hr./25 mm (min. 30 mts)

Shielding

N.A.

--

----

Others:

Nil

Trailing

N.A

---

---

Backing

N.A.


See table

Polarity: See table

Amps. (Range):

See table

Volts: N.A.


N.A.


N.A.


N.A.


N.A.


Root: String; Others: String or Weave (3 Dia. Max.)


N.A.




N.A.

Oscillation:

N.A


N.A


Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Weld Layer

Process

Root & Capping

Current

Amps.

Volt Range

Travel speed range


DCEP

90-140

N.A.

N.A.

Nil

4.0

-do-

140-190

N.A.

N.A.

Nil

5.0

-do-

180-250

N.A.

N.A.

Nil

Class

Dia. mm

Type

SMAW

E 7018-1

3.15

Others

-do-

-do-

-do-

-do-

-do-

Approved by: (S.Ramesh) SDGM/WTC & WCMC

Prepared: (Dr.K.P.Dhandapani)

DGM / WTC & WCMC



WPS. No. Rev. No

: 1041 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 27/09/05 : 22/09/07

Page 1 of 2

Supporting PQR. No

526

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding in Carbon steel to 2¼ Cr.1Mo.steel components with preheat & with PWHT.


: Groove as per drawing : No. : No.

: 1 or 2 to P. No : Carbon steel to 2¼ Cr.1Mo.steels. : N.A. : Groove : 5.0 to 46.0mm : Groove : Unlimited : Nil

: 5A

Group No. : 1

Fillet : N.A Fillet : N.A.

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 46.0mm Max. GTAW :5.0mm.Max.; SMAW: Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1041

PWHT ( QW – 407 )


Temp. Range : 695 ± 15 0C Time Range :

2.5minutes/mm (Min.30minutes) : Nil

Others


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----


Process

Filler metal Class

Root Further --do---do---do--

GTAW SMAW SMAW SMAW SMAW

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) : 6 / 9 / 13 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

ER70S-A1 E7018-1 E7018-1 E7018-1 E7018-1

Current

Dia 2.4 2.5 3.15 4.0 5.0

Approved by

Type DCEN DCEP DCEP DCEP DCEP

Voltage range Amps 70 - 130 N.A. 70 - 100 N.A. 100 -140 N.A 140 -190 N.A 180 -260 N.A

Travel speed Range N.A N.A N.A N.A N.A

Others(Hot wire, Torch angle, ROL ) Nil Nil Nil Nil Nil






1040

Date: 19.08.05

Rev. No.:

00

Date: -----




Application: Groove and fillet welding of 1Cr 0.5Mo/1.25Cro.5Mo steel Components of Pr. Vessels / Heat Exchangers etc. With PWHT and without impact. JOINTS (QW-402) Joint Design

: Groove and fillet as per drg.

Backing (Yes/No)

: As per drg.


: Metal

Metal/Non fusing metal/ Non metallic/Others BASE METAL (QW-403) P. No.: 4 Group No.: 1 Spec. Type & Grade Chem. Analysis & Mech. Prop Thickness Range Groove: 5.0 TO 200 Pipe Dia. range Groove: Unlimited Others: Nil

to : N.A. : N.A.

P. No.: 4

Group No.: 1

Fillet: Unlimited Fillet: Unlimited


E 8018-B2

Specn. No. (SFA):

5.5


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

3

Consumable insert:

N.A.

Electrode |Flux (Class): N.A. Deposited weld metal thickness range Groove: 200max. (Max. 6 mm per pass) Fillet: Unlimited POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up / Down) Others:

All All Up hill only. Nil

PREHEAT (QW-406) Preheat temp (min). : 150oC O Inter pass temp. (Max.): 300 C Pre heat maintenance: Nil Others: : Nil



Page 2 of 2

WPS No.: 1040

PWHT (QW-407)

GAS (QW-408) 650-670Oc

Temp. Range: Time Range

1Hr/25mm (Min .0.5 hr)

Others:

Nil

Gases Mix%

Flow Rt.

Shielding

N.S.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


See table

Polarity: See table

Amps. (Range):

See table

Volts: See table


N.A.


N.A.


N.A.


Nil.

TECHNIQUES (QW-410) String or Weave Bead: Orifice or Gas cup size: Initial and inter pass cleaning: Method of back gouging: Oscillation: Contact tube to work distance: Multiple or single pass (per side): Multiple or single electrode: Electrode spacing: Peening:

String or Weave (3 Dia Max.) N.A. Brushing/Chipping/Grinding Nil N.A N.A Single or Multiple Single N.A. Nil.

Others:

Nil Filler

Weld Layer

Process

Amps.

Volt Range

Travel speed range


Current

Class

Dia. mm

Type

All

SMAW

E8018-B2

2.5

DCEP

70-100

N.A.

N.A.

N.A.

-DO-

SMAW

E8018-B2

3.15

DCEP

100-130

N.A.

N.A.

N.A.

-DO-

SMAW

E8018-B2

4.0

DCEP

140-180

N.A.

N.A.

N.A.

-DO-

SMAW

E8018-B2

5.0

DCEP

180-240

N.A.

N.A.

N.A.

Approved by: (S.Ramesh) SDGM/ WTC&WCMC

Prepared: (Dr.K.P.Dhandapani) DGM/WTC&WCMC



WPS. No. Rev. No

: 1039 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 30/10/2004 : 22/09/2007

Page 1 of 2

Supporting PQR. No

507

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of Carbon steel tubes with ½Mo. tubes with PWHT.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : Group No. Spec. Type & Grade Chem. Analysis & Mech. Prop. Thickness Range Pipe Diameter Range Others

: As per drawing : GTAW : No ; SMAW : Yes. : GTAW : Nil ; SMAW : Metal.

: 1 or 2 to P. No : 3 Group No. : 1 or 2 : Carbon steel + ½ Mo. Steel or equivalent : N.A. : Groove : 1.5 to 18.0mm Fillet : N.A : Groove : Unlimited Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –A1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 2 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 18.0mm Max. GTAW :4.0mm.Max.;SMAW:Balance (Max.3mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove

Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up

PRE HEAT ( QW – 406 ) Preheat Temp.(min) :t < 13mm : Nil (min 100C ) t > 13mm :1500C) Interpass Temp. (Max) : 300 0C Postheat Maintenance : Nil

Others

Others

: All

: Nil

: Nil


WPS. No. : 1039

PWHT ( QW – 407 )

GAS ( QW – 408 ) Gases Mix/Purity % Flow.Rt.(lpm ) Shielding : Argon 99.99 6 - 12 Trailing : N.A ----Backing : N.A. -----

Temp. Range : 620 – 650 0C Time Range : 2.5 minutes/mm ( Min.30 minutes ) Others

:


Nil


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) : 6 / 9. : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-A1 --do-- SMAW E7018-A1

Current

Dia 2.4 2.5 3.15

Approved by

Voltage range

Type

Amps

DCEN DCEP DCEP

60 - 90 N.A. 70 - 100 N.A. 90 -130 N.A







WPS. No. Rev. No

: 1038 : 03

Welding Process

: GTAW + SMAW

Application

Date Date

: 31/07/2003 : 22/09/2007

Page 1 of 2

Supporting PQR. No

904 & 1099

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of 2 ¼Cr.1Mo.steel (P22/T22/F22/Gr22) to 9Cr.1Mo. ¼V steel ( P91 / T91 / F91 / Gr.91 ) for site fabrication with preheat & with PWHT. ( For t < 20mm only )

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 5A Group No. Spec. Type & Grade Chem. Analysis & Mech. Prop. Thickness Range Pipe Diameter Range Others



: 5B

Group No. : 2


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER90S – B3 E9018 –B3 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 4 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 20.0mm Max. GTAW : 4.0mm.Max.( Max. 2 mm / pass ) SMAW : Balance (Max.5 mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 220 0C Interpass Temp. (Max) : 350 0C Preheat Maintenance : Nil Others : After welding cool the joint to 80 – 100 0C & hold it for 1 hour minimum, before PWHT.



WPS. No. : 1038

PWHT ( QW – 407 ) Temp. Range : 745 ± 15 0C Time Range : 2.5minutes/mm (Min.60minutes) Others : Induction heating ROH ( Above 350 0C ) : 120 0C / hr max. ROC ( Upto 350 0C ) : 120 0C / hr max.

GAS ( QW – 408 ) Gases Mix/Purity % Flow.Rt.(lpm ) Shielding : Argon 99.99 8 - 14 Trailing : N.A ----Backing : Argon . 99.99 8 - 14 ( For Root welding )


Process

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER90S-B3 Further SMAW E9018-B3 --do-- SMAW E9018-B3 --do-- SMAW E9018-B3

Current

Dia 2.4 2.5 3.15 4.0

Approved by

Type DCEN DCEP DCEP DCEP

Voltage range Amps 70 - 100 N.A. 70 - 100 N.A. 90 -120 N.A 140 -180 N.A

Travel speed Range N.A N.A N.A N.A

Others(Hot wire, Torch angle, ROL ) Nil Nil Nil Nil





WPS. No. Rev. No

: 1036 : 05

Welding Process

: GTAW

Application

Date Date

: 26/11/2002 : 22/09/2007

Page 1 of 2

Supporting PQR. No

1257

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of 9 Cr.1Mo. ¼V (T91) steel tubes with preheat & with PWHT. for site applications.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 5B Group No. Spec. Type & Grade Chem. Analysis & Mech. Prop. Thickness Range Pipe Diameter Range Others

: Groove as per drawing : As per drawing. : Metal

: 2 to P. No : SA 213 T91 or equivalent : N.A. : Groove : 1.5 to 11.0mm : Groove : Unlimited : Nil

: 5B

Group No. : 2


FILLER METALS ( QW – 404 ) AWS No. ( class ) : ER90S – B9 Spec. No. ( SFA ) : 5.28 F. No. : 6 A. No. : -Deposited weld metal thickness range (t) Groove : 11.0mm Max. (Max.3mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

Size of Filler metal : Refer Table Flux trade name : N.A. Electrode-flux (Class ) : N.A.. Consumable insert : N.A.

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 220 0C Interpass Temp. (Max) : 350 0C Preheat Maintenance : Nil Others : After welding cool the joint to 80 – 100 0C & hold it for ½ hour minimum,before PWHT.



WPS. No. : 1036

PWHT ( QW – 407 ) Temp. Range : 750 - 770 0C Time Range : 2.5minutes/mm (Min.90minutes) Others : Induction heating ROH (Above 350 0C) : 120 0C / Hr. Max. ROC (Upto 350 0C) : 120 0C / Hr. Max.

GAS ( QW – 408 ) Gases Mix/Purity % Flow.Rt.(lpm ) Shielding : Argon 99.99 6 - 14 Trailing : N.A ----Backing : Argon 99.99 10 - 25 ( For Root welding )

ELECTRICAL CHARACTERISTICS (QW – 409 ) Current (AC / DC ) : Refer Table Polarity : Refer Table Amps ( Range ) : Refer Table Volts : Refer Table Tungsten Electrode type & size : EW Th-2 / EW Ce-2 Ø 2.4mm Mode of Metal transfer for GMAW : N.A. Electrode wire feed speed range : N.A. Pulsing current ( GTAW ) : N.A. TECHNIQUES ( QW – 409 ) String or weave bead Orifice or Gas cup size Initial and Interpass cleaning Method of Back Gouging Oscillation Contact tube to work distance Multiple or Single pass per side Multiple or Single Electrode Electrode Spacing Peening Others

Weld Layer

Process

Filler metal Class

All Layers

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : For preheating & PWHT resistance heating technique can be used

GTAW ER90S-B9

Current

Dia 2.4

Approved by

Voltage range

Type

Amps

DCEN

80 - 120

N.A.

Travel speed Range N.A

Others(Hot wire, Torch angle, ROL ) Nil





WPS. No. Rev. No

: 1035 : 03

Welding Process

: GTAW + SMAW

Application

Date Date

: 17/04/99 : 22/09/07

Page 1 of 2

Supporting PQR. No

904

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of 2 ¼Cr.1Mo.steel (P22/T22/F22/Gr22) to 9Cr.1Mo. ¼V steel ( P91 / T91 / F91 / Gr.91 ) for site fabrication with preheat & with PWHT. ( For t > 20mm )



: 1 to P. No : 5B : N.A. : N.A. : Groove : 20.0 to 200.0mm : Groove : Unlimited : Nil

Group No. : 2


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER90S – B3 E9018 –B3 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 4 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200.0mm Max. GTAW : 5.0mm.Max.( Max. 3mm / pass ) SMAW : Balance (Max.5 mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 220 0C Interpass Temp. (Max) : 350 0C Preheat Maintenance : Nil Others : After welding cool the joint to 80 – 100 0C & hold it for 1 hour minimum, before PWHT.



WPS. No. : 1035

PWHT ( QW – 407 ) Temp. Range : 745 ± 15 0C Time Range : 2.5minutes/mm (Min.60minutes) Others : Induction heating ROH / ROC :Above 350 0C as below t upto 50mm : 110 0C / hr max. t 50 – 75mm : 75 0C / hr max. t above 75mm : 55 0C / hr max.

GAS ( QW – 408 ) Gases Mix/Purity % Shielding : Argon 99.99 Trailing : N.A --Backing : Argon . 99.99 ( For Root welding )

Flow.Rt.(lpm ) 8 - 14 --10 - 25


Process


Filler metal Class


Current

Dia 2.4 2.5 3.15 4.0

Approved by


Voltage range Amps

Travel speed Range

70 - 100 N.A. 70 - 100 N.A. 90 -120 N.A 140 -180 N.A

N.A N.A N.A N.A






WPS. No. Rev. No

: 1034 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 30/03/2000 : 22/09/2007

Page 1 of 2

Supporting PQR. No

1173

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of 9 Cr.1Mo.¼V ( P91 / F91 / Gr.91 etc. ) steel components for site fabrication with preheat & with PWHT.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 5B Group No. Spec. Type & Grade Chem. Analysis & Mech. Prop. Thickness Range Pipe Diameter Range Others


: 2 to P. No : 5B : 9 Cr.1Mo.¼V or equivalent : N.A. : Groove : 20.0 to 200.0mm : Groove : Unlimited : Nil

Group No. : 2


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER90S – B3 E9015 –B9 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 5 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200.0mm Max. GTAW : 3.0mm.Max.( One pass only ) SMAW : Balance (Max.4mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 220 0C Interpass Temp. (Max) : 350 0C Preheat Maintenance : Nil Others : After welding cool the joint to 80 – 100 0C & hold it for 1 hour minimum,before PWHT.



WPS. No. : 1034

PWHT ( QW – 407 ) Temp. Range : 745 ± 15 0C Time Range : 2.5minutes/mm (Min.60minutes) Others : Induction heating ROH / ROC :Above 350 0C as below t upto 50mm : 110 0C / hr max. t 50 – 75mm : 75 0C / hr max. t above 75mm : 55 0C / hr max.

GAS ( QW – 408 ) Gases Mix/Purity % Shielding : Argon 99.99 Trailing : N.A --Backing : Argon 99.99 ( For Root welding )

Flow.Rt.(lpm ) 6 - 14 --10 - 25


Process


Filler metal Class


Current

Dia 2.4 2.5 3.2 4.0

Approved by


Voltage range Amps

Travel speed Range

70 - 100 N.A. 70 - 100 N.A. 90 -130 N.A 140 -160 N.A

N.A N.A N.A N.A






WPS. No. Rev. No

: 1033 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 17/04/99 : 22/09/07

Page 1 of 2

Supporting PQR. No

296

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of P4 steel to P1 Group 1 carbon steel with PWHT.


: Groove as per drawing : Yes. : Metal.


: 4

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200.0mm Max. GTAW :5.0mm.Max.; SMAW: Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil

BHEL Trichirappalli – 14 PWHT ( QW – 407 )



2.5minutes/mm (Min.60minutes) : Nil

Others


WPS. No. : 1033


Process

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) : 6 / 9 / 13 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-1 --do-- SMAW E7018-1 --do-- SMAW E7018-1

Current

Dia 2.4 2.5 3.15 4.0

Approved by


Voltage range Amps

Travel speed Range

90 - 120 N.A. 70 - 100 N.A. 100 -140 N.A 140 -200 N.A

N.A N.A N.A N.A







1032

Date: 19.03.98

Rev. No.:

00

Date: ------


Welding Process: GTAW + SMAW


Application: Groove welding of type 316 Stainless Steel components. JOINTS (QW-402) Joint Design

: Groove as per production Drawing

Backing (Yes/No)

: GTAW : No ; SMAW: Yes


: GTAW : Nil ; SMAW : Metal


Group No.:

1

Spec. Type & Grade

: N.A


: N.A

To

P. No.: 8

Group No.: 1

Thickness Range Groove: 1.6 to 50.0

Fillet: N.A.


Fillet: N.A.


ER347, E316

Specn. No. (SFA):

5.9,

5.4


See table

F. No.:

6,

5

Flux Trade Names:

N.A

A. No.:

8

Consumable insert:

Nil

Electrode |Flux (Class): N.A. Deposited weld metal thickness range Groove: 50.0 Max. {GTAW: Max: 5.0; SMAW: Balance} (max: 6 mm per pass) Fillet: N.A. PREHEAT (QW-406)

POSITION (QW-405)

Nil (Min.10oC)

Position of Groove:

All


Position of fillet:

N.A.



Vertical up

Pre heat maintenance: Nil Others

:

Nil



Page 2 of 2

WPS No.: 1032

PWHT (QW-407)

GAS (QW-408)

Temp. Range: Nil

Gases

Time Range

Nil

Shielding

N.A.

Others:

Nil

Trailing

N.A

Backing

N.A.

Mix% -----

Flow Rt. 6-10 LPM ---

---

6-7 LPM

Travel speed range



Polarity: See table

Amps. (Range):

Volts: See table

See table


EWTh-2; Dia. 2.4


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: 6/9 Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Current

Class

Dia. mm

Type

Amps.

Volt Range

GTAW

ER 347

2.4

DCEN

60-90

N.A.

N.A.

Nil

All

SMAW

E 316

2.5

DCEP

60-90

N.A.

N.A.

Nil

-Do-

-Do-

-Do-

3.15

-Do-

90-130

N.A

N.A

Nil

Weld Layer

Process

Root

Approved by: (V. Ravindran) Sr. Manager /WTC

Prepared: (P. Sivasubramanian) Welding Engineer/WTC




1031

Date: 08.10.97

Rev. No.:

00

Date: ------

Supporting PQR No.: 644.



Application: Fillet & Socket welding of P8 stub material to CS Stub/Tube material without PWHT. JOINTS (QW-402) Joint Design

: Fillet as per Drawing.

Backing (Yes/No)

: Yes


: Metal


Group No.:

1 or 2 to

Spec. Type & Grade

: N.A


: N.A

P. No.: 1

Group No.: 1 or 2

Thickness Range Groove: N.A

Fillet: Unlimited.

Pipe Dia. range Groove: N.A.

Fillet: Unlimited.


EniCrFe-3

Specn. No. (SFA):

5.11


See table

F. No.:

43

Flux Trade Names:

N.A

A. No.:

Nil

Consumable insert:

N.A.

Electrode |Flux (Class): N.A. Deposited weld metal thickness range Groove: N.A. Fillet: 9.0 mm max. (Max. 6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406) o

: Nil (Min.10 C)

Position of Groove:

N.A.

Preheat temp (min).

Position of fillet:

All.

Inter pass temp. (Max.) : 300oC


Vertical up

Pre heat maintenance

: Nil

Others

: Nil



Page 2 of 2

WPS No.: 1031

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

Root

SMAW

Others

-Do-

Class EniCrFe-3 -Do-

Approved by: (V.Ravindran) Sr.Manager /WTC

Travel speed range


Current Dia. mm

Type

Amps.

Volt Range

2.5

DCEP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

Prepared: (P.Sivasubramanian) Welding Engineer/WTC




1030

Date: 08.10.97

Rev. No.:

01

Date: 04.04.06




Application: Fillet & Socket welding P4 Tubes/Pipes with Pre heat and without PWHT. JOINTS (QW-402) Joint Design

: Fillet as per Drawing.

Backing (Yes/No)

: Yes


: Metal


Group No.:

1

to

Spec. Type & Grade

: N.A


: N.A

P. No.: 4

Group No.: 1


Fillet: 13 mm max.

Pipe Dia. range Groove: Unlimited Others: Nil FILLER METALS (QW-404) AWS No. (Class):

E 8018-B2

Specn. No. (SFA):

5.5


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

3

Consumable insert:

Nil.

Electrode |Flux (Class): N.A. Deposited weld metal thickness range Groove: N.A. Fillet: 13 mm max. (Max.6 m per pass) PREHEAT (QW-406)

POSITION (QW-405)

120oC

Position of Groove:

N.A.


Position of fillet:

All.



Vertical up

Post heat maintenance: Nil Others

:

Nil



Page 2 of 2


PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table Volts: N.A N.A. N.A. N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: Root & H: String: Others: String or Weave (3 Dia. Max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

Root

SMAW

Others

-Do-

Class E8018-B2 -Do-

Approved by: (S.Ramesh) SDGM/WTC&WCMC

Current

Travel speed range


Dia. mm

Type

Amps.

Volt Range

2.50

DCEP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

Prepared: (Dr.K.P.Dhndapani) DGM,/WTC&WCMC




1029

Date: 06.10.97

Rev. No.:

00

Date: ------




Application: Fillet & Socket welding 18Cr8Nri Stainless steel Tubes/Pipes without PWHT. JOINTS (QW-402) Joint Design

: Fillet as per prodn. drg.

Backing (Yes/No)

: Yes


: Metal


Group No.:

1

to

Spec. Type & Grade

: N.A


: N.A

P. No.: 8

Group No.: 1


Fillet: Unlimited


Fillet: Unlimited


E 347

Specn. No. (SFA):

5.4


See table

F. No.:

5

Flux Trade Names:

N.A

A. No.:

8

Consumable insert:

N.A

Electrode |Flux (Class): N.A. Deposited weld metal thickness range: Groove: N.A. Fillet: Unlimited. (Max. 6.00 mm per pass) PREHEAT (QW-406)

POSITION (QW-405)

Nil (Min 10oC)

Position of Groove:

N.A.


Position of fillet:

All.

Inter pass temp. (Max.): 300 Deg. C


Vertical up

Pre heat maintenance: Nil Others

:

Nil



Page 2 of 2

WPS No.: 1029

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A.


N.A.


N.A.


N.A.


String


N.A.




N.A.

Oscillation:

N.A


N.A


Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Current


Dia. mm

Type

Amps.

Volt Range

Travel speed range

E 347

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

-Do-

3.15

-Do-

80-120

N.A.

N.A.

Nil

-Do-

-Do-

4.00

-Do-

120-150

N.A

N.A

Nil

Weld Layer

Process

Root

SMAW

Others ---Do--

Class

Approved by: (V.Ravindran) Sr.Manager /WTC

Prepared: (P.Sivasubramanain) Welding Engineer/WTC



WPS. No. Rev. No

: 1028 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 16/03/95 : 22/09/07

Page 1 of 2

Supporting PQR. No

1057

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of Carbon steel to 1 Cr. ½Mo. / 1¼Cr. ½Mo steel Tubes /Pipes( Dia. Upto 100mm ) with preheat & without PWHT.


: Groove as per drawing : With or without : Metal

: 1 to P. No : N.A. : N.A. : Groove : 1.5 to 13.0mm : Groove : Dia upto 100mm : Nil

: 4

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5. Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 13.0mm Max. GTAW :5.0mm.Max.; SMAW: Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1028

PWHT ( QW – 407 )



Nil

Others

Nil

:


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 10 -----


Process


Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-1 --do-- SMAW E7018-1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP

Voltage range Amps 60 - 110 N.A. 70 - 100 N.A. 100 -140 N.A








1027

Date: 03.10.97

Rev. No.:

02

Date: 04.04.06


Supporting PQR No.:

578&673


Application: Fillet and Socket welding of P4/P5A steel components to P8 Steel with Preheat and without PWHT. JOINTS (QW-402) Joint Design

: As per Production Drawing

Backing (Yes/No)

: Yes


: Metal


Group No.: 1 or 2

to

P. No.: 8

Group No.: 1or 2

P 5A Group No: 1 Spec. Type & Grade

: N.A


: N.A


Fillet:

13 mm max.

Pipe Dia range: Unlimited Others: Nil FILLER METALS (QW-404) AWS No. (Class):

E 309


See table

Specn. No. (SFA):

5.4

Flux Trade Names:

Nil

F. No.:

5

Consumable insert:

Nil

A. No.:

8


Deposited weld metal thickness range: Groove: N.A Fillet: 13 mm max. (Maximum 6 mm per pass) PREHEAT (QW-406)


N.A.

Position of fillet:

All.


Vertical up

150OC (On P4/P5A side only)


Inter pass temp. (Max.): 300oC Pre heat maintenance: Nil Others

:

Nil



Page 2 of 2


PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A.


N.A.


N.A.


N.A.

TECHNIQUES (QW-410) String or Weave Bead: String. Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil. Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

Root

SMAW

Others

-Do-

Current

Travel speed range


Dia. mm

Type

Amps.

Volt Range

E309

2.50

DCEP

70-100

N.A.

N.A.

Nil

E309

3.15

DCEP

100-130

N.A.

N.A.

Nil

Class


Prepared: (Dr.K.P.Dhandapani) DGM/WTC&WCMC




1026

Date: 10.09.97

Rev. No.:

01

Date: 13.03.03




Application: Fillet and Socket welding of Carbon steel to1Cr 0.5Mo/1.25Cr 0.5Mo Steel Tubes/Pipes (Dia. up to 100) with Preheat and without PWHT. JOINTS (QW-402) Joint Design

: Fillet as per production drg.

Backing (Yes/No)



: Metal


Group No.: 1 or 2

to

Spec. Type & Grade

: N.A


: N.A

P. No.: 4

Group No.: 1


Fillet: 13.00 mm max.

Pipe Dia range Groove: N.A

Fillet: Dia. Up to 100.00 mm


E 7018-1

Specn. No. (SFA):

5.1


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

1

---

Consumable insert: Electrode |Flux (Class):

Nil N.A.

Deposited weld metal thickness range: Groove: N.A Fillet: 9.0 mm max. (maximum 3 mm/pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

N.A..


Position of fillet:

All.

Inter pass temp. (Max.): 300 Deg. C


vertical up

Pre heat maintenance: Nil Others Others:

125 Deg.C

:

Nil Nil




PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A.

---

---

Trailing

N.A

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A.


N.A.


N.A.


Nil


Root : string, Others: string or weave (3 Dia. Max.)


N.A.




N.A.

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Weld Layer

Process

Root Others Layers

Travel speed range


Current

Class

Dia. mm

Type

Amps.

Volt Range

SMAW

E 7018-1

2.5

DCEP

70-100

N.A.

N.A.

Nil

SMAW

E 7018-1

3.15

DCEP

90-130

N.A.

N.A.

Nil

Approved by: (K.Narasimhan) DGM/WTC

Prepared (R.Rajanarayanan) DM/WTC




1025

Date: 08.09.07

Rev. No.:

01

Date: 06.09.05




Application: Groove welding of Carbon Steel Pipes/Stubs to Stainless Steel thermo well with PWHT. JOINTS (QW-402) Joint Design

: Groove as per production drg.

Backing (Yes/No)



: Metal


Group No.: 1or 2

to

Spec. Type & Grade

: N.A


: N.A

P. No.: 8

Group No.: 1


Fillet: N.A

Pipe Dia range Groove: Unlimited

Fillet: N.A


GTAW: ERNiCr-3; SMAW: ENiCrFe -3

Specn. No. (SFA):

5.14, 5.11


See table

F. No.:

43

Flux Trade Names:

N.A

A. No.:

Nil

---

Consumable insert: Nil Electrode |Flux (Class): N.A.

Deposited weld metal thickness range: Groove: 40.0 max. (GTAW: 5.0 max; SMAW: 35.0 mm max.) (Max.6mm/pass) Fillet: Nil POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up / Down)

F.H. N.A. N.A

PREHEAT (QW-406) Preheat temp (min). :

Upto 25 mm: Nil (min.10 Deg. C) Above 25 mm 150 Deg. C. Inter pass temp. (Max.): 300oC Preheat maintenance: Nil Others: Nil



Page 2 of 2

WPS No.: 1025 Rev 01 GAS (QW-408)


610±15 Deg. C.

Time Range

2.5 minutes/mm


Nil

Gases

Mix%

Flow Rt.

Shielding

Argon

--

6-12 LPM

Trailing

N.A

---

---

Backing

Argon

---

4-6 LPM


Polarity: See table Volts: N.A EWTh-2; Dia.2.4 mm. N.A. N.A.


Nil

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: 6/9 Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Current

Travel speed range


Dia. mm

Type

Amps.

Volt Range

ERNiCr-3

2.4

DCEN

70-100

N.A.

N.A.

Nil

SMAW

ERNiCrFe-3

2.5

DCEP

70-100

N.A.

N.A.

Nil

-Do-

SMAW

ERNiCrFe-3

3.15

DCEP

90-130

N.A

N.A

Nil

-Do-

SMAW

ERNiCrFe-3

4.0

DCEP

120-170

N.A

N.A

Nil

Weld Layer

Process

Root Pass

GTAW

Others Layers

Class


Prepared by: (Dr.K.P.Dhandapani) DGM/WTC&WCMC




1024

Date: 08.08.97

Rev. No.:

00

Date: ----




Application: Groove welding of 2 ¼ Cr1Mo Steel Pipes/Stubs with Stainless Steel Thermo well with PWHT JOINTS (QW-402) Joint Design

: Groove as per production drg.

Backing (Yes/No)



: ---do---

Metal/Non fusing metal/ Non metallic/Others BASE METAL (QW-403) P. No.: 5A

Group No.: 1

TO

Spec. Type & Grade

: N.A


: N.A

P. No.: 8

Group No.: 1

Thickness Range Groove: 5.0 to 40 mm

Fillet: N.A

Pipe Dia range: Groove: Unlimited

Fillet: N.A


GTAW : ERNiCr-3; SMAW : ENiCrFe -2

Specn. No. (SFA):

5.14, 5.11


See table

F. No.:

43

Flux Trade Names:

N.A

A. No.:

Nil

---

Consumable insert: Nil Electrode |Flux (Class): N.A.

Deposited weld metal thickness range: Groove: 40.0 max. (GTAW: 5.0 max,; SMAW: 35.0 mm max.) (Max.6mm/pass) Fillet: N.A POSITION (QW-405)

PREHEAT (QW-406) O

Position of Groove:

All

Preheat temp. : 150 c (On P5A side)

Position of fillet:

All.



Vertical up

Pre heat maintenance:

Nil

Others:

Nil



Page 2 of 2

WPS No.: 1024 GAS (QW-408)

PWHT (QW-407) O

Temp. Range:

680-720 c

Time Range

1Hr/25mm(min.1 Hr.)

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

Argon

---

6-12 LPM

Trailing

N.A

---

---

Backing

Argon

---

4-6 LPM


Polarity: See table

Amps. (Range):

Volts: N.A

See table


EWTh2 ; Ø 2.4mm


N.A.


N.A.


Nil

TECHNIQUES (QW-410) String or Weave Bead: String Orifice or Gas cup size: 6/9 Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others: Weld Layer

Nil Filler Process Class

Current Dia. mm

Type

Amps.

Volt Range

Travel speed range


Root

GTAW

ERNiCr-3

2.40

DCEN

70-130

N.A.

N.A.

Nil

Others

SMAW

EniCrFe-2

2.50

DCEP

70-100

N.A.

N.A.

Nil

-Do-

SMAW

EniCrFe-2

3.15

DCEP

100-130

N.A

N.A

Nil

Approved by: (V.Ravindran) Sr.Manager/WTC

Prepared by: (PSivasubramainan) WELDING ENGINEER/WTC




1023

Date: 01.08.97

Rev. No.:

00

Date: ----

Supporting PQR No.: 509.118.



Application: Fillet & Socket welding of P5A tubes/ pipes with PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: Yes.


: Metal

Metal/Non fusing metal/ Non metallic/Others BASE METAL (QW-403) P. No.:5A

Group No.: 1

TO

Spec. Type & Grade

: N.A


: N.A

P. No.: 5A

Group No.: 1


Fillet: Unlimited

Pipe Dia range: Groove: N.A

Fillet: Unlimited


E 9018B3

Specn. No. (SFA):

5.5


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

4

---

Consumable insert: N.A Electrode |Flux (Class): N.A.

Deposited weld metal thickness range: Groove: N.A Fillet: Unlimited (Max.6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406)

Position of Groove:

N.A.

Position of fillet:

All.

Weld Progression:

Vertical up

Preheat temp. : t < 13: Nil (Min10OC min) o

t > 13: 150 C Inter pass temp. (Max.): 300oC Pre heat maintenance: pipes

200Oc for 2 hrs. for

Others:

Nil



WPS No.: 1023

PWHT (QW-407)

Page 2 of 2

GAS (QW-408)

Temp. Range:

Gases

Mix% Flow Rt.

Shielding

N.A

--

----

Trailing

N.A

---

---

Backing

N.A.

---

---

680-750 ºC

Time Range 1Hr/25mm (min.1 Hr. for pipe & ½ hr for tube) Others:

Nil


Polarity: See table

Amps. (Range):

Volts: -do-

-Do-


EWTh2 ; Ø 2.4mm


N.A.


N.A.


Nil

TECHNIQUES (QW-410) String or Weave Bead: Root & H: String; Others: String/Weave (3 Dia. max.) Orifice or Gas cup size: N.A. Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: N.A Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

All

SMAW

-Do-

-Do-

-Do-

-Do-

Current Amps.

Volt Range

Travel speed range


DCEP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

4.0

DCEP

140-190

N.A

N.A

Nil

Class

Dia. mm

Type

E9018B3

2.5

-Do-Do-


Prepared by: (PSivasubrmainan) WELDING ENGINEER/WTC




1022

Date: 01.08.97

Rev. No.:

00

Date: ----




Application: Fillet & Socket welding of P1 Gr 2 components to P1 group 1 or 2 without Preheat and without PWHT. (Other than SA 106 Gr C). JOINTS (QW-402) Joint Design


Backing (Yes/No)

: Yes.


: Metal


Group No.: 2

TO

Spec. Type & Grade

: N.A


: N.A

P. No.: 1Group No.: 1 or 2


Fillet: 9 mm max.

Pipe Dia Groove: NA

Fillet: Unlimited


E 7018-1

Specn. No. (SFA):

5.1


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

1

---

Consumable insert: N.A Electrode |Flux (Class): N.A.

Deposited weld metal thickness range: Groove: N.A Fillet: 9.0 mm max. (Max. 6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406) O

Nil (10 C min)

Position of Groove:

N.A.

Preheat temp. :

Position of fillet:

All.


Weld Progression:

Vertical up


Nil

Others:

Nil



Page 2 of 2

WPS No.: 1022

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

N.A

--

----

Trailing

Nil

---

---

Backing

N.A.

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A


N.A.


N.A.


N.A


Root & H: String; Others: String/Weave (3 Dia. max.)


N.A.




Nil

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Weld Layer

Process

All

SMAW

-Do-

-Do-

Current Amps.

Volt Range

Travel speed range


DCEP

70-100

N.A.

N.A.

Nil

DCEP

100-140

N.A.

N.A.

Nil

Class

Dia. mm

Type

E7018-1

2.5 3.15

-Do-


Prepared by: (PSivasubrmainan) WELDING ENGINEER/WTC




1021

Date: 01.08.97

Rev. No.:

01

Date: 04.04.06

Supporting PQR No.: 517, 522.



Application: Fillet & Socket welding of P1 Gr 1 tubes / pipes & SA 106 Gr C pipes without Pre heat and without PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: Yes.


: Metal


Group No.

: 1 /2*

TO P. No.: 1

Group No.: ½*

Spec. Type & Grade

: N.A

*Gr2, only SA 106 Gr. C up to 19mm


: N.A

Thickness Range Groove:

N.A

Pipe Dia Range:

Unlimited

Others:

Nil

Fillet:

19 mm max.


E 7018-1

Specn. No. (SFA):

5.1


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

1

---


N.A N.A.

Deposited weld metal thickness range: Groove: N.A Fillet: 19 mm max. (Max.6 mm per pass) POSITION (QW-405)

PREHEAT (QW-406) Nil (10OC min)

Position of Groove:

All.

Preheat temp. :

Position of fillet:

All.



Vertical up


Nil

Others:

Nil

Other

Nil

:

o



WPS No.: 1021 Rev.01

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Page 2 of 2

Gases

Mix%

Flow Rt.

Shielding

N.A

--

----

Trailing

Nil

---

---

Backing

Nil

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A


N.A.


N.A.


N.A

TECHNIQUES (QW-410) String or Weave Bead: Root & H: String; Others: String/Weave (3 Dia. Max.) Orifice or Gas cup size: Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

All

SMAW

-Do-

-Do-

-Do-

-Do-

Current Amps.

Volt Range

Travel speed range


DCEP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

4.0

DCEP

140-190

N.A

N.A

Nil

Class

Dia. mm

Type

E7018-1

2.5

-Do-Do-


Prepared by: (Dr.K.P.Dhanapani) DGM/WTC&WCMC




1020

Date: 01.08.97

Rev. No.:

01

Date: 04.04.06




Application: Fillet & Socket welding of P5A components without PWHT JOINTS (QW-402) Joint Design


Backing (Yes/No)

: Yes.


: Metal


Group No.: 1

TO

P. No.: 5A

Spec. Type & Grade

: N.A


: N.A

Group No.: 1


Fillet: 13 mm max.

Pipe Dia Range

Unlimited


E 9018B3

Specn. No. (SFA):

5.5

F. No.:

4

A. No.:

4


See table

Flux Trade Names: ---

N.A


N.A N.A.

Deposited weld metal thickness range: Groove: N.A Fillet: 13 mm max. (Max.6 mm per pass) POSITION (QW-405) Position of Groove: Position of fillet:

N.A All


Vertical up

Other

Nil

:

PREHEAT (QW-406) Preheat temp. : Inter pass temp. (Max.): Pre heat maintenance: Others:

150oC 300oC Nil Nil



WPS No.: 1020 Rev.01

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Page 2 of 2

Gases

Mix%

Flow Rt.

Shielding

N.A

--

----

Trailing

N.A

---

---

Backing

N.A

---

---


Polarity: See table

Amps. (Range):

Volts: N.A

See table


N.A


N.A.


N.A.


N.A

TECHNIQUES (QW-410) String or Weave Bead: Root & H: String; Others: String/Weave (3 Dia. max.) Orifice or Gas cup size: Initial and inter pass cleaning: Brushing/Chipping/Grinding Method of back gouging: Nil Oscillation: N.A Contact tube to work distance: N.A Multiple or single pass (per side): Single or Multiple Multiple or single electrode: Single Electrode spacing: N.A. Peening: Nil Others:

Nil Filler

Weld Layer

Process

All

SMAW

-Do-

-Do-

-Do-

-Do-

Current Amps.

Volt Range

Travel speed range


DCEP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

4.0

DCEP

140-190

N.A

N.A

Nil

Class

Dia. mm

Type

E9018B3

2.5

-Do-Do-


Prepared by: (Dr. K.P. Dhanapani) DGM/WTC&WCMC




1019

Date: 01.08.97

Rev. No.:

00

Date: ----

Supporting PQR No.: 543,544



Application: Fillet & Socket welding of P4 tubes/pipes with P5A tubes/pipes with PWHT. JOINTS (QW-402) Joint Design


Backing (Yes/No)

: As per drg.


: -do-


Group No.: 1

TO

Spec. Type & Grade

: N.A


: N.A

P. No.: 5A

Group No.: 1


Fillet: Unlimited

Pipe Dia. Groove: N.A

Fillet: Unlimited


E 8018B2

Specn. No. (SFA):

5.5


See table

F. No.:

4

Flux Trade Names:

N.A

A. No.:

3

---


N.A N.A.

Deposited weld metal thickness range: Groove: N.A Fillet: Unlimited (Max .6mm per pass) POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression:

N.A All Vertical up

PREHEAT (QW-406) Preheat temp. : t < 13: Nil (Min.10oC) T> 13: 150OC Inter pass temp. (Max.): 300oC Pre heat maintenance: 2000C for 2 hrs. for pipes Others: Nil



Page 2 of 2

WPS No.: 1019

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

680-720oC

Time Range

1 Hr / 25mm

Gases

Mix%

Shielding

N.A

--

----

(Min .1 Hr. for pipe & ½ hr. for tube)

Trailing

Nil

---

---

Others:

Backing

Nil

---

---

Nil

Flow Rt.


Polarity: See table

Amps. (Range):

Volts: N.A

---do--


N.A


N.A.


N.A.


N.A

TECHNIQUES (QW-410) String or Weave Bead: Orifice or Gas cup size: Initial and inter pass cleaning: Method of back gouging: Oscillation: Contact tube to work distance: Multiple or single pass (per side): Multiple or single electrode: Electrode spacing: Peening:

Root & H: String; Others: String/Weave (3 Dia. max.) N.A Brushing/Chipping/Grinding N.A N.A N.A Single or Multiple Single N.A. Nil

Others:

Nil Filler

Weld Layer

Process

All

SMAW

-Do-

-Do-

-Do-

-Do-

Current Amps.

Volt Range

Travel speed range


DCEP

70-100

N.A.

N.A.

Nil

3.15

DCEP

100-140

N.A.

N.A.

Nil

4.0

DCEP

140-190

N.A

N.A

Nil

Class

Dia. mm

Type

E8018B2

2.5

-Do-Do-

Approved by: (V.Ravindran) Sr. Manager / WTC

Prepared by: (P.Sivasubramanian) Welding Engineer/WTC

-Form No. 101 - 401 BHARAT HEAVY ELECTRICALS LIMITED TIRUCHIRAPPALLI-620014 WELDING TECHNOLOGY CENTRE


WPS. No. Rev. No

: 1018 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 16/03/95 : 22/09/07

Page 1 of 2

Supporting PQR. No

947

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of 1 Cr. ½Mo. / 1¼Cr. ½Mo components to Carbon steel components with preheat & with PWHT.


: As per drawing : With or without : Metal

: 2 to P. No : 4 Group No. : 1 : N.A. : N.A. : Groove : 5.0 to 50.0mm Fillet : N.A : Groove : Unlimited Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –A1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 2 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 50.0mm Max. GTAW :5.0mm.Max.; SMAW: Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1018

PWHT ( QW – 407 )



2.5minutes / mm

Others

Nil

:


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----


Process

Filler metal Class

Root Further --do---do---do--

GTAW SMAW SMAW SMAW SMAW

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) : N.A : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

ER70S-A1 E7018-A1 E7018-A1 E7018-A1 E7018-A1

Current

Dia 2.4 2.5 3.15 4.0 5.0

Approved by

Type DCEN DCEP DCEP DCEP DCEP

Voltage range Amps 60 - 110 N.A. 70 - 100 N.A. 100 -140 N.A 130 -170 N.A 170 -220 N.A

Travel speed Range N.A N.A N.A N.A N.A

Others(Hot wire, Torch angle, ROL ) Nil Nil Nil Nil Nil





WPS. No. Rev. No

: 1017 : 03

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

1057

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of Carbon steel to 1 Cr. ½Mo. / 1¼Cr. ½Mo tubes / pipes ( Dia upto 127mm ) with preheat & without PWHT.



: 1 or 2 to P. No : 4 Group No. : 1 : N.A. : N.A. : Groove : 1.5 to 13.0mm Fillet : N.A : Groove : Max. 127mm Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 13.0mm Max. GTAW :5.0mm.Max.;SMAW:Balance (Max.3mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1017

PWHT ( QW – 407 )



Nil

Others

Nil

:


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 10 -----


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) : 6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-1 --do-SMAW E7018-1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP









1016

Date: 06-11-93

Rev. No.:

01

Date: 17.07.03

Welding Process: GTAW+SMAW



Application: Groove welding of stainless steel tubes without Preheat and without PWHT. JOINTS (QW-402) Joint Design

: As per drawing.

Backing (Yes/No)

: GTAW: No: SMAW: Yes


: Metal


Group No.: 1

TO

P. No.: 8

Spec. Type & Grade

: N.A


: N.A

Group No.: 1


Fillet: N.A.

Pipe Dia.: Groove: Unlimited

Fillet: N.A

Others: Nil FILLER METALS (QW-404) GTAW

SMAW

AWS No. (Class):

ER347

E347

Specn. No. (SFA):

5.9

5.4

Size of filler metal; Refer table

F. No.:

6

5

Flux Trade Names: N.A

A. No.:

8

8

Consumable insert: N.A Electrode |Flux (Class): N.A

Deposited weld metal thickness range: Groove: 12 mm max. [(GTAW: 4mm Max: Max.2mm/pass) (SMAW: Balance)] Fillet: N.A. POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression: (Up/Down)

All N.A. Vertical up

PREHEAT (QW-406) o Preheat temp. : Nil (Min.10 C) Inter pass temp. (max): 2500C Pre heat maintenance: Nil Others: Nil




PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Page 2 of 2

Gases

Mix%

Flow Rt.

Shielding

Argon

--

Trailing

N.A

---

---

Backing

Argon

---

3-6LPM

6-14 LPM



Amps. (Range):

Volts: Refer table

Refer table


EWTh2; ø 2.4 mm


N.A.


N.A.


N.A


String only


6/9




N.A

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

N.A

Others:

Nil Filler

Weld Layer

Process

Root

GTAW

Others Others

Current Amps.

Volt Range

Travel speed range


DCEN

60-110

N.A.

N.A.

Nil

2.5

DCEP

60-100

N.A.

N.A.

Nil

3.15

DCEP

90-130

N.A

N.A

Nil

Dia. mm

Type

ER347

2.4

SMAW

E347

SMAW

E347

Class

Approved by: (K.Narasimhan) DGM/WTC

Prepared by: (R.Rajanarayanan) DM/WTC




1015

Date: 06-11-93

Rev. No.:

00

Date: ---


Welding Process: GTAW


Application: Butt welding of P5A tubes P8 tubes with P8 tubes with Preheat and without PWHT JOINTS (QW-402) Joint Design

: Groove as per drawing

Backing (Yes/No)

: As per drg.


: -do-


Group No.: 1

TO

Spec. Type & Grade

: N.A


: N.A

P. No.: 8

Group No.: 1

Thickness Range Base Metal:

Groove: 1.6 to 8.0

Fillet:

N.A.

Weld Metal

Groove: Max 8.0

Fillet :

N.A

Pipe dia.:

Groove: Unlimited

Fillet:

N.A


ERNiCr3

Specn. No. (SFA):

5.14

Size of filler metal: see table

F. No.:

43

Flux Trade Names: N.A

A. No.:

N.A

Consumable insert: Nil Electrode |Flux (Class): N.A

POSITION (QW-405) Position of Groove: Position of fillet: Weld Progression:

All N.A. Vertical up

PREHEAT (QW-406) Preheat temp. : Inter pass temp. (Max.): Pre heat maintenance: Others:

1500C 0 300 C Nil Nil



Page 2 of 2

WPS No.: 1015

PWHT (QW-407)

GAS (QW-408)

Temp. Range:

Nil

Time Range

Nil

Others:

Nil

Gases

Mix%

Flow Rt.

Shielding

Argon

--

Trailing

Nil

---

---

Backing

Nil

---

---

6-14 LPM


Polarity: See table

Amps. (Range):

Volts: --do--

--do--


EWTh2; ø 2.4 mm


N.A.


N.A.


Nil


Root & 2G: String; Others: String/Weave (3 Dia. Max.)


6/9




Nil

Oscillation:

N.A


N.A


Single or Multiple


Single

Electrode spacing:

N.A.

Peening:

Nil

Others:

Nil Filler

Weld Layer

Process

A1

GTAW

Current

Class

Dia. mm

Type

ERNiCr3

2.4

DCEN

Approved by: (V.Ravindran) Manager /WTC Date: 06/11/93

Amps.

Volt Range

Travel speed range


60-110

N.A.

N.A.

Nil

Prepared by: (D.N.Ravishankar) S.W.E./WTC Date: 06/11/93



WPS. No. Rev. No

: 1014 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

118 & 509

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Groove welding of P5A tubes / pipes with preheat & with PWHT.



: 1 to P. No : 5A : N.A. : N.A. : Groove : 5.0 to 200.0mm : Groove : Unlimited : Nil

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER90S – B3 E9018 –B3 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 4 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200.0mm Max. GTAW :5.0mm.Max.;SMAW:Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove


PRE HEAT ( QW – 406 ) Preheat Temp.(min) :t < 13mm : Nil (min 100C ) t > 13mm :1500C) Interpass Temp. (Max) : 300 0C Preheat Maintenance : 150 0C for 2 hrs. for pipes

Others

Others

: All

: Nil

: Nil


WPS. No. : 1014

PWHT ( QW – 407 ) Temp. Range : 680 – 750 0C Time Range : 2.5 minutes/mm ( Min.30 minutes for tubes & Min. 60 minutes for pipes )

Others

:



Nil


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) : 6 / 9. : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class


Current

Dia 2.4 2.5 3.15 4.0

Approved by


Voltage range Amps 60 - 110 70 - 110 100 -140 140 -190

N.A. N.A. N.A N.A







WPS. No. Rev. No

: 1013 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

547

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P5A tubes with preheat & without PWHT.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 5A Group No. Spec. Type & Grade Chem. Analysis & Mech .Prop. Thickness Range Pipe Diameter Range Others

: Groove as per drawing : With or without : Metal :


: 5A

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER90S – B3 E9018 –B3 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 4 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 8.0mm Max. GTAW :4.0mm.Max.;SMAW:Balance Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil




Nil

Others

Nil

:


WPS. No. : 1013

Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----


Process

: Root & H :String ; Others :String / weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER90S-B3 Further SMAW E9018 -B3 --do-SMAW E9018 -B3

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP

Voltage range Amps

Travel speed Range

60 - 110 N.A. 70 - 100 N.A. 100 -140 N.A

N.A N.A N.A






WPS. No. Rev. No

: 1012 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

543 & 544

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P4 tubes / pipes with P5A tubes / pipes with preheat & with PWHT.



: 1 to P. No : 5A : N.A. : N.A. : Groove : 5.0 to 200.0mm : Groove : Unlimited : Nil

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER80S – B2 E8018 –B2 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 3 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200.0mm Max. GTAW :5.0mm.Max.;SMAW:Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove


PRE HEAT ( QW – 406 ) Preheat Temp.(min) :t < 13mm : Nil (min 100C ) t > 13mm :1500C) Interpass Temp. (Max) : 300 0C Preheat Maintenance : 200 0C for 2 hrs. for pipes

Others

Others

: All

: Nil

: Nil

BHEL Trichirappalli – 14 PWHT ( QW – 407 ) Temp. Range : 680 – 720 0C Time Range : 2.5 minutes/mm

( Min.30 minutes for tubes & Min. 60 minutes for pipes )

Others

:


WPS. No. : 1012


Nil


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) : 6 / 9. : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER80S-B2 Further SMAW E8018-B2 --do-SMAW E8018-B2 --do-SMAW E8018-B2

Current

Dia 2.4 2.5 3.15 4.0

Approved by


Voltage range Amps 60 - 110 70 - 110 100 -140 140 -190

N.A. N.A. N.A N.A







WPS. No. Rev. No

: 1011 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

529

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P4 tubes to P5A tubes with preheat & without PWHT


: As per drawing : With or without : Metal :


: 5A

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER80S – B2 E8018 –B2 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 3 3 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 8.0mm Max. GTAW :4.0mm.Max.;SMAW:Balance Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : 1500C) Interpass Temp. (Max) : 300 0C Preheat Maintenance : Nil

Others

Others

: Nil

: Nil




Nil

Others

Nil

:


WPS. No. : 1011

Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER80S-B2 Further SMAW E8018-B2 --do-SMAW E8018-B2

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP








WPS. No. Rev. No

: 1010 : 05

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

555

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of 1 Cr. ½Mo. / 1¼Cr. ½Mo tubes / pipes with preheat & with PWHT.


: As per Production drawing : With or without : Metal :

: 1 to P. No : 4 Group No. : 1 : N.A. : N.A. : Groove : 5.0 to 200.0mm Fillet : N.A : Groove : OD > 127mm Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER80S – B2 E8018 –B2 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 3 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200.0mm Max. GTAW :5.0mm.Max.;SMAW:Balance (Max.5mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1010

PWHT ( QW – 407 )


Temp. Range : 655 ± 150C Time Range :

2.5 minutes/mm ( Min.30 minutes) : Nil

Others



Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) : 6 / 13. : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER80S-B2 Further SMAW E8018-B2 --do-SMAW E8018-B2 --do-SMAW E8018-B2

Current

Dia 2.4 2.5 3.15 4.0

Approved by





Prepared by (Dr. K. P .Dhandapani) DGM / WTC

(S. Singaravelu) Manager / WTC



WPS. No. Rev. No

: 1009 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

528

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of 1 Cr. ½Mo. / 1¼Cr. ½Mo tubes / pipes with preheat & without PWHT.



: 1 to P. No : N.A. : N.A. : Groove : 1.5 to 13.0mm : Groove : Max. 127mm : Nil

: 4

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER80S – B2 E8018 –B2 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 3 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 13.0mm Max. GTAW :4.0mm.Max.;SMAW:Balance (Max.4mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1009

PWHT ( QW – 407 )



Nil

Others

Nil

:


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 12 -----


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) : N.A. : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER80S-B2 Further SMAW E8018-B2 --do-SMAW E8018-B2

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP

Voltage range Amps

Travel speed Range

60 - 110 N.A. 70 - 100 N.A. 100 -140 N.A

N.A N.A N.A






WPS. No. Rev. No

: 1008 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

548

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of ½Cr or ½Cr. ½Mo. tubes to 1 Cr. ½Mo. / 1¼Cr. ½Mo tubes with preheat & without PWHT.



: 1 or 2 to P. No : 4 Group No. : 1 : N.A. : N.A. : Groove : 1.5 to 13.0mm Fillet : N.A : Groove : Max. 127mm Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –A1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 2 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 13.0mm Max. GTAW : 5.0mm.Max.;SMAW:Balance (Max.4mm / pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up


Others

Others

: Nil

: Nil


WPS. No. : 1008

PWHT ( QW – 407 )



Nil

Others

Nil

:


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 12 -----


Process

: Root : String; Others : String /weave bead ( Max. 3 Dia. ) : N.A. : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-A1 --do-SMAW E7018-A1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP








WPS. No. Rev. No

: 1007 : 01

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

527

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P3 tubes without preheat & without PWHT.



: 1 to P. No : ½ Mo steel : N.A. : Groove : 1.6 to 10.0mm : Groove : Unlimited : Nil

: 3

Group No. : 1


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 – A1 Size of Filler metal : Refer Table Specn. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 2 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 10.0mm Max. GTAW : 5.0mm.Max.;SMAW:Balance Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : Nil (min. 100C) Interpass Temp. (Max) : 300 0C Preheat Maintenance : Nil

Others

Others

: Nil

: Nil




Nil

Others

Nil

:


WPS. No. : 1007

Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----


Process

: Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-A1 --do-SMAW E7018-A1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP








WPS. No. Rev. No

: 1006 : 02

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

527

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P1 tubes to P3 tubes without preheat & without PWHT.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 1 Group No. Spec. Type & Grade Chem. Analysis & Mech .Prop. Thickness Range Pipe Diameter Range Others

: Groove as per drawing : With or without : Metal :

: 1 or 2 to P. No : 3 Group No. : 1 : Carbon steel to ½ Mo steel : N.A. : Groove : 1.5 to 9.0mm Fillet : N.A : Groove : Unlimited Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 – 1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 9.0mm Max. GTAW : 5.0mm.Max.;SMAW:Balance Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : Nil (min. 100C) Interpass Temp. (Max) : 300 0C Preheat Maintenance : Nil

Others

Others

: Nil

: Nil




Nil

Others

Nil

:


WPS. No. : 1006

Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----


Process

: String / weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Single or multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-1 --do-SMAW E7018-1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP








WPS. No. Rev. No

: 1005 : 05

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

1327

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P1 Gr. tubes / pipes with PWHT.

JOINTS ( QW – 402 ) Joint Design Backing ( Yes / No ) Backing Material Type (Metal/Non fusing metal/Non metallic/Others) BASE METAL ( QW – 403 ) P. No. : 1 Group No. Spec. Type & Grade Chem.Analysis & Mech.Prop. Thickness Range Pipe Diameter Range Others


: 2 to P. No : : N.A. : N.A. : Groove :9.0 to 200mm : Groove :Unlimited : Nil

1

Group No. : 2


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 – A1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 2 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200 mm Max. GTAW : 5.0mm.Max.; SMAW: Balance (Max.5mm/pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : t < 25mm:Nil (min 100C) t 25 to75mm : 100 0C t >75mm :1500C Interpass Temp. (Max) : 300 0C Preheat Maintenance :150 0C for 2hrs.on completion & interruptions for Gr. C pipes Others : Nil


WPS. No. : 1005

PWHT ( QW – 407 )


Temp. Range : 620 -650 0C Time Range : 2.5 minutes / mm (Min.30 minutes) Others


Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----

: Nil


Process

: String / weave bead ( Max. 3 Dia. ) : 6 / 9/13 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-A1 --do-SMAW E7018-A1 --do-SMAW E7018-A1

Current

Dia 2.4 2.5 3.15 4.0

Approved by









WPS. No. Rev. No

: 1004 : 03

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

516 & 632

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P1 Gr.1 tubes / pipes to P1 Gr.1 or 2 tubes / pipes with PWHT.



: 1 to P. No : : N.A. : N.A. : Groove :5.0 to 200mm : Groove :Unlimited : Nil

1

Group No. : 1 or 2


FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 – 1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 200 mm Max. GTAW : 5.0mm.Max.; SMAW: Balance (Max.5mm/pass) Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : t < 25mm:Nil (min 100C) t 25 to75mm : 100 0C t >75mm :1500C Interpass Temp. (Max) : 300 0C Preheat Maintenance : Nil Others : Nil



Temp. Range : 610 ± 15 C Time Range : 2.5 minutes / mm (Min.½ hr ) 0

Others


WPS. No. : 1004

Mix/Purity % 99.99 -----

Flow.Rt.(lpm ) 6 - 14 -----

: Nil


Process

: String / weave bead ( Max. 3 Dia. ) :6/9 : Chipping / Brushing / Grinding : Nil : Nil : N.A. : Multiple : Single : N.A. : N.A. : Nil

Filler metal Class

Root GTAW ER70S-A1 Further SMAW E7018-1 --do-SMAW E7018-1 --do-SMAW E7018-1

Current

Dia 2.4 2.5 3.15 4.0

Approved by









WPS. No. Rev. No

: 1003 : 03

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

517,522

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P1 Gr.1 Tubes / Pipes & SA106 Gr. C Pipe without preheat & without PWHT.



: 1/2* to P. No : 1 Group No. : 1 or 2* : P1 Gr1/ Gr2* (Only SA106 Gr. C. carbon content < 0.25%) : N.A. : Groove : 1.5 to 19.0mm Fillet : N.A : Groove : Unlimited Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 – 1 Size of Filler metal : Refer Table Spec. No. ( SFA ) : 5.28 5.1 Flux trade name : N.A. F. No. : 6 4 Electrode-flux (Class ) : N.A.. A. No. : 2 1 Consumable insert : N.A. Deposited weld metal thickness range (t) Groove : 19.0 mm Max. GTAW : 5.0mm.Max.;SMAW: Balance Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : Nil ( Min.100C ) Interpass Temp. (Max) : 300 0C Postheat Maintenance : Nil Others : Nil



Temp. Range : Nil Time Range : Nil Others


WPS. No. : 1003

Mix/Purity % Flow. Rt. (lpm ) 99.99 6 - 14 ---------

: Nil


Process


Filler metal Class

Root GTAW ER70S -A1 Further SMAW E7018-1 --do-SMAW E7018-1 --do-SMAW E7018-1

Current

Dia 2.4 2.5 3.15 4.0

Approved by









WPS. No. Rev. No

: 1002 : 03

Welding Process

: GTAW + SMAW

Application

Date Date

: 06/11/93 : 22/09/07

Page 1 of 2

Supporting PQR. No

522

Type : Manual (Auto/Semi-Auto/Manual/Machine) : Butt welding of P1 Gr.2 tubes / pipes to P1 Gr1 or 2 tubes / pipes other than SA106 Gr. C without pre heat & without PWHT.



: 2 to P. No : 1 Group No. : 1 or 2 : N.A. : Carbon content not exceeding 0.3% : Groove : 1.5 to 9.0mm Fillet : N.A : Groove : Unlimited Fillet : N.A. : Nil

FILLER METALS ( QW – 404 ) GTAW SMAW AWS No. ( class ) : ER70S – A1 E7018 –1 Spec. No. ( SFA ) : 5.28 5.1 F. No. : 6 4 A. No. : 2 1 Deposited weld metal thickness range (t) Groove : 9.0 mm Max. GTAW : 5.0mm.Max.; Fillet : N.A. Others : Nil POSITION ( QW – 405 ) Position(s) of Groove : All Position(s) of Fillet : N.A. Weld Progression.(Up/Down): Vertical up Others : Nil

Size of Filler metal : Refer Table Flux trade name : N.A. Electrode-flux (Class ) : N.A.. Consumable insert : N.A. SMAW: Balance

PRE HEAT ( QW – 406 ) Preheat Temp.(min) : Nil ( Min.100C ) Interpass Temp. (Max) : 300 0C Postheat Maintenance : Nil Others : Nil



Temp. Range : Nil Time Range : Nil Others


WPS. No. : 1002

Mix/Purity % 99.99 -----

Flow. Rt.(lpm ) 6 - 14 -----

: Nil


Process


Filler metal Class

Root GTAW ER70S -A1 Further SMAW E7018-1 --do-SMAW E7018-1

Current

Dia 2.4 2.5 3.15

Approved by

Type DCEN DCEP DCEP

Voltage range Amps 60 - 110 70 - 100 100 -140

N.A. N.A. N.A





WPS FOR DIFFERENT MATERAIL BY BHEL

Recommend Documents