QW -482 WELDING PROCEDURE SPECIFICATION

(WPS)
(SEE QW 201.1, SECTION IX, ASME BOILER
AND PRESSURE VESSEL CODE




SHEET 1 OF 2
Company Name DCMS ENGINEERING CO.
Welding Procedure Specification No DCMS/WPS/099 Rev-0 Date : 19/04/2012
Supporting PQR no. (S) DCMS/PQR/099 Rev - 0 Date : 7.05.2012
Welding Process (es) GTAW Type (s) Manual
(Automatic, Manual, Machine or semi Automatic)

JOINTS (QW-402)
Joints Design Single V Groove Joint
Backing Yes ___________ No ____X______
Backing Material (Type) _ARGON GAS______
(Refer to both backing & retailers).
Metal Nonfusing Metal
Non Metallic Other

DETAILS
* BASE METAL (QW 403)
P.No. 8 Group no. 1 to P.no. 8 Group no. 1
OR
Specification type and grade Plates ASTM-A-240 Gr 304L
To specification type and grade Plates ASTM-A-240 Gr 304L
OR
Chem. Analysis and Mech. Prop ___________NA___________________________
To Chem Analysis and Mech. Prop ________NA___________________________
Thickness Range :-
Base Metal :- Groove 1.6 to 12 mm Fillet All thickness, all sizes & all diameters
Other WPS shall be applicable for both without and with backing (Stainless Steel Material)

FILLER METALS (QW-404)
Spec No. (SFA) SFA-5.9
AWS No. (Class) ER-308L
F-No. 6
A-No 8
Size of Filler Metals 1.6mm
Weld Metal
Thickness Range
Groove 1.6 mm to 12mm
Fillet All thicknesses
Electrode-Flux (Class) N.A.
Flux Trade Name N.A.
Consumable Insert N.A.
N.A.
POSITION (QW-405)
Position (s) of Groove All Positions(Test piece 1G)
Welding Progression : Up Uphill Down NA
Position (s) of Fillet All Positions
POST WELD HEAT TREATMENT (QW-407)
Temperature Range ____NA_____
Time Range _____NA____









Plates ASTM-A240-Gr 304L
(S.S. to S.S.)

QW-482
WPS NO : DCMS/WPS/099 Dated 19/4/2012
REV : 0






SHEET 2 OF 2

PREHEAT (QW-406)

Preheat Temp. Min NA__________
Interpass Temp. Max _________125
0
C________
Preheat maintenance _________NA__________
(Continuous or special heating where applicable should
be recorded)
GAS (QW-408)
Percent Composition
Shielding (Mixtures) Flow Rate
Shielding Argon 99.99% Pure 12-15Ltr./min
Trailing Argon --
Backing Argon 99.99% Pure 5-10Ltr./min

ELECTRICAL CHARCTERISTICS (QW-409)

Current AC or DC _DC_ Polarity, DCEN (STRAIGHT)
Amp (Range) 65-85 Amp Volts (Range) 10-12 Volts
(Amp and volts range should be recorded for each electrode size, positions and thickness etc.)
Tungsten Electrodes Size & Type 1.6mm, 2.4mm, 2% Thoriated Tungsten Electrodes
(Pure tungsten 2% Thoriated etc.)
Mode to metal transfer for GMAW ____________ NA ________________________
(Spray arc short circulating arc etc.)
Electrodes Wire feed speed range ____________ NA ________________________

TECHNIQUE (QW-410)
String or weave bead Root (stringer) & Final (weaving).
Orifice or Gas Cup Size ceramic nozzle of
Initial and Inter pass (Cleaning Brushing, Grinding etc.)Degreasing with acetone, wire brushing, if required grinding of all pass.
Method of Back Gouging _____NA ______________
Oscillation 2.5 times of size of filler wire_____________
Contact Tube to Work Distance _____NA______________
Single Pass (per side) __ Multiple____________
Multiple or Single Electrode __Single_____________
Travel Speed (Range) 40-65 mm/min.__
Peening Not Allowed
Other _NA__________________

WELD
LAYER(S)
PROCESS
FILLER METAL CURRENT
VOLT
RANGE
TRAVEL
SPEED
RANGE
(mm/min)
OTHER
CLASS DIAMETER TYPE /
POLARITY
AMP
RANGE
Root
(1
st
Pass)
GTAW ER 308-L 1.6mm DCEN 65-75 10-12 40-50
2
nd
Pass GTAW ER 308-L 1.6mm DCEN 75-85 10-12 55-65
3
rd
&
Subsequent
Passes
GTAW ER 308-L 1.6mm DCEN 75-85 10-12 55-65










QW-483PROCEDURE QUALIFICATION RECORD
(PQR)
(SEE QW200.2, SECTION IX ASME BOILER AND
PRESSURE VESSEL CODE)
RECORD ACTUAL CONDITION USED TO WELD TEST
COUPON





SHEET 1 OF 3
Company Name M/S. DCMS Engineering Ltd. Mumbai
Procedure Qualification Record No. DCMS / PQR/099 Date : 7/5/2012 Rev 0
WPS No. DCM/WPS/099 Date : 19/4/2012 Rev. 0
Welding Process(es) GTAW
Types (Manual, Automatic, Semi-Automatic) Manual

JOINTS (QW-402)







Plates ASTM - A -240 Gr. 304L to Plate ASTM A - 240 Gr. 304L
Groove Design of Test Coupon

BASE METAL (QW-403)
Material Spec. SA - 240
Type of Grade 304 L
P.No. ________8________ to P. No. ______8_________
Thickness of Test Coupon 6mm
Diameter of Test Coupon NA
Other Weld thickness range qualified 1.6 mm to 12 mm

POST WELD HEAT TREATMENT (QW-407)
Temperature ___NA_______
Time ___NA_______
Other ___NA_______
FILLER METALS (QW-404) GAS (QW-408)
Percent Composition
Shielding (Mixtures) Flow Rate
Shielding Argon 99.99% Pure 12-15Ltr./min
Trailing ----
Backing Argon 99.99% Pure 12-15Ltr./min
SFA Specification 5.9
AWS Classification ER 308-L
Filler Metal F-No 6
Weld Metal Analysis A-No 8 ELECTRICAL CHARACTERISTICS (QW-409)
Current __________DC_____________
Polarity STRAIGHT (DCEN)
Amps. 85-90 Amp. Volts 12 (Refer Annexure)
Tungsten Electrode Size ________2.4mm ___________
Other NA____
Size of Filler Metal 1.6mm &
2mm
Other

Weld Metal Thickness 6mm
POSITION (QW-405)
Position of Groove __________1G___________
Weld Progression (Uphill, Downhill) N.A.
Others __________________N.A.___________

TECHNIQUE (QW-410)
Travel Speed 48.8 to 66.7 mm /min (Refer Annexure)
String or Weave Bead _Root(stringer) ,Final(weave)
Oscillation final pass weaving not exceeding 2.5 times dia of filler
wire.
Multipass or Single Pass (Per Side) ___Multipass____
Single or Multiple Electrodes _________Single ______
Other -------------------------------------

PREHEAT (QW-406)
Preheat Temperature (Minimum) __N.A _
InterpassTemperature (Maximum) 125
0
C
Other ________________N.A._______________














2007 SECTION IX
QW -483
PQR
Tensile Test (QW 150) Page 2 of 3

Specimen
No.
Width
mm
Thickness
mm
Area
mm
2

Ultimate
Total Load N
Ultimate Unit
Stress N/mm
2

Type of Failure and
Location
T-1 19 5.90 112.10 70400 628.01 weld metal
T-2 18.80 5.94 99.75 62400 625.56 weld metal

Guided Bend Tests (QW-160) Mandrel dia 24 mm (4t)
Type and Figure No. Result
Root Bend RB -1 Satisfactory
Root Bend RB -2 Satisfactory
Face Bend FB -1 Satisfactory
Face Bend FB -2 Satisfactory

Toughness Tests (QW-170)
Specimen
No.
Notch
Location
Specimen
Size
Test
Temperature
Impact Values Drop Weight Break (Y/N)
ft.lb % Shear Mills


NA




Comments ________________________________________NA__________________________________

Fillet Weld Test (QW-180)

Result Satisfactory Yes _________No. _________ Penetration into Parent Metal Yes ______ No. ___
Macro Results_________________ NA ___________________________________________________
Other Tests
Type of Test ___________________________________________________________________________
Deposit Analysis _________ _______________ NA __________________________________________
Other _________________________________________________________________________________

Welders Name N. MADHAVAN Stamp/ID: NMV
Test Conducted by Geo Chem Lab(P)Ltd. Laboratory Test No. M LD /12/04/2012 dt.4.5.2012
We Certify that the statement in this record are correct and that the test welds were prepared, welded, and
tested in accordance with the requirements of Section IX of the ASME BOILER AND PRESSURE VESSEL
CODE.


Manufacture By DCMS Engg. Co.
Date:7.05.2012

Details of record of tests are illustrative only and may be modified to confirm to the type and number of tests
required by the Code.







PQR No. DCMS/WPS/099
Dt. 8/5/2012 Rev - 0



Page 3 of 3

Annexure to PQR No. DCMS/PQR/099 Date: 7/5/2012 Rev: 0

Name of Welder: N. MADHAVAN Stamp/ID: NMV Process: GTAW

Numbers
of Runs /
Weld
Passes
Electrode
Th 2%
(Tungsten)
Filler Wire
Gas
Shielding
ltrs / min

Backing
Gas
Ltrs./min


Current
Speed
mm/min
Volts Amp
1
st

(Root)
2.4 mm

1.6 mm dia
ER 308-L

14 12 11 72 48.8
2
nd
pass


2.4mm


1.6 mm dia
ER 308-L


14

12

12
87

66.7



3
rd
pass



2.4mm

1.6 mm dia
ER 308-L

14

12

12
87

53.04

4
th
pass


2.4mm


1.6 mm dia
ER 308-L

14

12

12
87

49.4









Prepared By Reviewed By Accepted By



Abhishek Nag P.V.Khambatkone Client
(QC Engineer) (Ex-NPCIL QA)




















QW-484 MANUFACTURERS RECORD OF WELDER OR
WELDING OPERATOR PERFORMANCE
QUALIFICATION TESTS (SEE QW-301, SECTION XI,
ASME BOILER AND PRESSURE VESSEL CODE)




WELDER NAME PURAN SINGH Stamp/ID: PN
Welding process(es) used GTAW
Identification of WPS followed by welder during welder during welding of test coupon : DCMS/WPS/099Rev-0 dt.15.09.11
Base material(s) welded SA-240 Gr 304L Thickness 6mm Thick Plate

Manual for Each Process (QW-350) Actual Values Range Qualified
Backing (Metal, weld metal, welded from both sides, flux etc.)
(QW-402)
Without with or without
ASME P.No. 8 to ASME P.No. 8 (QW-403)
( ) Plate (X ) Pipe (enter diameter, if pipe) 6 mm thk plate 1.6 to 12mm Plate
Filler metal specification (SFA) : 5.9 and 5.1 Classification
(QW-404)
ER-308L
A No.8
ER-308L
A.No.8
Filler metal F No. 6 6
Filler Metal variety for GTAW, PAW (QW 404) NA N.A.
Consumable insert for GTAW or PAW NA N.A.
Weld deposit thickness for each welding process 1.6mm GTAW 1.6 mm (GTAW)
Welding position (1G,5G, etc) (QW-405) 1G 1G & all fillet welds
Progression (uphill/downhill) N.A. N.A.
Backing gas for GTAW, PAW or GMAW : Fuel gas for QFW
(QW-408)
Argon Gas
99.995%
Argon Gas
99.995%
GMAW transfer mode (QW-409) N.A. N.A.
GTAW welding current type / polarity DCEN (GTAW) DCEN (GTAW)

Machine Welding Variables for the Process Used (QW-360) Actual Values Range Qualified
Direct / remote visual control
Automatic voltage control (GTAW)
Automatic joint tracking NA
Welding position (1G, 5G, etc)
Consumable insert
Backing (metal, weld metal, welded from both sides, flux etc.)

GUIDED BEND TEST RESULTS
Guided Bend Tests Type ( ) QW- 462.2 (Side) Results ( ) QW 462.3 (a) (Trans. R & F) Type ( ) QW-462.3
(b) (Long, R & F) Results
FB-1 Satisfactory RB-1 Satisfactory
FB-2 Satisfactory RB-2 Satisfactory
Visual examination results (QW-302.4): Satisfactory
Radiographic test results (QW-304 and QW-305): Satisfactory
(For alternative qualification of groove welds by radiography)
Fillet Weld Fracture test N.A. Length and percent of defects NA
Macro test fusion NA Fillet leg size NA in X inch Concavity / convexity NA in.
Welding test conduced by DCMS Engineering Co. Ltd.
Radiographic tests conducted by M/s. Geo chem Lab, Mumbai. Laboratory Test No. MLD/11/08/06896
DT.17.9.2011
We certify that the statements in this record are correct and that the test coupons were prepared
welded and tested in accordance with the requirements of Section IX of the ASME Code

DCMS Engineering Co. CLIENT

Date __________ Date _________________