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SWATHI INDUSTRIES

A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032

[QW483PROCEDUREQUALIFICATIONRECORD(PQR)]
Procedure Qualification Record No.: SI-107
WPS No.: SI-007
Welding Process (es):

DATE.:

08.10.2010

GMAW

Type (Manual; Automatic; Semi Automatic):

Semi-Automatic

JOINT(QW402)

GrooveDesignofTestCoupon

BASEMETALS(QW403)
Materialspecification.: SA 516-70
TypeorGrade:
GR -70
P.No.:
ToP.No.:
1 Gr. 2
ThicknessofTestCoupon:
40mm
DiameterofTestCoupon:
Other:
FILLERMATERIALS(QW404)
SFASpecification:
5.1
AWSClassification:
ER70S6
FillerMetalF.No.:
6

1 Gr. 2

POSTWELDHEATTREATMENT(QW407)
Temperature:
620DegC
Time/Soaking:
AsperUCS56
Other:SR.Cycle.No:131/2010, Date:29092010.
SRCarriedoutatM/sVijayEngineeringIndustires

GAS(QW 408)
PercentageComposition
Gas(es)
Mixture
Flowrate
Shielding
CO2
100%
1220LPM

WeldMetalAnalysisANo.:

5.1

Trailing

SizeofFillerMetal:
WeldMetalThickness:

1.2mm
40mm

POSITION(QW405)
PositionofGroove: 2G,Vertical

Backing

ELECTRICALCHARACTERISTICS(QW409)
Current: DC
Polarity: Electrodepositive
Amps: 140 350A
Volts: 20 32V
TungstenElectrodesize:
Other

WeldProgression:

TECHNIQUE(QW410)

Other:

Uphill

Other:
PREHEATING(QW406)
10 C Upto 30mm
PreheatTemp.:
31-100mm - 100 C
Above 100mm - 150 C
InterpassTemp.:
Other:

350Cmax.

TravelSpeed:
String/WeaveBead:

Multipass/Singlepass(perside):

String&WeaveBead

MULTIPASS

SingleorMultipleElectrodes:

SINGLE

Other: Cleaneachlayerbeforestartweldingnewpasses/
layers.WeavingMaximum3timesthediameterofElectrode.

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QW483(Back)
PQRNo: SI-107.

TensileTest(QW150)

UltimateTotalLoad.
kN

UltimateUnitStress.
Mpa(410Min)

SpecimenNo

Width(mm)

Thickness

Areamm

SAMPLE1

19.00

18.00mm

342.00

170

497.08

SAMPLE2

19.00

17.60mm

334.4

167

499.40

SAMPLE3

19.00

17.20mm

326.80

165

504.90

SAMPLE4

19.00

18mm

342.00

169

494.15

TypeofFailure
&Location
Brokenaway
fromweld
Brokenaway
fromweld
Brokenaway
fromweld
Brokenaway
fromweld

GuideBendTests(QW160)
TypeandFigureNo.

Result

SideBendtest4Nos180o,4T

Satisfactory

WeldersName:

MUNNAKUMARSINGH

ClockNo:

StampNo.:

MKS01

TheWeldingtestsareconductedandsupervisedbyM/s.SWATHIINDUSTRIES,R.C.PuramandMechanicalTestscarriedoutby
M/s.SMSMETALLURGICALSERVICES,VideTESTREPORTNO:1011/0198,DT:08.10.10WeldingtestandMechanicalTestsare
WitnessedbyM/s.BHEL,HPEP,Hyderabad,QualitycontrolDepartment.
Wecertifiesthatthestatementinthisrecordarecorrectandtheweldtestcouponswereprepared,welded,andtestedin
accordancewiththerequirementsofSectionIXofASMEcode.

Witnessed/CertifiedBy.
Manufacturer:
Signature:

Signature:

Date:
Date:

SWATHI INDUSTRIES
A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032

QW482WELDINGPROCEDURESPECIFICATION(WPS)
WeldingProcedureSpecificationNo. SI-007
RevisionNo.: 00

Date.:

Date.

26.08.2010

WeldingProcess(es):

SupportingPQRNo. SI-107
Type(s):

GMAW

Semi Automatic

(Automatic;Manual;MachineorSemiAutomatic)

JOINTS(QW402):

JointDesign:
Backing(Yes)

AsperManufacturersDrawing(Groove/Fillet)
ForDoublesideandbackingstripgroovewelds

(No.)

ForSinglesideGroovewelds

BackingMaterial(Type):
Metal: Yes
Retainer:
No

Basemetal/weldmetal
NonfusingMetal:

No

BASEMETALS(QW403)
PNo.:

GroupNo.:

1&2

ToPNo.:

GroupNo.:

1&2

OR
SpecificationTypeandGrade:

SA51670

ToSpecificationTypeandGrade:

SA51670

OR
ChemicalAnalysisandMech.Properties:

ToChemicalAnalysisandMech.Properties:

THICKNESSRANGE:
BaseMetal
PipeDia
Range
Other:

Groove: 4.75to200mm

Fillet:

AllSizes

Groove:

Fillet:

AllSizes

AllDia

Root spacing for backing strip joints : 8 - 10 mm


For others : 1-3 mm
(403.13 : not applicable)

FILLERMATERIALS(QW404)
SpecificationNo.:(SFA):

5.18

AWSNo.:

ER70S6

F.No.:

A.No.:

SizeofFillerMaterials:

1.2,1.6

Depositedweldmetal:

ThicknessRange: Groove:
ElectrodeFlux(Class):

Basic

ConsumableInsert.:
Max.BeadThickness:

No
4mm

5.0to200mm

Fillet:

AllSizes

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POSITIONS.(QW405)
Positionofgroove:
AllPosition
WeldingProgression: UpHill,Vertical
Position(s)ofFillet:

DownHill:

ALL

WQ 482(BACK) WPSNo: SI-007.Rev.00


POSTWELDHEATTREATMENT(QW 407)
TemperatureRange:
600 C- 650 C
TimeRange:
UCS56
(AsperUCS56)

PREHEAT(QW406)

GAS(QW408)

PREHeatingTemperatureMin.:
InterpassTemperatureMax.:
PreheatMaintenance.:

10 C Up to 30 mm
100 C max.above 30 mm
Above 100mm - 150 C

Shielding
Trailing
Backing

250Cmax.
NIL

PercentageComposition
Gas(es)
Mixture
CO2
100%

Flowrate
1220LPM

ELECTRICALCHARACTERTISTICSIQW409)
Current(ACorDC):

DIRECT CURRENT

Polarity(+veor_ve): ELECTRODE POSITIVE

Amperes(Range):

150 to 350 A

Volts.(Range):

TungstonElectrodeSizeandType.:

NA

ModeofMetalTransferforGMAW.:

GMAWSPRAY

20 - 30 V

ElectrodeWireFeedSpeedRange:
TECHNIQUE(QW410)
StringorWeaveBead:

string and weave

OrificeorGasCupSize:

20mm(ID)

Initial&Interpasscleaning:

ByBrushing/Grinding./ChippingEtc.(usestainlesssteeltools)

MethodofBackGouging:

Grinding

Oscillation:

Contacttubetoworkdistance:

25to40mm

Multiple/SinglePass(perside):

MultiplePasses

Multiple/SingleElectrode:

SingleElectrode.

Peening:

Notallowed.

Travelspeed(Range): 150200mm/min
Min1oneithersideoftheweldareatobecleanedandfreefromDirt,rust,paints,Oil,
grease,etc.(Beforestartthewelding).

Other(WeldDiscipline):

FillerMetal
Dia(mm)

Current
Typepolar

Weld
Layers

Process

Rootrun

GMAW

ER70S6

1.2

DC +

150-200

GMAW

ER70S6

1.6

DC +

250-350

2n

Class

ApprovedBy:
Date:

Remarks
Amps

STRING & WEAVE

SWATHI INDUSTRIES
A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032
{QW484AMANUFACTURERSRECORDOFWELDERPERFORMANCEQUALIFICATION(WPQ)}

WeldersName:

MUNNAKUMARSINGH

MKS01

IdentificationNo.

TestDescription
TestCoupon:Yes

IdentificationofWPSfollowed

SI-007

SpecificationofBasemetal(s)

SA51670toSA51670

ProductionWeld.
Thickness:

No

40mm

TestingConditionsandQualificationLimits.
Weldingvariables(QW350)

ActualValues

WeldingProcess(es):
Type(Manual,Semi,Auto):
Backing(metal,weldmetal,doubleweldedetc.

Plate

GMAW

MANUAL

MANUAL

WITHOUT

Pipe(enterifpipeortube)

Fillermetalorelectrodespecification(s)(SFA)
FillermetalorelectrodeClassification(s)
Consumableinsert(GTAWorPAW):
FillerType(Solid/metalorfluxcored/powder(GTAW
orPAW))
DepositThicknessforeachProcess.
GMAW

3layersmin.

3layersmin.

Yes/No
Yes/No

P1

P1
5.18

ER70S6

ER70S6

F6

F6

SOLID

SOLID

40mm

Maximumtobewelded

Positionqualified(2G,6G,3Fetc.)

2G
Groove
Fillet

Verticalprogression(Up/Downhill)
Inertgasbacking(GTAW,PAW,GMAW)
Transfermode(spray/globularorpulsetoshortcircuit
GMAW))
GTAWcurrenttype/Polarity(AC,DCEP,DCEN)

Pipebendspecimen,

Type
Tensile

UPHILL

UPHILL

NA

NA

NA

NA

NA

NA

Transverserootandface(QW462.3(a));

CorrosionresistantOverlay(QW462c)

Macrotestforfusion(QW462.5(b)
Result
Satisfactory

1G,2G,1F,2F&3F
PLATE&PIPEOD>610mmF&V
FLATPOSITIONFORPIPEOD73mmto<OD610mm
PLATE&PIPEF,H&V

RESULTS
SATISFACTORY

VisualExaminationofCompletedWeld(QW302.4):
BendTest;SATISFACTORY

PlateMaxtobewelded&pipe73andabove

5.18

FillermetalFNumber(s):

Process2:

WITH/WITHOUT

PLATE40mm

BaseMetalPorSNumbertoPorSNumber:

Process1:

RangeofQualified

GMAW

Longitudinalrootandface(QW462.2)

Platebendspecimen,corrosionresistantoverlay(QW462.5(d))

Macrotestforfusion(QW462.5(e)
Type
Sidebend

Result
Satisfactory

Type

Result

TheWeldingtestsareconductedandsupervisedbyM/s. SWATHIINDUSTRIES,R.C.PuramandMechanicalTestscarried
outbyM/s.SMSMETALLURGICALSERVICES,VideTESTREPORTNO:1011/0198,DT:08.10.10WeldingtestandMechanical
TestsareWitnessedbyM/s.BHEL,HPEP,Hyderabad,QualitycontrolDepartment.

Wecertifythatthestatementsinthisrecordandthatcoupon wereprepared,welded, andtestedinaccordancewiththerequirementsofsectionIXofthe


ASMEBoilerandPressureVesselCode.

Certified/WitnessedBy.

Date:

Organization: