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Larsen & Toubro Limited,

Water & Effluent Treatment - SBG

Format No :

LTCD/W&RE/WSBG/PQP/FMT/D04, Rev 0

FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)


Company Name

L&T CONSTRUCTION - WET SBG - TDWSP Medak and Sangareddy Segments

Welding Procedure Specification No.


Supporting PQR No. (s)

L&T- WET/ TDWSP/ WPS-01

By :

Revision No.

LT-TDWSP-PQR-001, Rev-0

Welding Process (es)


Code Applied :

SMAW
ASME Sec IX

Year :

9/2/2015

Date

IMPACT TEST

Type(s)
MANUAL
(Automatic, Manual<Machine, or Semi-Auto.)

2013

JOINTS (QW-402)

Details

Joint Design

Single V

Backing

NO

a - 30 5 deg t -thickness

Backing Material (Type)

NA
(Refer to both backing and retainers.)

Metal

Nonfusing Metal

Nonmetal

Other

c - rootgap

d - root face

Sketches, Production Drawings, weld Symbols or Written Description


should show the general arrangement of the parts to be welded. Where
applicable, the root spacing and the details of weld groove may be
specified.

Root gap

(At the option of the Mfgr., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness
procedures, for multiple process procedures, etc.)

Inside root - seal run

*Base Metals (QW-403)


P-No.

Group No.

to P-NO.

Group No.

OR
Specification type and grade

IS: 2062 Gr B

or

Equivalent

to Specification type and grade


OR

IS: 2062 Gr B

or

Equivalent

Chem. Analysis and Mech. Prop.

N.A.

to Chem. Analysis and Mech. Prop.


Thickness Range :

N.A.

Base Metal :
Pipe Dia. Range :

Groove

5mm to 38mm

Fillet

ALL

Groove

Any diameter ( procedure qualification wise)

Fillet

ALL

Other

N.A.

*FILLER METALS (QW-404)

1st Pass

Filling and caping

Spec. No. (SFA)

5.1

5.1

5.1

AWS No. (Class)

E6013

E6013

E6013

Brand Name

Root

D&H (or) Equivalent

D&H (or) Equivalent

D&H (or) Equivalent

F-No.

A-No.

3.15

3.15

Upto 3 mm

Rest

1 pass

1st pass

Rest

1 pass

Electrode-Flux (Class)

NA

NA

NA

Flux Trade Name

NA

NA

NA

Consumable Insert

NA

NA

NA

Size of Filler Metals


Welds Metal
Thickness Range :
Groove
Fillet

Other

L&T
SIGNATURE
NAME
DATE

REVIEWED BY

APPROVED BY

Larsen & Toubro Limited,


Water & Effluent Treatment - SBG

Format No :

WPS No.
POSITIONS (QW-405)

Rev.

L&T- WET/ TDWSP/ WPS-01

POSTWELD HEAT TREATMENT (QW-407)

Position(s) of Groove
Welding Progression :

LTCD/W&RE/WSBG/PQP/FMT/D04, Rev 0

All position

yes

Up

Down

Position(s) of Fillet

Temperature Range

NA

Time Range

NA

N.A

ALL
GAS (QW-408)
Precent Composition

PREHEAT (QW-406)

Gas(es)

Preheat Temp.

Min.

Interpass Temp.

Max.

Ambient temp.
250-350 deg

(Continuous or special heating where applicable should be recorded.)

(Mixture)

Shielding

NA

NA

Trailing

NA

NA

Backing

NA

NA

Flow Rate
NA
NA
NA

ELECTRICAL CHARACTERISTICS (QW-409)


Current AC or DC
Amps (Range)

DC

Polarity

80-180 A

DCEP

Volts (Range)

24-32 V

As per QW 409.5 15 % will be permitted in amperage and voltage from the PQR tested
values

(Amps and volts range should be recorded for each electrode size,
position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type

N.A.
(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW

N.A.
(Spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range

N.A.

TECHNIQUE (QW-410)
String or Weave Bead
Orifice or Gas Cup Size

String or Weave
NA

Initial and Interpass Cleaning (Brushing, Grinding, etc.)


Method of Back Gouging

Through wire brush, chipping and grinding


By grinding or chipping

Oscillation

NA

Contact Tube to Work Distance

NA

Multiple or Single Pass (per side)

Multi pass

Multiple or Single Electrodes

Multiple

Travel Speed (Range)

55-60 mm/min

Peening

NA

Other

NA

Weld Layer(s)

Process

Filler Metal
Dia.
Class
( mm )

Current
Amp. Range
Type Polar.
( A)

Volt Range
(V)

Travel Speed
Range
CM / MIN

Other
(e.g., Remarks, Comments, Hot Wire
Addition, Technique, Torch Angle etc.)

Root

SMAW

E6013

3.15

DCEP

80-140 A

24-32 V

1 mm/s

As per QW 409.5 15 % (Plus or minus) will be


permitted in amperage and voltage from the
PQR tested values

Filler pass II

SMAW

E6013

DCEP

105-180 A

24-32 V

1 mm/s

ditto

Filler pass III

SMAW

E6013

DCEP

105-180 A

24-32 V

1 mm/s

ditto

Back welding

SMAW

E6013

3.15

DCEP

80-140 A

24-32 V

1 mm/s

ditto

Larsen & Toubro Limited,


Water & Effluent Treatment - SBG

Format No :

LTCD/W&RE/WSBG/PQP/FMT/D04, Rev 0

FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)


Company Name

L&T CONSTRUCTION - WET SBG - TDWSP Medak and Sangareddy Segments

Procedure Qualification Record No.


WPS No.

L&T- WET/ TDWSP/ PQR-01

Revision No.

9/2/2015

Date

L&T- WET/ TDWSP/ PQR-01

Welding Process (es)


Code Applied :

SMAW
ASME Sec IX

Year :

Type(s)
MANUAL
(Automatic, Manual<Machine, or Semi-Auto.)

2013

JOINTS (QW-402)

a - 30 5 deg
c - rootgap= 3 mm

t -thickness= 14 mm
d - root face= 3 mm

t
3 mm
Inside root - seal run
*Base Metals (QW-403)
Material Spec.
Type/Grade or UNS No.
P.No
1 Grade No.
Thickness of Test Coupon
Maximum Pass Thickness

IS 2062 Gr.B (Fe 410WA)


1

to P.No.
14 mm
5 mm

Grade No.

POSTWELD HEAT TREATMENT (QW-407)


Temperature
Nil
Time
Other
GAS (QW-408)

*FILLER METALS (QW-404)


Spec. No. (SFA)
5.1
5.1
AWS No. (Class)
E6013
E6013
F-No.
2
2
A-No.
1
1
3.15 mm
4 mm
Size of Filler Metals
Weld Metal Thickness
3 mm
4 mm
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert
Other
POSITION (QW-405)
1G (Qualification in 1G qualifies all) (position not essential)
Position of Groove
Nil
Weld Progression (Uphill, Downhill)
Other
PREHEAT (QW-406)
Preheat Temperature
Ambient Temp
Interpass Temperature
300-350C
Other

Shielding
Trailing
Backing
Other

Width
19 mm
19 mm

Thickness
14 mm
14 mm

Tensile Test (QW-150)


Area
Ultimate Total Load
266 mm
266 mm

PQR No.

Guided Bend Tests (QW-160)


Result

4 Side Bend Tests


or
2 Root and 2 Face bend Tests
Toughness Tests (QW-170)

N.A

Fillet Weld Test (QW-180)

N.A

24 V

Ultimate Tensile Stress (psi or Mpa)

Type and Figure No.

Date:

Mixture

ELECTRICAL CHARACTERISTICS (QW-409)


Current
DC
Polarity
EP
Amps
100-150 A
Volts
Heat Input
Max. 4200 J/mm
Other
TECHNIQUE (QW-410)
Travel Speed
1 mm/s
String or Weave Bead
String & Weave
Oscillation
Multiple or Single Pass
Multiple
Single or Multiple Electrodes
Multiple
Other

FORM QW-483 (Back)

Specimen No.
1
2

Gas(es)
Nil

Type of Failure

Flow Rate

Welder's Name

FORMAT FOR WELDING PERFORMANCE QUALIFICATION (WPQ)


Identification No.

WPS followed
1
Specification and grade of Base Metal

Test Coupon
Production Weld Yes
IS 2062 Gr.B
Thickness
14 mm
Testing Variables and Qualification Limits
Welding Variables (QW-350)
Actual Values
Range Qualified
Welding Processes
SMAW
SMAW
Type(manual/automatic)
Manual
Manual
Backing(with/without)
without
with(1), both(2)
No
Plate
Yes
Pipe(Dia.)
Pipe OD 1200mm
73 mm to Maximum
Base Metal P-Number to P-Number
1
1-15F, 34, 41, 49
Filler metal or Electrode Specification (SFA) (info)
5.1
Filler metal or Electrode Classification (info)
E6013
Filler Metal F-No.
2
2(both), 1(backing)
Process 1 SMAW 3 Layers Minimum
Yes
15 mm
Upto 30 mm
Position Qualified
5G
F,V,O
Vertical Progression
Uphill
Both

Results
Visual Examination of Completed Weld (QW-302.4)
Yes
Transverse face and root bends (QW-462.3(a))
2 each
Side Bends(QW-462.2)
Type of Test
2 Face Bend Tests
2 Root Bend Tests
(or)
4 Side Bend Tests
(or)
Volumetric Examination Radiography Test Full Joint
(or)
Volumetric Examination Ultrasonic Test Full Joint
QW-190 RT Defects
QW-163 Bend Test Acceptance Criteria
Date:

Material Properties
IS 2062:1992, Fe 410WA Gr.B
C.E=0.42
C=0.23%, Mn=1.5% max, Si=.40% max, S=0.045%, P=0.045%
Tensile Strength=410 Mpa, Yield Strength=250 Mpa, %El=23%
For PQR

4
Result

Material Properties
IS 2062:1992, Fe 410WA Gr.B
C=0.23%, Mn=1.5% max, Si=.40% max, S=0.045%, P=0.045%, CE=0.42
Tensile Strength=410 Mpa, Yield Strength=250 Mpa, %El=23%
For PQR

For PQR & WPQ

For PQR

For WPQ