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Client

Contractor
Procedure No.

M/S. INDIAN OIL CORPN. LTD. PJPL PROJECT, PANIPAT


M/S. INDCON PROJECTS & EQUIPMENT LTD., NEW DELHI

INDCON-PJPL-STN-MECH-WPS-15

PROCEDURE FOR
DESTRUCTIVE TESTING PRODUCTION WELD

22.09.07

Anuj

Vijay

GSB

REV. NO.

DATE

DRN. BY

CHKD.BY

APPV.BY

Approved (IOCL)

PROCEDURE FOR DESTRUCTIVE TESTING PRODUCTION


WELD
PROCEDURE No: INDCON-PJPL-STN-MECH-WPS-15.
WELDING PROCEDURE SPECIFICATIONS (WPS)
(See QW-200.1, Section: IX, ASME Boiler & Pressure Vessel Code)

Company name
Welding Procedure
Welding PQR No.
Welding Process

Indcon Projects & Equipment Ltd.


WPS/15
Revision : 0
PQR-15
Revision : 0
GTAW + SMAW
Type : Manual

JOINT (QW-402)
Joint Design : As per fabrication drawing
Backing
: Without backing
Backing material : Weld metal
Retainers : Not required

By : Head QC
Dated : 26.09.2007
Dated -

JOINT DETAIL
As Per Fabrication Drawing

BASE METALS (QW-403)


P. No. 1
Group No. : Any
TO
Specification type and grade
SA 106 Gr. B
Thickness range: -Base metal
Groove : 1.6 mm to 17.48mm
Pipe Dia. Range
Groove All
T/t Limits > 8
Not applicable
P No. 5/9/10
Not applicable

P No.: 1

Group No. : Any


Fillet : All

FILLER METALS (QW-404)


Spec. No. (SFA)
AWS No. (Class)
F - No.
A No.
Size of Filler Metals (Dia)
WELD METAL:
Thickness range:
Groove
Fillet
Consumable insert

GTAW
5.18
ER-70S-2
6
1
2.4 mm

SMAW
5.1
E7018-NC
6&4
1
2.5 mm

1.6 mm to 17.48 mm
All sizes
None

All sizes
None

POSITIONS (QW 405)


Position (s) of Groove All
Welding progression
Up hill
Position of Fillet
All

POST WELD HEAT TREATMENT (WQ-407)


Temperature range
620 - 650
Time range
Min. 2 Hours

PREHEAT (QW 406)


Preheat temp.Min.
16 C min
1)
Interpass temp. Max.
250 C
Preheat maintenance
Not Required

GAS (QW 408)


Percent Composition
Shielding
Trailing
Backing

Gas(es)
Argon
None
None

Mixture

Flow rate

---

---

ELECTRICAL CHARACTERISTICS (QW 409)


Current
DC
Amps range
See table
Tungsten electrode size & type
Mode of metal transfer for GMAW
Electrode wire feed speed range
Pulsing

Polarity
Volts
3 mm, EWTH-2
Not applicable
Not applicable
None

WPS -15
Dated : 26.09.2007
EN for GTAW, EP for SMAW
See table

TECHNIQUE (QW 410)


String OR weave bead
Orifice or gas cup size
Initial & interpass cleaning
Method of back gouging
Oscillation

String & weave ( 3 x Core Dia. Max)


5-8 mm
Brushing & grinding
Grinding
None

Electrode spacing
Multiple or single pass (per side)
Multiple or single electrodes
Travel speed (range)
Peening

Not applicable
Multiple. No singe pass is greater than 13 mm)
Not applicable (Manual)
Refer table
Not allowed

Weld-

Proces

FILLER METAL

CURRENT

Class

Dia.

Type

Root run

GTAW

ER-

2.4 mm

DCEN

1st run

GTAW

ER-

2.4 mm

DCEN

2nd run &


Subsequ

SMAW

ER-7018

2.5 mm

DCEP

Volt

Travel

Heat input
K
J/
m
m
( Max )

Amp.

Approved by

Head QC/Head welding

PROCEDURE QUALIFICATION RECORD (PQR)


(See QW 200.2, Section IX,ASME Boiler and Pressure Vessel Code)
Company Name
Procedure Qualification Record No.
WPS No.
Welding Process (es)
Type Of Welding Process (es)

Indcon Projects & Equipment Limited


PQR /15
Dated
WPS / 15
Dated
GTAW + SMAW
Manual

26.09.2007
26.09.2007

JOINTS ( QW 402 )

BASE METALS (QW-403)


Material Specs. SA 106
Type or grade
Gr. B
P No.
1
To
Thickness of Test Coupon
Diameter of Test Coupon

P No.
8.74 mm
DN 50

POST WELD HEAT TREATMENT (QW-407)


Temperature
Time
Other

FILLER METALS (QW 404)


SFA Specification
AWS Classification
Filler Metal F No.
Weld Metal Analysis
A No.
Size Of Filler Metal
Other (Electrode
trade name)
Weld Metal Thickness

GAS (QW 408 )

GTAW
5.18
ER 70S2
6
1

SMAW
5.1
E-7018
4
1

2.4 MM
KISWEL

2.5 MM
HONAVAR

1.6 mm

7.14 mm

POSITION (QW 405 )


Position of Groove
Weld Progression
Other

----

6G
Uphill
--

Percent Composition
Gas (es)
Mixture
Shielding

ARGON

99.95%

Trailing
Backing

---

---

16 C

Inter pass Temperature


Other

250 C
-

Flow rate
10-20
LPM
---

ELECTRICAL CHARACTERISTICS (QW 409)


Current
Polarity
Amps
Volt
Tungsten Electrode Size
Other

PREHEAT ( QW 406 )
Preheat Temperature
(Min.)

FOR GTAW ONLY

DC
EN for GTAW, EP-SMAW
80 160
10-24
3.00 mm EW TH-2
--

TECHNIQUE ( QW 410 )
Travel Speed

60 90 mm / Min.

String or Weave Bead


Oscillation
Multi pass or Single
pass (per side)
Single or Multiple
Electrodes
Other

Root string, balance weave


Not applicable.
Multiple. No single pass is
greater than 13 mm
N/A (Manual)
-

Page 2 of 2
TENSILE TEST (QW 150 )
Specime
n No.

Widh
( mm )

Thickness
( mm )

Area
( mm )

Ultimate
Total Load
(Newton)

T1

19.44

8.67

168.5

82080

Ultimate
Tensile
Strength
(MPa)
487.1

T2

19.28

8.70

167.7

83440

497.5

PQR NO. 15
Date26.09.2007
Type of Failure &
Location
Ductile, Broken in
Parent Metal
Ductile, Broken in
Parent Metal

GUIDED BEND TESTS (QW 160 )


Type and Figure No.
Root Bend RB 1, QW 462.3a
Root Bend RB 2, QW 462.3a
Face Bend FB 1, QW 462.3a
Face Bend FB 2, QW 462.3a
(Bend dia 4 t x 180 C)

Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory

TOUGHNESS TESTS ( QW 170 )


Specime
n No.

Notch
Location

Specimen
Size

Test
Temp.

Impact Values
Joules

1
2
Comments :

Yes

Macro Results
OTHER TESTS
Type of Test

Welders Name
Test Conducted By

Mils

N/A

FILLET WELD TESTS ( QW 180 )


Result Satisfactory

Shear

Type of Failure &


Location

N/A
No

Penetration into
Parent Metal
N/A

Yes

No

Radiography Satisfactory, Report no. RR/705/02 dated 4/12/2006


Visual inspection - satisfactorily
Dilip kumar
Clock No.
M/s Spectro Analytical Labs Ltd. &
Indcon Projects & Equipment Ltd.

Stamp No.
Laboratory Test Report No.

W 16

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 & Pressure Vessel Code.
Manufacturer: INDCON PROJECTS & EQUIPMENT LTD.

HEAD QC /HEAD WELDING

INSPECTION AGENCY