WELDING PROCEDURE SPECIFICATION

(WPS) (QW-482)
In accordance with QW-200.1, Section IX, ASME BPVC
Company Name Precision profiles India , Chennai.
WPS No. PPI/L&T/WPS/014 Rev 0 Date 6/4/2014
PQR No. PPI/L&T/PQR/014 Date
Welding Process GMAW Type: MANUAL
This procedure applying for fabrication welding/repair welding of P 1
Scope
material with PWHT
JOINTS (QW-402)
Joint Design Refer Sketch
Root Space (A) 2mm
Root land (B) 2mm
Bevel Angle 60°±5˚
Backing Yes
Backing Material Weld area
Retainer Nil
BASE METALS (QW-403)
P.NO 1 Group No. 2 to P. No. 1(all P.NO 1 material) Group No 2 2
Material Specification SA516 Grade GR 70
Chemical Analysis As per specification
Mechanical Properties As per specification
Base Metal 5-200mm Fillet All size
Thickness Range
Pipe Diameter Greater than 73mm Fillet All dia
Weld pass thickness ≥ 13 mm Yes
FILLER METALS (QW-404)
Specification No. (SFA) A5.18
AWS No. (Classification) E R70S-6
F-No. 6
A-No. 1
Size of Electrode / Filler Metal Ø1.2mm Dia
Filler Metal Product Form Wire
Supplemental Filler Metal NA
Weld Metal Thickness Range 5-200mm Fillet All Size

Electrode Flux (Classification) NA Consumables Brand Name ESAB MW1

ESAB INDIA
Consumable Insert NA Manufacturer LTD
Powder Feed Rate NA
Diameter > 6 mm (1/4 in.) NA
Change of Alloy Element NA
POSITIONS (QW-405) PREHEAT (QW-406)

Position 1G Preheat Temperature, min. 150˚C

Welding Progression NA Interpass Temperature, max. 300°C

Position(s) of Fillet All Preheat Maintenance NIL

POST WELD HEAT TREATMENT (QW-407)
Type
Holding Temperature 620-640°C
Time Range, min 1 1/2hr min
Time Range, max 2 hrs
Rate of Heating Max. 100°C
Loading / Unloading
300°C Rate of Cooling Max. 100°C
Temperature, Max
 WELDING PROCEDURE SPECIFICATION
(WPS) (QW-482)
In accordance with QW-200.1, Section IX, ASME BPVC

GAS (QW-408)
Gas Mixture composition (%) FlowRate(litres/minute)
Shielding Gas CO2 99.99 15-20
Trailing Gas NA NA NA
Backing Gas NA NA NA
ELECTRICAL CHARACTERISTICS (QW-409)
Filler Metal Current Travel Speed
Volt
Weld Pass Process Diameter (range)
Classification Type Polarity Amps (Range) (Range)
(mm) (mm/min)

Root run GMAW E R70S-6 1.2 DC RP 120-160 20-24 120-180

Sub sequence
GMAW E R70S-6 1.2 DC RP 150-220 20-30 120-180
layers
Pulsing Current NA

Heat input (max) NA

Tungsten Electrode Size & Type NA

Mode of metal transfer Globular Transfer

Electrode wire feed speed range 4-6 m/min

TECHNIQUE (QW-410)
String or Weave Bead Both (Weave not more than 3 times of the electrode)

Oriffice, Nozzle and Gas cup size NA

Initial and interpass cleaning method Wire brushing & Chipping

Method of back gouging Grinding

Oscillation NA

Multiple or single pass (per side) Multiple Pass

Multiple or single layer Multiple

Multiple or single electrode single

Electrode Spacing NA

Welding Process GMAW

Peening NA

Use of thermal process NA

Note:
The filler metal shall be stored, issued and controlled as per manufacturer's recommendation / Precision Profiles India
procedures.

PPI FLOWSERVE DNV

Name: Name: Name:

Signature: Signature: Signature:

 WELDING PROCEDURE QUALIFICATION RECORD
(PQR) (QW-483)
In accordance with QW-200.2, Section IX, ASME BPVC
Company Name Precision Profiles India,Chennai.
WPS NO PPI/L&T/WPS/014 REV 0 Date 10/29/2013
PQR No. PPI/L&T/PQR/014 REV 0 Date
Welding Process GMAW Type :Manual
Date of Welding 29-Oct-13
JOINTS (QW-402)
Joint Design Refer Sketch
Root gap / Space 2mm
Root land 2mm
Backing yes
Backing Material weld area
Retainer nil
Bevel Angle 60˚±5˚
BASE METALS (QW-403) PREHEAT (QW-406)
Material Specification SA516 Preheat temperature 150 ˚c
Grade GR 70 Interpass temperature 300 ˚c
. Preheat Maintenance nil
P.No 1 Gr. No. 2 to P.No 1 Gr. No. 2 POST WELD HEAT TREATMENT (QW-407)
Thickness of test coupon 32mm Temperature 620-640 ˚c
Diameter of test coupon na Time 1hr
Size (l x w x t) (mm) 300x150x32 Rate of Heating 100 ˚c
Weld pass thickness <13mm Yes Rate of Cooling 100 ˚c
Loading / Unloading Temperature (max.) 400 ˚c

FILLER METALS (QW-404) GAS (QW-408)

SFA Specification 5.18 Flow Rate
Gas Mixture composition(%)
AWS Classification ER70S-6 (lpm)
Filler Metal F-No. 6 Shielding Gas C02 99.99 15-20
Weld Metal Analysis A-No. 1 Trailing Gas NA NA
Filler Metal Product Form wire Backing Gas NA NA
Size of Filler metal Ø1.2mm dia
Weld metal thickness 13mm

POSITION (QW-405)
Position 1G
Weld Progression na
.
ELECTRICAL CHARACTERISTICS (QW-409)
Filler Metal Current
Travel Speed (range)
Weld Pass Process Volt (Range)
Diameter Amps (mm/min.)
Classification Type Polarity
(mm) (Range)
Root run GMAW E R70S-6 1.2 DC RP 120-160 20-25 120-180
Sub
sequence GMAW E R70S-6 1.2 DC RP 150-220 20-30 120-180
layers

TECHNIQUE (QW-410)
Travel Speed 120-180mm/min
String or Weave Bead Both (weave not more than 3 times of the electrode)
Initial and interpass cleaning Wire brushing & Chipping
Method of back gouging Grinding
Oscillation NA
Multiple or single pass (per side) Multiple pass
Multiple or single layer Multiple
Multiple or single electrode Single
Welding Process GMAW
Peening HT
Use of thermal process NA

Form No: QP-051-R0

 WELDING PROCEDURE QUALIFICATION RECORD
(PQR) (QW-483)
In accordance with QW-200.2, Section IX, ASME BPVC

TENSILE TEST (QW-150)

Ultimate total Type of failure

Specimen No. Width, mm Thickness, mm Area, mm2 Ultimate unit stress, MPa
load, kN & location
T1 19.08 31.99 610.37 320.95 525.83 BASE
T2 19.31 31.85 615.02 319.3 519.17 BASE

GUIDED-BEND TESTS (QW-160)

Specimen Size(mm) 300 x 33 x 10.4

Type and Figure No.QW462.3a` Bend Angle Result
Sample ID-SB(1) 180 No cracks or fissures observed
Sample ID-SB(2) 181 No cracks or fissures observed
Sample ID-SB(3) 182 No cracks or fissures observed
Sample ID-SB(4) 183 No cracks or fissures observed
FILLET-WELD TESTS (QW-180)
Results NA

Penetration into parent metal NA

Macro - Results NA
OTHER TESTS

Sl. No Type of Examination Result

1 Visual Examination Free from spatters

2 Liquid Penetrant Examination No indication found in weld areas
3 Radiographic Examination Report no:PPIL 004/13-14
Hardness (HV10)
4 Base 145 / 164
Weld 157 / 191
HAZ 168 / 194

5 Macro Examination Specimen did not reveal any cracks or other defects

Welder's Name P.PANDIYAN Identification No. PP

Test Conducted by M/s Precision Profiles India
We certify that the statements 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.

Prepared by Reviewed & Approved by

O.Rajesh E.X.Xavier
Quality Assurance Quality Assurance

Form No: QP-051-R0

 WELDER PERFORMANCE QUALIFICATION
(WPQ) (QW-484A)
In accordance with QW-301, Section IX, ASME BPVC
WPQ No. PPI/L&T/WPQ/014 Date 1/2/2014
Welder's Name P.Pandiyan Identification No. PP
Weld Shop M/s Precision Profiles India .
TEST DESCRIPTION
Identification of WPS followed PPI/L&T/WPS/014
Test Coupon or Production Weld Test Coupon
Material Specification SA516 Grade 70
Base Metal Thickness 32mm
Date of Welding 15-Nov-13

TESTING VARIABLES AND QUALIFICATION LIMITS

Welding Variables (QW-350)
Welding Process(es) GMAW
Type (i.e.; manual, semi-automatic) used Manual
Backing (with / without) with backing
Plate or Pipe (enter diameter if pipe or tube) Plate
Base metal P-Number to P-Number 1 to 1
Filler metal or electrode specification(s) (SFA) (info. only) 5.18
Filler metal or electrode classification(s) (info. only) ER70S-6
Filler metal F-Number(s) 6
Consumable insert (GTAW or PAW) NA
Filler Metal Product Form (solid/metal or flux cored/powder) solid wire
(GTAW or PAW)
Deposit thickness for each proces , mm 2mm
Deposit thickness for each process (3 layers min) 6mm
Position qualified (1G, 6G, 3F, etc.) 1G
Vertical progression (uphill or downhill) NA
Type of fuel gas (OFW) CO 2
Inert gas backing (GTAW, PAW, GMAW) GMAW
RESULTS
Visual Examination Results (QW-302.4)
Liquid Penetrant Examination results(QW-195.2)
Radiographic Examination results (QW-190) Report no:PPIL 004/13-14
Mechanical Test conducted by M/s.MICRO LAB
Hardness Test conducted by M/s.MICRO LAB
Macro Examination conducted by M/s.MICRO LAB
Bend test results (QW-462.2)
Type Result Type Result Type Result

No cracks or
Side Bend - - -
fissures observed

Welding qualification conducted by M/s.PrecisionProfiles India

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 Boiler and Pressure Vessel Code.

Prepared by Reviewed & Approved by

O.Rajesh E.X.Xavier
Quality Assurance Quality Assurance

Form No: QP-051-R0