Format No. WCL/SAWL/OPN/F/23 Rev.

02

WELSPUN Document No. PQR/SAWL/SOC/15.88/2015-38

Revision 0

Date / Shift 17.08.2015/G

Operation Page 01 of 02
PROCEDURE QUALIFICATION RECORDS FOR GMAW & SAW (AS PER ASME SEC.IX 2015 QW-483 & CUSTOMER
Document SPECIFICATION )
Company Name & Location Welspun Corp Ltd. & Anjar, Gujarat, India
Plant/Department Name SAWL Plant/ Operation
PQR No : PQR/SAWL/SOC/15.88/2015-38, Rev. 0 Welding Process(es) GMAW & SAW
Supporting WPS No : WPS/SAWL/SOC/15.88/2014-61, Rev. 0 Type GMAW (Auto & Semi Auto) & SAW (Auto)
Client Name : SOUTH OIL COMPANY (SOC), IRAQ JOINT (QW - 402)
Name of Welders : 90˚
GMAW (Auto) Mr. Dilip Parmar SAWL-081
GMAW (SemiAuto) Mr. Vijay Kumar SAWL-048
6.38 mm OD
SAW - Internal Mr. Suresh Dabhi SAWL-056 15.88 mm
5.50 mm RF
SAW - External Mr. Shamsher Singh SAWL-054 4.00 mm ID
Backing YES NO
Backing Material (Type) GMAW (Base Material) & SAW (Weld Metal) 90˚
BASE METAL (QW - 403) PRE - HEAT (QW - 406)
P No : 1
Pre-heat Temp. Ambient (36°C)
Group No : 2
Spec. Type & Grade API 5L X60M PSL 2 Inter pass Temp. NA
Pipe Thickness (mm) 15.88 POST WELD HEAT TREATMENT (QW - 407)
Pipe Diameter (mm) 1066.80 Temperature NA
Maximum Pass Thickness NA Time NA
FILLER MATERIAL (QW - 404) GAS (QW - 408)
Process GMAW(A) GMAW(SA) SAW ID SAW OD Gas Flow Rate
Shielding Gas for GMAW Gases
Spec. No - (SFA) 5.18 5.18 5.23 5.23 Mixture (%) (LPM)
AWS No - (Class) ER70S-6 ER70S-6 EA2, EM12K EA2, EM12K Auto CO2 100% 55
Filler Metal : F No. 6 6 6 6 Semi Auto CO2
100% 20
Weld Metal Analysis : A No. 1 1 1 1 ELECTRICAL CHARACTERISTICS (QW - 409)
Size of Filler Metal (mm) 4.0 1.6 4.0, 4.0, 4.0 4.0, 4.0, 4.0 Process SAW GMAW
F55TA0G-EA2-EM12K
Flux - Electrode - (Class) - - Current As per table As per table
Weld metal thickness (mm) 15.88 Heat Input As per table As per table
Type Manufacturer Brand/ Trade Name Polarity DCEP / AC DCEP
Flux (Agglomerated) LINCOLN 995N Mode of Metal Transfer (GMAW Auto) - Globular

SAW Wire PITTARC S2Mo, S2 Mode of Metal Transfer (GMAW Semi auto) - Globular

GMAW Wire PRECISION PWL MIG 2 TECHNIQUE (QW - 410)

Flux Preheat Temp = Heating at 270 ºC for 1 Hrs; String or Weave String
Holding at minimum 120 ºC in intermediate tank for ID and supply tank on OD.
Note :-Repair of tack welds perfomed by using Semi Auto GMAW grounded up to height of Oscillation NA
Automatic GMAW.
POSITION (QW - 405) Single Pass or Multi Pass Single Pass
Position of Weld Groove 1G Multiple for SAW
Single or Multiple Electrode
Weld Progression NA Single for GMAW
FILLER METAL CURRENT VOLTAGE SPEED HEAT I/P Wire distances & Angles
Sr. No.
NAME SIZE TYPE ( AMP ) (V) ( Mtr./min) (KJ/mm)
1 Auto Tack Welding
ER70S-6 4.0 DC 1250 22.5 4.35 0.39 5º
2 Semiauto Tack Repair 18
ER70S-6 1.6 DC 265 22.5 0.45 0.80
3 Internal SAW
T2 +15º T1-0º L -15º
EA2 4.0 DC 750 34.0

EM12K 4.0 AC 625 35.0 1.37 2.98

30 28 26
EM12K 4.0 AC 575 36.0 20 18
4 External SAW
T2 +15º T1-0º L -10º
EA2 4.0 DC 1025 34.0

EA2 4.0 AC 775 36.0 1.45 3.42

30 29 28
EM12K 4.0 AC 525 38.0 20 18
BATCH NO. of GMAW Wire ER70S6 (1.6 mm dia): RC5010216; GMAW Wire ER70S6 (4.0 mm dia) : DC5050840; SAW Wire EA2 (4.0 mm dia): 12010 2012,
REMARK
10249 2011; SAW Wire EM12K (4.0 mm dia): 981 2015; Flux 995N: F1FX150410

PREPARED BY REVIEWED BY APPROVED BY INSPECTION AGENCY

KHUSHAL ADWANI ASHIF SHEIKH SATYANARAYANA SAMAVEDAM
Engineer-Operation Section Head - Welding H.O.D - QA/QC
 Format No. WCL/SAWL/OPN/F/23 Rev.02

WELSPUN Document No. PQR/SAWL/SOC/15.88/2015-38

Revision 0

Date / Shift 17.08.2015/G

Operation Page 02 of 02

Document PROCEDURE QUALIFICATION RECORDS FOR GMAW & SAW (AS PER ASME SEC.IX 2015 QW-483 & CUSTOMER SPECIFICATION )
Company Name & Location Welspun Corp Ltd. & Anjar, Gujarat, India
Plant/Department Name SAWL Plant/ Operation
SPEC. API 5L 45th Edition, December 2012 WPS NO. WPS/SAWL/SOC/15.88/2014-61, Rev. 0

THICKNESS 15.88 MM PQR NO. PQR/SAWL/SOC/15.88/2015-38, Rev. 0

WELDING PROCESS (ES) GMAW & SAW MATERIAL GRADE API 5L X60M PSL 2
TYPE(S) GMAW (Auto & Semi Auto) & SAW (Auto) INSPECTION AUTHORITY SOC

Chemical Testing: Report No.:CTR/2015/02, Date of issue: 14.08.2015

Specified Requirements : For information only

PLATE/PIPE
ELEMENT C Si Mn P S Cr Ni Mo Cu Ti Nb V B
NO.
% 0.08 0.37 1.57 0.02 0.004 0.04 0.05 0.07 0.1 0.00 0.02 0.00 0.0009
J15031925
ELEMENT N Al Ca Nb+V+Ti CE(IIW) CE(PCM) -
(WELD)
% 0.004 0.021 0.001 0.02 0.37 0.18 -
PLATE/PIPE
ELEMENT C Si Mn P S Cr Ni Mo Cu Ti Nb V B
NO.
% 0.07 0.37 1.56 0.02 0.004 0.04 0.05 0.07 0.1 0.00 0.02 0.00 0.0009
J15031925
ELEMENT N Al Ca Nb+V+Ti CE(IIW) CE(PCM) -
(WELD)
% 0.005 0.021 0.001 0.02 0.37 0.18 -

Mechanical Testing: Report No.: UTM/2015/02, Date of issue: 14.08.2015

Specified Requirements - 520 MPa Min. - -
YIELD
FINAL LOAD ULTIMATE
AREA GAUGE Y.S. Rt0.5 U.T.S. Elongation REMARKS
PLATE/PIPE WIDTH / DIA THICK/ DIA GAUGE FRt0.5 LOAD
SR NO LENGTH YS/UTS
NO. (MM) (MM) (MM²) (MM)
LENGTH (kN )
(MM)
( kN ) (kN ) (MPa ) (MPa) %

1 19.03 16.09 306.19 ------ ------ ------ 184.33 ------ 602.00 ------ ------ TWT-1
J15031925
2 19.21 16.13 309.86 ------ ------ ------ 184.38 ------ 595.05 ------ ------ TWT-2
Mechanical Testing: Report No.: UTM/2015/07, Date of issue : 17.08.2015

Specified Requirements 415 MPa Min. 415 MPa Min. 520 MPa Min. 18% - -

FINAL YIELD YIELD

PLATE/PIPE WIDTH / DIA GAUGE ULTIMATE
SR NO AREA GAUGE LOAD LOAD Y.S. Rp0.2 Y.S. Rt0.5 U.T.S. Elongation
NO. (MM) LENGTH LOAD YS/UTS % Uniform Elongation
(MM²) (MM)
LENGTH FRp0.2 FRt0.5
(MM)
( kN ) (kN ) (kN ) (MPa ) (MPa ) (MPa) %
1 J15032195 6.19 30.09 25.00 31.21 16.37 16.14 19.53 543.99 536.49 648.90 24.84 0.83 10.12

GUIDED BEND TEST HARDNESS (VICKERS),

MACRO TEST
For Information Only
Specified Requirements: GBT - 180 ° Report No.: MACRO/2015/01, Date of issue: 14.08.2015
Base Metal: AT HV10 Max, Weld & HAZ : AT HV10 Max.
Required Jig Diameter = 172 mm Max.

Report No.: GBT/2015/02, Date of issue: 14.08.2015 Report No.: HTR/2015/01, Date of issue: 14.08.2015 Specified Requirements:
Misalignment : 3mm Maximum Observation at 10X Magnification
Used Jig Diameter Misalignment (mm)
PIPE NO. BASE HAZ WELD
SR NO A = 170 mm
ROOT FACE
1 J15031925 SAT SAT 178-192 201-229 215-229 0.20 Complete Penetration of Internal & External Weld observed & found satisfactory.
2 SAT SAT
IMPACT TESTING: Report No.: CIT/2015/01, Date of issue: 14.08.2015
ABSORBED ENERGY (JOULES) AT TEMPERATURE = 0°C
WELD (REQUIRED MIN 20J INDIVIDUAL,27 J
PIPE NO. BASE-T (REQUIRED MIN 30J INDIVIDUAL,40 J AVG) HAZ / FL (REQUIRED MIN 20J INDIVIDUAL, 27J AVG)
AVG) Remarks
1 2 3 AVG 1 2 3 AVG 1 2 3 AVG

J15031925 302 246 320 289.33 130 132 100 120.67 290 302 282 291.33 SATISFACTORY
RADIOGRAPHY TESTING PREVISUAL INSPECTION REPORT
REPORT NO: RTR/2015/2022, DATE/SHIFT: 10.08.2015/C REPORT NO: PVIR/2015/556, DATE/SHIFT: 10.08.2015/B
PIPE NO: J15031925 PIPE NO: J15031925
RESULT : SATISFACTORY RESULT : SATISFACTORY

Officer /Engineer (LAB) Officer /Engineer (NDT)

We certify that the statement in this record are correct and that the welds are prepared, welded and tested in accordance with the requirement in API 5L 45th Edition, December 2012 /ASME SEC IX 2015, ASME SEC II PART C 2015 &
Customer Requirements.

Remarks : Y.S.:- Yield Strength, U.T.S. :-Ultimate Tensile Strength, % E.L.:- Percentage Elongation, W.M.:- Weld Metal, F:- Flat, Rt0.5 : Yield strength (0.5% EUL)
LBT.:- Longitudenal Base tensile, TBT.:- Tansverse base tensile , TWT.:- Transverse Weld tensile, BOW.:- Broken Out of Weld
AWT.:-All Weld Tensile, FL : Fusion line, HAZ : Heat Affected Zone, SA : Shear Area, J : Joule, Ind. : Individual, Avg. : Average, Min. : Minimum, T-Transverse , L - Longidutinal

PREPARED BY REVIEWED BY APPROVED BY INSPECTION AGENCY

KHUSHAL ADWANI ASHIF SHEIKH SATYANARAYANA SAMAVEDAM

Engineer-Operation Section Head - Welding H.O.D - QA/QC