WELDING PROCEDURE SPECIFICATION (WPS)

Construction Code: (AWS D1.1)

PROJECT : 2 x 600 MW DB TP PROJECT.

Company Name : Sunil Hitech Engineers Ltd. Identification SHEL/L&T/DBPL/WPS/STR-003

Welding Process(es): GMAW Rev No : 00 Date : 21.02.11
Supporting PQR No(s): - SHEL/L&T/DBPL/PQR/2.03.2011 Type ( Manual/Automatic/Semi Automatic ) : Semi automatic
JOINT DESIGN USED PREHEAT
2.5
30±
1.5-2mm Preheat Temperature(min) - t 20 TO 40mm 20°C,40 TO 63mm 66°C,
25mm t >63 mm 110°C
2.5-3 mm

Interpass Temperature, Maximum: 250° C

POST WELD HEAT TREATMENT

Backing Material: Weld metal Backing (Yes/ No) : Yes Soaking Temp : N/A Soaking Time : N/A
Radius (J-U): N/A Back Gouging ( Yes/No):Yes Rate of Heating : N/A Rate of Cooling : N/A
BASE METALS
Material Spec: IS 2062 ELECTRICAL CHARACTERISTCS
Type of Grade: Gr.A/B Current
(Amps) Shall be as per below table / Approved
PQR Polarity DCEP
Thickness : As per PQR Fillet : As per PQR
Diameter (Pipe) : Over 600mm Voltage(Volts)

Metal Transfer Mode for GMAW/FCAW: Globular

FILLER METALS Tungsten Electrode Size and Type: N/A
AWS Specification : SFA 5.18 Electrode Wire Feed Speed Range: 80-310mm/min
AWS Classification : E 70S-6
SHIELDING TECHNIQUE
Gas : CO2 String or Weave Bead: Either
Mixture : 99.995% Multiple or Single Pass (per side) : Multiple
Flow Rate : 12-20 lpm Multiple or Single Electrodes : Single.
Gas Cup Size : 14mm Method of Back Gouging :Grinding
POSITIONS Oscillation: N/A
Positions of groove: 4G Contact Tube to Work Distance : 15 - 25mm
Welding Progression (Up/Down) : Up Peening : NA
Position(s) of Fillet: 4F Initial & Interpass Cleaning : Brushing, Chipping, or Grinding.

Fillet Metal Current Trav.

Weld
Electrode SFA Type & Speed Other
Layer(s) Process F.No A-No. Dia Amp.Range Volt.Range
Class No. Polarity mm/min
Root GMAW E 70S-6 5.18 6 1 1.2 DCEP 70-130 20-26 80-100

Fill up GMAW E 70S-6 5.18 6 1 1.2 DCEP 110-180 22-30 150-350

Final GMAW E 70S-6 5.18 6 1 1.2 DCEP 110-180 22-30 150-350

0 Rakesh kale Amjad Pathan

Rev.No Prepared By Reviewed by Approved by

 Welding Procedure Specification ( WPS) WPS No. : 01
Name of Address of Manufacture Rev No. 00
M/s. Larsen & Toubro Ltd. Date : 21.02.2011
Vadodara Page : 1 of 2
Project : DB STPP -2x600 MW Sub Contractor : M/s SHEL
Package : Balance of Plant package. Item : Structural Steel work
Project No. : DBC104.
Supporting PQR No. : 01 Date :
Welding Process (es) : SMAW Type(s) : Automatic / Semi-Auto / Manual
Welding Process (es) : Shield Metal Arc Welding Type(s) : Manual

Joints (QW-402)
Joint Design : But Joint Single "V" as per sketch
Backing : Not required
Backing material (type) : Nil

Metal Non fusing metal

Nonmetal Others
Sketches, Production, Drawing, Weld Symbols or Written Description should show the general arrangements
of the parts to be welded where application, the root spacing and the details of weld groove may be specified.
At the option of the Mfgr. Sketch may be attached to illustrate joint design. Weld layers and bead sequances
i.e. notch, Thoughness procedure for multiple process precedure etc.
Base Metal (QW 403)
P.No. : P1 Group No. : 2 to P.No. : P1 Group No. 2
or
Specification type and grade IS 2062 Gr. 'B'
To Specification type and grade : IS 2062 Gr. 'B'
or
Chemical Analysis and Mech Prop. : ________________________
To Chem. Analysis and Mech Prop : ________________________
Thickness Range base metal groove -
Groove : 4.76 to 20 mm Fillet : All
Pipe Dia Range : N/A
Other : N/A
Filler Metals (QW-402)
Spec No. (SFA) : : 5.1 & 5.5
AWS No. (Class) : E 6013
F.No. (Class) : 4
A.No. (Class) : 1
Size of Filler Metals : 2.5 mm/3.15 mm/4.0 mm
Deposited Weld Metal :
Thickness Range
Groove : Upto 20 mm
Fillet : All
Electro Flux (Class) : Rutile
Consumable Trade Name : Electrode Make and Brand shall be as per
L&T Approved list of Electrodes.

Consumable Insert : N/A

Other : : N/A
"Each base metal - filler metal combination should be recorded individually"
Note : QS-482 Suggested format as per 2001 ASME Sec IX Boiler & Pressure Vessels (Code). (refer QW 2001)
Manuf / Sub-contractor MAIN Contractor Doc. No.:L609000-WO1

SIGNATURE Reviewed By Approved By

 Welding Procedure Specification(WPS) WPS No: 01
Name and Address of Manufacturer : Rev No: 00
Date 21.02.2011
M/s. Larsen & Toubro Ltd.
Page 2 0f 2
Project DB STPP -2x600 MW. Sub. Contractor M/s SHEL
Package Balance of Plant package. Item Structural Steel Works
Pkg. No. DBC104.
Positionss (QW -405) POSTWELD HEAT TREATMENT (QW-407)
Position of Groove 3G Temerature Range NA
Welding Progression Up Time Range NA
Position of fillet N/A
PREHEAT (QW -406) GAS (QW - 408) Percentage Composition NA
Preheat Temperature NA Gas(es) Mixture Flow Rate
Min.
Interpass Temp. NA Shielding NA NA NA
Preheat Maintenance 20 deg cel Trailing NA NA NA
(Contineous for special heating where Backing NA NA NA
applicable should be recorded)
ELECTRICAL CHARACTERS (QW - 409)

Current AC or DC : DC Polarity : Positive (DCEP)

Amps Range : 100-190 Amps Volts Range : 24 V - 32 V
(Amps and Volts range should be recorded for each electrode size position and thickness etc.This information may be listed.)
Tungsten Electorde Size and Type NA

Mode of Metal transfer for GMAW NA

Electrode Wire Transfer speed range NA

TECHNIQUE (QW-410)
String or Weave Bead Weave Bead
Orifice or Gas Cup Size NA
Initial and interpass cleaning (Brushing, Chipping and Chipping And Wire Brushing
Branching)
Method of Back Gouging
Oscillation NA
Contact Tube to work distance NA
Multiple or Single Pass (per side) Multiple pass
Multiple or Single Electrodes Single Electrode
Travel Speed Range 100 mm / min
Penning NA
Other NA

Weld Layer (s) Process Filler Metal Current Volt Speed Travel Other (e.g Remarks /
Range Range Feed Comments) hot wire
Class Dia Type Amp (V) mm/min Range addition. Technic Torch
Polarity Range Angle etc.
(A)
Root Run SMAW E-7018 2.5 mm +' Ve 70-100 24-26 100
First Run SMAW E-7018 3.15 mm +' Ve 110-140 25-28 100 As per Manufacturer's
Second Run SMAW E-7018 4.00 mm +' Ve 140-190 30-32 100 recommendation
Third Run SMAW E-7018 4.00 mm +' Ve 140-190 30-32 100
MANUFACTURER'S SIGN DATE AND STAMP Doc. No.:L609000-WO1
NTPC TNECL APPROVAL SIGN DATE AND STAMP

Approved Subject to Satisfaction PQR

 Welding Procedure Specification ( WPS) WPS No. :
Name of Address of Manufacture Rev No.
M/s. Larsen & Toubro Ltd. Date :
Vadodara Page :
Project : DB STPP -2x600 MW Sub Contractor : M/s SHEL
Package : Balance of Plant package. Item : Structural Steel work
Project No. : DBC104.
Supporting PQR No. : 03 Date : 02.03.2011
Welding Process (es) : SMAW Type(s) : Automatic / Semi-Auto / Manual
Welding Process (es) : Shield Metal Arc Welding Type(s) : Manual

Joints (QW-402)
Joint Design : But Joint double "V" as per sketch
Backing : Not required
Backing material (type) : Nil
25
mm
Metal Non fusing metal

Nonmetal Others
Test Piece Details
Sketches, Production, Drawing, Weld Symbols or Written Description should show the general arrangements
of the parts to be welded where application, the root spacing and the details of weld groove may be specified.
At the option of the Mfgr. Sketch may be attached to illustrate joint design. Weld layers and bead sequances
i.e. notch, Thoughness procedure for multiple process precedure etc.
Base Metal (QW 403)
P.No. : Group No. : to P.No. : Group No.
or
Specification type and grade IS 2062 Grade "B"
To Specification type and grade : IS 2062 Grade "B"
or
Chemical Analysis and Mech Prop. : ________________________
To Chem. Analysis and Mech Prop : ________________________
Thickness Range base metal
Groove : 20 mm to 40 mm Fillet : All Shall be as per approved PQR
Pipe Dia Range : N/A
Other : N/A
Filler Metals (QW-402)
Spec No. (SFA) : : 5.1
AWS No. (Class) : E 7018
F.No. (Class) : 4
A.No. (Class) : 1
Size of Filler Metals : 3.15 / 4.00 mm
Weld Metal :
Thickness Range
Groove : Upto 40 mm
Fillet : All
Electro Flux (Class) : Rutile
Flux Trade Name : Electrode Make and Brand shall be as per
L&T Approved list of Electrodes.
Only electodes od ADOR ,ESAB,D & H , Modi
shall be used

Consumable Insert : N/A

Other : : N/A
"Each base metal - filler metal combination should be recorded individually"
Note : QS-482 Suggested format as per 2001 ASME Sec IX Boiler & Pressure Vessels (Code). (refer QW 2001)
Manuf / Sub-contractor MAIN Conteractor Doc. No.:L609000-WO3

Amjad I.Pathan - QA
SIGNATURE Reviewed By Approved By
 Welding Procedure Specification(WPS) WPS No: 03
Name and Address of Manufacturer : Rev No: 00
Date 21.02.2011
M/s. Larsen & Toubro Ltd.
Page 2 0f 2
Project DB STPP -2x600 MW. Sub. Contractor M/s SHEL
Package Balance of Plant package. Item Structural Steel Works
Project No. DBC104.
Positions (QW -405) POSTWELD HEAT TREATMENT (QW-407)
Position of Groove 3G Temerature Range NA
Welding Progression Up Time Range NA
Position of fillet N/A
PREHEAT (QW -406) GAS (QW - 408) Percentage Composition
Preheat Temperature 20oc for thickness Gas(es) Mixture
Min. 20 mm & upto and Shielding N/A
including 40 mm . Trailing N/A
Backing N/A

Interpass Temp. 250 deg.

Preheat Maintenance Do
(As per Technical Specification)
(Contineous for special heating where applicable should be recorded) For preheating and interpass temperature maitenance all care
should be taken as per clause 3.10.02,3.10.03 & 3.10.04 of Technical Specification(Part B,Section-3)
ELECTRICAL CHARACTERS (QW - 409)
Current AC or DC : DC Polarity : Positive (DCEP)
Amps Range :Shall be as per below table Volts Range : Shall be as per below table
as per below
(Amps table
and Volts range should be recorded for each electrode size position and thickness etc.This information may be listed.)
Tungsten Electorde Size and Type NA
Mode of Metal transfer for GMAW NA
Electrode Wire Transfer speed range NA
TECHNIQUE (QW-410)
String or Weave Bead String Bead
Orifice or Gas Cup Size NA
Initial and interpass cleaning (Brushing, Chipping and Chipping And Wire Brushing
Branching)
Method of Back Gouging Grinding
Oscillation NA
Contact Tube to work distance NA
Multiple or Single Pass (per side) Multiple pass
Multiple or Single Electrodes Single Electrodes
Travel Speed Range 100 mm/min (Max)
Penning NA
Other NA

Filler Metal Current

Volt Speed
Weld Layer (s) Process Type Range Range
Class Dia Amp Range (A) (V) mm/min
Polarity

One side Root run SMAW E-7018 3.15 mm +' Ve 100-120 24-28 100 Max
First run SMAW E-7018 4.0 mm +' Ve 150-170 28-32 100 Max
Second run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Third run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Fourth run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Fifth run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Other side after BG root SMAW E-7018 3.15 mm +' Ve 100-120 24-28 100 Max
First run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Second run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Third run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Fourth run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
Fifth run SMAW E-7018 4.0 mm +' Ve 150-190 28-32 100 Max
MANUFACTURER'S SIGN DATE AND STAMP Doc. No.:L609000-WO3
L&T APPROVAL SIGN DATE AND STAMP

Approved Subject to Satisfaction PQR

 03
00
21.02.2011
1 of 2
Sub Contractor : M/s SHEL
Item : Structural Steel work

Doc. No.:L609000-WO3

Approved By
 03
00
21.02.2011
2 0f 2
M/s SHEL
Structural Steel Works
04.
POSTWELD HEAT TREATMENT (QW-407)
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Approved Subject to Satisfaction PQR i
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