Welding related points to recall

1. PQR gives data used in PQR test and test results, and cannot be
revised.
2. WPS gives parameters to be used in production job, and must be
within ranges qualified by the PQR test.
3. Essential variables (EV), if changed require new procedure
qualification. Non essential variables (NEV) may be changed in
WPS without new PQR.
4. Bend test crack shall not exceed 1/8” in any direction.
Radiography criteria are stricter than radiography for job.
5. Supplementary essential variables (SEV) are considered as (EV)
only if there is impact strength requirement. Otherwise, they are
“non-essential” variables.
6. EV and SEV are included in PQR document. EV, SEV and NEV are
included in WPS document.
7. Tensile test for procedure qualification is passed if failure is in:
Weld metal at strength >= Base metal SMTS, or
Base metal at strength >= 95% of base metal SMTS
8. P-numbers represent parent metal groupings of similar
composition and properties, i.e., similar strength and ductility.
F-numbers give similar usability aspects of filler material.
A — numbers give similar chemical compound of weld metal.
In “As welded” condition.
9. For performance, 1G is flat, 2G is horizontal, 3G is vertical and 4G
is overhead position. Pipe 5G qualifies 1G, 3G and 4G, but pipe 6G
qualifies all positions.
10. For acceptance criteria of production welds refer to Table 341.2.3
of B31.3 for:

Weld reinforcement
For radiographic results
General acceptance of welds
Calculated heat input variation between PQR & actual
welding + 20% & - 10%
PQR heat input ranges for various materials are
Carbon & LAS – 3 KJ/mm
6% Mo duplex SS – 1.0 KJ/mm
22% Cr duplex SS – 0.5 to 1.75 KJ/mm
25% Cr duplex SS
Root– 1.0 to 1.5 KJ/mm
2nd & 3rd pass - 0.5 to 1.2 KJ/mm
Remain – 0.5 to 1.75 KJ/mm
Ni alloy – unrestricted
Austenitic SS - Unrestricted
Duplex SS ferrite and Austenitic phase balance, Ferrite level
40-60% for base metal & 30-70% for HAZ
PWHT
Preheat band width 2t or 100 mm
PWHT band width 5√DT where D-Inside dia & T – thickness,
insulation band width 10√DT
Number of thermocouples
1 for dia < 10/40
2 for dia > for 10/40 to 300/250
3 or 4 for dia > 300/250
PWHT
for P1 & P2 as per code
for P3 to P6, it should start immediately after
welding
Spacing between welds
Longitudinal seams 45° or 50 mm whichever is less
Circumferential welds 4t (toe to toe)
Attachments 2t or 40 mm (toe to toe) whichever is
less
Weld bevel preparation
C-Mn steels mechanical, thermal and oxy cuts are
acceptable, if oxy cut is used remove 2 mm steel by grinding
P6 & above no oxyfuel cut is acceptable
Austenitic SS, 6% Mo Duplex, Duplex, Cu-Ni, Ti etc., only
mechanical or plasma cutting is acceptable. Wire brush with
SS bristle only to be used. For titanium material the grinding
disc should be made of carborundum.
Repair WPS should have following points taken care
Method of excavation
Shape & size of excavation
Inspection prior to welding
Type of WPS to be used
Minimum ligament after excavation
Weld root gap guide
1.5 mm for pipe dia < 50 mm
1.5 to 2.5 mm for pipe dia > 50 mm to 250 mm
 2.5 to 3.5 for pipe dia > 250 mm
Ferrite number
FN # 3-10 FN for Austentic SS, AWS 4.2, ISO 2849 or
calculated from Welding Research Council (WRC) 1992 ferrite
diagram.
Carbon equivalent for pressure vessel plates & pipe material
CE = 0.41 = C + Mn/6 + (Cr+Mo+V)/5 + (Cu+Ni)/15
Maximum carbon content for pressure vessel and piping
material is 0.21
Plate material elements composition
C-0.21, Mn-1.2, Si-0.45, S-0.003, P-0.015, V-0.08, Niobium-
0.03, Ti-0.02, Cu-0.2, Ni-0.3, Cr-0.2, Mo-0.2, Al-0.05, Bo-
0.0005, Ca-0.006
Piping material elements composition
C-0.18, Mn-1.1, Si-0.33, S-0.003, P-0.015, V-0.08, Niobium-
0.03, Ti-0.02, Cu-0.2, Ni-0.3, Cr-0.2, Mo-0.2, Al-0.05, Bo-
0.0005, Ca-0.006
Pressure vessel Steel plate, Fittings specifications
SA 234, 337, 350, 765, 352, 420, 450, 516, 517, 530, 578,
671, 703, 240, 263, 264, 265, 20, 105, 106, 179, 193,
194,216
Disimilar metal welding
Material - 1 Material - 2 Temp °C Electrode
P-1 to P7 Austenitic SS > 315°C ENiCrFe-2
ENiCrFe-3
ERNiCr-3
Austenitic SS Ni-Cr material > 315°C ENiCrFe-2
ERNiCr-3
Austenitic SS Ni-Cr material ≤ 315°C ENiCrFe-2
ENiCrFe-3
ERNiCr-3
Consumables for 6% Mo Group UNS 31254, UNS 8367 use electrodes of AWS 5.4
ER5.4 ER NiCrMo-3 & AWS 5.11 ENiCrMo-3 for SMAW
Piping P4 to P8 root pass with GTAW & back purging with inert gas for upto 6mm
material buildup for materials of sour services
WPS
WPS made of 316 is qualified for 316L and not vice versa
WPS made of 304 is qualified for 304L and not vice versa
This is due to the L which is for carbon content.