kanon loading equipment (m) sdn bhd welding procedure...
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KANON LOADING EQUIPMENT (M) SDN BHD WELDING PROCEDURE SPECIFICATION (WPS)
(ASME SECT.lX)
WPS NO. KLEM-WPS-026 Revision o -------SUPPORTING PQR KLEM-PQR-026
Date _____ 2_6_10_4_n_0_11 _____ By Ng Boon Swee
26/04/2011
Welding Process(es) FCAW Type(s) Manual (GTAW) , Semi-Auto (FCAW) ------------------ (Automatic, Manuai, Machine, or Semi-Auto)
JOiNTS (QW-402)
Joint Design
Backing (Yes) FCAW (No) GTAW
Backing Material (Type) ___ W_e_ld_M_e_ta_I _______ _
(Refer to both backing and retainers.)
o Metal D Nonfusing Metal
DNonmetallic DOther
Sketches, Production Drawings, Weld Symbols or Written Description
should show the general arrangement of the parts to be welded. Where
applicable, the root spacing and the details of weld groove may be
specified.
(At the option of the Mfgr., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness
procedures, for multiple process procedures, etc.)
"'BASE METAlS (QW-403)
P-No. to P-No. ----- _____ Group No. ______ Group No.
OR
Specification type and grade
to Specification type and grade
OR
Chern. Analysis and Mech. Prop.
to Chern. Analysis and Mech. Prop.
Thickness used for the qualification
Thickness Range Qualified
Gr. 6
WNr. 1.4462 (x2CrNiMoN22-5)
No
7.0mm (Machined from 9.53mm)
Base Metal: Groove 1.5 - 14.0mm Fillet All ----------------------------Other 1. Any weld pass shall not be greater than 13mm thick.
"'FIllER METALS (QW-404)
Spec. No. (SFA)
. AWS No. (Class)
F-No.
A-No.
Size of Filler Metals
Weld Metal
Thickness Range:
Groove
Fillet
Electrode-Flux (Class)
Flux Trade Name
A 5.9 (GTAW)
ER 2209
8
2.4mm Dia.
6.68mm Max.
All
No
No -----------------Consumable Insert No
Other Filler Type: Solid
A 5.22 (FCAW)
E 2209T1-1/4
6
8
1.2mm Dia.
7.32mm Max.
All
No
No
Tubular
Product Name: ESAB OK TIGROD 2209 Metrode Supercore 2205P
" Each base metal-filler metal combination should be recorded individually.
I
WELDING PROCEDURE SPECIFICATION (WPS) (ASME SECTJX)
WPS-026
PAGE I 2
Rev.O
OF 2
POSITIONS (QW405)
Position( s) of Groove
POS1fWElD HEAT TREATMENT (QW401)
Welding Progression: Up __ Y_es ___ Down No
Position( s) of Fillet All
Temperature Range
Time Range
No
No
~N_o~te~: _______________ N_o ________________________ ~IGAS(QW408)
PREHEAT (QW406)
Preheat Temp.
Interpass Temp.
Preheat Maintenance
Min.
Max.
(Continuous or special heating where applicable should be recorded)
Note: No
ELECTRICAl CHARACTERISTICS (QW409)
Current AC or DC See Table Polarity See Table
Amps (Range) See Table Volts (Range) See Table
(Amps and volts range should be recorded for each electrode size,
position, and thickness, etc. This information may be listed in a
tabular form similar to that shown below.)
Shielding
Trailing
Backing
Note:
Percent Composition
Gas(es) (Mixture)
Note 99.90%
No No
Argon (GTAW) 99.90%
Argon (GTAW), CO2 (FCAW)
Flow Rate
15-25Umin
No
15-25Umin
Tungsten Electrode Size and Type ____ = ______ ...".f.":2:::::.C"i4I":":m:::"m=D:'::ia==i.'i'i'!l2:r'*"I"0I::"':T~hr::::':0rE"ia5"t_::ed~------_-------~ (Pure Tungsten, 2% Thonated, etc.)
Mode of Metal Transfer for GMAW Spray Arc (Spray arc, short circuiting arc, etc.)
Electrode Wire feed speed range ________________ N_o ____________________ _
TECHNIQUE (QW410)
String or Weave Bead ----------------------------------------------------------------Orifice or Gas Cup Size
---------------------~----~--------------------------InW~andl~e~assC~aning(Brushing,Grin~ng,~~) ______ B_ru_s_h_~~g~,_C_h~~~p_in~g~o_r_G_r_~_d_in~g~ _________________ _
Method of Back Gouging Oscillation Contact Tube
No
Multiple or Single Pass (per side) ----------=------:::--~---------------------~ Multiple or Single Electrodes Single
Travel Speed (Range) Refer To Table Below -------------------------------------+ ~~~:ng------------------------------------------~-~-------------------~
-------------------------------------------
Filler Metal Current
Weld Type Amp.(A) Volt(V) Layer(s) Process Class Dia.(mm) Polar Range Range
1-2 GTAW ER 2209 2.4 DCEN 130-205 11-18 (ESAB OK TIGROD 2209)
3-End FCAW E 2209T1-1/4 I 1.2 DCEP 155-200 26-35 (Metrode Supercore 220SP)
Travel Speed (mm/min)
Range
65-90
200-390
* Unless specifically required otherwise by the welding variables (QW-2S0), a qualification in any pOSition qualifies the procedure for all positions.
Other Heat Input (kJ/mm)
0.9-3.5
0.6-2.1
KANON LOADING EQUIPMENT (M) SDN SHD PROCEDURE QUALIFICATION RECORD
KLEM-POR-026
1 of 3
POR No. KLEM-POR-026 Revision _0 __ _ Date 26/04/2011 By N Boon Swee Reference WPS No. KLEM-WPS.:.026 Welding process(es) GTAW FCAW Weld Type:
JOINTS (QW.402)
Type
Single [KJ Double weld D Backing? Yes 0 No D Backing Material (type) _W_e_ld_M_et_al ___ _
o Metal
D Nonmetallic D Notes: Backing - FCAW only
BASE METAL (QW-403)
P-No. Group No.
Nonfusing metal
Other
Material Specification SA 333
Manual (GTAW) Semi-Auto (FCAW)
to P-No Group No. ----to WNr. 1.4462 (x2CrNiMoN22-5)
Type or Grade Gr. 6 to
Thickness of Test Coupon mm (machined from 9.53mm pipe)
Diameter of Test Coupon
Chern. Analysis
Mech. Prop.
Notes:
FillER METAl (QW-404)
Spec. No (SFA)
AWS No.(Class)
F-No
A-No
Size of Filler Metals
Solid or Tubular
Weld Metal Thickness
Electrod-Flux Class
Flux Trade Name
Consumable Insert
Chern. Analysis
Other
Notes:
323.90D mm
A5.9 (GTAW)
ER 2209 E 2209T1-1/4
2.4mm Dia.
Solid
3.34mm
No
No ~N~o ____________ _
ESAB OK TIGROD 2209 Metrode Supercore 2205P
KANON LOADING EQUIPMENT (M) SDN BHD PROCEDURE QUAL~FICAT~ON RECORD
POSI1IONS (QW-405)
Position( s) of Groove
Welding Progression
Notes No
PREHEAl (QW-406)
1G
Up
Preheat Temp. Min. 25°C
Fillet No
Down
Interpass Temp. Min. _,.;;;;2~5°...;;;;C __ Max. 150°C
Preheat Maintenance _....;.;. ________ _
Notes
POSTWElD HEAllREA1MEN1(QW-407)
Required? [ill Temp. Range
Time Range
Notes
No
No
lECHNIQUE (QW-410)
Stringer or weave Bead
Initial and Inter Pass Cleaning
Method Of Back Gouging
Grinding, Chipping, Brushing
No
Multiple or Single Pass(Per Side)_M_ul....ltip_le ____ _
Multiple or Single Electrods _,.,;;;S;.;;,;.in,;,:ig:.;.;;le~ ____ _
Travel Speed(Range) _S.;;;..e,;;,.;e;...T,;..;a;;.;,;b...;.;le~ _____ _
Notes
PAIRAME1ER lABlE
Weld Pass Process or La er Classification
GTAW ER2209
2 GTAW ER 2209
3 FCAW E 2209T1-1/4
4 FCAW E 2209T1-1/4
GAS (QW-408) % Composition
Gas(es) (Mixture) Flow Rate
Shield. Note 99.9 15-25Umin
Trail. No
Back. Argon (GTAW) 99.9 15-25Umin
Notes: FCAW)
ElEC1RICAl CHARAC1ERISliC (QW-409)
Current DAC [8]DCEP [KjDCEN DPulsed
Amps (Range): See Table Volts: See Table
Notes DCEN (GTAW), DECP (FCAW)
Tungsten Elec. Size
Type 2% Thoriated
Transfer Mode For GMAW Spray Arc
Electrode Wire Feed Speed Range No
Orifice or Gas Cup Size 6-12mm (GTAW)
Oscillation No
Contact Tube to Work Distance 10-30mm (FCAW)
Peening No
Wire fd Spd Volts Travel Spd Other n) V) (mm/min) Heat Input (kJ/mm)
14 85 1.37
15 72 2.47
31 382 0.88
30 198 1.60
KANON LOADING EQUIPMENT (M) SDN BHD PROCEDURE QUALIFICATION RECORD
TESTS (OW-483)
POR No. KLEM-POR-026
PAGE: 3 of 3
TENSilE TEST (QW-150) Width Thickness
Specimen No. mm mm
TT1 19.05 6.76
TT2 19.01
GUIDED BEND TESTS (QW.160)
Specimen No. Bend Type Figure No.
Face Face Root Root
TOUGHNESS TESTS (QW-170) Specimen No. Notch
Location
No
FillET-WELD TEST (QW180)
Result: Satisfactory: DYes
Macro results:
Notch Type
No
D No
No No No No
Area
mm2
Ultimate
total load (N)
128.78 61246
57465
Result
Satisfactory Satisfactory Satisfactory Satisfactory
Ultimate unit
stress (N/mm2)
475.60 (68981 psi)
470.12 (68186psi)
Remarks
Type of failure
& location
Ductile @ Base Metal
(SA 333 Gr 6) Ductile @ Base Metal
(SA 333 Gr 6)
No Visible Open Defects Were Observed No Visible Open Defects Were Observed No Visible Open Defects Were Observed No Visible Open Defects Were Observed
Impact Values(J)
Lateral Exp. Drop Wei ht mm Mils Break No Break
No No No
Penetration into Parent Metal: DYes D No
OTHER TESTS Type of test: 1. Macro Examination Test - Satisfactory
Deposit analysis Other
2. Hardness Test - Max. 260 HVN @ HAZ @ Top & Bottom (WNr. 1.4462) No No
Welder's name Mazli B. Mohd. (GTAW) Welder's NO'_.,;;.W~13~ __ _ Kamarulzaman (FCAW) _...:.W.:....;:.04...:...-____ --
Test conducted by Metallurgical Testing Laboratory Sdn. Bhd. Laboratory Test No.
Stamp No. ____ _
11 ML 186
. We certify that the statemants 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 Code.
Manufacturer
Certified By
Date 26/04/2011
Remark:
Kanon Loading (M) Sdn. Bhd, Lot 203G, Gebeng Industrial Estate, 26080 Kuantan, Pahang Darul Makmur. DOCUMENT
WELDING PROCEDURE QUALIFICATION TEST
Our Control No. = ML 11-172
Our Ref. No. = ML/62/11
Our Doc. No. Il-ML186
Our Job No. KLESB-17
Sample Date Received 18-04-2011
Date Tested 25-04-2011
Issued Date = 25-04-2011
KLESB-17
11-ML186
Attention = Mr. Ng Boon Swee :-6~-r-C~~diti~~- -----------------------~- --pi~~s~ d~ ~~t-~~~~Pt this ~~p~-rt -if-it -i~ -da~~~d -i~-~~y-~~Y.- -----------------: '-Sllbject- -------------------------------W eldll1-g -Pi'ocedtlre-Qll-cifification -Test -----------------------------"
DATE
Material Spec.
Sample 10
Pipe Diameter
Schedule/Thickness
Welding Position
Welding Process
Welding Configuration
WPSNo.
PQRNo.
Welder's Particulars
Test Code
SA333 GR. 6 TO WNr. 1.4462
WPS-026
12"
7.0 mm (Machined from 9.53mm)
IG
GTAW+FCAW
= Single Vee
= KLEM -WPS-026
= KLEM-PQR-026
= Name Ie No. Tag No.
= ASME IX
: Mazli B. Mohd 1 Kamarulzaman Daud : 740712-11-56871731006-11-5327 : w131 W04
Test Required 1) Transverse Tensile Test 2 pcs 2) Transverse Face Bend Test 2 pcs 3) Transverse Root Bend Test 2 pcs 4) Hardness Survey 1 pc 5) Macro Examination 1 pc
Thank you for choosing Metallurgical Testing LaboratOlY Sdn. Bhd. as your preferred testing laboratory Please verifY photocopy of this report with the original
The report shall not be reproduced without the written approval of the laboratory
114 PREPARED BY ~, __
(232540-X)
20, Jalan U5/1 Seksyen US (Panasuria) 25-04-2011 ." ."' •• ~. 11 BY 40150 Bandar Shah Selangor, Malaysia.
Tel: 03-7845 0730 Fax: 03-7845 0739
Kanon Loading Equipment (M) Sdn. Bhd., Lot 203G, Gebeng Estate, 26080 Kuantan, Pahang Darul Makmur.
Job No.: KLESB-17 Doc. No. : 11-ML186 METALLURGICAL TESTING
LABORATORYSDN.BHD.
WELDING PROCEDURE QUALIFICATION TEST
OUR REF. : ML/62111 :~9~~~ ~9~4[t}9~i ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~!~~~~~ ~~ ~~{ ~~~~P! ~thi~~ ~~p~~~ {{ -----------------------------------WPS NO. KLEM-WPS-026 OUR CONTROL NO. : ML 11-172
1. Transverse Tensile Test
00 Width, mm Thklluness, mm Area, mm 2 Max. Load 6.245 tf
TT 1 19.05 6.76 128.78 61246 N 5.860 tf
TT2 19.01 6.43 122.23 57465 N
TT 1: The specimen show ductile failure at the base meta! (SA 333 GR. 6) . TT 2: The specimen show ductile failure at the base meta! (SA 333 GR. 6);rr" iv\
Test conducted by : Mr. Mohd Faizal b. Esran
2. Transverse Face Bend Test
Ul -<\
''6
Former Diameter = 28 mm Angle of Bend = 1800
Specimen 1 : No visible open defects were observed. Specimen 2 : No visible open defects were observed.
Test conducted by : Mr. Hamidi b. Abd. Aziz
3. Transverse Root Bend Test Former Diameter = 28 mm Angle of Bend = 180
0
Specimen 1 : No visible open defects were observed. Specimen 2 : No visible open defects were observed.
Test conducted by : Mr. Hamidi b. Abd. Aziz
4. Hardness Survey -LOAD -JO kg', TYPE = HVN Hardness values corresponding to the point indicated in the figure below: TOP NO HVN Base Metal 1, 2, 10, 11 160,159,251,249 HAZ 3,4,8,9 168,162,260,260 Weld Metal 5,6,7 254,258,256 BOTTOM NO HVN Base Metal 12,13,20,21 160,161,243,247 HAZ 14,15,18,19 193,192,254,260 Weld Metal 16,17 254,254
Test conducted by : Ms. Nurshafina bt. Abd. Ghani
Please ver(fY photocopy of this report with the original
Max Stress 68981 psi
475.60 N/mnl
68186 psi
470.12 N/mm2
The report shall not be reproduced without the written approval of the laboratory.
Page: 2/4 METALLURGICAL TESTING LABORATORY SDN. BUD. Prepared by : Suzana (232540-X)
No. 20 lalan U5/17, Seksyen U5 (PS), 40150 Bandar Shah Alam, Selangor, Malaysia
Tel: 603-78450730/40 Fax: 603-78450729/37/39 Date: 25-04=2011 Checked by:
Kanon Loading Equipment (M) Sdn. Bhd., Lot 203G, Gebeng Industrial Estate, 26080 Kuantan, Pahang DarllJlI Makmur.
Job No. : KLESB-17 Doc. No. : 11-ML186
METALLURGICAL TESTING
LABORATORY SON. BHO.
WELDING PROCEDURE QUALIFICATION TEST
OUR REF. : ML/62111 :~9~~1~ ~9~!
Kanon Loadling Eq uipment (M) SOln. BhOl., Lot 203G, Gebeng Indlustrial Estate, 26080 Kuantan, Pahang Darul Malkmur.
Job No.: KLESB=17 Doc. No. : 11=ML186
WELDING PROCEDURE QUALIFICATION TEST
Transverse Tensile Test (TTl)
Transverse Tensile Test (TTl)
11 12
GR.6}
Please verifY photocopy of this report with the original
METALLURGICAL TESTING
LABORATORYSDN.BHD.
The report shall not be reproduced without the written approval of the laboratory.
Page: 4/4
Date: 25=04=2011
METALLURGICAL TESTING LABORATORY SJl)N. BHJl). (2325410-X)
No. 20 lalan U5/17, Seksyen U5 (PS), 40150 Bandar Shah Alam, Selangor, Malaysia
Tel: 603-78450730/40 Fax: 603-78450729/37/39
P:repa:red! by : Suzana
Checked! by : -=-=~