QW -482 WELDING PROCEDURE SPECIFICATION

(WPS)

(SEE QW – 201.1, SECTION IX, ASME BOILER

AND PRESSURE VESSEL CODE

SHEET 1 OF 2

Company Name DCMS ENGINEERING CO.

Welding Procedure Specification No DCMS/WPS/099 Rev-0 Date : 19/04/2012

Supporting PQR no. (S) DCMS/PQR/099 Rev - 0 Date : 7.05.2012 Welding Process (es) GTAW Type (s) Manual

(Automatic, Manual, Machine or semi – Automatic)

JOINTS (QW-402) Joints Design Single ‘V’ Groove Joint

Backing Yes ___________ No ____X______

Backing Material (Type) _ARGON GAS______ (Refer to both backing & retailers).

Metal Nonfusing Metal

Non Metallic Other

DETAILS

* BASE METAL (QW – 403)

P.No. 8 Group no. 1 to P.no. 8 Group no. 1

OR

Specification type and grade Plates ASTM-A-240 Gr 304L

To specification type and grade Plates ASTM-A-240 Gr 304L

OR Chem. Analysis and Mech. Prop ___________NA___________________________

To Chem Analysis and Mech. Prop ________NA___________________________

Thickness Range :- Base Metal :- Groove 1.6 to 12 mm Fillet All thickness, all sizes & all diameters

Other WPS shall be applicable for both without and with backing (Stainless Steel Material)

FILLER METALS (QW-404)

Spec No. (SFA) SFA-5.9

AWS No. (Class) ER-308L

F-No. 6

A-No 8

Size of Filler Metals 1.6mm

Weld Metal

Thickness Range

Groove 1.6 mm to 12mm

Fillet All thicknesses

Electrode-Flux (Class) N.A.

Flux Trade Name N.A.

Consumable Insert N.A.

N.A.

POSITION (QW-405) Position (s) of Groove All Positions(Test piece 1G)

Welding Progression : Up Uphill Down NA

Position (s) of Fillet All Positions

POST WELD HEAT TREATMENT (QW-407) Temperature Range ____NA_____

Time Range _____NA____

Plates ASTM-A240-Gr 304L

(S.S. to S.S.)

QW-482

WPS NO : DCMS/WPS/099 Dated 19/4/2012 REV : 0

SHEET 2 OF 2

PREHEAT (QW-406)

Preheat Temp. Min NA__________

Interpass Temp. Max _________1250C________

Preheat maintenance _________NA__________

(Continuous or special heating where applicable should

be recorded)

GAS (QW-408)

Percent Composition

Shielding (Mixtures) Flow Rate

Shielding Argon 99.99% Pure 12-15Ltr./min

Trailing Argon -- Backing Argon 99.99% Pure 5-10Ltr./min

ELECTRICAL CHARCTERISTICS (QW-409)

Current AC or DC _DC_ Polarity, DCEN (STRAIGHT)

Amp (Range) 65-85 Amp Volts (Range) 10-12 Volts (Amp and volts range should be recorded for each electrode size, positions and thickness etc.)

Tungsten Electrodes Size & Type 1.6mm, 2.4mm, 2% Thoriated Tungsten Electrodes (Pure tungsten 2% Thoriated etc.)

Mode to metal transfer for GMAW ____________ NA ________________________

(Spray arc short circulating arc etc.)

Electrodes Wire feed speed range ____________ NA ________________________

TECHNIQUE (QW-410)

String or weave bead Root (stringer) & Final (weaving).

Orifice or Gas Cup Size ceramic nozzle of ¼” Initial and Inter pass (Cleaning Brushing, Grinding etc.)Degreasing with acetone, wire brushing, if required grinding of all pass.

Method of Back Gouging _____NA ______________

Oscillation 2.5 times of size of filler wire_____________ Contact Tube to Work Distance _____NA______________

Single Pass (per side) __ Multiple____________

Multiple or Single Electrode __Single_____________

Travel Speed (Range) 40-65 mm/min.__ Peening Not Allowed

Other _NA__________________

WELD

LAYER(S) PROCESS

FILLER METAL CURRENT

VOLT

RANGE

TRAVEL

SPEED

RANGE

(mm/min)

OTHER CLASS DIAMETER TYPE /

POLARITY

AMP

RANGE

Root (1

st Pass)

GTAW ER 308-L 1.6mm DCEN 65-75 10-12 40-50

2nd

Pass GTAW ER 308-L 1.6mm DCEN 75-85 10-12 55-65

3rd

& Subsequent

Passes

GTAW ER 308-L 1.6mm DCEN 75-85 10-12 55-65

QW-483PROCEDURE QUALIFICATION RECORD

(PQR) (SEE QW200.2, SECTION IX ASME BOILER AND

PRESSURE VESSEL CODE)

RECORD ACTUAL CONDITION USED TO WELD TEST

COUPON

SHEET 1 OF 3 Company Name M/S. DCMS Engineering Ltd. Mumbai Procedure Qualification Record No. DCMS / PQR/099 Date : 7/5/2012 Rev 0 WPS No. DCM/WPS/099 Date : 19/4/2012 Rev. 0 Welding Process(es) GTAW Types (Manual, Automatic, Semi-Automatic) Manual

JOINTS (QW-402)

Plates ASTM - A -240 Gr. 304L to Plate ASTM – A - 240 Gr. 304L Groove Design of Test Coupon

BASE METAL (QW-403) Material Spec. SA - 240 Type of Grade 304 L P.No. ________8________ to P. No. ______8_________ Thickness of Test Coupon 6mm Diameter of Test Coupon NA Other Weld thickness range qualified 1.6 mm to 12 mm

POST WELD HEAT TREATMENT (QW-407) Temperature ___NA_______ Time ___NA_______ Other ___NA_______

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

Percent Composition

Shielding (Mixtures) Flow Rate

Shielding Argon 99.99% Pure 12-15Ltr./min

Trailing ---- Backing Argon 99.99% Pure 12-15Ltr./min

SFA Specification 5.9 AWS Classification ER 308-L Filler Metal F-No 6

Weld Metal Analysis A-No 8 ELECTRICAL CHARACTERISTICS (QW-409) Current __________DC_____________ Polarity STRAIGHT (DCEN) Amps. 85-90 Amp. Volts 12 (Refer Annexure) Tungsten Electrode Size ________2.4mm ___________ Other NA____

Size of Filler Metal 1.6mm & 2mm

Other Weld Metal Thickness 6mm POSITION (QW-405) Position of Groove __________1G___________ Weld Progression (Uphill, Downhill) N.A. Others __________________N.A.___________

TECHNIQUE (QW-410) Travel Speed 48.8 to 66.7 mm /min (Refer Annexure) String or Weave Bead _Root(stringer) ,Final(weave) Oscillation final pass weaving not exceeding 2.5 times dia of filler wire. Multipass or Single Pass (Per Side) ___Multipass____ Single or Multiple Electrodes _________Single ______ Other -------------------------------------

PREHEAT (QW-406) Preheat Temperature (Minimum) __N.A _ InterpassTemperature (Maximum) 125

0 C

Other ________________N.A._______________

2007 SECTION IX

QW -483

PQR Tensile Test (QW – 150) Page 2 of 3

Specimen

No.

Width

mm

Thickness

mm

Area

mm2

Ultimate

Total Load N

Ultimate Unit

Stress N/mm2

Type of Failure and

Location

T-1 19 5.90 112.10 70400 628.01 weld metal

T-2 18.80 5.94 99.75 62400 625.56 weld metal

Guided – Bend Tests (QW-160) Mandrel dia 24 mm (4t) Type and Figure No. Result

Root Bend RB -1 Satisfactory

Root Bend RB -2 Satisfactory Face Bend FB -1 Satisfactory Face Bend FB -2 Satisfactory

Toughness Tests (QW-170) Specimen

No.

Notch

Location

Specimen

Size

Test

Temperature

Impact Values Drop Weight Break (Y/N)

ft.lb % Shear Mills

NA

Comments ________________________________________NA__________________________________

Fillet – Weld Test (QW-180)

Result – Satisfactory Yes _________No. _________ Penetration into Parent Metal Yes ______ No. ___

Macro – Results_________________ NA ___________________________________________________

Other Tests

Type of Test ___________________________________________________________________________

Deposit Analysis _________ _______________ NA __________________________________________

Other _________________________________________________________________________________

Welder’s Name N. MADHAVAN Stamp/ID: NMV

Test Conducted by Geo Chem Lab(P)Ltd. Laboratory Test No. M LD /12/04/2012 dt.4.5.2012

We Certify that the statement 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.

Manufacture By DCMS Engg. Co. Date:7.05.2012 Details of record of tests are illustrative only and may be modified to confirm to the type and number of tests required by the Code.

PQR No. DCMS/WPS/099

Dt. 8/5/2012 Rev - 0

Page 3 of 3

Annexure to PQR No. DCMS/PQR/099 Date: 7/5/2012 Rev: 0 Name of Welder: N. MADHAVAN Stamp/ID: NMV Process: GTAW

Numbers

of Runs /

Weld

Passes

Electrode

Th 2%

(Tungsten)

Filler Wire

Gas

Shielding

ltrs / min

Backing

Gas

Ltrs./min

Current Speed

mm/min Volts Amp

1st

(Root) 2.4 mm

1.6 mm dia ER 308-L

14 12 11 72 48.8

2nd

pass

2.4mm

1.6 mm dia ER – 308-L

14

12

12 87

66.7

3rd

pass

2.4mm

1.6 mm dia ER – 308-L

14

12

12 87

53.04

4th pass

2.4mm

1.6 mm dia ER – 308-L

14

12

12 87

49.4

Prepared By Reviewed By Accepted By Abhishek Nag P.V.Khambatkone Client (QC Engineer) (Ex-NPCIL QA)

QW-484 MANUFACTURERS RECORD OF WELDER OR

WELDING OPERATOR PERFORMANCE

QUALIFICATION TESTS (SEE QW-301, SECTION XI,

ASME BOILER AND PRESSURE VESSEL CODE)

WELDER NAME PURAN SINGH Stamp/ID: PN

Welding process(es) used GTAW Identification of WPS followed by welder during welder during welding of test coupon : DCMS/WPS/099Rev-0 dt.15.09.11

Base material(s) welded SA-240 Gr 304L Thickness 6mm Thick Plate

Manual for Each Process (QW-350) Actual Values Range Qualified

Backing (Metal, weld metal, welded from both sides, flux etc.)

(QW-402)

Without with or without

ASME P.No. 8 to ASME P.No. 8 (QW-403)

( ) Plate (X ) Pipe (enter diameter, if pipe) 6 mm thk plate 1.6 to 12mm Plate

Filler metal specification (SFA) : 5.9 and 5.1 Classification

(QW-404)

ER-308L

A No.8

ER-308L

A.No.8

Filler metal F – No. 6 6

Filler Metal variety for GTAW, PAW (QW – 404) NA N.A.

Consumable insert for GTAW or PAW NA N.A.

Weld deposit thickness for each welding process 1.6mm GTAW 1.6 mm (GTAW)

Welding position (1G,5G, etc) (QW-405) 1G 1G & all fillet welds

Progression (uphill/downhill) N.A. N.A.

Backing gas for GTAW, PAW or GMAW : Fuel gas for QFW

(QW-408)

Argon Gas

99.995%

Argon Gas

99.995%

GMAW transfer mode (QW-409) N.A. N.A.

GTAW welding current type / polarity DCEN (GTAW) DCEN (GTAW)

Machine Welding Variables for the Process Used (QW-360) Actual Values Range Qualified

Direct / remote visual control

Automatic voltage control (GTAW)

Automatic joint tracking NA

Welding position (1G, 5G, etc)

Consumable insert

Backing (metal, weld metal, welded from both sides, flux etc.)

GUIDED BEND TEST RESULTS

Guided Bend Tests Type ( ) QW- 462.2 (Side) Results ( ) QW – 462.3 (a) (Trans. R & F) Type ( ) QW-462.3

(b) (Long, R & F) Results

FB-1 Satisfactory RB-1 Satisfactory

FB-2 Satisfactory RB-2 Satisfactory

Visual examination results (QW-302.4): Satisfactory

Radiographic test results (QW-304 and QW-305): Satisfactory

(For alternative qualification of groove welds by radiography)

Fillet Weld – Fracture test N.A. Length and percent of defects NA

Macro test fusion NA Fillet leg size NA in X inch Concavity / convexity NA in.

Welding test conduced by DCMS Engineering Co. Ltd.

Radiographic tests conducted by M/s. Geo chem Lab, Mumbai. Laboratory Test No. MLD/11/08/06896

DT.17.9.2011

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 Code

DCMS Engineering Co. CLIENT

Date __________ Date _________________