QW-482 WELDING PROCEDURE SPECIFICATION (WPS)

(See QW-200.1,ASME Section IX (2021) Boiler and Pressure Vessel code)

WPS NO. : SHF-WPS-04 POSTWELD HEAT TREATMENT (QW-407) ELECTRICAL CHARACTERISTICS (QW-409)
Date of WPS Preparation: 28.08.2023 Type of PWHT (QW407.1) NO Current (AC or DC) QW409.4 DC
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Revision : 1 Revision Date:05.09.2023 Welding Process (es) GMAW Temperature Range: C NA Polarity (EN or EP)QW409.4 EP
Supporting PQR (S): SHF-PQR-04 Welding Type(s) (QW410.25) Semi-Automatic Time Range (QW407.2) NA Amperes & Voltage : QW409.5 /
SEE BELOW
JOINTS (QW-402) Scope: W e l d i n g of Groove, Butt Joints & Fillet Welds Method of PWHT NA QW409.8 / QW409.23 /
Groove Design (QW402.1) Refer drawings for actual TYPICAL : QW409.25
Tungsten Type & Size NA
Backing : (QW402.4 / QW402.5) YES Other : NA (QW409.12)
Mode of Metal Transfer Spray Arc
Backing Material (type) Base / Weld Metal (QW409.2)
Pulsing Current (QW409.3) NA
Retainers (QW402.11): NO QW405. 1/ 405.4 T Limits (QW407.4) NA Travel Speed Range SEE BELOW
QW405.2/QW GAS (QW-408)
Other: NA
Gas(es) Composition Flow rate (LPM)
BASE METALS (QW-403) MATERIAL MATERIAL Shielding Gas (QW408.2) CO2 (%) 100% (QW408.3)NA
P.NO./S. No.(QW403.1/QW 1
1 2
1 Trailing Gas (QW408.1) NA NA NA
403.11/QW403.20)
Group No. (QW403.4 / QW403.5): 1, 2 1, 2 Backing Gas (QW408.5) NA NA NA
Material Specification / Grade: SA 516 Gr. 60 / 70, SA 105, SA 106 Gr. B, etc. SA 516 Gr. 60 / 70, SA 105, SA 106 Gr. B etc QW408.9 / QW408.10 NA
P. No. 5 / 9 / 10 (QW403.13) NA Other NA
Thickness Range : (mm) (QW403.8 / QW403.23) TECHNIQUE (QW-410)
Base Metal : Groove: 5- 32 mm Fillet: ANY String / Weave Bead (QW410.1) String / weave* Gas Cup / Orifice / Nozzle Size NA
Pipe Dia Range : ANY Fillet: ANY Closed to Out Chamber NA (QW410.3)
Cont. Tube to Work Dist.(QW410.8) NA
Thickness of Individual Pass Greater than 13 mm (QW403.9): NO T Limits Impact (QW403.6): NA (QW410.11)
Multiple/Single NA Multi / Single pass (per side) (QW410.9) MULTI PASS
Electrode(QW410.10)
Oscillation (QW410.7) NA Peening (QW410.26) NO
OTHER NA
Use of Thermal Process NA Electrode Spacing (QW410.15) NA
FILLER METALS (QW-404) (QW410.64)
Method of Back Gouging Arc Gouging & Grinding / Grinding
Process (es) : GMAW 2 3 (QW410.6)
Initial - Interpass Wire Brush / Grinding
F.NO. (QW404.4) 6 Cleaning(QW410.5)
Other * Weaving shall be three time of core dia. Meter max.
A.NO. (QW404.5 / QW404.37) 1
Spec No.(SFA) (QW404.12) 5.18 Filler Metal Current Volt Travel HEAT INPUT
Weld Speed Kj/mm
QW409.1 /
AWS NO.(Class) (QW404.33) ER70S-6 Process Dia Type & Amp. Range
Layer(s) Class Range QW409.26
Size of Filler Metals/Electrodes (mm) Polarity Range (mm / min) Min Max
(mm) Ø 1.2 mm
(QW404.6 / QW404.38 / ROOT / HOT GMAW ER70S-6 1.2 DCEP 80-250 18-30 60-140 -- --
QW404.3)
Deposited Weld Thickness (mm)
32 mm Max
QW404.30 / QW 404.32) 1.2 DCEP 80-250 18-30 60-140 -- --
FILLUP
Electrode / Flux (Class) PASSES
GMAW ER70S-6 -- --
NA
(QW404.9 / QW404.35) -- --
Flux Trade Name (QW404.29) NA
Change in Electrode Diameter for above 6 W404.7): Consumable Insert (QW404.22):
mm (Q
Supplemental (QW404.24): NA NO NA
Flux Type (QW404.34): NA
Filler Metal Product NA Recrushed Slag (QW404.36) :
Form(QW404.23)
Filler Addition / Deletion NA NA
Flux Addition / Deletion (QW404.50): NA
(QW404.14):
Other NA NOTES:
PREHEAT (QW-406) POSITION (QW-405) 1) Preheat temperature to be strictly followed for tacking also.
Thickness Range (mm) < 25 mm 25<32mm Position(s) of Groove : 2) Preheat temperature shall be maintained at least 75 mm on each side of weld joint and through wall thickness.
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ANY
Preheat Temp.(Min): C (QW406.1 / 25°C 50°C QW405.1/QW405.2/QW40 3) Interpass temperature limits shall be maintained at least 30 mm or 4X T (whichever is minimum) on either side of weld.
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Interpass Temp. (Max) : C (QW406.3) 250°C Welding
5.4 Progression(QW405.3) UPHILL 4) Hand held cutting torches shall not be used for heating purposes.
Preheat Maintenance : (QW406.2) NO Position(s) of Fillet : ANY 5) QW409.1 Increase in Heat Input is a Non Essential Variable.
Other NA Other NA 6) This WPS can be used for Repair also.
Prepared By
ReviewedBy Approved By W.P.S. No. Rev. No.

SHF-WPS-04 R01
 PROCEDURE QUALIFICATION RECORDS (PQR)

QW-482(See QW-200.2,Section IX,ASME Boiler and Pressure Vessel Code)

Record of Actual Variables Used to Weld Test coupon.
DATE: 28.08.2023
PQR No. with Revision No.: SHF-PQR-04
Supporting PWPS No. with revision No.: SHF-WPS-04 Rev.-00
Welding Process(es) GMAW
Types (Manual/Automatic,Semi-Automatic) Manual
JOINT ( QW-402 )

(Groove Design of Test Coupon)

(For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal and process used.)
BASE METALS ( QW-403 ) POSTWELD HEAT TREATMENT(QW-407)
Material Specification IS 2062 Loading Temp. NA
Type or Grade or UNS No.: E250 BR Heating Rate NA
P No.: 1 Group no.: 1,2 to P No.: 1 Group no.: 1,2 Soaking Temp. NA
Thk. of Test Coupon 16 mm Soaking Time NA
Dia. of Test Coupon --- Cooling Rate NA
Maximum pass thickness 1.5 mm Others NA
Other NA GAS(QW-408)
FILLER METALS ( QW-404 ) Gas Flow rate (LPM) % Comp.
1 2 Shielding CO2 NA 100%
SFA Specification 5.18 Backing NA NA NA
AWS Classification ER70S-6 Trailing NA NA NA
Filler Metal F-No. 6 ELECTRICAL CHARACTERISTICS (QW-409)
Weld Metal A-No. 1 Size 1.2
Size of Filler Metal Ø1.2 mm Current DC
Filler Metal Product Form NA Polarity EP
Supplemental Filler Metal NA Amps. 80-250
Flux Classification NA Volts 18-30
Flux Type NA Tungsten Electrode Size NA
Filler Metal Trade Name D&H Secheron Mode of Metal Transfer Spray
Weld Metal Thickness 18 mm Heat Input NA
Filler Metal Batch No.: U80145 TECHNIQUE ( QW-410 )
Other NA Travel Speed 60-140 mm/Min.
POSITION (QW-405) String/weave bead String/Weave*
Position(s) of Groove 3G Initial & Interpass Cleaning Yes,By Wire Brush or Grind
Weld Progression Vertical Uphill Method of back gouge Grinding
Other NA Multi/single pass (per side) Multipass
PREHEAT ( QW-406 ) Single/multiple electrode Single
Preheat Temp. (°C) 25 Oscillation NA
Interpass Temp. (°C) 250 Others NA
Other NA *Three times of core dia. Or 10 mm Max.
Prepared By.: Certified By:
 PROCEDURE QUALIFICATION RECORDS (PQR)
QW-482(See QW-200.2,Section IX,ASME Boiler and Pressure Vessel Code)

Record of Actual Variables Used to Weld Test coupon.

PQR NO:SHF-PQR-04_R0

TENSILE TEST ( QW - 150 ) TEST REPORT NO :GE177/N/2/G1; DATE:26.08.2023

SR Width Thickness Area Ultimate UTS

2
Result
no. mm mm mm Total load(N) (MPa)

T1 19.00 15.80 300.20 138560 461.55 Satisfactory

T2 19.10 15.80 301.78 138500 458.94 Satisfactory

GUIDED BEND TESTS ( QW-160 ) TEST REPORT NO :BJ10/N/1/W1; DATE:09.01.2019

Specimen No. Figure No. Type Mandrel Dia(mm) Result

S1 QW. 462.2 Side Bend (40 mm) Satisfactory

S2 QW. 462.2 Side Bend (40 mm) Satisfactory

S3 QW. 462.2 Side Bend (40 mm) Satisfactory

S4 QW. 462.2 Side Bend (40 mm) Satisfactory

TOUGHNESS TEST (QW-170)

Specimen Specimen Size (mm) Test Impact Val. Drop Weight
Notch Location
Location Temp.(°C) ft-lb or J %Shear mm Break (Y/N)
Not Appli

Result — Satisfactory: (Yes/No) NA Penetration into Parent Metal:(Yes/No) NA

Chemical Test

Elements Carbon Silicon Manganese Phosphorus Sulpher Chromium Nickle Copper

Molybdenum
Req.Val.(%)
Act.Val.(%)
C arbon Equivalent
Result NA
OHER TEST
Type of Test
Report No. NA
Other
OTHER DETAILS
Welder Name Mr. Vikram Kumar Jha
Welder Stamp Number SHF/WL/08
Tests Conducted by Advance Metallurgical Services, Makarpura GIDC, Vadodara, Gujarat
Laboratory Test No. TENSILE & BEND TEST; TEST REPORT NO :GE177/N/2/G1; DATE:26.08.2023

We certify that the statements 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(2017).

Manufacturer or Contractor

Prepared By.: Cerified By:

Mahesh Patel
 QW-484A WELDER PERFORMANCE QUALIFICATIONS (WPQ)
(See QW-301, Section IX, ASME Boiler and Pressure Vessel Code)

Welder's Name Mr.Vikram Kumar Jha Test Description PLATE

Welding Process(es) used GMAW Welder Stamp No SHF/WL/08
Identification of WPS followed SHF-WPS-04 Type MANUL
Specification of base metal(s) IS 2062 E250 BR Thickness 16 mm
Filler metal or electode specification(s) 5.18 (GMAW)
Test Coupon/Production Weld
Filler metal or electrode classification(s) ER70S-6 (GMAW)

Testing conditions and Qualification Limits

Welding Variables (QW-350) Actual Value Range Qualified

Welding process(es) GMAW GMAW

Type (i.e.; manual, semi-automatic) used Manual Manual
Backing (with/without) Without Backing With / Without Backing
Plate Pipe (enter diameter if pipe or tube) Plate Plate & Pipe
Base metal P-Number to P-Number P no.: 1 P1 throgh P 15 F,P34 & P41 Through P49
Filler metal or electrode specification(s) (SFA) (info. only) 5.18 5.18
Filler metal or electrode classification(s) (info. only) ER70S-6 ER70S-6
FIller metal F-Number(s) F6 F6
Consumable insert (GTAW or PAW) Not Applicable Not Application
Filler Metal Product Form (solid/metal or flux cored/powder) Not Applicable Not Application
Deposit thickness for each process

Process:1 3 layer Minimum (Yes/No) 16 mm (SMAW) Any

Process:2 3 layer Minimum (Yes/no)
Groove Pipe Over 24 Inch OD: F,V, Groove Pipe ≤ 24 Inch
Position qualified (2G, 6G, 3F, etc.) 3G
OD:F & Fillet: F,H,V
Vertical progression (uphill or downhill) Uphill Uphill
Type of fuel gas (OFW) Not Applicable Not Application
Inert gas backing (GTAW, PAW, GMAW) Not Applicable Not Application
Transfer mode (spray/globular or pulse to short circuit-GMAW) Not Applicable Not Application
GTAW current type/polarity (AC, DCEP, DCEN) Not Applicable Not Application

RESULTS
Visual examination of completed weld (QW-302.4) (Y/N) Y Pipe bend specimen, corrosion-resistant weld metal overlay [QW-462.5(c)] N
Transverse face and root bends [QW-462.3(a)] (Y/N) N Plate bend specimen, corrosion-resistant weld metal overlay [QW-462.5(d)] N
Longitudinal bends [QW-462.3(b)] (Y/N) N Pipe specimen, macro test for fusion [QW-462.5(b)] (Y/N) N
Side bends (QW-462.2) (Y/N) Y Plate specimen, macro test for fusion [QW-462.5(e)] (Y/N) N
Type Result Type Result Type Result
Side bends
Satisfactory Tensile Test (QW-150) Satisfactory
(QW-
462.2)

Alternative Volumetric Examination Results (QW-191) NA RT Satisfactory UT NA

Fillet weld — fracture test (QW-181.2) NA Length and percent of defects NA
Fillet welds in plate [QW-462.4(b)] NA Fillet welds in pipe [QW-462.4(c)] NA
Macro examination (QW-184) NA Fillet size NA Concavity/convexity NA
Other tests NA
RT examination Result(QW304,305) Accepted Report No. G-174/22-
23
Mechanical tests conducted by Advance Metallurgical Services, Vadodara, Guajarat Laboratory test no. GE177/N/2/
G1
Welding supervised by Mr. Himanshu D. Patel(BV)
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requi SME BOILER AND PRESSURE VESSEL CODE.
Manufacturer or Contractor Shree Hindustan abricator
F F
Date Certified By:

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