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WPS
A written document that provides direction to
the welder or welding operator for making
production welds in accordance with the
CODE requirements. It establishes the
properties of the weldment, not the skill of
the welder.
PQR
Shall document what occurred during welding
the test coupon and results of testing of the
coupon.
As a minimum, the PQR shall document all the
essential variables and other specific
information for each process used during
welding the test coupon and the results of the
required testing.
Variables
Essential
Non-essential
Supplementary
essential
Essential Variables
A change in welding condition which will
affect the mechanical properties of the
weldment.
e.g.:
A) Change in P Number
B) Filler metal
C) Electrode
D) PWHT, etc.
Supplementary Essential
Variables
of construction
Detailed drawing of
weldment
Material
Thickness
Configuration
Process
Contract/Customer/
Code/TPI
Preheat/Postheat/ PWHT
requirements
Skilled welder
Good welding m/c with
accessories
Application
CONTENTS
OF
WPS / PQR
Joints (QW-402)
Joint Design
(V-groove, U-groove, Single-bevel etc.)
Backing
(YES/NO)
Thickness
Range
Groove : ______
Pipe
Diameter Range
Groove : ______
Fillet:______
Fillet :_______
Thickness Range
Thickness T of Test Coupon,
Welded, (mm)
2T
2t
1.5
2T
2t
2T
2t
19 to less than 38
2T
2t when t < 19
2T when t > 19
38 and over
200
2t when t < 19
200 when t > 19
Classification
SFA Number
F. Number
A. Number
Size
of Filler metal
Flux trade name
Consumable insert
Electrode flux class
Fillet:______
F - NUMBERS
A - NUMBERS
Position (QW-405)
Position
Of Groove
Position
Of Fillet
Weld
Progression (UP/DOWN)
Others
Preheat (QW-406)
Preheat
Temperature (min.)
Interpass
Preheat
Others
Temperature (max.)
Maintenance
PWHT (QW-407)
Temperature
Time
Range
Others
Range
GAS (QW-408)
Gas
Shielding
Trailing
Backing
Mix %
Flow Rate
(AC/DC)
Polarity (EP/EN)
Amps & Volts
W-Electrode type & size
Mode of Metal Transfer (GMAW)
Electrode Wire Feed Speed range
Techniques (QW-410)
Stringer
or Weave Bead
Orifice/Gas Cup Size
Initial or Interpass Cleaning
Method of Back Gauging
Oscillation
Contact Tip to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrode
Electrode Spacing
Peening
Others
Form No.
101-403
Page 1 of 2
Date :
Type :
(Auto,Semi-Auto,Manual,Machine)
JOINTS (QW-402)
POSITION (QW-405)
Welding Position
Weld Progression
(Uphill/Downhill)
Others:
PREHEAT (QW-406)
Preheat temp.
Interpass temp.
Postheat
Others
GAS (QW-408)
Shielding
:
Trailing
:
Backing
:
Gas
-------------
:
:
:
:
:
:
:
TECHNIQUE (QW-410)
String/Weave Bead
:
Oscillation
:
Multipass or single pass :
Multiple or single electrode:
Travel speed
:
Others
:
BHEL
Tiruchirappalli-14
Specimen
No.
Page 2 of 2
PQR No.:
Width
mm
Thickness
mm
Failure
Location
Specimen
No
Notch
Location
Result
Type &
Fog No. QW-462.2
Result
Drop Weight
Break
No
Break
:
:
:
:
Welders Name:
Stamp No.:
Test conducted by: BHEL Plant Laboratory
Test No. :
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 Sec IX of the ASME code Edition 2004 and
addenda July 2005.
Approved by :
Prepared by :
(XXXXXXXX)
XXXXXXX
(XXXXXXXX)
XXXXXXXXX
BHEL
Tiruchirappalli 14
Page 2 of 2
WPS No : Rev :
PWHT(QW-407)
GAS ( QW - 408)
Gases
Shielding :
Trailing :
Backing :
Temp. Range :
Time Range :
Others
:
ELECTRICAL CHARACTERISTICS ( QW 409 )
Current (AC/DC)
: See table
Amps (Range)
: See table
Tungsten Electrode type and size
: .
Mode of Metal transfer for (GMAW) : .
Electrode wire feed speed range
: .
Pulsing current (GTAW)
: .
TECHNIQUES (QW-410)
String or Weave Bead
Orifice or Gas cup size
Initial and Interpass Cleaning
Method of Back Gouging
Oscillation
Contact tube to work distance
Multiple or single pass (per side)
Multiple or single Electrode
Electrode spacing
Peening
Others
:
:
:
:
:
:
:
:
:
:
Process
Class
.
Nil
Current
Dia.
mm.
flow Rt
-------
Filler
Weld
Layer
Mix %
-------
Type
Amps.
Voltage
Range
Travel speed
Range
Others (Hot
wire,Torch
angle,ROL.)
Root &
Capping
Others
-- do --
Approved by :
(xxxxxxxxx)
xxxxxxxxxxxxxxxxxxxx
Prepared by :
(xxxxxxxxxxxx)
xxxxxxxxxxxxxxxxxx
Form No.
101 - 401
Page 1 of 2
WPS No. :
Rev No. :
Welding Process :
Date :
Date : ----
Supporting
PQR No:
Type :
(Auto/Semi-Auto/Manual/Machine)
Application :
JOINTS (QW-402)
Joint Design
Backing (Yes/No)
Backing Material (Type)
Metal/Non fusing metal
Non metallic/Others
:.
:
:
TO
P.No.:
Group No.:
.
.
Fillet :
Fillet :
PREHEAT (QW-406)
Preheat Temp. (min)
:
Inter pass Temp. (max) :
Post heat
:
Others
:
:
:
:
:
P3/Gr1
P4/Gr1
P5A/Gr1
ER80S-G
P1/Gr1,2 (RT Mo)
E7018-1
ER80S-G
(RT Mo)
E7018-1
ER80S-G
(RT Mo)
E7018-1
ER80S-G
(RT Mo)
E7018-1
P3/Gr1
ER80S-G
(RT Mo)
E7018-A1
ER80S-G
(RT Mo)
E7018-A1
ER80S-G
(RT Mo)
E7018-A1
P4/Gr1
P1/Gr1,2
P5B/Gr2
P8/Gr1,2
ERNiCr-3
ENiCrFe-3
ER80S-G
ER80S-G
ER80S-G
ERNiCr-3
(1Cr Mo) (1Cr Mo) (1Cr Mo)
ENiCrFe-3
E8018-B2
E8018-B2
E8018-B2
P5A/Gr1
ER90S-G
ER90S-G
ERNiCr-3
(2Cr1Mo) (2Cr1Mo)
ENiCrFe-3
E9018-B3
E9018-B3
P5B/Gr2
ER90S-B9
E9018-B9
ERNiCr-3
ENiCrFe-3
Dr.K. P. Dhandapani
DGM / Welding Technology Centre
BHEL, Tiruchirapalli
Repair Welding
Postweld Operation
EXAMPLE
WELDING TECHNOLOGY CENTRE
BHEL TIRUCHIRAPALLI
DATE: 09/09/2006
WELDING PROCEDURE FOR REPAIR OF HEADER
Suitable support to be provided at the two ends of the header so as to fix it at its
position. Cut/machine out the central portion of the header that requires
replacement by suitable means. The tubes shall be cut at appropriate distance.
Edge prepare on the two ends of the header and on the tubes as per the relevant
drawing. The header shall be free from chips prior to fit up & welding.
Circumferential Groove Welding. (WPS No.1005/04)
1. Properly align the axis of the central new portion of the header with the old two
header ends and also the axes of the nipple with the tubes and do the fit-up.
2.
Clean the surfaces to be weld and its vicinity (upto a distance of 15mm
minimum) to remove oil, dirt, rust etc.
3.
4.
Do the root welding using GTAW Process. Use ER80S-G (RT Mo) filler
metal.
5.
Use SMAW process to fill up the groove and complete the welding. Properly
dried E7018-A1 (as per required drying procedure) to be used for welding.
6.
Do the post heating for 2hrs at 1500C temperature and allow it to cool down
slowly to room temperature.
7.
Conduct Radiography Testing on the joint as per the relevant NDT procedure.
8.
If any defect is found do the rework by repeating the above relevant steps after
properly removing the defect by Grinding/Machining/gauging.
9.
When the weld is free from defects, carry out PWHT at 635+150C temperature
with a soaking time of 80min. The rate of heating and cooling above 400 0C
shall be 1100C/hr.
Clean the surfaces on the tube and nipple to be weld and its vicinity (upto a
distance of 15mm minimum) to remove oil, dirt, rust etc.
Do the root welding using GTAW Process. Use ER80S-G (RT Mo) filler
metal.
Use SMAW process to fill up the groove and complete the welding. Properly
dried E7018-1 (as per required drying procedure) to be used for welding.
Conduct Radiography Testing on the joints as per the relevant NDT procedure.
If any defect is found do the rework after properly removing the defect by
Grinding/Machining/ gauging.
Carry out the final inspection on the job as per the relevant approved procedure.
REPAIR
WELDING
P. No. &
Gr. No
P1 Gr1
COMMON
NAME
CARBON
STEELS
TUBES
PIPES
PLATES
FORGINGS
CASTINGS
SA179
SA192
SA210GrA1
SA334Gr1
SA334Gr6
SA106GrB
SA333Gr1
SA333Gr6
SA266CL1
SA350LF1
SA216WCA
SA352LCA
SA352LCB
-do-
SA210GrC
SA106GrC
SA105
SA266CL2S
SA350LF2
SA216WCB
SA216WCC
SA352LCC
OTHER
SPEC.
-do-
IS1239
API5LGrB
P3 Gr1
SA209T1
SA213T2
SA213T12
SA213T11
SA213T22
SA213T91
SA199T91
SA335P1
SA335Gr2
SA335P12
SA335P11
SA335P22
SA335P91
SA182F12
SA182F11
SA182F22
SA182F91
SA217WC6
P5A Gr1
P5B Gr2
C Mo
Cr 1/2Mo
1Cr MO
1Cr Mo
2, Cr 1Mo
9Cr1Mo V
SA36
SA515Gr55
SA515Gr60
SA515Gr65
SA516Gr55
SA516Gr60
SA516Gr65
SA515Gr70
SA516Gr70
SA299
IS226
IS2062
BMC10
BMC16
BMC20
SA204GrA
SAA387Gr2
SA387Gr12
SA387Gr11
SA387Gr22
SA387Gr91
P1 Gr2
P8 Gr1
18Cr 8Ni
SA376TP304
SA376TP304H
SA376TP316
SA376TP321
SA376TP347
SA376TP347H
SA240TP304
SA240TP321
SA240TP347
P8 Gr2
25Cr-20Ni
(Type 310)
SA213TP304
SA213TP304H
SA213TP316
SA213TP321
SA213TP347
SA213TP347H
SA213TP310H
SA182F304
SA182F321
SA182F347
SA336F304
SA336F321
SA336F347
SA182F310
SA351CF3
SA351CF8
SA351CF3M
SA351CF8M
SA351CF10
SA351CF10M
SA351CK20
P4 Gr1
SA240TP310
SA217WC1
SA217WC9
TUBES
PIPES
Filler material
SA179
SA192
SA210GrA1
SA106GrB
SA333Gr1
SA333Gr6
ER 80S-G
0.5 Mo.
SA210GrC
SA106GrC
C Mo
Cr
1/2Mo
SA209T1
SA213T2
SA335P1
SA335Gr2
1Cr MO
1Cr Mo
SA213T12
SA213T11
2, Cr 1Mo
Electrodes.
Pre heat
PWHT
610 15 Deg C
E 7018-1
NIL
ER 80S-G
0.5 Mo.
E 7018-1
NIL
635 15 Deg C
SA335P12
SA335P11
ER 80S-G
1 Cr, 0.5 Mo.
E 8018-B2
125 Deg C
655 +- 15 Deg
C
SA213T22
SA335P22
ER 90S-G
2.25 Cr, 1 Mo.
E 9018-B3
150 Deg C
695 15 Deg C
9Cr1Mo V SA213T91
SA199T91
SA335P91
ER 90S-B9
E 9018-B9
220 Deg C
760 15 Deg C
18Cr 8Ni
SA376TP304
SA376TP304H Inconnel.
SA376TP316
SA376TP321
SA376TP347
SA376TP347H
SA213TP304
SA213TP304H
SA213TP316
SA213TP321
SA213TP347
SA213TP347H
E308, E309,
E310, E316
E347
(Based on
Material
Specification.)
One metal from P-No. 3 to any metal from P-No. Any P or S No. 3 metal to any metal
3
assigned P or S No. 3 or 1
One metal from P-No. 4 to any metal from P-No. Any P or S No. 4 metal to any metal
4
assigned P or S No. 4, 3 or 1
One metal from P-No. 5A to any metal from PNo. 5A
One metal from P-No. 4 to any metal from P-No. Any P or S No. 4 metal to any metal
3 or 1
assigned P or S No. 3 or 1
Any unassigned metal to the same unassigned
metal
S - Number
They are mostly ASTM specification
materials that have not been adopted within
Section II, Part D but that are referred within
Code Cases and the ASME B31 Code.
e.g. A 588 Gr A
A 576 G10100
S-No. 3
Group No. 1
S-No. 1
Group No. 1
SFA NO.
5.01
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
DESCRIPTION
Filler Metal Procurement Guidelines
Carbon Steel Electrodes for Shielded Metal Arc Welding
Carbon and Low Alloy Steel Rods for Oxy Fuel Gas Welding
Aluminum and Aluminum Alloy Electrodes for Shielded Metal Arc Welding
Stainless Steel Electrodes for Shielded Metal Arc Welding
Low Alloy Steel Electrodes for Shielded Metal Arc Welding
Covered Copper and Copper Alloy Arc Welding Electrodes
Copper and Copper Alloy Bare Welding Rods and Electrodes
Filler Metal for Brazing and Braze Welding
Bare Stainless Steel Welding Electrodes and Rods
Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods
Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding
Tungsten and Tungsten Alloy Electrodes for Arc Welding and Cutting
Solid Surfacing Welding Rods and Electrodes
Nickel and Nickel Alloy Bare Welding Electrodes and Rods
Welding Electrodes and Rods for Cast Iron
Titanium and Titanium Alloy Welding Rods and Electrodes
Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
Carbon Steel Filler Metals for Gas Shielded Arc Welding
5.23
5.24
5.25
5.26
5.27
5.28
5.29
5.30
5.31
5.32
Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding
Zirconium and Zirconium Alloy Welding Electrodes and Rods
Carbon and Low Alloy Steel Electrodes and Fluxes for Electro-slag Welding
Carbon and Low Alloy Steel Electrodes for Electro-gas Welding
Low Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding
Low Alloy Steel Electrodes for Flux Cored Arc Welding
Consumable Inserts
Fluxes and Brazing and Braze Welding
Welding Shielding Gases
F-Number
Description
---
---
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.4
SFA-5.4
SFA-5.5
SFA-5.5
EXX20
EXX22
EXX24
EXX27
EXX28
EXXX(X)-25
EXXX(X)-26
EXX20-X
EXX27-X
2
2
2
2
2
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.5
EXX12
EXX13
EXX14
EXX19
E(X)XX13-X
3
3
3
3
SFA-5.1
SFA-5.1
SFA-5.5
SFA-5.5
EXX10
EXX11
E(X)XX10-X
E(X)XX11-X
4
4
4
4
4
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.1
SFA-5.1
EXX15
EXX16
EXX18
EXX18M
EXX48
AWS Classification
EXXX(X)-15
EXXX(X)-16
EXXX(X)-17
E(X)XX15-X
E(X)XX16-X
E(X)XX18-X
E(X)XX18M
E(X)XX18M1
EXXX(X)-15
EXXX(X)-16
EXXX(X)-17
6
6
6
6
6
6
6
6
6
6
6
6
6
6
All classifications
All classifications
All classifications
All classifications
All classifications
All classifications
All classifications
All classifications
All classifications
All classifications
All classifications
INMs-X
IN5XX
IN3XX(X)
SFA-5.2
SFA-5.9
SFA-5.17
SFA-5.18
SFA-5.20
SFA-5.22
SFA-5.23
SFA-5.25
SFA-5.26
SFA-5.28
SFA-5.29
SFA-5.30
SFA-5.30
SFA-5.30
ANo.
Cr
Mo
Ni
Mn
Si
Mild Steel
0.20
1.60
1.00
Carbon-Molybdenum
0.15
0.50
0.40-0.65
1.60
1.00
0.15
0.40-2.00
0.40-0.65
1.60
1.00
0.15
2.00-6.00
0.40-1.50
1.60
2.00
0.15
6.00-10.50
0.40-1.50
1.20
2.00
Chrome-Martensitic
0.15
11.00-15.00
0.70
2.00
1.00
Chrome-Ferritic
0.15
11.00-30.00
1.00
1.00
3.00
Chromium-Nickel
0.15
14.50-30.00
4.00
7.50-15.00
2.50
1.00
Chromium-Nickel
0.30
19.00-30.00
6.00
15.00-37.00
2.50
1.00
10
Nickel to 4%
0.15
0.55
0.80-4.00
1.70
1.00
11
Manganese-Molybdenum
0.17
0.25-0.75
0.85
1.25-2.25
1.00
12
Nickel-ChromeMolybdenum
0.15
1.50
0.25-0.80
1.25-2.80
0.75-2.25
1.00
304L 308
309
309S
310
310S
316,316H 316L
317
321,321H 347,347H,348,348H
304,304H,305 308L 308L 308,309 308,309 308,309, 310 308,309, 310 308,316
308,316
304L
308
309
308
308,316
308,347
309,310
309,310
308,316
309,316
309,316
309,347
309,347
309,310
309S,310S
308,316
309S,316L 310,317
309,347
309,347
316
310,316
317
308,310
308,310
310S
316
316,317
308,310
308,310
316,316H
316
317
308,316
308,316, 347
316L
316L
316L,347
317
308,317
308,317, 347
309S
310
321,321H
309
308L,347
Carbon Steel
BM SPECIFICATION
SA210GrA1, SA210GrC
FILLER METAL
PWHT TEMPERATURE
610+15 deg.C
Diameter
mm
Thickness
mm
Preheat (min.)
Deg. C
PWHT
Remarks
ALL
< 19
Nil
Nil
C < 0.25%
ALL
<9
Nil
Nil
C < 0.30%
SA209T1
FILLER METAL
PWHT TEMPERATURE
635+15 deg.C
Diameter
mm
< 127
Thickness
mm
< 13
Preheat (min.)
Deg. C
Nil
PWHT
Nil
Remarks
SA213T11, SA213T12
FILLER METAL
PWHT TEMPERATURE
655+15 deg.C
Diameter
mm
< 127
Thickness
mm
< 13
Preheat (min.)
Deg. C
125
PWHT
Nil
Remarks
SA213T22
FILLER METAL
PWHT TEMPERATURE
695+15 deg.C
Diameter
mm
< 102
Thickness
mm
<8
Preheat (min.)
Deg. C
150
PWHT
Nil
Remarks
C < 0.15%
Cr < 3.0%
SA213T91
FILLER METAL
ER90S-B9, E9018-B9
PWHT TEMPERATURE
760+10 deg.C
Kinkar P. Narzary
Welding Engineer / Welding Technology Centre
BHEL, Tiruchirapalli
Ph. 0431-2575546
E-mail: kinkar@bheltry.co.in