Supporting PQR No
Welding process(es)
: SMAW
Type
: Manual
Scope
: This welding procedure specification is applicable for repair welding of P No.1.
Materials without PWHT.
JOINTS: -(QW 402)
Joint Design
Root gap
Root land
Bevel Angle
Backing
Base material
Retainer
Base material
: Single V Groove Joint or as per approved drawing
: 1.5-3.0 mm or as per approved drawing
: 1.5-3.0 mm or as per approved drawing
: 65 5 C
: Nil
: NA
: Nil
: 10 mm
JOINT DESIGN (TYPICAL)
BASE METALS (QW 403)
P.No. / Group No.
: P.No. 1 Group No 2 to P.No.1 Group No 2
Specification Type & Grade
:-
Chemical Analysis
:-
Mechanical Properties
:-
Thickness Range Base Metal
Fillet
: 1.50 20 mm
: All
Weld pass thk < 13 mm
: Yes
FILLER METALS (QW 404)
Specification No. (SFA)
: A5.1
AWS No. Classification
: E7018
F.No.
:4
A.No.
:1
Size of Electrode/Filler metal
: 3.15 & 4.00 mm dia
Filler metal product from
: Electrode
Weld metal Thickness Range
: 20 mm Max.
Electrode Flux
: NA
Supplemental Filler Metal: NA
Fillet: NA
Consumable insert: NA
Change of alloy element
: NA
Brand Name / Trade Name
: NA
Power Feed rate: NA
POSITIONS (QW 405)
Position of Groove
Welding Progression
: All
: NA
Position of Fillet: All
PREHEAT (QW 406)
Preheat Temperature Min.
Inter pass Temperature Max.
: 30 C
: 300 C
Preheat Maintenance: NA
POST WELD HEAT TREATMENT (QW 407)
Type
: None
Temperature Range
: None
Rate of heating / cooling
: None
Time Range
: None
Loading / unloading (max)
: None
GAS (QW 408)
Flow Rate (lpm)
Gas
Shielding gas
: NA
Trailing
: NA
Backing
%Composition / Mixture
: NA
ELECTRICAL CHARACTERISTICS (QW 409)
Weld Pass
Process
Filler metal
Classification
Root Pass
Fill up &
Cap
SMAW
SMAW
E-7018
E-7018
Pulsing Current
Diameter
(mm)
3.15
3.15
4.00
Current
Type &
Polarity
Amps
(Range)
DC/EP
DC/EP
DC/EP
100-140
100-140
140-180
Volt
Travel Speed
Heat Input
(Range) Range (mm/min) K.I/mm (max)
24-28
24-28
24-28
150-200
150-200
200-250
: N.A
Heat Input (max)(KJ/mm)
: Refer table above
Tungsten Electrode Size & Type
: NA
Mode of metal transfer
: NA
Electrode wire feed speed range
: NA
TECHNIQUE (QW 410)
String or weave Bead
: Both (Weave not more than 3 times dia of electrode)
Office, Nozzle or Gas cup Size
: NA
Initial and Inter pass Cleaning
: Wire Brushing and Grinding
Method of back gouging
: Grinding if required
Oscillation
: N.A
Contact tube to work distance
: NA
Multiple or Single pass (per side)
: Multiple pass
Multiple or Single electrode
: Single
Electrode spacing
: N.A
Travel Speed (Range)
: Refer table above
Peening
: Not allowed
Use of thermal process
: Nil
Transfer mode
: NA
Torch orifice dia
Filler metal delivery
: NA
: NA
1.57
1.57
1.51
JOINTS: -(QW 402)
Joint Design
given
Root gap (A)
Root land (B)
Bevel angle
Backing
Base Material
Retainer
Base material thickness (t)
: Single V Groove Joint as per Sketch
Joint design (refer sketch encl)
: 1.5-2.0 mm
: 1.5-2.0 mm
: 65 5 C
: Nil
: NA
: NA
: 10 mm
BASE METALS (QW 403)
PREHEAT (QW 406)
Material Specification
: ASTM A216
Preheat Temperature
Type or Grade
: WCB
Inter pass Temperature : 300 C
P.No. Gr.No.
: P.No. 1 Gr.No.2
Thickness of Test Coupon
: 10 mm
Diameter of Test Coupon
: N.A
Size (mm) (l x w x t)
: 300 x 150 x 10 Thk
: 30 C
Others
: N.A
POST WELD HEAT TREATMENT (QW 407)
Temperature
Time Range
: None
: None
Cooling
: None
Rate of heating / cooling
: None
Loading / Unloading
FILLER METALS (QW 404)
Flow Rate (lpm)
: None
GAS (QW 408)
Gas
Shielding Gas
%Composition
SFA Specifications
: A5.1
: NA
AWS Classification
: E7018
Filler Metal F.No.
:4
Backing Gas
Weld Metal Analysis A.No.
:1
ELECTRICAL CHARECTERISTICS (QW 409)
Size of Filler Metal
: 3.15 mm dia
Current (A.C. or D.C.)
Filler Metal product from
(EP)
: Electrode
Polarity
Weld metal thickness (t)
: 10 mm
Amps
: 130 A
Trade name / brand name
: (ESAB 36H of M/s ESAB
Volts
: 27 V
Trailing Gas
India ltd Chennai, Ref TC Enclosed)
: NA
: NA
: D.C.
: Reverse (Electrode +ve)
Tungsten Electrode size
: NA
SIZE 3.15mm
Others: Heat Input
SIZE 4.00mm
Mode of metal transfer : NA
POSITION (QW 405)
( Refer Attached Welding Parameter Sheet)
Position of Groove
: 1G
Weld Progression
: N.A
: 1.40 KJ/mm
TECHNIQUE (QW 410)
Travel Speed
: 150 160 mm /min (for all pass / all layer)
String or weave Bead
: Both (Weave width not more than 3 times dia of electrode)
Oscillation
: N.A
Multi pass or Single pass (pre side)
: Multi pass
Single or Multiple electrodes
: Single
Method of back gauging
: None
Change of process
Orifice / nozzle size
: N.A
Peening
Gas cup size
: N.A
Transfer mode
Method of cleaning
: Wire brushing, Grinding
: N.A
: Nill
Torch orifice dia
: N.A
: N.A
Filler metal delivery
: NA
TENSILE TEST (QW 150): Report Ref:
Specimen
No
T1
T1
Width (mm)
Thickness (mm)Area (mm)
18.71
18.73
10.01
9.66
187.29
180.93
Ultimate Load (KN)
Ultimate Stress (Mpa)
Type of fracture &
location
99.15
97.90
529.39
541.09
Ductile & base
Ductile & base
GUIDED BEND TEST (QW 160):
Specimen size (mm) ( l x w x t ): 300 x 10 x 10
Specimen ID
FB1
FB2
FB1
FB2
Nature of Bend
Face Bend
Face Bend
Root Bend
Root Bend
Angle of Bend (Deg)
180
180
180
180
Dia of Roller (mm)(4t)
38.1
38.1
38.1
38.1
Free
Free
Free
Free
from
from
from
from
Result
defects. Satisfactory
defects. Satisfactory
defects. Satisfactory
defects. Satisfactory
TOUGHNESS TESTS (QW-170) : NA
FILLET-WELD TEST (QW-180)
Results
: N.A
Penetration into Parent metal: Yes/No
: N.A
Macro Results
: N.A
OTHER TESTS
SI. NO Type of ExaminationAcceptance standard/ Requirement
1 Visual Examination QW-302.4 of ASME Section IX
2 Liquid Penetrate Testing
As per ASME Sec. VIII Div. 1.A.8
3 Radiography
QW-191.2. of ASME Section IX
Acceptable Refer Lab Report
4 Hardness (HV10)
As per NACE MR 0175 / ISO 15156-2
Hardness survey as per sketch enclosed in report
:2003
Base
200 HV max
Base
: Average 158 HV
Weld
200 HV max
Weld
: Average 199 HV
HAZ
200 HV max
HAZ
: Average 191 HV
Acceptable Refer Lab Report
5 Macro examination Shall be free from defects
Free from crack, pin hole, porosity and other abnormalities.
Fusion Satisfactory.
Acceptable Refer Lab Report
We certify that statement in this record are correct and that the test welds were prepared, welded and tested in accordance
with the
