0. 8 To 1

60 To 70

3

QW-482 WELDING PROCEDURE SPECIFICATION(WPS)

Welding Procedure specification No.: WPS/RE/TPL/04 REV - 0 Date: 15-11-2009

Supporting PQR No.: PQR/RE/TPL/04 Date: 18/11/2009

Welding Process (es): FCAW Types (Manual, Automatic, Semi Auto): Semi Auto

JOINTS: (QW-402) 600 - 700

Joint Design: Single ‘’V’’ 16 mm

Backing: Yes 1.5-2.5mm 1.5 mm

[ √ ] Metal [ ] Non-fusing metal [ ] Nonmetallic [ ] Others

METAL METALS (QW-403) PREHEAT : QW-406P. No. 1 Gr.NO.2 To P.No.1 Gr.NO.2Material Spec. SA-516 Type of Grade. Gr. 70

Thickness of Test Coupon:16mm Thickness Range: Base metal: Groove: 5-32 mm Fillet : AnyOther

Preheat temp.(Min.): 300C for T≤ 25mm 1000C for T>25mmInterpass temp.(Max.): 250ºC

Post Weld Heat Treatment (QW-407)

Temperature oC NATime Range :- Others

FILLER METALS: (QW-404) SFA Specification: 5.20AWS Classification: E71T1F.NO. 06A.NO. 01Size of Filler Metal: Φ1.2mmWeld Metal : Thickness Range: Groove: 32 mm max. Fillet - AnyElectrode flux (class): NA Flux Trade Name: NA Other

Gas: (QW-408)

Gas(es) Percent Composition(Mixture) Flow Rate

Shielding CO2 100% 12-15 Lts/min.Trailing NA NA NABacking NA NA NA

ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC : DC Polarity: EPAmps(Range) : 130 - 248 Volts (Range) : 23 - 31Tungsten Electrode Size and Type : NAMode of Metal Transfer for GMAW(FCAW): SprayElectrode wire feed speed range:

POSITION (QW-405)

Position of Groove: AnyWelding progression : Up for 3G Position of Fillet : Any

TECNIQUE (QW-410)

Stringer or Weave Bead: String and WeaveOrifice or Gas Cup Size: NA

Initial & Interposes Cleaning : By Wire Brushing Oscillation :NAMultiple Or Single Pass(pre Side): MultipleContact Tube to work distance :Multiple Or Single Electrode: SingleTravel Speed (Range) :2.0 – 3.0 mm/secPeening: Others: Clean the joint bevel & 25 mm wide area adjacent to the joint on both sides by wire brushing to remove rust,dirt,oil,grease & other material detrimental to welding to be removed by solvent.

Weld Layer

ProcessFiller Metal Current Voltage

Travel Speed Range

mm/secClass Dia mm Type polar Amp Range

1

FCAW E71T1

1.2 DCEP 130-145 23-24 2.00

2 1.2 DCEP 204-228 27-28 2.363 1.2 DCEP 205-220 28-30 3.03

4 1.2 DCEP 237-248 28-31 2.72

BACK CHIPPING + DP

5FCAW

E71T1 1.2 DCEP 208-220 28-30 3.06

6 1.2 DCEP 210-230 28-30 2.85

Prepared By Examiner or Test Body Rakhoh Enterprises

0. 8 To 1

60 To 70

3

QW-483 PROCEDURE QUALIFICATION RECORD (PQR)

Procedure Qualification Record No.PQR/RE/TPL/04 Date :-18/11/2009

WPS No. - WPS/RE/TPL/04 REV-0 Date: 15-11-2009

Welding Process (es): FCAW Types (Manual, Automatic, Semi Auto): Semi Auto

JOINTS: (QW-402) 600 - 700

Joint Design: Single ‘’V’’ 16 mm

Backing: Yes 1.5-2.5mm 1.5 mm

[ √ ] Metal [ ] Non-fusing metal [ ] Nonmetallic [ ] Others

METAL METALS (QW-403) PREHEAT : QW-406Material Spec. SA-516 Type of Grade. Gr. 70

Thickness of Test Coupon:16mm Thickness Range: Base metal: Groove: 5-32 mm Fillet : AnyOther

Preheat temp.(Min.): 300C for T≤ 25mm 1000C for T>25mmInterpass temp.(Max.): 250ºC

Post Weld Heat Treatment (QW-407)

Temperature oC. : NATime RangeOthers:FILLER METALS: (QW-404)

SFA Specification: 5.20AWS Classification: E71T1F.NO. 06A.NO. 01Size of Filler Metal: Φ1.2mmWeld Metal : Thickness Range: Groove: 32 mm max. Fillet - AnyElectrode flux (class): NA Flux Trade Name: NA Other

Gas: (QW-408)

Gas(es) Percent Composition(Mixture) Flow Rate

Shielding CO2 100% 12-15 Lts/min.Trailing NA NA NABacking NA NA NA

ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC : DC Polarity: EPAmps(Range) : 130 - 248 Volts (Range) : 23 - 31Tungsten Electrode Size and Type : NAMode of Metal Transfer for GMAW(FCAW): SprayElectrode wire feed speed range:

POSITION (QW-405)

Position(s) of Groove : 1GWelding progression : NAPosition of Fillet : Any

TECNIQUE (QW-410)

Stringer or Weave Bead: String and WeaveOrifice or Gas Cup Size: NA

Initial & Interposes Cleaning : By Wire Brushing Oscillation :NAMultiple Or Single Pass(pre Side): MultipleContact Tube to work distance :Multiple Or Single Electrode: SingleTravel Speed (Range) :2.0 – 3.0 mm/secPeening: Others: Clean the joint bevel & 25 mm wide area adjacent to the joint on both sides by wire brushing to remove rust,dirt,oil,grease & other material detrimental to welding to be removed by solvent.

TENSILE TEST (QW-150)Specimen No. Width

(mm)Thickness (mm)

Area (mm2)

Ultimate Total Load, KN

Ultimate Unit Stress N/mm2

Type of Failure & Location

1 18.90 15.70 296.73 169.90 572.57 In Parent Metal

2 19.10 15.60 297.96 171.50 575.58 In Parent Metal

GUIDED-BEND TEST (QW-160)Type and figure No. Result

FACE BEND-1 QW-462.3 SatisfactoryFACE BEND-2 QW-462.3 SatisfactoryROOT BEND-1 QW-462.3 SatisfactoryROOT BEND-2 QW-462.3 Satisfactory

Welder Name: Mr. Jalinder Mane

Test Conducted By Mr. Manoj Naik Laboratory Test No. HF3760C Dated: 06/12/2009

We certify that the statements made in this record are correct and the test welds were prepared, welded, and tested in accordance with the requirements of SECTION IX Of ASME Boiler and Pressure Vessel Code.

Manufacturer: Rakhoh ENT for Tata Projects Ltd.

QW-484A WELDER PERFORMANCE QUALIFICATION (WPQ)

Welder name __________________________ Identification No.__________________________________ TEST DESCRIPTIONIdentification of WPS followed _________________________________Specification of Base Metal(s)__________________________ Thickness _______________________ TESTING CONDITION AND QUALIFICATION LIMIT

Welding Variables(QW-350) Actual Value Range Qualified

Welding Process(es) _______________________ ______________________Type(ie;manual,semi-auto) used _______________________ ______________________Backing (metal,weldmetal,double-welded,etc) _______________________ ______________________Plate or Pipe _______________________ ______________________Base metal P-or S-Number to P-or S-Number _______________________ ______________________Filler metal or Electrode Specification(s) (SFA) _______________________ ______________________ Filler metal or Electrode Classification(s) (SFA) _______________________ ______________________Filler Metal F-Number(s) _______________________ ______________________Consumable insert (GTAW/PAW) _______________________ ______________________Filler type (solid/metal or flux cored/powder) _______________________ ______________________ Deposit Thickness for each processProcess1:_________3 layer Minimum ( Yes/No) _______________________ ______________________Process2:_________3 layer minimum ( Yes/No) _______________________ ______________________Position Qualified (2G, 6G, 3F etc.) _______________________ ______________________Vertical Progression ( Uphill or Downhill) _______________________ ______________________Type of fuel gas (OFW) _______________________ ______________________Inert gas backing (GTAW,PAW,GMAW) _______________________ ______________________Transfer mode ( spray/globular or short circuit-GMAW) _______________________ ______________________SMAW Current Polarity (AC,DCEP,DCEN) _______________________ ______________________

RESULTSVisual Examination of Completed Weld (QW-302.4)___________________________Bend Test, Transfer root and face(QW-462.3(a); longitudinal root and face (QW-462.3(b);Side (QW-462.2);Pipe bend specimen, corrosion-resistant overlay (QW-462.5(c);Plate bend specimen,Crrosion-resistant overlay [(QW-462.5(d)];Macro test for fusion[QW462.5(b)];Macro test for fusion[QW-462.5(e)]

Type Result Type Result Type

Alternative radiographic examination result (QW-191) __________ Film or specimen evaluatedby_____________Company________________ Mechanical tested conducted by___________ Laboratory test________Welding Supervised by __________________We certify that the statement in this record are correct and that the coupons were prepared,welded,and tested in accordance with the requirement of Section -9 of the ASME Boiler and presser vessel code. Organization_____________________________Date ____________________ By_________________________________