DOCUMENT TITLE DOCUMENT No. TASHA DOC. NO. TITLE DOCUMENT No. TASHA DOC. NO. ... Position(s) of...

OWNER

CLIENT:

National Iranian Gas Company

IGAT 5 Gas Compressor Stations

DOCUMENT TITLE DOCUMENT No. TASHA DOC. NO. 602-106-TSH-VD-017 Rev. 0

PROJ STATION ORG DOC SEQ REV WPS, PQR

602 106 TSH VD 017 4 SH. 1 of 1

4 23/02/2006 FOR APPROVAL N.A. M.S.KH M.S.KH S.P.Z.

3 16/01/2006 FOR APPROVAL N.A. M.S.KH M.S.KH S.P.Z.

2 27/11/2005 FOR APPROVAL H.N. M.S.KH M.S.KH S.P.Z.



REV.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED

CONSURTIUM

EngineeringCompany

Sabz

CONSURTIUM:

TASHA Manufacturing Company SABZ Engineering Company

FBM Hudson Italiana FBM KNM FZCO.

WPS, PQR

FOR

SPY-2-1106/2106/3106/4106-EA-101

TASHA DOC. NO.: 602-106-TSH-VD-017 Rev. 4 TOTAL PAGES: 30

(EXCLUDING COVER SHEET)

OWNER

CLIENT:




PROJ STATION ORG DOC SEQ REV WPS , PQR

602 106 TSH VD 017 4 SH. 1 of 30

EngineeringCompany

Sabz

WPS No.: WP-001 (Top & Bottom plate to Tube &

Plug sheet)

Item:SPY-2-(1~4)106-EA-101 Code: ASME SEC. IX ED.2001

Welding Proc(es): S.A.W. Supp. PQR No.: Will Be Submitted Later Type(es): Automatic

Joints (QW-402):

Joint Design: AS Detail

Backing: Yes (x) No( )

Backing Material: Weld metal

Details

Base Metals (QW-403) P No.: 1 Gr. No.: 2 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 516 Gr. 70 N To Specification Type and Grade: A 516 Gr. 70 N Thickness Range: Base Metal: Groove: 16-30mm Fillet: Pipe Dia. Range: Groove: Fillet:

Filler Metals (QW-404) Process: Spec No. (SFA): AWS No.: F-No.: A-No.: Size of Filler Metals: Filler Metal Trade Name: Deposited Weld Metal Range: FILLET: Electrode Flux (Class): Flux Trade Name: Consumable Insert: Flux Baking Condition;

SAW 5.17

EM12K 6 1

2.5-4 AMA

16-30 mm --

F7P5(AMA OP120TT) AMA N.A.

Acc. To manufacturer recommendation (300°C to350°C )

10

8

15°

TOP

OR

BO

TTO

M P

LATE

TUB

E O

R P

LUG

SHEE

T

R7

10

15°

min min

min

18

INSIDE

OUTSIDE

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 2 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: 1G Welding Progression: UP ( ) DOWN ( ) Position(s) of Fillet:

Preheat (QW-406): Preheat Temp. Min.: 75°C Inter pass Temp. Max.: 300°C Preheat Maintenance: Gas Burner

Post weld Heat Treatment (QW-407): Temp. Range: 620 ~ 630°C Time Range: 1 hr/in Heating Rate: 120°C/hr Cooling Rate: 120°C/hr

PERCENT COMPOSITION GAS (QW-408):

Electrical Characteristics (QW-409): Current : AC ( ) DC ( X ) Polarity: SP ( ) RP ( x ) Amps Range : AS PER TABLE Tungsten Electrode Size and Type: N.A. Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range:

GAS (es) Mixture Flow Rate Shielding --- --- --- Trailing --- --- --- Backing --- --- ---

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 3 of 30

EngineeringCompany

Sabz

Technique (QW-410): String or Weave Bead: STRING Orifice Gas Cup: N.A. Initial or Inter pass Cleaning: Grinding or Brushing Method of Back Gouging: Machining/ Grinding/ DP Oscillation: Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: See Table Peening: N.A. Note: No single pass greater than 1/2" (13mm)

Filler Metal Current Weld Layer Process Class Dia. (mm) Polarity AMP.

Range Volt Range

Travel Speed

(cm/min)

Max Heat Input (J/cm)

1 (in) SAW EM12K 2.5 DCRP 250-350 18-26 25-40 2496 2 (out) SAW EM12K 2.5 DCRP 250-350 18-26 25-40 2496 Rest &

Cap SAW EM12K 3.25-4 DCRP 320-480 18-27 25-40 31104

Welding Sequence:

1. Assembly and tack weld 2. Welding layer of inner side 3. Milling from outside 4. Penetration test 5. Welding of outer side

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 4 of 30

EngineeringCompany

Sabz

WPS No.: WP-002

(End plate to Top & Bottom plate) Item:SPY-2-(1~4)106-EA-101 Code: ASME SEC. IX ED.2001

Welding Proc(es): GTAW + SMAW Supp. PQR No.: PQ-PV-22 Type(es): Manual

Joints (QW-402):


Backing: Yes ( ) No(x)

Backing Material: N.A

Details

Base Metals (QW-403) P No.: 1 Gr. No.: 2 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 516 Gr. 70 N To Specification Type and Grade: A 516 Gr. 70 N Thickness Range: Base Metal: Groove: 16-30mm Fillet: Pipe Dia. Range: Groove: Fillet:


G.T.A.W. SMAW 5.18 5.1

ER 70S-6 E 7018-1 6 4 1 1

2.4 2.5,3.25-4 AMA AMA

--- --- N.A N.A.

F7P5(AMA OP120TT) F7P5(AMA OP120TT) AMA AMA N.A N.A N.A (230°C-260°C 2hr)

45°

t/3 Min

+0.5

0-12.

5

45°~

50°

END PLATE TH'K. = t

18 o

r 20

INSIDE OUTSIDE

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 5 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: 1G, 2G Welding Progression: UP ( ) DOWN ( ) Position(s) of Fillet:


Post weld Heat Treatment (QW-407): Temp. Range: 620°C Time Range: 1 hr/in Heating Rate: 120°C/hr Cooling Rate: 120°C/hr


Electrical Characteristics (QW-409): Current : AC ( ) DC ( X ) Polarity: SP ( x ) RP ( x ) Amps Range : AS PER TABLE Volts Range: As Per Table Tungsten Electrode Size and Type: EWTH.2 DIA.2.4mm Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range:

GAS (es) Mixture Flow Rate Shielding Argon 99.99% 8 Lit/min Trailing --- --- --- Backing --- --- ---

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 6 of 30

EngineeringCompany

Sabz

Technique (QW-410): String or Weave Bead: STRING & WEAVE Orifice Gas Cup: 1/4" Initial or Inter pass Cleaning: Grinding / Brushing Method of Back Gouging: N.A Oscillation: Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: As Per Table Peening: N.A. Note: No single pass greater than 1/2" (13mm)


Range

Volt Range

Travel Speed

(cm/min)

Heat Input (J/cm

) 1 GTAW ER 70S-6 2.4 DCSP 120-160 18-22 8-15 26400 2 SMAW E 7018-1 2.5 DCRP 120-150 18-20 8-15 22500

Rest & Cap SMAW E 7018-1 3.25 , 4 DCRP 120-180 18-20 8-15 27000

Welding Sequence:

1. Assembly and tack weld 2. Welding layer of outer side 3. Penetration test

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 7 of 30

EngineeringCompany

Sabz

WPS No.: WP-003

(Stay plate to Tube & Plug sheet) Item:SPY-2-(1~4)106-EA-101 Code: ASME SEC. IX ED.2001

Welding Proc(es): S.A.W. Supp. PQR No.: Will Be Submitted Later

Type(es): Automatic

Joints (QW-402):


Backing: Yes ( ) No( x )


Details

Base Metals (QW-403) P No.: 1 Gr. No.: 2 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 516 Gr. 70 N To Specification Type and Grade: A 516 Gr. 70 N Thickness Range: Base Metal: Groove: 12-22mm Fillet: Min 4mm Pipe Dia. Range: Groove: Fillet:


SMAW 5.17

EM12K 6 1

2.4 ~ 4mm AMA

12-24 mm 4 mm 10.61

F7P5(AMA OP120TT) N.A.

Acc. To manufacturer recommendation (350°C for 2hr)

20

1.5 ~ 2

2 ~

2.5

45°

Min

6 m

m W

ITH

GTA

W

12

< 4

INSIDE

OUTSIDE

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 8 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: 2F Welding Progression: UP ( ) DOWN ( ) Position(s) of Fillet:


Post weld Heat Treatment (QW-407): Temp. Range: 620°C (+ 10/-0) Time Range: 1 hr/in Heating Rate: 120°C/hr Cooling Rate: 120°C/hr


Electrical Characteristics (QW-409): Current : AC ( ) DC ( X ) Polarity: SP ( ) RP ( x ) Amps Range : AS PER TABLE Tungsten Electrode Size and Type: N.A. Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range:


OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 9 of 30

EngineeringCompany

Sabz

Technique (QW-410): String or Weave Bead: STRING Orifice Gas Cup: N.A. Initial or Inter pass Cleaning: Grinding / Brushing Method of Back Gouging: N.A Oscillation: N.A Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: As Per Table Peening: N.A. Note: No single pass greater than 1/2" (13mm)

Filler Metal Current Weld Layer Process Class Dia.

(mm) Polarity AMP. Range

Volt Range

Travel Speed

(cm/min)


1 SAW EM12K 2.4-3 DCRP 250-350 18-26 25-40 21840 2 SAW EM12K 2.4-3 DCRP 250-350 18-26 25-40 21840

Rest & Cap SAW EM12K 4 DCRP 320-480 18-27 25-35 31104

Welding Sequence:

1. Assembly and tack weld 2. Welding layer of inner side 3. Penetration test 4. Completion of welding

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 10 of 30

EngineeringCompany

Sabz

WPS No.: WP-004 (Nozzle to Flange)



Joints (QW-402):




Details

Base Metals (QW-403) P No.: 1 Gr. No.: 1 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 333-6 To Specification Type and Grade: A 350-LF2 Thickness Range: Base Metal: Groove: 14-20mm Fillet: Pipe Dia. Range: Groove: 4"-6" Fillet:


G.T.A.W. SMAW A 5.18 A 5.1

ER 70S-6 E 7018-1 6 4 1 1

2.4 mm 2.3, 3, 4 mm AMA AMA

0-5 mm 5-28 mm N.A N.A.

F7P5(AMA OP120TT) F7P5(AMA OP120TT) AMA AMA N.A N.A

(230°C-260°C FOR 2hr)

75°~80°

2.5

0~1

+0.5

INSIDE

OUTSIDE

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 11 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: 6G Welding Progression: UP ( x ) DOWN ( ) Position(s) of Fillet:




Electrical Characteristics (QW-409): Current : AC ( ) DC ( X ) Polarity: SP ( x ) RP ( x ) Amps Range : AS PER TABLE VOLTS RANGE: AS PER TABLE Tungsten Electrode Size and Type: EWTH.2 DIA.2.4mm Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range:


OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 12 of 30

EngineeringCompany

Sabz

Technique (QW-410): String or Weave Bead: STRING & WEAVE Orifice Gas Cup: 1/4" Initial or Inter pass Cleaning: Grinding / Brushing Method of Back Gouging: N.A Oscillation: Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: 19-25 cm/min , 5-11 cm/ min Peening: N.A. Note: No single pass greater than 1/2" (13mm)


Range

Volt Range

Travel Speed

(cm/min)


1 GTAW ER 70S-6 2.4 DCSP 120-160 18-22 8-15 26400 2 SMAW E 7018-1 2.5 – 3.25 DCRP 120-150 18-22 14-21 14142

Rest & Cap SMAW E 7018-1 3.25 - 4 DCRP 120-180 18-22 14-21 16971

Welding Sequence:

1. Assembly and tack weld 2. Welding layer of outer side 3. Penetration test 4. Completion of welding

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 13 of 30

EngineeringCompany

Sabz

WPS No.: WP-005

(Tube to Tube sheet) Item:SPY-2-(1~4)106-EA-101 Code: ASME SEC. IX ED.2001

Welding Proc(es): GTAW (SEAL WELD)

Supp. PQR No.: Not Required Type(es): AUTOMATIC

Joints (QW-402):


Backing: Yes ( ) No( x)


Details

Base Metals (QW-403) P No.: 1 Gr. No.: 1 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 334-6 (Sml) To Specification Type and Grade: A 516 Gr. 70 N Thickness Range: Base Metal: Groove: Fillet: 5 mm Pipe Dia. Range: Groove: Fillet:


G.T.A.W A 5.18

ER 70S-6 6 1

0.8 – 1.2 mm AMA

1.6-5 mm --

N.A F7P5(AMA OP120TT)

N.A N.A.

TUBETUBE-SHEET

2.77

90°

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 14 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: 5F Welding Progression: UP ( ) DOWN ( ) Position(s) of Fillet: 5F



Electrical Characteristics (QW-409): Current : AC ( ) DC ( X ) Polarity: SP ( x ) RP ( ) Amps Range : AS PER TABLE VOLTS RANGE: AS PER TABLE Tungsten Electrode Size and Type: EWTH-2.4 DIA. 2.4mm Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range:

Technique (QW-410): String or Weave Bead: String & weave Orifice Gas Cup: 1/4" Initial or Inter pass Cleaning: Grinding / Brushing Method of Back Gouging: N.A Oscillation: N.A Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: As Per Table Peening: N.A.

GAS (es) Mixture Flow Rate Shielding Argon 99 .99% 8 Lit/min Trailing --- --- --- Backing --- --- ---

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 15 of 30

EngineeringCompany

Sabz



Volt Range Travel Speed

(cm/min)


1 GTAW ER 70S-6 0.8 DCSP 100-120 18-22 5-12 31680 2 GTAW ER 70S-6 0.8 DCSP 100-120 18-22 5-12 31680

Welding Sequence:

1. Welding layer 2. Penetration test

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 16 of 30

EngineeringCompany

Sabz

WPS No.: WP-006

(Vent & Drain to Top & Bottom plate)


Welding Proc(es): S.M.A.W. Supp. PQR No.: PQ-PV-22 Type(es): Manual

Joints (QW-402):


Backing: Yes ( ) No( x )


Details

Base Metals (QW-403) P No.: 1 Gr. No.: 2 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 516 Gr. 70 N To Specification Type and Grade: A 350-LF2 Thickness Range: Base Metal: Groove: Fillet: 8-14 mm Pipe Dia. Range: Groove: Fillet:


GTAW A 5.1

E 7018-1 4 1

3.25 & 4mm AMA N.A

3-5 mm/ pass N.A

F7P5(AMA OP120TT) N.A.

230°C-260°C For 2hr

NOZZLE TO TOP & BOTTOM PLAT FOR1 1/2" LWN

1.5~2

45°

INSIDE

OUTSIDE

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 17 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: Welding Progression: UP ( ) DOWN ( ) Position(s) of Fillet: 1F




Electrical Characteristics (QW-409): Current : AC ( ) DC ( X ) Polarity: SP ( ) RP ( x ) Amps Range : AS PER TABLE Tungsten Electrode Size and Type: N.A. Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range: N.A


OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 18 of 30

EngineeringCompany

Sabz

Technique (QW-410): String or Weave Bead: STRING & WEAVE Orifice Gas Cup: N.A. Initial or Inter pass Cleaning: Grinding / Brushing Method of Back Gouging: N.A Oscillation: N.A Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: As Per Table Peening: N.A.



Volt Range

Travel Speed

(cm/min)


1 SMAW E 7018-1 3.25 DCRP 90-130 22-24 6~15 31200 2 SMAW E 7018-1 4 DCRP 90-160 22-26 6~15 41600

Welding Sequence:


OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 19 of 30

EngineeringCompany

Sabz

WPS No.: WP-007

(Nozzle to Top & Bottom plate) Item:SPY-2-(1~4)106-EA-101 Code: ASME SEC. IX ED.2001


Joints (QW-402):




Details

Base Metals (QW-403) P No.: 1 Gr. No.: 1 To P No.: 1 Gr. No.: 2 Specification Type and Grade : A 333-6 To Specification Type and Grade: A 516 Gr. 70 N Thickness Range: Base Metal: Groove: 14-22mm Fillet: 4-6mm Pipe Dia. Range: Groove: 4"-8" Fillet:


G.T.A.W. SMAW A 5.18 A 5.1

ER 70S-6 E 7018-1 6 4 1 1

2.4 3.25-4 -- --

0-5 mm 5-20 mm 3-5 mm/pass

F7P5(AMA OP120TT) F7P5(AMA OP120TT) AMA AMA N.A N.A N.A (230°C-260°C FOR 2hr)

2.5

a = NOZZLE TH'K.

45°

a

0 ~ 1

TOP / BOTTOM PLATE NOZZLE PIPE TO

FOR 2" AND LARGER

22

INSIDE OUTSIDE

OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 20 of 30

EngineeringCompany

Sabz

Positions (QW-405): Position(s) of Groove: 1G & 2G Welding Progression: UP ( ) DOWN ( ) Position(s) of Fillet: 1F




Electrical Characteristics (QW-409): Current : AC ( ) DC ( x ) Polarity: SP ( x ) RP ( x ) Amps Range : AS PER TABLE VOLTS RANGE: AS PER TABLE Tungsten Electrode Size and Type: EWTH.2 DIA.2.4mm Mode of Metal Transfer for G.M.A.W: N.A. Electrode Wire Feed Speed Range: N.A


OWNER

CLIENT:





602 106 TSH VD 017 4 SH. 21 of 30

EngineeringCompany

Sabz

Technique (QW-410): String or Weave Bead: STRING & WEAVE Orifice Gas Cup: 1/4" Initial or Inter pass Cleaning: Grinding / Brushing Method of Back Gouging: N.A Oscillation: N.A Contact Tube to Work Distance: N.A. Multiple or Single Pass (Per Side) : Multiple Multiple or Single Electrodes: Single Travel Speed Range: As Per Table Peening: N.A.



Volt Range Travel Speed

(cm/min)


1 GTAW ER 70S-6 2.4 DCSP 120-160 18-25 8-15 30000 2 SMAW E 7018-1 2.4 DCRP 120-150 18-22 6-15 33000

Rest & Cap SMAW E 7018-1 3.25 - 4 DCRP 120-180 18-24 6-15 17280

Welding Sequence:


DOCUMENT TITLE DOCUMENT No. TASHA DOC. NO. TITLE DOCUMENT No. TASHA DOC. NO. ... Position(s) of...

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