WELDING - IV.ppt

Transcript of WELDING - IV.ppt

By:P.SIVASANKARAN
WELDINGWelding is a process of joining two or more pieces of the same or dissimilar materials to achieve complete coalescence.

DEFINITION AS PER AWS / ASMEA localised coalescence of metals or non-metals produced either by heating the materials to the welding temperature with or without the application of pressure alone, and with or without the application of filler material.
WELDING PROCESSES

Shielded Metal Arc Welding (SMAW)Submerged Arc Welding (SAW)Gas Metal Arc Welding (GMAW )- MIG , MAGGas Tungsten Arc Welding (GTAW / TIG)
SELECTION OF WELDING PROCESS DEPENDS ON

Thickness & Size of part to be weldedLocation and position of weld jointsJoint designWelding equipment availabilityProcess and operation requirementProduction cost
SHIELDED METAL ARC WELDINGSMAW process defined as an arc welding process which produces coalescence of metals by heating them with an arc between a covered metal electrode and the work-piece.

Shielding is obtained from decomposition of the electrode covering.

Pressure is not used and filler metal is obtained from the electrode.
SHIELDED METAL ARC WELDING
MODE OF OPERATION

Arc melts parent plate and electrode to form a weld pool which is protected by flux cover.Operator adjusts electrode feed rate, I.e. hand movement to keep arc length constant. Slag must be removed after depositing each bead. Normally a small degree of penetration, requiring plate edge preparation. Butt welds in thick plate or large fillets are deposited in a number of passes.The process can also be used to deposit metal to form a surface with alternative properties.
CONSUMABLES

Metal rods 1.5 - 8mm diameter with flux covering (1-5mm radial thickness). Widely used: 2.5x 250, 3.15 x350/450, 4 mm x 450 mmThe characteristics of manual metal arc electrodes, i.e., arc stability, depth of penetration, rate of deposition, position of welding, depends on the chemical composition of the electrode coating classified by AWS specifications.
SMAW - OPERATING PARAMETERSCurrent range: 75-300 AOpen Circuit Voltage: 65 - 80 VRange of Thickness: 2mm upwardsDeposition rate: 2-11 lb/HrTypes of joint: AllWelding position : all (depending on flux coating)Access: GoodPortability: Good
MATERIALSMostly confined to ferrous alloys, but can be used for some others.TYPICAL APPLICATIONSStructural steel work.Ship BuildingRepair and Hard facing of construction plant.
OVERALL ADVANTAGESLow Equipment CostUsage possible with restricted access.OVERALL LIMITATIONSSkilled operator is required for good quality welds.Slow, mainly because flux must be chipped away.SAFETYArc emits visible and ultraviolet radiation.High open circuit voltage present while electrode is fitted to holder.
SUBMERGED ARC WELDING

SAW is defined as an arc welding process in which an arc is maintained between an end of a bare wire electrode and work piece.

The arc is fully submerged in a layer of dry granular flux.

Pressure is not used and filler metal is obtained from the electrode.
SUBMERGED ARC WELDING
OVERALL ADVANTAGESHigh weld metal QualitySmooth and uniform weld bead with no spatters.Extremely high deposition rate and welding speed. Current Range: 450 - 3000 A High Arc time can be achieved through automation.Minimum operator fatigue.OVERALL LIMITATIONSHigh initial costLimited welding positions.Requirement of special jigs and fixtures.Difficulty in welding low thickness metals.Full penetration weld joints not possible from single side.
GAS METAL ARC WELDING

GMAW is defined as an arc welding process which produces coalescence of metals by heating them with an arc between a continuous filler metal (consumable) electrode and the work piece.

Shielding is obtained entirely from an externally supplied gas or gas mixture.
TYPE OF OPERATION: Semi-automatic / Fully automatic.EQUIPMENT: Power Source Wire feed Unit Welding gun or torch Gas supply system travelling unit, if fully mechanised.

An arc is maintained between the end of the bare wire electrode and the work. The wire is fed at a constant speed, selected to give the required current, and the arc length is controlled by the power source. The operator is not therefore concerned with controlling the arc length and can concentrate on depositing the weld metal in the correct manner. Hence the name semi-automatic for manual operation, in which wire, gas and power are fed to a hand held gun via a flexible conduit.GAS METAL ARC WELDINGContd.
The process can be operated at high currents (250-500A) when metal transfer is in the form of spray but except for aluminium, this technique is confined to welding in the flat and horizontal positions. For welding in the vertical and overhead positions. Special low-current techniques must be used, I.e. dip transfer or pulsed arc shielded by a stream of Gas.GAS METAL ARC WELDING
GMAW - OPERATING PARAMETERSCurrent range : 65-500 AMetal Transfer modes:Globular - in CO2 welding ( Non-axial metal transfer) for StructuresSpray Transfer - Thk > =6mm; in MIG ( Axial Transfer) for piping ( with Argo-CO2 shield) high thickness range.Dip Transfer ( Short Circuit ) - suitable for thin sheet metal works ( thk @ 3 mm or less): Dip transfer, pulsed arc Above 0.5mm Spray transfer 6mm upwardsDeposition rate :12-10 Kg/Hr (2-20 Lb/Hr)Types of joint: All including spot weldsAccess: FairPortability: Fair
ConsumablesElectrodes, bare wire (m.s. is normally copper coated) 0.6-1.6mm dia. Layer wound on spools 0.5-12 Kg (1-25lb) weight. Composition of wire selected to suit parent material; wire specifications covered by BS 2901. Electrodes, flux cored are available for high deposition rate welding.Shielding gas in cylinders containing compressed gas which will expand to 7Cu.M (250 Cu.Ft) at atmospheric pressure. Composition to suit parent material usually carbon dioxide (CO2) for mild steel, argon for non-ferrous materials and argon with 1.5% oxygen or 5-20% CO2 for high strength and corrosion resisting ferrous alloys.Other mixtures are used in special circumstances.
TYPICAL APPLICATIONSCO2 Welding ( MAG )- For structuresMIG Welding with Argon / Helium/ Mixed Gases - for Low Alloy, Mild Steel, Aluminium alloy, Copper and Copper allloys Spray Transfer method - for heavy wall thickness pipes, structuresDip Transfer ( Short Circuit) - for Thin sheet metal working. Vehicle manufacturing.
OVERALL ADVANTAGESContinuous processReduced finishing operationsThin sheets can be welded in all positions by dip transfer mode.OVERALL LIMITATIONSNo independent control of filler addition.Range of action limited by wire feed.SAFETYArc emits visible and ultraviolet radiation.
GAS TUNGSTEN ARC WELDING

GTAW is defined as an arc welding process which produces coalescence of metals by heating them with an arc between a tungsten (non- consumable) electrode and the work piece.

Gas Tungsten Arc Welding (GTAW) uses a non consumable tungsten electrode which must be shielded with an inert gas. The arc is initiated between the tip of the electrode and work to melt the metal being welded, as well as the filler metal, when used. A gas shield protects the electrode and molten weld pool, and provides the required arc characteristics.
GAS TUNGSTEN ARC WELDING
STRAIGHT POLARITYREVERSE POLARITY
OVERALL ADVANTAGESSuperior quality welds Welds can be made with or without filler metal Precise control of welding variables (heat) Free of spatter Slag free Low distortionOVERALL LIMITATIONS Requires greater welder dexterity than MIG or stick welding Lower deposition rates More costly for welding thick sections
Sheet1

RECOMMENDED ELECTRODES / FILLER WIRES

SL.NOBASE MATERIALCOATED ELECTRODESFILLER WIRES

ASMEAWSASMEAWS

CARBON STEELSFA 5.1E 7018SFA 5.18ER 70 S2

2CARBON MOLYSFA 5.5E 7018 A1SFA 5.28ER 80 SB2

311/4 Cr - 1/2 MoP11SFA 5.5E 8018 B2SFA 5.28ER 80 SB2

421/4 Cr - 1 MoP22SFA 5.5E 9018 B3SFA 5.28ER 90 SB3

55 Cr - 1/2 MoP5SFA 5.4E 502SFA 5.9ER 502

69Cr - 1 MoP9SFA 5.4E 505SFA 5.9ER 505

718 Cr 8 NiSFA 5.4E 308SFA 5.9ER 308

816 Cr 13 Ni MoSFA 5.4E 316SFA 5.9ER 316

918 C 10 Ni cbSFA 5.4E 347SFA 5.9ER 347

1018 Cr 10 Ni TlSFA 5.4E 347SFA 5.9ER 347

1123 Cr 12 NiSFA 5.4E 309SFA 5.9ER 309

1225 Cr 20 NiSFA 5.4E 310SFA 5.9ER 310

13MiscelleneousSFA 5.11E Ni Cr Fe2SFA 5.14ER Ni Cr3

Sheet2

Sheet3
STANDARD REBAKING PROCEDURE FOR LOW HYDROGEN ELECTRODESRebake the electrodes at 250-300 Deg. C for one hour.Cool them in the same oven to 100 Deg. CTransfer them to a holding oven maintained at 60-70 Deg. CDraw from this oven for use.Do not keep the rutile type electrodes in the same oven.
WELDING PROCEDURE SPECIFICATION (WPS)WPS shall be written as per ASME Section IX or IS 7307 ( For Cross Country Pipelines: API 1104)WPS is a written qualified welding procedure prepared to provide direction for making production welds to code requirements.The WPS or other documents may be used to provide direction to the welder or welding operator to assure compliance with the code requirements.WPS shall describes all of essential, non-essential and supplementary variables for each welding process.
PROCEDURE QUALIFICATION RECORD (PQR)PQR shall be written as per ASME Section IX or IS 7307.PQR is a record of the welding data used to weld a test coupon.The PQR is a record of variables recorded during the welding of the test coupons.It is a record of what happened during a particular welding test.
WELDERS PERFORMANCE QUALIFICATION (WPQ)WPQ shall be written as per ASME Section IX or IS 7310.WPQ test shall be welded in accordance with qualified WPS.Each manufacturer or contractor shall qualify each welder or welding operator for each welding process to be used in production welding.
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wps-001

QW-482 WELDING PROCEDURE SPECIFICATIONS (WPS)

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

Company NameLarsen & Toubro Limited - ECC Construction Group

Welding Procedure Specification noL&T/CPCL/Rev.0Date29.12.2K

Supporting PQR No.(s)Rev.-Date-

Welding Process(es)SMAWType(s)Manual

JOINTS (QW-402)

Joint DesignDouble 'V' Groove

BackingYes / No

Backing Material (Type)Nil

(Refer to both packing and retainers)

Metal Non Fusing Metal

Non mettalic Other

BASE METALS(QW-403)

P.No. 01 Group No 02 to P.No. 01 Group No. 02____

or

Specification Type & Grade ASTM SA 516 GR 70

to Specification Type & Grade ASTM SA 516 GR 70

or

Chem.Analysis and Mech. Prop. -

to Chem.Analysis and Mech. Prop. -

Thickness Range

Base MetalGroove 4.76 - 50 mmFillet All

Pipe Dia RangeGroove AllFillet All

Other-

FILLER METALS(QW-404)

ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01

Size of Filler metals2.5, 3.15 & 4.0mm

Electrode Flux(class)NA

Flux Trade NameNA

Consumable InsertNA

Other

2.5+0.5mm mm

1.5 .5mm

.5mm

60

t
XXXXX

wps-001back

QW-482 (Back)

WPS No. L&T/CPCL/ Rev. 0

POSITIONS (QW-405)POST WELD HEAT TREATMENT(QW-407)

Position(s) of Groove AnyTemparature Range 595 to 650 Deg. C

Welding Progression : Up Yes Down XHeating & Cooling Rate 160 Deg. C / Hr

Positions of Fillet AllGAS (QW-408)

Percent Composition

PREHEAT(QW-406)Gas(es)MixtureFlow Rate

Preheat Temp. Min 150 Deg. C for T > 19mmShieldingNA

Interpass temp.Max 250 Deg.CTrailingNA

Preheat Maintanence -BackingNA

(Contininous or special heating where applicable should be recorded)

ELECTRICAL CHARECTRASTICS (QW-409)

Current AC or DCDCPoloritySMAW - RP

Amps (Range)60-180Volts Range 18 - 24 V

(Amps and volts range should be recorded for each electrode size,position, and thick etc.

Tungsten electrode Size and TypeNA

(Pure Tungsten,2% Thoriated etc)

Mode of metal Transfer for GMAWNA

Spray arc,short circuiting etc.

Eletrode Wire feed speed rangeNA

TECHNIQUE (QW-410)

String or Weave BeadBoth

Orifice or Gas Cup SizeNA

Intial and Interpass Cleaning (Brushing,Grinding etc.) Wire Brushing, Grinding

___________________________________________________________________________________________

Method of Back GougingGrinding

OcillationNA

Contact tube to Work distance--

Multiple or Single pass (per side)Multipass

Multiple or Single ElectrodesSingle

Travel Speed ( Range)See Table

PeeningNA

OtherNA

___________________________________________________________________________________________

Weld LayersProcessFiller MetalsCurrentAmp RangeVolt RangeTravel speed RangeOthers

ClassDiaTypePoloritymm/min

01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE70183.15DCRP90-13018-2260-120--

04SMAWE70184.0DCRP130-18018-2460-120--

Prepared byReviewed and Approved byReviewed and Accepted by

for LTCGfor LTCGfor CLIENT / CONSULTANT
XXXXX

wps-004




Welding Procedure Specification noL&T/CPCL/004Rev.0Date18.04.01

Supporting PQR No.(s)L&T/CCPP/016Rev.0Date20.05.98


JOINTS (QW-402)

Joint DesignSingle 'V' Groove

BackingYes / No



MetalNon fusing metal

Non mettalicOtherSketch

BASE METALS(QW-403)

or

Specification Type & Grade

to Specification Type & Grade

or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAWSMAW

Spec. No (SFA)5.15.1

Aws. No(Class)E6010E6013

F.No.0302

A.No0101

Size of Filler metals2.5 mm3.15 & 4.0 mm

Electrode Flux(class)NANA

Flux Trade NameNANA

Consumable InsertNANA

Other

2.5+0.5 mm

1.5+0.5 mm

37.5 + 2.5

T

wps-004back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA



Current AC or DCDCPolority

Amps (Range)50-140 Amps



(Pure Tungsten,2% Thoriated etc.)




TECHNIQUE (QW-410)


Orifice or Gas Cup Size-

___________________________________________________________________________________________

Method of Back GougingNA

OcillationNA





Peening--

OtherNA

___________________________________________________________________________________________



01SMAWE60102.5DCRP50-7020-2275-120--

02SMAWE60133.15DCSP70 - 9022-2475-120--

03SMAWE60134.0DCSP110 - 14022-2475-120--



wps-005





Supporting PQR No.(s)L&T/PQR/005Rev.0Date20.06.98


JOINTS (QW-402)


BackingYes / No





BASE METALS(QW-403)

or



or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAWSMAW



F.No.0302

A.No0101



Flux Trade NameNANA


Other

2.5+0.5 mm

1.5+0.5 mm

37.5 + 2.5

T

wps-005back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA











TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





Peening--

OtherNA

___________________________________________________________________________________________



01SMAWE60102.5DCRP50-7020-2275-120--

02SMAWE70183.15DCSP70 - 9022-2475-120--

03SMAWE70184.0DCSP110 - 14022-2475-120--



wps-001







JOINTS (QW-402)


BackingYes / No




Non mettalic Other

BASE METALS(QW-403)

or

or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01



Flux Trade NameNA

Consumable InsertNA

Other







JOINTS (QW-402)


BackingYes / No




Non mettalic Other

BASE METALS(QW-403)

or

or

Thickness Range12 mm

Base MetalGroove

Pipe Dia RangeGroove NA

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E 6013

F.No.2

A.No01

Size of Filler metals2.5, 3.15 MM


Flux Trade NameNA

Consumable InsertNA

Other

wps-001back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA




Amps (Range)60-180







TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





PeeningNA

OtherNA

___________________________________________________________________________________________



01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE70183.15DCRP90-13018-2260-120--

04SMAWE70184.0DCRP130-18018-2460-120--



QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA




Amps (Range)70 to 140







TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





PeeningNA

OtherNA

___________________________________________________________________________________________



01SMAWE60132.5DCRP70-14018-2260-80--

02SMAWE60132.5DCRP60-9018-2060-80--

03SMAWE60133.15DCRP90-13018-2260-80--

04SMAWE60134.0DCRP130-18018-2460-80--



wps-002







JOINTS (QW-402)


BackingYes / No




Non mettalic Other

BASE METALS(QW-403)

or

or

Thickness Range

Base Metal

Pipe Dia RangeGroove -

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01



Flux Trade NameNA

Consumable InsertNA

Other

wps-002back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA




Amps (Range)60-180







TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





PeeningNA

OtherNA

___________________________________________________________________________________________



01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE80183.15DCRP90-13018-2260-120--

04SMAWE80184.0DCRP130-18018-2460-120--



wps-108




Welding Procedure Specification noL&T/CPCL/T01Rev.0Date23.03.01



JOINTS (QW-402)

Joint Designsingle 'V' Groove

BackingYes / No




Non mettalic OtherSKETCH

BASE METALS(QW-403)

or

or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01



Flux Trade NameNA

Consumable InsertNA

Other

2.5+0.5 mm

1.5+0.5 mm

37.5 + 2.5

T

wps 108 back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA



Amps (Range)70-140






TECHNIQUE (QW-410)




OcillationNA





PeeningNA

OtherNA

Weld LayersProcessFiller MetalsCurrentAmps RangeVolts RangeTravel speed RangeOthers


01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE70183.15DCRP90-13018-2260-120--

04SMAWE70184.0DCRP130-18018-2460-120--



PQR-001

QW-482 PROCEDURE QUALIFICATION RECORDS (PQR)


Record of Actual conditions used to Weld Test Coupon

Company NameLarsen & Toubro Limited - ECC Construction Division

Procedure Qualification Record No.L&T/CPCL/ 01Rev.0Date15.02.2001

WPS No.L&T/CPCL/ 01Rev.0Date


JOINTS (QW-402)

Groove design of Test Coupon

BASE METALS(QW-403)POSTWELD HEAT TREATMENT(QW-407)

Other :

Rate of Heating : 160 Deg. C/ Hr

Rate of Cooling: 130 Deg. C/ Hr

GAS (QW408)

Percent Composition

Gas(es)(Mixture)Flow Rate

ShieldingNA

FILLER METALS(QW-404)TrailingNA

BackingNA


Weld Metal Thickness

POSITION(QW-405)TECHNIQUE(QW-410)

PREHEAT (QW-406 )

2.5+0.5mm mm

1.5 .5mm

.5mm

60

25mm

PQR-001 Back

QW-483 (Back)

Tensile Test (QW -150)

SpecimenWidthThicknessAreaUltimate TotalUltimateType of

No.Load KNunit Stress Mpafailure & Loc.

T112.625.1316.261.5706697021496.74Fractured away

T212.625.1316.261.568835768496.16from the welded

area

Guided - Bend Tests (QW -160)

Type and Figure NoResult

1. Face Bend FB1No Significant defect




Toughness Tests (QW-170)

SpecimenNotchSpecimenTestImpact ValuesDrop Weight

No.LocationSizeTempFt. LBS% ShearMilsBreak (Y / N)

NANANANANANANANA

Fillet - Weld (QW-180)

Result - Satisfactory : yesNopenetration into parent metal:yesmetal : yes ______No _________

Macro--ResultsNA

Other ResultsNA

Type of testNA

Deposit analysisNA

otherNA

Welder's NameA.ARUL SELVAMClock no _____________ Stamp no ______________

Tests conducted by : __________________________Laboratory test No ______________________________M/s sargam metalsLaboratory Test NoSM/MT/256A/2000-2001 dated 14.02.2001

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 Code.

for L&T-ECCDfor M/s SGS India Limited
XXXXX

wps-004







JOINTS (QW-402)


BackingYes / No





BASE METALS(QW-403)

or



or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAWSMAW



F.No.0302

A.No0101



Flux Trade NameNANA


Other

2.5+0.5 mm

1.5+0.5 mm

37.5 + 2.5

T

wps-004back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA











TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





Peening--

OtherNA

___________________________________________________________________________________________



01SMAWE60102.5DCRP50-7020-2275-120--

02SMAWE60133.15DCSP70 - 9022-2475-120--

03SMAWE60134.0DCSP110 - 14022-2475-120--



wps-005







JOINTS (QW-402)


BackingYes / No





BASE METALS(QW-403)

or



or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAWSMAW



F.No.0302

A.No0101



Flux Trade NameNANA


Other

2.5+0.5 mm

1.5+0.5 mm

37.5 + 2.5

T

wps-005back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA











TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





Peening--

OtherNA

___________________________________________________________________________________________



01SMAWE60102.5DCRP50-7020-2275-120--

02SMAWE70183.15DCSP70 - 9022-2475-120--

03SMAWE70184.0DCSP110 - 14022-2475-120--



wps-001







JOINTS (QW-402)


BackingYes / No




Non mettalic Other

BASE METALS(QW-403)

or

or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01



Flux Trade NameNA

Consumable InsertNA

Other







JOINTS (QW-402)


BackingYes / No




Non mettalic Other

BASE METALS(QW-403)

or

or

Thickness Range12 mm

Base MetalGroove

Pipe Dia RangeGroove NA

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E 6013

F.No.2

A.No01

Size of Filler metals2.5, 3.15 MM


Flux Trade NameNA

Consumable InsertNA

Other

wps-001back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA




Amps (Range)60-180







TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





PeeningNA

OtherNA

___________________________________________________________________________________________



01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE70183.15DCRP90-13018-2260-120--

04SMAWE70184.0DCRP130-18018-2460-120--



QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA




Amps (Range)70 to 140







TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





PeeningNA

OtherNA

___________________________________________________________________________________________



01SMAWE60132.5DCRP70-14018-2260-80--

02SMAWE60132.5DCRP60-9018-2060-80--

03SMAWE60133.15DCRP90-13018-2260-80--

04SMAWE60134.0DCRP130-18018-2460-80--



wps-002







JOINTS (QW-402)


BackingYes / No




Non mettalic Other

BASE METALS(QW-403)

or

or

Thickness Range

Base Metal

Pipe Dia RangeGroove -

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01



Flux Trade NameNA

Consumable InsertNA

Other

wps-002back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA




Amps (Range)60-180







TECHNIQUE (QW-410)



___________________________________________________________________________________________


OcillationNA





PeeningNA

OtherNA

___________________________________________________________________________________________



01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE80183.15DCRP90-13018-2260-120--

04SMAWE80184.0DCRP130-18018-2460-120--



wps-108




Welding Procedure Specification noL&T/CPCL/T01Rev.0Date23.03.01



JOINTS (QW-402)

Joint Designsingle 'V' Groove

BackingYes / No




Non mettalic OtherSKETCH

BASE METALS(QW-403)

or

or

Thickness Range

Base Metal

Pipe Dia Range

Other-


ProcessSMAW

Spec. No (SFA)5.1

Aws. No(Class)E7018

F.No.04

A.No01



Flux Trade NameNA

Consumable InsertNA

Other

2.5+0.5 mm

1.5+0.5 mm

37.5 + 2.5

T

wps 108 back

QW-482 (Back)


GAS (QW-408)

Percent Composition


ShieldingNA

TrailingNA

BackingNA



Amps (Range)70-140






TECHNIQUE (QW-410)




OcillationNA





PeeningNA

OtherNA

Weld LayersProcessFiller MetalsCurrentAmps RangeVolts RangeTravel speed RangeOthers


01SMAWE70182.5DCRP60-9018-2060-120--

02SMAWE70182.5DCRP60-9018-2060-120--

03SMAWE70183.15DCRP90-13018-2260-120--

04SMAWE70184.0DCRP130-18018-2460-120--



PQR-001

QW-482 PROCEDURE QUALIFICATION RECORDS (PQR)


Record of Actual conditions used to Weld Test Coupon

Company NameLarsen & Toubro Limited - ECC Construction Division

Procedure Qualification Record No.L&T/CPCL/ 01Rev.0Date15.02.2001

WPS No.L&T/CPCL/ 01Rev.0Date


JOINTS (QW-402)

Groove design of Test Coupon

BASE METALS(QW-403)POSTWELD HEAT TREATMENT(QW-407)

Other :

Rate of Heating : 160 Deg. C/ Hr

Rate of Cooling: 130 Deg. C/ Hr

GAS (QW408)

Percent Composition

Gas(es)(Mixture)Flow Rate

ShieldingNA

FILLER METALS(QW-404)TrailingNA

BackingNA


Weld Metal Thickness

POSITION(QW-405)TECHNIQUE(QW-410)

PREHEAT (QW-406 )

2.5+0.5mm mm

1.5 .5mm

.5mm

60

25mm

PQR-001 Back

QW-483 (Back)

Tensile Test (QW -150)

SpecimenWidthThicknessAreaUltimate TotalUltimateType of

No.Load KNunit Stress Mpafailure & Loc.

T112.625.1316.261.5706697021496.74Fractured away

T212.625.1316.261.568835768496.16from the welded

area

Guided - Bend Tests (QW -160)

Type and Figure NoResult





Toughness Tests (QW-170)

SpecimenNotchSpecimenTestImpact ValuesDrop Weight

No.LocationSizeTempFt. LBS% ShearMilsBreak (Y / N)

NANANANANANANANA

Fillet - Weld (QW-180)

Result - Satisfactory : yesNopenetration into parent metal:yesmetal : yes ______No _________

Macro--ResultsNA

Other ResultsNA

Type of testNA

Deposit analysisNA

otherNA

Welder's NameA.ARUL SELVAMClock no _____________ Stamp no ______________

Tests conducted by : __________________________Laboratory test No ______________________________M/s sargam metalsLaboratory Test NoSM/MT/256A/2000-2001 dated 14.02.2001

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 Code.

for L&T-ECCDfor M/s SGS India Limited
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WELDING - IV.ppt

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