[QW483PROCEDUREQUALIFICATIONRECORD(PQR)]
Procedure Qualification Record No.: SI-107
WPS No.: SI-007
Welding Process (es):
DATE.:
08.10.2010
GMAW
Semi-Automatic
JOINT(QW402)
GrooveDesignofTestCoupon
BASEMETALS(QW403)
Materialspecification.: SA 516-70
TypeorGrade:
GR -70
P.No.:
ToP.No.:
1 Gr. 2
ThicknessofTestCoupon:
40mm
DiameterofTestCoupon:
Other:
FILLERMATERIALS(QW404)
SFASpecification:
5.1
AWSClassification:
ER70S6
FillerMetalF.No.:
6
1 Gr. 2
POSTWELDHEATTREATMENT(QW407)
Temperature:
620DegC
Time/Soaking:
AsperUCS56
Other:SR.Cycle.No:131/2010, Date:29092010.
SRCarriedoutatM/sVijayEngineeringIndustires
GAS(QW 408)
PercentageComposition
Gas(es)
Mixture
Flowrate
Shielding
CO2
100%
1220LPM
WeldMetalAnalysisANo.:
5.1
Trailing
SizeofFillerMetal:
WeldMetalThickness:
1.2mm
40mm
POSITION(QW405)
PositionofGroove: 2G,Vertical
Backing
ELECTRICALCHARACTERISTICS(QW409)
Current: DC
Polarity: Electrodepositive
Amps: 140 350A
Volts: 20 32V
TungstenElectrodesize:
Other
WeldProgression:
TECHNIQUE(QW410)
Other:
Uphill
Other:
PREHEATING(QW406)
10 C Upto 30mm
PreheatTemp.:
31-100mm - 100 C
Above 100mm - 150 C
InterpassTemp.:
Other:
350Cmax.
TravelSpeed:
String/WeaveBead:
Multipass/Singlepass(perside):
String&WeaveBead
MULTIPASS
SingleorMultipleElectrodes:
SINGLE
Other: Cleaneachlayerbeforestartweldingnewpasses/
layers.WeavingMaximum3timesthediameterofElectrode.
Contdpage2
Page2of2
QW483(Back)
PQRNo: SI-107.
TensileTest(QW150)
UltimateTotalLoad.
kN
UltimateUnitStress.
Mpa(410Min)
SpecimenNo
Width(mm)
Thickness
Areamm
SAMPLE1
19.00
18.00mm
342.00
170
497.08
SAMPLE2
19.00
17.60mm
334.4
167
499.40
SAMPLE3
19.00
17.20mm
326.80
165
504.90
SAMPLE4
19.00
18mm
342.00
169
494.15
TypeofFailure
&Location
Brokenaway
fromweld
Brokenaway
fromweld
Brokenaway
fromweld
Brokenaway
fromweld
GuideBendTests(QW160)
TypeandFigureNo.
Result
SideBendtest4Nos180o,4T
Satisfactory
WeldersName:
MUNNAKUMARSINGH
ClockNo:
StampNo.:
MKS01
TheWeldingtestsareconductedandsupervisedbyM/s.SWATHIINDUSTRIES,R.C.PuramandMechanicalTestscarriedoutby
M/s.SMSMETALLURGICALSERVICES,VideTESTREPORTNO:1011/0198,DT:08.10.10WeldingtestandMechanicalTestsare
WitnessedbyM/s.BHEL,HPEP,Hyderabad,QualitycontrolDepartment.
Wecertifiesthatthestatementinthisrecordarecorrectandtheweldtestcouponswereprepared,welded,andtestedin
accordancewiththerequirementsofSectionIXofASMEcode.
Witnessed/CertifiedBy.
Manufacturer:
Signature:
Signature:
Date:
Date:
SWATHI INDUSTRIES
A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032
QW482WELDINGPROCEDURESPECIFICATION(WPS)
WeldingProcedureSpecificationNo. SI-007
RevisionNo.: 00
Date.:
Date.
26.08.2010
WeldingProcess(es):
SupportingPQRNo. SI-107
Type(s):
GMAW
Semi Automatic
(Automatic;Manual;MachineorSemiAutomatic)
JOINTS(QW402):
JointDesign:
Backing(Yes)
AsperManufacturersDrawing(Groove/Fillet)
ForDoublesideandbackingstripgroovewelds
(No.)
ForSinglesideGroovewelds
BackingMaterial(Type):
Metal: Yes
Retainer:
No
Basemetal/weldmetal
NonfusingMetal:
No
BASEMETALS(QW403)
PNo.:
GroupNo.:
1&2
ToPNo.:
GroupNo.:
1&2
OR
SpecificationTypeandGrade:
SA51670
ToSpecificationTypeandGrade:
SA51670
OR
ChemicalAnalysisandMech.Properties:
ToChemicalAnalysisandMech.Properties:
THICKNESSRANGE:
BaseMetal
PipeDia
Range
Other:
Groove: 4.75to200mm
Fillet:
AllSizes
Groove:
Fillet:
AllSizes
AllDia
FILLERMATERIALS(QW404)
SpecificationNo.:(SFA):
5.18
AWSNo.:
ER70S6
F.No.:
A.No.:
SizeofFillerMaterials:
1.2,1.6
Depositedweldmetal:
ThicknessRange: Groove:
ElectrodeFlux(Class):
Basic
ConsumableInsert.:
Max.BeadThickness:
No
4mm
5.0to200mm
Fillet:
AllSizes
Contdpage2
Page2of2
POSITIONS.(QW405)
Positionofgroove:
AllPosition
WeldingProgression: UpHill,Vertical
Position(s)ofFillet:
DownHill:
ALL
PREHEAT(QW406)
GAS(QW408)
PREHeatingTemperatureMin.:
InterpassTemperatureMax.:
PreheatMaintenance.:
10 C Up to 30 mm
100 C max.above 30 mm
Above 100mm - 150 C
Shielding
Trailing
Backing
250Cmax.
NIL
PercentageComposition
Gas(es)
Mixture
CO2
100%
Flowrate
1220LPM
ELECTRICALCHARACTERTISTICSIQW409)
Current(ACorDC):
DIRECT CURRENT
Amperes(Range):
150 to 350 A
Volts.(Range):
TungstonElectrodeSizeandType.:
NA
ModeofMetalTransferforGMAW.:
GMAWSPRAY
20 - 30 V
ElectrodeWireFeedSpeedRange:
TECHNIQUE(QW410)
StringorWeaveBead:
OrificeorGasCupSize:
20mm(ID)
Initial&Interpasscleaning:
ByBrushing/Grinding./ChippingEtc.(usestainlesssteeltools)
MethodofBackGouging:
Grinding
Oscillation:
Contacttubetoworkdistance:
25to40mm
Multiple/SinglePass(perside):
MultiplePasses
Multiple/SingleElectrode:
SingleElectrode.
Peening:
Notallowed.
Travelspeed(Range): 150200mm/min
Min1oneithersideoftheweldareatobecleanedandfreefromDirt,rust,paints,Oil,
grease,etc.(Beforestartthewelding).
Other(WeldDiscipline):
FillerMetal
Dia(mm)
Current
Typepolar
Weld
Layers
Process
Rootrun
GMAW
ER70S6
1.2
DC +
150-200
GMAW
ER70S6
1.6
DC +
250-350
2n
Class
ApprovedBy:
Date:
Remarks
Amps
SWATHI INDUSTRIES
A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032
{QW484AMANUFACTURERSRECORDOFWELDERPERFORMANCEQUALIFICATION(WPQ)}
WeldersName:
MUNNAKUMARSINGH
MKS01
IdentificationNo.
TestDescription
TestCoupon:Yes
IdentificationofWPSfollowed
SI-007
SpecificationofBasemetal(s)
SA51670toSA51670
ProductionWeld.
Thickness:
No
40mm
TestingConditionsandQualificationLimits.
Weldingvariables(QW350)
ActualValues
WeldingProcess(es):
Type(Manual,Semi,Auto):
Backing(metal,weldmetal,doubleweldedetc.
Plate
GMAW
MANUAL
MANUAL
WITHOUT
Pipe(enterifpipeortube)
Fillermetalorelectrodespecification(s)(SFA)
FillermetalorelectrodeClassification(s)
Consumableinsert(GTAWorPAW):
FillerType(Solid/metalorfluxcored/powder(GTAW
orPAW))
DepositThicknessforeachProcess.
GMAW
3layersmin.
3layersmin.
Yes/No
Yes/No
P1
P1
5.18
ER70S6
ER70S6
F6
F6
SOLID
SOLID
40mm
Maximumtobewelded
Positionqualified(2G,6G,3Fetc.)
2G
Groove
Fillet
Verticalprogression(Up/Downhill)
Inertgasbacking(GTAW,PAW,GMAW)
Transfermode(spray/globularorpulsetoshortcircuit
GMAW))
GTAWcurrenttype/Polarity(AC,DCEP,DCEN)
Pipebendspecimen,
Type
Tensile
UPHILL
UPHILL
NA
NA
NA
NA
NA
NA
Transverserootandface(QW462.3(a));
CorrosionresistantOverlay(QW462c)
Macrotestforfusion(QW462.5(b)
Result
Satisfactory
1G,2G,1F,2F&3F
PLATE&PIPEOD>610mmF&V
FLATPOSITIONFORPIPEOD73mmto<OD610mm
PLATE&PIPEF,H&V
RESULTS
SATISFACTORY
VisualExaminationofCompletedWeld(QW302.4):
BendTest;SATISFACTORY
PlateMaxtobewelded&pipe73andabove
5.18
FillermetalFNumber(s):
Process2:
WITH/WITHOUT
PLATE40mm
BaseMetalPorSNumbertoPorSNumber:
Process1:
RangeofQualified
GMAW
Longitudinalrootandface(QW462.2)
Platebendspecimen,corrosionresistantoverlay(QW462.5(d))
Macrotestforfusion(QW462.5(e)
Type
Sidebend
Result
Satisfactory
Type
Result
TheWeldingtestsareconductedandsupervisedbyM/s. SWATHIINDUSTRIES,R.C.PuramandMechanicalTestscarried
outbyM/s.SMSMETALLURGICALSERVICES,VideTESTREPORTNO:1011/0198,DT:08.10.10WeldingtestandMechanical
TestsareWitnessedbyM/s.BHEL,HPEP,Hyderabad,QualitycontrolDepartment.
Certified/WitnessedBy.
Date:
Organization: