Welding related points to recall

1. 2. 3. 4. 5. 6. 7. PQR gives data used in PQR test and test results, and cannot be revised. WPS gives parameters to be used in production job, and must be within ranges qualified by the PQR test. Essential variables (EV), if changed require new procedure qualification. Non essential variables (NEV) may be changed in WPS without new PQR. Bend test crack shall not exceed 1/8 in any direction. Radiography criteria are stricter than radiography for job. Supplementary essential variables (SEV) are considered as (EV) only if there is impact strength requirement. Otherwise, they are non-essential variables. EV and SEV are included in PQR document. EV, SEV and NEV are included in WPS document. Tensile test for procedure qualification is passed if failure is in: Weld metal at strength >= Base metal SMTS, or Base metal at strength >= 95% of base metal SMTS 8. P-numbers represent parent metal groupings of similar composition and properties, i.e., similar strength and ductility. 9. F-numbers give similar usability aspects of filler material. A numbers give similar chemical compound of weld metal. In As welded condition.

For performance, 1G is flat, 2G is horizontal, 3G is vertical and 4G is overhead position. Pipe 5G qualifies 1G, 3G and 4G, but pipe 6G qualifies all positions.

10. For acceptance criteria of production welds refer to Table 341.2.3 of B31.3 for: Weld reinforcement For radiographic results General acceptance of welds

Calculated heat input variation between PQR & actual welding + 20% & - 10% PQR heat input ranges for various materials are Carbon & LAS 3 KJ/mm 6% Mo duplex SS 1.0 KJ/mm 22% Cr duplex SS 0.5 to 1.75 KJ/mm 25% Cr duplex SS Root 1.0 to 1.5 KJ/mm 2nd & 3rd pass - 0.5 to 1.2 KJ/mm Remain 0.5 to 1.75 KJ/mm Ni alloy unrestricted Austenitic SS - Unrestricted

Welding points to recall

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Duplex SS ferrite and Austenitic phase balance, Ferrite level 40-60% for base metal & 30-70% for HAZ PWHT Preheat band width 2t or 100 mm PWHT band width 5DT where D-Inside dia & T thickness, insulation band width 10DT Number of thermocouples 1 for dia < 10/40 2 for dia > for 10/40 to 300/250 3 or 4 for dia > 300/250 PWHT for P1 & P2 as per code for P3 to P6, it should start immediately after welding Spacing between welds Longitudinal seams 45 or 50 mm whichever is less Circumferential welds 4t (toe to toe) Attachments 2t or 40 mm (toe to toe) whichever is less Weld bevel preparation C-Mn steels mechanical, thermal and oxy cuts are acceptable, if oxy cut is used remove 2 mm steel by grinding P6 & above no oxyfuel cut is acceptable Austenitic SS, 6% Mo Duplex, Duplex, Cu-Ni, Ti etc., only mechanical or plasma cutting is acceptable. Wire brush with SS bristle only to be used. For titanium material the grinding disc should be made of carborundum. Repair WPS should have following points taken care Method of excavation Shape & size of excavation Inspection prior to welding Type of WPS to be used Minimum ligament after excavation

Weld root gap guide 1.5 mm for pipe dia < 50 mm 1.5 to 2.5 mm for pipe dia > 50 mm to 250 mm 2.5 to 3.5 for pipe dia > 250 mm Ferrite number FN # 3-10 FN for Austentic SS, AWS 4.2, ISO 2849 or calculated from Welding Research Council (WRC) 1992 ferrite diagram.

Carbon equivalent for pressure vessel plates & pipe material CE = 0.41 = C + Mn/6 + (Cr+Mo+V)/5 + (Cu+Ni)/15 Maximum carbon content for pressure vessel and piping material is 0.21

Welding points to recall

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Plate material elements composition C-0.21, Mn-1.2, Si-0.45, S-0.003, P-0.015, V-0.08, Niobium-0.03, Ti-0.02, Cu-0.2, Ni0.3, Cr-0.2, Mo-0.2, Al-0.05, Bo-0.0005, Ca-0.006 Piping material elements composition C-0.18, Mn-1.1, Si-0.33, S-0.003, P-0.015, V-0.08, Niobium-0.03, Ti-0.02, Cu-0.2, Ni0.3, Cr-0.2, Mo-0.2, Al-0.05, Bo-0.0005, Ca-0.006 Pressure vessel Steel plate, Fittings specifications SA 234, 337, 350, 765, 352, 420, 450, 516, 517, 530, 578, 671, 703, 240, 263, 264, 265, 20, 105, 106, 179, 193, 194,216 Disimilar metal welding

Material - 1
P-1 to P7 Austenitic SS Austenitic SS

Material - 2
Austenitic SS Ni-Cr material Ni-Cr material

Temp C
> 315C > 315C 315C

Electrode
ENiCrFe-2 ENiCrFe-3 ERNiCr-3 ENiCrFe-2 ERNiCr-3 ENiCrFe-2 ENiCrFe-3 ERNiCr-3

Consumables for 6% Mo Group UNS 31254, UNS 8367 use electrodes of AWS 5.4 ER5.4 ER NiCrMo-3 & AWS 5.11 ENiCrMo-3 for SMAW Piping P4 to P8 root pass with GTAW & back purging with inert gas for upto 6mm material buildup for materials of sour services WPS WPS made of 316 is qualified for 316L and not vice versa WPS made of 304 is qualified for 304L and not vice versa This is due to the L which is for carbon content.

Welding points to recall

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