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NCPFIRST
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WPQR for STRUCTURAL; SHAPES, PIPE & PLATE STEEL WELDING: *CERTIFIED by QUALIFICATION TEST*
WPQR-No X= Company Initial <> T = PWHT <> Cs = Carbon Steel <> 12 =Thickness of Test Coupon <> I =Impact Tested <> P = Pipe <> St = Plate <> tb = Temper-bead-weld <> b = Back-gouge
Provided the verification of this WPQR meets the requirements of local laws/regulations and when required - 3rd Party “Supplementary Approval Certification (SAC)”
Fitness For Use
are acceptance --- This WPQR shall be qualified and applicable for use globally [QW-201. Para. 3]. for both Onshore and Offshore Structural welding applications
WPS Templates Unless otherwise agreed by EPC: Only NCPfirst WPS-Templates_ X-Forms; WPX01 thru 10, “Shall” be used with NCP, WPQR- Templates.
Qualified Supplementary Welding Standards NACE-MR 0175-Part 2 <> DNV-OS-C401
Design & Construction Supporting WPS/s that is to be used to produce Structural-shapes, pipe, plate weldments for Nuclear, Subsea, Marine, offshore & Onshore structures
Filler Material Limits Filler material Qualification range of approval are limited to the same, A and F number (QW-422 & 404.15), _except when the WPS conforms to AWS-D1.1
Base metal Limitations Base Metal qualified in WPQR _qualifies the WPS for base metals of same Group only. MDMT shall not exceed this WPQR impact “Temperature”
WPQR Verifications Test performed in this WPQR are for establishing the Filler metal “Low Temperature susceptibility” and material weld-ability via welding process selection
WPS _Base Metal Limits Only base materials in the same group and sub-group tested in this WPQR shall qualified the WPS for production welding applications
WPS_QW-Position Limits As per QW-Code: {ASME-IX_QW-203 = All in Plate} <> { API-1104_Clause-7 } <> { EN-ISO_EN ISO 6947 }
QW-Impact Test Range Impact Tested @ - 25 0C with average weld-metal impact strength above 40 Joules have been assured. See Table 11
Attachments Appendix A1: (a) Legend, (b) Instructions For WPS Preparation, (c ) Welder Tips and Welding Requirements
Pipeline Welds Acceptance Criteria according to API-1104_Section-9 +Appendix-A_ Alternative Acceptance Standard for Girth Welds
Pressure / Process Pipe Welds Acceptance Criteria according to EN ISO-5817-Part-5 Table-1_Level C & B + ASME B31.3: §.311.2.2-Table 341.3.2. Criterion “A”
QW-Acceptance
Structural Pipe Welds Acceptance Criteria according to AWS-D1.1_Clause 5.24_Table 6.1_Figure 5.4 “A”
Standard &
NAVSEA Acceptance Criteria shall be according to: NAVSEA:>MIL-STD-2035A _Chapter -5.2.2: Class -1
Criterion Unless otherwise instructed by EPC: Production WPS/s shall be qualified in accordance with the same Acceptance Criteria as per this WPQR. WPS qualification in accordance to
AWS-D1.1 for structural pipe work with unlisted AWS material shall conform to Para. 4.8.3. (unlisted Materials)
Note In addition to ‘Special Procedure Qualification (SPQ) Test with the spares from the original Test coupon & SA test, -- “only editorial correction & code addendum shall be permitted [QW-200.2 c].
Actual Tests That Was Performed In This PQR
Required Tests For Mechanical Toughness & Properties Required Tests For Weld Soundness & Quality Required Tests For Weld Improvement
• Tensile test (Transverse: Reduced Section) >>TRR-No: XXX-XXXXX -XXXX • Macro test (etching, 5% Nital): >> TRR-No: XXX-XXXXX -XXXX • PWHT: >>TRR-No: XXX-XXXXX -XXXX
• Guided Bend test: >> TRR-No: XXX-XXXXX -XXXX • MCM [x 200], (etching, 2% Nital): >> TRR-No: XXX-XXXXX -XXXX • Pre-heat Treatment >>TRR-No: XXX-XXXXX -XXXX
• Fillet Fracture Toughness test: >> TRR-No: XXX-XXXXX -XXXX • NDE –Visual Test (VT): >>TRR-No: XXX-XXXXX -XXXX • Hydrogen Bake-Out >>TRR-No: XXX-XXXXX -XXXX
• Toughness test (Charpy-V): >> TRR-No: XXX-XXXXX -XXXX • NDE –Volumetric UT: >>TRR-No: XXX-XXXXX -XXXX • FLI -Dressing: >>TRR-No: XXX-XXXXX -XXXX
• Crack Tip Open Displacement (CTOD): >> TRR-No: XXX-XXXXX -XXXX • NDE –Volumetric RT: >>TRR-No: XXX-XXXXX -XXXX • Temper Bead Welding >>TRR-No: XXX-XXXXX -XXXX
• Macro-hardness test (EEMUA-158_HV10): >> TRR-No: XXX-XXXXX -XXXX • NDE –Magnetic Particle Test (MPT): >>TRR-No: XXX-XXXXX -XXXX • Cyclic Pressure Test >>TRR-No: XXX-XXXXX -XXXX
• Macro-hardness test (NACE-MR0175_HV10): >> TRR-No: XXX-XXXXX -XXXX • NDE –Liquid Penetrant Test ( LPT): >>TRR-No: XXX-XXXXX -XXXX • SIV -Test >>TRR-No: XXX-XXXXX -XXXX
• CTOD (Crack Tip Opening Displacement): >>TRR-No: XXX-XXXXX -XXXX • Test Pad: Undiluted_ Chemical Analysis: >>TRR-No: XXX-XXXXX -XXXX • Corrosion test: VCI : >>TRR-No: XXX-XXXXX -XXXX
• SOHIC (Stress-Oriented H2 Induce Crack): >>TRR-No: XXX-XXXXX -XXXX • PMI: Particular Material Identification: >>TRR-No: XXX-XXXXX -XXXX
• HIC (Hydrogen Induce Crack Test): >>TRR-No: XXX-XXXXX -XXXX
• Butt weld nick-break test: >>TRR-No: XXX-XXXXX -XXXX
Acronym FLI = Fatigue Life Improvement, TRR = Test Report Reference, § = AWS-D1.1: Clause, ф = API-1104: Clause, H2 = Hydrogen, MCM = Microscopic Metallurgy, VCI = Volatile Corrosion Inhibitor, SIV = Stress Induced Vibration,
Legal Statement (LS) Weld Soundness Guarantee and documentation Quality
The Engineering Procurement Contractor (EPC) has the rights to reject any WPS and WPQR template The guarantee of production weld/s shall be a 100% liable to the Fabrication Company/s of whom
which is not a registered NCP _X-Form format It is a Violation and shall not be permitted to support deposited the actual weld/s. The deposited weld/s shall equal the warrantee/guarantee of the weldment
this WPQR. These rights extend also to the Owner of the Weldment also. and or the equipment’s design life respectively.
TABLE-1 (QW-402) JOINT PREPARATION & TEST COUPON REQUIREMENTS (QW-210 / 211)
Metal Standard XXXXXXXXXX <&> XXXXXXXXXX Metal Heat Numbers for XXXXXX = XXXXX <&> XXXXXX = XXXXX Metal Certification EN 10204-3.1
(ф 7.4.2) Joint Preparation Flame Cutting + Machining Weld Face Preparation Grinding & Sanding High-low Tolerance (mm)
Groove Weld Toe-overlap (mm) Groove Weld Crown Height (mm) (§ C-8.4.1) Fatigue-Life Improvement Method None
Metal Temperature before Welding (0C) Test Pipe MDMT (0C) (Qw-200.2(f) Thickness Range (mm) 12 > 24 Preliminary WPS / QW QW-256 & 255
(EN ISO-15608) Material Designator None Sub-group None welded to Sub-group None (QW-403.8) Coupon Thickness (mm) 12
Joint Fit-up Method QW-200.4 (b) Root Backing Proof Test: Fillet leg-length (mm) Fillet Weld Theoretical Throat (mm)
(§ 4.1.1:T-4.1) Joint Type CJP Joint Design V Pipe Coupon Length (mm) 300 Welding Position 5G Welding Progression Horizontal (H)
(QW-451.1) Butt-joint groove Radius Groove Angles 0C Root Face (mm) Root Gap (mm) Pipe Diameter (mm) 250
(QW-451.4) Fillet-joint groove Radius Fillet-groove Angles 0C Fillet Root Face (mm) Fillet Root Gap (mm) Weld End/Tab
(QW-403.4) Base Metal Carbon Steel ASME-IX- P-No 1 Group No 1 Group No 2 Metal Grade ASTM-A106-Gr.A welded to ASTM-A106-Gr.C
Visual Acceptance Criteria API-1104_Section-7_Design & Preparation of Joints for Production Welding & Weld Quality Levels for Imperfections according to EN ISO-25817
Note (a) For symmetrical Fillet Leg-length = 0.707 x Tn. (b) For asymmetrical Fillet Leg-length = 1.09 x Tn (where: Tn = Smallest Thickness (or joint Web). (c ) Joint-prep soundness Test Method = UT or LPT
(d) Theoretical Throat = Cos 45 x Fillet Leg-length or ( 0.7071 x Fillet Leg-length).
Remark (1) Filler Metal Qualification Range of approval is limited to filler materials with the same, A and F number as per (Qw-404.15)
(2) Unless otherwise instructed by the Weldment Owner _ only the filler material Brand tested in this WPQR “Shall” qualify the WPS for production welding.
Documents on Request (a) Material 3.1 Certification. (b) Consumable Test Report. (c) NDE Test Reports. (d) Mechanical Test-Reports. (e) Welder Certification. (f) PMI Reports
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Table-2a (QW-402) + (API-1104_Para.5.3.2.4 + 5.3.2.5 ) JOINT DIMENSIONAL DRAWING and BEAD SEQUENCE SKETCH
Figure-2a (QW-403.2) + ( ф 7.8.2) Actual deposited weld-metal thickness Figure-2b (QW-350) & (ф 5.3.2.3 + ф 5.4.2.3): WPS - Joint Design QW-Range
(Figure: QW-462.13) Temper Bead (%) Overlap length = (a - b)/a × 100% _(Qualified) None Remark (ф 5.4.2.8) Time between root & Hot Pass – constitute an essential Variable
Table-2b SINGLE or DOUBLE SIDED JOINT (QW-200.4 + 451.1) MULTI-PROCESS <&> RECORDED WELDING PARAMETERS (API-1104_Section_5.4.2 + ф 5.3.2.1 )
Process: 1 (QW-XXX) XXXX (XXX Process: 2 (QW-XXX) XXXX (XXX Process: 3 NONE
QW-403 Current & (§ 3.2) QW-404 QW-404 QW-406. 8+403.2 QW-409 QW-409 QW-409 QW-409 Cup QW-408 QW-410 QW-409 Joint- (QW- 410.1)
Bead Polarity Weld Filler Metal Filler Inter-pass Amps Volts Travel Wire Size Shield CTWD Heat sides: (462.12 /13)
No Process Classification Size: mm Thickness & Speed: Feed Gas: mm Input: A&B Weld-Bead
Temperature mm/min (♦) Lt/min kJ/mm Technique
() mm oC (◘) () inch/min mm ()
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
N* S* N* E* S* E* N* S* E* S* E* S* N* S* E* E* S* S* N* S*
QW _Formula for Heat Input, kJ/mm = Amps x Volts x 60 ÷ TS __ (where: TS = Travel Speed x 1000) __According to (QW-409.1a) + (NACE 5.2.4_Equa. 2)
(a) Please refer to Attachment *A*; Section Zb --for the description of the following designators: (●) (♣) (◘) (♦) (♪) () () & (). (b ) The same WPS that was used for producing the weld/s can be used for weld-repairs.
NOTE (c) WPS maximum inter-pass temperature shall NOT be higher than 56 0C of the maximum recorded inter-pass temperature qualified in the WPQR (QW-406.8). (e) Walking the cup = whip-weave
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<<>>
Table-3 WPS _QW-Data (ф 5.3.2) FIRST PROCESS SECOND PROCESS THIRD PROCESS
(QW-200.4) & (ISO)_ WELDING PROCESS DESIGNATOR (QW-XXX) XXXX / (XXX) (QW-XXX) XXXX / (XXX) (QW-254) SAW / (12)
TYPE: >Manual, Automatic, or Semi-automatic: ф 5.3.2.1 Manual Semi-Automatic Full-Automatic
{Further Information: See Table-18}
FILLER METALS (QW-404) + EN 439 + (ф 5.4.2.1 + 5.4.2.6) Diffusible H2 = API-582: § 5.2.4.4/3_Table 5-1 Diffusible H2 = API-582: § 5.2.4.4/3_Table 5-1 Diffusible H2 = API-582: § 5.2.4.4/3_Table 5-1
Flux Trade Name & Type (SAW) None None -
Wire -Flux Classification (SAW) (♣) see table18 None None -
SFA/AWS: Specification & Classification XX.XX: XXXX-XX HX XX.XX: XXXX-XX HX -
Filler Metal Manufacturer XXXXXXXXX XXXXXXXXX -
Filler Metal Product Form XXXXXXXXX - XX XXX-X XXXXXXXXX - XX XXX-X -
Weld Metal Analysis A-No. X X -
Filler Metal F-No. X X -
Filler Metal Size (mm) X.X X.X -
Weld Pass Thickness; Max. (mm) X.X X.X -
Deposited Weld Metal Thickness Per Process (mm) X.X X.X -
Weld-Deposit Chemistry (Test-pad). (also SAW -Alloy Flux ) (See Table: 8) < X.XX% Carbon < X.XX% Carbon -
Ferrite Contents % (Max) XXXX XXXX -
Root Contour :_ Height (mm) (▲) See table18 X.X (See Za: Table 18) XXXX -
Crown/Cap Profile :_ Height (mm) NA X.X -
TECHNIQUE (QW-410 + 462.12) Clean each layer before welding Clean each layer before welding
Stringer, Weave, Circle, Whip, Dip or Push-pull - - -
Multiple or Single (Electrodes/Wire/Rod) Single-Rod Single-Wire -
Multiple or Single Passes - - -
Single-side or Double-side Weld Single-side Single-side -
Orifice of Nozzle/Cup Size (mm) Cups No = X Nozzle ID = XX -
CTWD or Visible Stick-out (mm) Tungsten: Visible Stick-out = X Visible Stick-out = X -
Method of Back Gouging: (Arc-air, Grinding) XXXX XXXX -
Welding Torch angle to work piece (900, 850, 250 , 150,) XX0 XX0 -
Temper Bead Weld-Overlay Range (mm) XXXX XXXX -
Peening: (For welding *Nickle* base material) XXXX XXXX -
Metal Cleaning & Joint Preparation. (API-1104_Section-7) Sanding Disc + Machining Sanding Disc + Machining -
Inter-pass Cleaning: (Grinding, brushing, Sanding, Dressing) Brushing + Dressing Grinding-wheel + Brushing -
Thermal Process (QW-410.60) XXXX XXXX -
Fatigue Dressing: (GTAW, Burr-grinding, UP) (BS-7608) () See table18} XXXX XXXX -
POSTWELD HEAT TREATMENT (QW- 407) + ф 7.11 PWHT (ф 5.4.2.14) PWHT (ф 5.4.2.14)
PWHT According to (QW-407.2) 80% Rule. XXXX XXXX -
PWHT According Div. 1-UCS -56 / Div-2:T—6.7 XXXX XXXX -
Source: Induction / Electric Resistance Heater XXXX XXXX -
Heating Rate ( 0C / Minute) XXXX XXXX -
Soaking Time (Minutes) XXXX XXXX -
Cooling Rate (0C / Minute) XXXX XXXX -
Thermocouple Type (Brand Name) XXXX XXXX -
Thermocouple Total (1T/C, 2T/C, 3T/C, 4T/C XXXX XXXX -
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Coupon-No Base Material Grade/s XXXXXXX to XXXXXXX WPQR-No Weld-No Welder-ID-No NDE-ID
Table-5 (QW-162) & (QW-160) GUIDE BEND TEST ACCORDING TO: (EN 910) + (API-1104_Para. 5.6.4.3)
Specimen Test Specimen TEST TYPE Bend Mandrel Space between Figure No. Elongation Test Test Results
No. Location Size: (LW) (TV or Lateral) Direction Diameter 4T Rollers [QW-462.3 (a)] (%) Temp.
(mm x mm) (mm) (mm) (●)
( 0C)
XX x XX Transverse TV-F Mandrel = 4T@ 1800
XX x XX Transverse TV-R Mandrel = 4T@ 1800
XX x XX Transverse TV-F Mandrel = 4T@ 1800
XX x XX Transverse TV-R Mandrel = 4T@ 1800
Acronyms TV = Transverse, S = Side, R = Root, F = Face, NR =Not required, LW = Length x Width Remark (●) Not required according to EN ISO 15614-1: § or Para: 7.4.3,
Figure: 5a VERIFICATION OF TVS SIDE BEND TEST SPECIMEN Figure: 5b
Guide Bend Acceptance Criteria (QW-163) & (AWS-D1.1: Para. 4.8.3.3) + (ф API-1104_Section 5.6.4 ) Remark
Table-6 (QW-180) MACROSCOPIC and MICROSCOPIC TEST
Figure-6a Macro-Hardness_ EN 1043-1 Figure-6b Macro-Hardness _NACE MR 0175- Part 2_§7.3.3.2 –Fig.2 Figure-6c Microscopic EN 1321,
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Table-6d (QW-180 ) HV10 ≤ 248__MACRO-HARDNESS VALUES and INDENT LOCATOIN: EEMUA 158_Para. 4.4.4c __Figure 8
Table-6e (QW-180 ) HV10 ≤ 248__MACRO-HARDNESS VALUES and INDENT LOCATOIN: NACE MR 0175-Part 2_Para. 7.3.3.2 _Figure 2
Table-7 (QW-151) PRISMATIC or TRANSVERSE (TV) TENSILE TEST ACCORDING TO: (EN 895) + (API-1104_Para. 5.6.2.3)
Specimen Test Specimen AREA Elongation Ultimate Total Ultimate Unit Yield Point Test Temp. Reduction Type of Failure and
No Location Dimension (mm2) (%) Load, Stress (N/mm2) (N/mm2) ( 0C) of Area Location
(♦) (♦) (♦)
(mm x mm) (kN) (%)
MINIMUM REQUIRED TARGET XXX XXX XXX ≥ XXX XXX ≥ XXX XXX
Figure-6a VERIFICATION OF TENSILE TEST SPECIMEN Figure-6b
Tensile Acceptance Criteria ( QW-153) & (EN 10025-2 / 04) & (API-1104_Section 5.6.2 ) & (AWS-D1.1: Para. 4.8.3.5)
Acronyms NR = Not-required, TV = Transverse Remark (♦) Not required for TV -tensile test as per EN 15614-1 and ASME Section IX
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Table-8 TEST PAD: FILLER METAL UNDILUTED CHEMICAL ANALYSIS ASME BPVC Section-II _Part-C _Table 5 & 4: _Figure-1
Specimen Classification Filler C Mn Ni Cr Mo Si V Cu Ti Nb P S B Al
No. (SFA/AWS) Size (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)
1
2
3
4
Figure 8a Test-Pad: XXXXXXX Figure 8b Test-Pad: XXXXXXX Figure 8c Test-Pad: XXXXXXX Figure 8d Test-Pad: XXXXXXX
Formula Design Weld Strength (DWS) = FS x 0.707 x a x 0.60 x FEXX x Lw __ { Where: a = Fillet Leg Length, FS = Safety Factor, Lw = Weld- Length, FEXX = Electrode Class,….ie. E70XX }
Figure 9a (QW-181) Fillet Fracture Test Filler: XXXXXXX Figure 9b (QW-181) Fillet Fracture Test Filler: XXXXXXX Figure 9c (QW-462.4a) Fillet Weld Procedure: (QW-XX)
Specimen No XXXXX Qualification Code: According to Pipe Branch Fillet Weld _ API-1104_Section-5.8 (applicable for Production WPS qualification)
Fillet Fracture Acceptance Criteria According to (QW-182), and if required by the EPC _ Production WPS qualification / mockup Test in accordance with (QW-181.2)
WPT of Table-2 _Bead No 7 Filler size = XX mm Amp = XXX Volts = XX.X TS = XXX mm/min Wire-feed = XXX inch/min Pre-Heat = XX 0C Weld Beads = X Plate Thk = XX mm
Remark (a) WPT = Welding Parameters, (b) Thk = Thickness, (c) ■ Single Preheat Time = 8 minutes (Max), TS = Travel Speed
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Table-11 (QW-170) IMPACT TESTING REQUIREMENTS ACCORDING TO: B31.3-Table 323.3.5 + EN 875,+ ( EN ISO 148-1 )
Average Impact Target @ -100 as per Code {ASME-IX = 19}, {ASME- B31.3 = 20 J }, {PED = 27 J }, { EEMUA-158= 36 J }, {AWS-D1.8 = 40 J } Impact Test Procedure as per SA-370
[QW-463.1(f)]
Specimen Location & Notch IMPACT-ENERGY Impact Strength Lateral Expansion.
Test Temperature & Notch (QW-172.1)
Specimen No. Dimension Position Joules (Value & TIA) (Elongation)
Type (Charpy-V / U) Drop Weight Break:
(♣)
Actual (Yes or No)
Location Size (mm) ( 0C ) Values (J/cm2) Average (J) Values (J/cm2) TIA (cm2) Shear (%) (mm)
(J/cm2)
BMp1 (*) (**)
BMp1 (*) (**)
BMp1 (*) (**)
FL1 (*) (**)
FL1 (*) (**)
FL1 (*) (**)
HAZ1 (*) (**)
HAZ1 (*) (**)
HAZ1 (*) (**)
WM (*) (**)
WM (*) (**)
WM (*) (**)
HAZ2 (*) (**)
HAZ2 (*) (**)
HAZ2 (*) (**)
FL2 (*) (**)
FL2 (*) (**)
FL2 (*) (**)
BM2 (*) (**)
BM2 (*) (**)
BM2 (*) (**)
Acronyms BM1 = A106-Gr. B_Base Metal , BM2 = A106-Gr. C _Base Metal, HAZ1 or 2 = Heat-affected Zone, WM = Weld-metal, FL1 or 2 = Fusion line, TIA = Total Impact Area
CALCULATIONS (* ) Impact Value = Actual J ÷ TIA (**) Shear % = (Ductile Area ÷ TIA ) x 100 Impact Target = Specimen size x multiply code requirement
TIA = Ductile Area + Fragile Area. <OR> {TIA = 8 x 10 x 0.01 } “Where” 8 is the distance from notch to base of the Specimen Other Reference
“Impact Testing Requirements for WPS –Qualification”
(a) Impact Testing of base metal is not required when the base material is certified PED 97/23/CE, or impact tested to ASTM/SA-370 __or as per EN 10204-3.1 inspection Certificate
NOTES
(b) (♣) Impact Testing of both base metals is not required, when the Materials has the same P-No. & Group-No., or if the specified temperature lower than qualified in this table.
(c) AWS-D1.1_Clause 4.33__Impact Testing shall be as per Contractual requirement s and in conformance with Para: 5.26.5 (3d).
(d) EEMUA-158_Para. 4.4.4e__Impact Testing of base & Weld metal, HAZ & Fusion line is required to demonstrate weld strength and toughness when the WPS welds are for Offshore structures
Acceptance Criteria According to EEMUA-158: Para. 4.4.4 (e) -Table 2. << And >> PED 97/23/CE
Acronyms CSR = Crack Sensitivity Ratio, CTR = Crack Thickness Ratio, CLR = Crack Length Ratio, CAR = Crack Area Ratio, RSK = Risk of Stress Sensitivity Factor
Apparatus Brand Name Method Used
Acceptance Criteria According to NACE 0284 + Owner’s Acceptance REMARKS Spares from the original Test Coupon have been stored for this Test
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NoBo - No XXXX Test-Position 5G (on Pipe Steel) NoBo - No XXXX
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Table-14 PROCEDURE RECORD MECHANICAL TEST PLAN (ASME-IX_QW-463.1d) + (API-1104: Para.5.6_Table 2_Figure 3)
Test Specimen Legend
1 = Micrographic - Metallurgy
2 = Macro Hardness
3 = Guide Bend (Root)
4 = Guide Bend (Face)
5 = Guide Bend (Root)
6 = Guide Bend (Face)
28 = Reduce section Tensile
29 = Reduce section Tensile
30 = Macro Hardness (extra)
31 & 32 =Neck Break
BM = Base Metal
HAZ = Heat Affected Zone
FL = Fusion Line
WM = Weld Metal
S = Spare coupon section
X = Discarded section
MD-Acronym Material Description Material Mechanical Characteristics Mandrill Details (MD)
BD = Bend Distance Base material Class Rm or UTS (N/mm2) 470 ≤ 630 Mandrill Diameter 4t
t = Thickness Base material Spec. welded to % Area ≥ 22 Distance between rollers (mm) 6t + 3.2
Material Type Carbon Steel Pipe Pipe _NPS (mm) 250 Average Required Chary-V, @ -20 0C 27 Joules Thickness of Coupon; t (mm)
Wall Thickness (mm) 12 Minimum Required Chary-V, @ -20 0C 19 Joules Angle of Bend: BD 1800
Filler Metal
Welding Process
Notes
Table-15 HEAT-TREATMENT ACCORDING TO AWS D1.1: Para. 5.6 _TABLE: 4.5 <and> HYDROGEN-BAKEOUT (EN ISO 15614-1: Para. 8.4.11 and 8.4.12)
Temperature HR & C Method Preheat Activity
Coupon (Open Flame or Thermocouple (total & Insulation (Yes/No) Test performed
Description (°C ) (minutes)
No Heat-pad) clock- position) Yes / None
Min. Max. H HR (min) C (min) Position Total Yes/No Action
(QW-406.1) Pre-heat Before welding
Weld Joint Stress Relieving After welding (***)
(QW-407) Pre-heat for PWHT Before PWHT
(QW-407.2) PWHT PWHT
(QW-406.11) BM H2 Bake-out Before welding (**)
(QW-406.11) Weld H2 Bake-out After welding (**)
Thermocouple Location Procedure for WPS Qualification with PWHT
Thermocouple layout Sketch
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Table 16 (EN 1321: 1996) Transformation Microstructure (50 µm) ( magnification: x200 <> Etching Reagent: 2%Nital )
Figure 1 MICROSCOPIC TEST ZONES AS PER TABLE 17 Figure 2 Microscopic Metallurgical Sample [2% Nital] (Origins of Figure 1)
Fig. D AREA-2 (HAZ: A106-Gr.B) Nodular-Pe with F + Pe Fig. E AREA-4 (Root Bead-Centre) Fine Grain (F and Pe) Fig. F AREA-6 (Base Metal: A106-Gr.C) Ferritic Pearlitic
Acronyms Tfm = Transformation, P = Primary, F = Ferrite, Pe = Pearlite, A =Acicular, S = Second-phase, FC = Ferrite-Carbide combined with Pe
Remark Ferritic Pearlitic: Typical microstructure for Carbon steel. (Refer to Table 8: Filler Metal undiluted chemical analysis)
Table-18 (QW-180 ) HV10 ≤ 248__ MACRO-HARDNESS TEST PROCEDURE :< EN ISO 6507-1: 2005 & EN ISO 9015-1: 2011>
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(b) We certify by verifications that the statements in this Welding Procedure Qualification Record, are correct and that the tested welds were prepared, welded, and mechanically tested in accordance with
the combined requirements of ASME-Section IX <> API-1104 <> EN ISO 15614-1 <> EEMUA-158 <> NACE MR 0175-Part 2 and DNV-OS-C401 respectively.
(c) Details of the recorded tests are accurate, and may only be modified to conform to the type and number of extra tests allowed by the Code, using the spares from the same test coupon, - including
addenda, editorial corrections or QW-XX changes. (add owner name here) reserves the rights to grant access for use to any fabricator working for us as we so see fit.
Table-20 OWNERSHIP and ORGANIZATIONAL RESPONSIBILITY as per ASME IX-2013 ed. GENERAL REQUIREMENT: QG-106
Owner’s Name Welding Engineer
WPQR Holding Company Name
Address & Address
Telephone FAX Owners Stamp here
Email / Website
Email Website Experience
Director Qualification
Signature Date xx / xx / 20xx Signature Date xx / xx / 20xx
(Digital signature here) (Digital signature here)
3Rd Party Authorization Authorization by Owner In accordance with [QG-107] & [ASME IX_2010_QW-201.1 (cf-13)]. Expiry Date: “At owners request”
Name: Terms Accepted by Fabricator
Address:
Fabrication Director: Signature:
Company ISO_9001-QA-Certificate No:
Details Phone: QC Manager / Welding Engineer: Signature:
Fax:
Email: Acceptance Date: xx / xx / 20xx
Website:
Technically
Evaluated On the, xx / xx / 20xx by Welding Specialist Mr/Miss. ……………………………………….‘under the instructions of (owners name here) for authorization for use approval.
The Owner reserves the rights to request additional information/s –should it be deemed necessary. The Fabricator (Add 3rd Party Name here) is not permitted to make any addendums,
Terms & Conditions plagiarize, Duplicate, combined third party PQR/s with this WPQR or grant access to third party/s. Should these requirements be ignored – all privileges’ shall be revoked immediately and
may result in legal breach of agreement charges. [Note: f-13: << The Quality Control System/Quality Assurance Program shall reflect the source of this PQR >>].
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