Annexure--1

Qualification of 2 Cr 1 Mo steel

ObjectiveTo qualify welding procedure of P5C material

Reference for qualification

i) ASME Sec IX Latest Edition and Addenda

ii) API 934 Dec2000
iii) ASME Sec VIII Div 2 inclusive mandatory appendix

Welding Process to be qualified

i) Submerged Arc Welding (SAW )
ii) Shielded Metal Arc Welding (SMAW)
iii) Strip cladding Overlay by ESW of EQ309L +EQ347

Base Material ------SA 541 Gr F22V Made by--------. Duly tested in simulated condition as per
Specification requirement.

Welding ConsumableWelding Consumables Of Bohler Thyssen duly tested as per simulated

condition

Coupon plate Size welded1500mm Length x 300mm width x 250mm thk For
i) PQR
ii) For temper embribrittlement test of weld and HAZ

Welding Procedure witness by

 Macro Flow chart of Qualifying the 2 Cr 1Mo V steel PQR

Sequence of operation

Cutting of Test pieces as per

drg. from Forging by machining 5-6 0

250 10R
Weld edge preparation by
5
machining
Root gap 0-1
All dimensions are in mm
i)Preheating by electrical heating/burner
DPE and ii)Burners and test plates shall be rested on
MPE of stand.
Weld edge iii) Proper supports from bottom to avoid
distortion
iv) Preheating to be monitored with infrared
temperature tester and data loggers

Set up of Test plate

Witness by AI with respect

to WPS i)PQR --- ASAW process
ii)PQR---B50mm portion by SMAW
+50mm portion by SAW
iii)PQR--- C-Step cooling test piece by SAW
Preheating of test plate as
per WPS of Test plate
Welding
SMAW and SAW as per preliminary
WPS

i)Respective temp. to be checked by infra

Check Inter pass, Preheat,
Volt, Amp, welding
speed, and also post
heating during welding
red temp. recorder.
ii)Current Voltage to be checked with Tong
tester.
iv)All parameters are to be checked w.r.t.
WPS

A
A
 ISR at 650-660C for 3 hrs.
ISR of Weld immediately after weld
W/O cooling to room Temp.

Chip back shall be by grinding. (Not

Chip back of welded plate by Grinding
by air arc gouging)

D.P.E and M.P.E Test of chip back area

Welding on chip back side as per WPS

Record preheat, ii) ISR at 650-660C for 1

inter pass, Volt, hr immediately before cooling the weld
amp, welding from preheat temperature
speed, and also
post heating during
welding

D.P. /UT/MP/RT
of
Weld after ISR at
room temp.

PWHT Refer PWHT for respective

test plate at Sr. No. A), B) &
C)

Testing of PQR under LRA inspection

Review of
results
Test Plan for 2 ,Cr 1Mo V steel PQR As per API934,ASME Sec VIII Div 2, ASME
SecIX
A)
Sample No --- A for PQR qualification
Process used SAW stamped by LRA

Sr Type of Testing Test No Of tests Acceptance PWHT Remark

No Temp. Standard
1) Transverse RT 2 sets (multiple UTS (Ksi)85-110 PWHT with
Tensile specimen to cover different
For SAW full thk.) soaking time
(refer note-1)
2 Side Bend test RT 4 Nos ASME sec IX PWHT with
For SAW process QW 163 different
soaking time
(refer note-1)
3 Hot Tensile 1sets (multiple 66.8 ksi,65.7Ksi,64.4 PWHT with
(Transverse) 4680 C, specimen to cover Ksi min different
for SAW and full thk.) soaking time
(refer note-1)
4 Impact Test Minus Weld, HAZ,PM Average 54J ,Min48J PWHT with In case of SAW
for SAW process 290C 3sets each 1.6mm different 1.6 mm from surface
Top and th T soaking time and T
(refer note-1)
5 Hardness Test Survey Across the section 235 Max HV10 PWHT with
Or Weld and HAZ different
soaking time
(refer note-1)
6 Chemical Weld metal of X factor = <15ppm 1. As welded
SAW ii)As per Table26-400.1 2. Refer note 3
of Appendex26 0f
ASME sec VIII div 1
7 Micro structure Weld and HAZ of %Banite and grain size As welded
SAW of 7-9

Note--
Note 1---Min PWHT 7050C +/-5 soaking time-5Hrs @ 40 0 C to 50 0 C Heating rate
above 200 0 C and 50 0 C to 60 0 C cooling rate up to 200 0 C
Max PWHT 7050C +/-5 soaking time-32Hrs @ 40 0 C to 50 0 C Heating rate above 200 0
C and 50 0 C to 60 0 C cooling rate up to 200 0 C

Note 2- Step cooling treatment cycle shall be

i) Heat To 5930C from 3000C @ 40-560C /hr

ii) Hold @ 5930C for 1 hr and cool @ max 60C /hr to next temperature.
iii) Hold @ 5380C for 15 hrs and cool @ max 60C /hr to next temperature
iv) Hold @ 5240C for 24 hrs and cool @ max 60C /hr to next temperature
v) Hold @ 4960C for 60 hrs and cool @ max 30C /hr to next temperature
vi) Hold @ 4680C for 100 hrs and cool @ max 280C /hr to 315 0C

Note 3- X factor of weld =(10P+5Sb+4Sn +As)/100=<15 ppm and weld metal chemistry

ii)As per Table26-400.1 of Appendex31 0f ASME sec VIII div 1

Note 4 All heat treatment to be carried in Electrical Furnace . Test piece should be properly loaded to have proper
circulation of air and heat . Min 3 thermocouples should be attached to each test piece.
B)
Sample No ---- B for PQR qualification
Process used SAW + SMAW stamped by
Sr Type of Testing Test Temp. No Of tests Acceptance PWHT Remark
No Standard
1) Transverse RT 2sets (multiple UTS (Ksi)85min- PWHT with
Tensile specimen to cover 110max different
For SAW and full thk.) soaking time
SMAW process (refer note-1)
2 Side Bend test RT 4 Nos ASME sec IX PWHT with
For SMAW and QW 163 different
SAW process soaking time
(refer note-1)
3 Hot Tensile 4680 C, 1sets (multiple To report PWHT with
(Transverse) specimen to cover different
for SAW and full thk.) soaking time
SMAW process (refer note-1)
4 Impact Test Minus 290C Weld, HAZ,PM Average 54J ,Min48J PWHT with In case of
for SAW and 3sets each 1.6mm different SAW+SMAW PQR
SMAW process Top and th T soaking time 1.6mm top will
(refer note-1) represent SMAW
and T will
represent SAW
5 Hardness Test Survey Across the section 235 Max HV10 a)Min PWHT Note 1
Or Weld and HAZ b)Max PWHT
for SMAW and c)Min PWHT +
SAW process Step cooling
Note 2
6 Chemical Weld metal of X factor = <15ppm 1. As welded
SAW and SMAW ii)As per Table26-400.1 2. Refer note 3
of Appendex26 0f
ASME sec VIII div 1
7 Micro structure Weld and HAZ of %Banite and grain size As welded
SAW and SMAW of 7-9

Note-
Note 1---Min PWHT 7050C +/-5 soaking time-5Hrs @ 40 0 C to 50 0 C Heating above 200 0 C and 50 0 C to 60 0 C cooling
rate up to 200 0 C
Max PWHT 7050C +/-5 soaking time-32Hrs @ 40 0 C to 50 0 C Heating above 200 0 C and 50 0 C to 60 0 C cooling rate up
to 200 0 C

Note 2- Step cooling treatment cycle shall be

vii) Heat To 5930C from 3000C @ 40-560C /hr

viii) Hold @ 5930C for 1 hr and cool @ max 60C /hr to next temperature.
ix) Hold @ 5380C for 15 hrs and cool @ max 60C /hr to next temperature
x) Hold @ 5240C for 24 hrs and cool @ max 60C /hr to next temperature
xi) Hold @ 4960C for 60 hrs and cool @ max 30C /hr to next temperature
xii) Hold @ 4680C for 100 hrs and cool @ max 280C /hr to 315 0C

Note 3- X factor of weld =(10P+5Sb+4Sn +As)/100=<15 ppm and weld metal chemistry

ii)As per Table26-400.1 of Appendex31 0f ASME sec VIII div 1

Note 4 All heat treatment to be carried in Electrical Furnace . Test piece should be properly loaded to have proper
circulation of air and heat . Min 3 thermocouples should be attached to each test piece.
C)

Sample No ----- C for Temper ebrittlement Screening

Process used SAW stamped by

Sr Type of Testing Test Temp. No Of tests Acceptance PWHT Remark

No Standard
1 Temper At 6 different To cover each VTr55 + 3 delta VTr55 a)Min PWHT SAW
Embrittlement Temp. process For Weld b)Min PWHT + To cover each
Screening Minus SMAW top and <= 100C Step cooling process For Weld
(SAW a process) 5,10,18,29,35, middle Note 2 top and middle
500 C SAW weld middle
and bottom
As marked
2 Temper At 6 different To cover each VTr55 + 3 delta VTr55 a)Min PWHT SAW+SMAW PQR
Embrittlement Temp process For HAZ b)Min PWHT + To cover each
Screening Minus SMAW top and <= 100C Step cooling process For HAZ
(SAW process 5,10,18,29,35, middle Note 2 top and middle
500 C SAW weld middle
and bottom As marked
As marked

3 Hardness Test Survey Across the section 235 Max HV10 a)Min PWHT Note 1
Or Weld and HAZ
of each process b)Min PWHT +
Step cooling
Note 2

Note
Note 1---Min PWHT 7050C +/-5 soaking time-5Hrs @ 40 0 C to 50 0 C Heating above 200 0 C and 50 0 C to 60 0 C cooling
rate up to 200 0 C

Note 2- Step cooling treatment cycle shall be

xiii) Heat To 5930C from 3000C @ 40-560C /hr

xiv) Hold @ 5930C for 1 hr and cool @ max 60C /hr to next temperature.
xv) Hold @ 5380C for 15 hrs and cool @ max 60C /hr to next temperature
xvi) Hold @ 5240C for 24 hrs and cool @ max 60C /hr to next temperature
xvii) Hold @ 4960C for 60 hrs and cool @ max 30C /hr to next temperature
xviii) Hold @ 4680C for 100 hrs and cool @ max 280C /hr to 315 0C

Note 3- X factor of weld =(10P+5Sb+4Sn +As)/100=<15 ppm and weld metalchemistry

ii)As per Table2-400.1 of Appendex31 0f ASME sec VIII div 1

Note 4 All heat treatment to be carried in Electrical Furnace . Test piece should be properly loaded to have proper
circulation of air and heat . Min 3 thermocouples should be attached to each test piece.