ORION S.P.A. TRIESTE DATA BOOK INDEX SECTIONS DB N° 01-2009 ITALY Section 8.5 Welding Procedure Specification (WPS ) & Procedure Qualification Records ( PQR’s)onion ‘TRIESTE ~ ITALY INDEX OF WPS Pag. 4 did Data: 26/07/2007 WPS BASE PROCESS |APPLICATION PQR NUMBER MATERIAL NUMBER 05 rev.1 WC6IF11-Cl.2 GTAW Stellite 6 05 rev.1 Overlay on _ _ Body & Bonnet _ | 18 rev.6 F3161 GTAW Stellite 6 18 rev.6 | Overlay on Disc & seat ring 68 rev.1 wcé GMAW Welding seat 68 rev.1 | ring to valve | - body a. DICE DELLE REVISIONI ISSUED VERIFIED | APPROVED REV. |DATA |OGGETTO RGQ RGQ RGQ 0 | 26/07/07 |IssuE E> 2.ORION S.p.A. Page 1 of 2 WELDING PROCEDURE SPECIFICATION | (WPS) QW-482 Prepared by: F-BRONZI QA Manager WELDING PROCEDURE SPECIFICATION No. 05 Rev.1_ Date: 26-06-2007 SUPPORTING PQR: 05 Rev. No. Date: 29-06-2007 WELDING PROCESS: __GTAW TYPE: MACHINE JOINTS (QW-402) Joint Design — See sketch SEER ee Backing (Yes)... ] (No) ....[X] 4mm DEPOSITED OVERLAY Backing Material (Type) N.A. Metal [X] Nonmetallic [ ] sreues 2eN LAYERS. ISTLAYER Nonfusing Metal [] 22m Other THICKNESS OF HARDFACING \__savazerwes. Of RLAY TO BE QUALIFIED 2mm & over BASE METAL (QW-403) P-No. 4 Group.No. 1 To P-No. NA GroupNo. N.A. Or Specification type and grade- SA/ A 217 Gr.WC6 To Specification type and grade - STELLITE No.6 — UNS R 30006 ~ Or 2 OF Chem. Analysis and Mech. Prop- SA/ A217 Gr. WC6 PAGE 2—— To Chem, Analysis and Mech. Prop— STELLITE No.6 — UNS R 30006 Thickness Range: Base Metal: 1 Inch & over Groove 1” to Unlimited Fillet: N.A. Pipe Dia. Range: N.A Groove Fillet: N.A. OL: None FILLER METAL — (QW-404) Spec.No. (SFA) 5.21 | AWS No. (Class) ERCoCrA | FNo. n ANo. NA Size of Filler Metal Smm Dia. Deposited Weld Metal Thickness Range Overlay 2mm & over Groove NA. Fillet NA. Electrode ~ Flux (Class) NA. Electrode ~ Flux Trade Name BOHLER THYSSEN Consumable Insert SCHWEISSTECHNIK GMBH NONE ot. ‘Notes: Approved by: F. BRONZI Date: 26-06-2007| | ORION S.p.A. ‘WELDING PROCEDURE SPECIFICATION | (WPS) _QW-482 Prepared by: F BRONZI QA Manager WELDING PROCEDURE SPECIFICATION No. 05 Rev.1 Date: 26-06-2007 | SUPPORTING PQR: 05 Rev. No.1 Date: 29-06-2007 WELDING PROCESS: GTAW ____ ‘TYPE: MACHINE POSITION (QW-405) POST WELD HEAT TREATMENT (QW-407) Postion (5) of Groove: 1G - CIRCULAR TEMPERATURE RANGE: NONE Welding Progression ‘Time Range: N.A. Uphill: NA. Minimum: N.A. Downhill: N.A. Heating & Cooling Rate: N.A. Position (s) of Fillet: N.A. PREHEAT (QW-406) GAS (QW-408) Preheat Temp. Min.: 121 °C Percent Composition Interpass Temp. Max.: 280°C Gas (es) (Mixture) Flow Rate Pi -atMaintenance: N.A. Shielding: 99.9% ARGON 12-14 LITRES /MIN (Continuous or special heating where applicable) | Trailing: None [Backing: None ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC: DC Polarity: SP Amps (Range): 180 - 190 Volts (Range): 21 - 22 Tungsten Electrode Size & Type: 4mm Diameter 2% throated Mode of Metal Transfer for GMAW: N.A. | Electrode Wire feed speed range: NOT MEASURED ___ _ TECHNIQUE (QW-410) Weave Bead: WEAVE Orifice or Cup Size: 16mm DIAMETER Interpass / Initial and Interpass Cleaning: _ By Solvent & Brushing ‘Method of Back Gouging: NA, Oscillation: 35 to 40 mm Contact Tube to Work Distance: NAA. ‘iple or Single Pass (per side): Multiple Mu.uple or Single Electrodes: Single Travel Speed (Range) : 71 to 76 mm / minute Peening: Not permitted Other: Weld | Process iller Filler ‘Current Amp. | Volt | Travel Speed | ‘Heat Input Layer Metal Metal AC/DC Range | Range Range J/mm ©) Class | Diam. ‘Type (A) | (V) | Gnm/min) | polarity | | _ 1 GTAW | ERCoCrA | 5mm DC/SP 180-190 | 21-22 71/76 | 3246 2 GTAW | ERCoCrA | 5mm DC/SP 180-190 | 21-22 71/76 j 3571 max. | limited by | PQR REQUIRED TEST 1. PT EXAM. ON OVERLAY AS PER ORION PROC. L002 -NO DEFECTS ALLOWED 2. VISUAL & MACRO EXAM. WITH 5X MAGNIFICATION on ETCHED SURFACE. NO CRACKS, LACK OF FUSION OR OTHER LINEAR DEFECTS ALLOWED ON BASE METAL AND HEAT A. ZONE. (| HARDNESS TEST: HV 10-400 Min. in OVERLAY, 250 Max. in H.A.Z. & 250 Max. in base material 4, DEPOSITED ANALISYS % : C=0,7-1,4 ; Co=Remaining ; Cr=25-32 ; Fe=5 Max. ; W=3.0 to 6.0 ; Mn=2.0 Max. ; Ni=3.0 Max. ; Si=2.0 Max.PROCEDURE QUALIFICATION RECORDS ( Prepared by: QA Manager | PROCEDURE QUALIFICATION RECORDS No. 05 Rev.1 WELDING PROCEDURE SPECIFICATION No. 05 Rev.1 WELDING PROCESS: GTAW UTYPE: MACHINE. ore ee HIALUIN 193.P.fae (PQR)_QW-483 JOINTS ( QW-402) Qc. .LIFIED THICKNESS : 2,0 mm minimum after machining 2-N LAYERS: ISTLAYER \ 26mm | chemical analisys at? mm of fuoton tine STELLITES: \ saatrwce BASE METAL ( QW-403) POST WELD HEAT TREATMENT (QW-407) Material Specification: A217 Type or grade Gr.WC6 ‘Temperature NONE PNo. 4 to PNo. NA. Time NA. Thickness of test coupon : 26 mm Heating / Cooling rate : NAL Diameter of test coupon : 270 mm Other: Ni Other: GAS (QW-408) PERCENT COMPOSITION GAS (MIXTURE) FLOW RATE Shielding :99.9%ARGON + — 13 LITRES / MIN, Trailing : NONE |Backing_: NONE _ FILLER METAL (QW-404) GTAW ELECTRICAL CHARACTERISTIC (QW-409) SFA Specification 5.21 Current =: DC AWS Classification ERCoCrA _| Polarity SP Filler Metal Amps : 185 (Average ) | ENo. 2 Volts 21.5 (Average) | Weld metal analysis A-No. NA. Tungsten electrode size : 4 mm Diam. Size of filler metal Smm Diam. — | Other: Other: Welded 2 passes with width of approx. 40 mm, Deposited approx. 6 mm thickness 2mm after machining. Heat input :3246 J/mm. POSITION ( QW-405) Position of groove : 1G - CIRCULAR PREHEAT ( QW-406) |Pr t Temperature: 121°C | Interpass Temperature : 280°C Other: Weld progression ( uphill,downhill ) :N.A. TECHNIQUE (QW-410) ‘Travel speed : Timm per minute | String or weave bead : WEAVE Oscillation 240 mm Single or Multipass ( per side ) : MULTIPLE, Single or Multiple electrodes: SINGLE| ORION S.p.A. PageZof2 | | PROCEDURE QUALIFICATION RECORDS | ( | (QR) _QW-483 | Prepared by: QA Manager | PROCEDURE QUALIFICATION RECORDS No. 05 Rev.1 | WELDING PROCEDURE SPECIFICATION No. 05 Rev.1 WELDING PROCESS: GTAW. TENSILE TEST ( QW-150) SPECIMEN |WIDTH(mm) [THICKNESS [AREAmm2 [ULTIMATE [ULTIMATE |TYPEOF No, | (mm ) TOTAL UNIT STRESS | FAILURE & LOAD(N) — |Nimm2 LOCATION 7 7 7 7 7 7 7 GUIDED BEND TEST ( QW-160) TYPE & FIGURE No. RESULTS NA. ‘TOUGHNESS TEST ( QW-170) ‘NOTCH [NOTCH TYPE [TEST ~_TIMPACT LATERAL JATERAL, LOCATION ‘TEMPERATURE | VALUES (J) | EXPANSIONS | EXPANSIONS JOULES %SHEAR | MILS. ] wo | APPLICABLE | FILLET WELD TEST (QW-180) RF“ ILTS-SATISFACTORY YES[] NO[] PENETRATION INTOMETAL YES[] NO[] MACRO - RESULTS: VISUAL EXAMINATION x 5 MAGNIFIED, SATISFACTORY. OTHER TEST DEPOSITED ANALISYS % : C=1,13 ; Fe= 0,72 ; W=5,05 ; Co~62,5 ; Cr=28,8 ; Ni-0,10 ; Si=1,28 ; Mn=0,42 CHEMICAL ANALYSIS PERFORMED at 2 mm from Fusion Line HARDNESS TEST= SATISFACTORY HV 10 PAGE @ OF BASEMETAL — : (216-214-211) HV 10 HAZ. —:(237-236-240 ) HVI0 WELD METAL STELLITE 6 (450-443-461 ) HV1O In accordance to NACE MR-01-75 E4.02 LIQUID PENETRANT TEST = SATISFACTORY ‘NAME OF WELDER: DARIS DAVIDE STAMP No..DD TEST CONDUCED BY : ORION $.p.A. & METAL SERVICES S.nc. LABORATORY TEST No. 5 & 14/01 WE CERTIFY THAT STATEMENTS IN THIS RECORDS ARE CORRECT AND THE TEST WELDS WERE PREPARED , WELDED AND TESTED IN ACCORDANCE WITH THE REQIREMENTS OF SECTION “IX” OF THE ASME CODE. 2. DATE: 29-06-2007 MANUFACTURER : ORION S.p.A. BY : F, BRONZIQ.A. Mgr< ~ ORION S§.p.A. Page 1 of 1 RECORD OF WELDER OR WELDING OPERATOR QUALIFICATION TEST (WPQ) QW-484 WELDER’S NAME : DARIS DAVIDE CLOCK No. STAMP No.:DD WELDING PROCESS (ES ) USED : GTAW-HARDFACING OVERLAY TYPE : MACHINE IDENTIFICATION OF WPS FOLLOWED BY WELDER DURING WELDING OF TEST COUPON : 05 Rev.1 BASE MATERIAL (S ) WELDED : SA217 Gr.WC6 + S.F.A. 5.21 ERCOCT-A Stellite No.6 UNS R30006. BASE METAL THICKNESS = ( 26mm ) MANUAL OR SEMIAUTOMATIC VARIABLES FOR EACH PROCESS ( QW-350) ‘ACTUAL VALUES | RANGE QUALIFIED | BACKING METAL, WELD METAL, WELDED FROM BOTH ‘Weld Metal Only with backing | SIDES, FLUX, ECT. ( QW-402 ) ASME P.No. 4 TO P.No. N.A. (QW-403) (X] PLATE [] PIPE | FILLER METAL Spec.No.(SFA).......CLASS.(QW-404) | FILLER METAL F-No. RQ Rn FILLER METAL VARIETY SOLID SOLID CONSUMABLE INSERT FOR GTAW OR PAW NONE. NONE WELD THICKNESS FOR EACH WELDING PROC. 2mm 2mm & OVER WFNING POSITION (16,5G,ECT. ) (QW-405 ) 1G FLAT Pi, JRESSION (UPHILL / DOWNHILL ) NA NA. BACKING GAS FOR GTAW, PAW OR GMAW ( QW-408 ) ARGON ARGON GMAW TRANSFER MODE : ( QW-409 ) NA. NA. GTAW WELDING CURRENT TYPE / POLARITY DC/SP, DC/SP MACHINE WELDING VARIABLES FOR THE PROCESS | ACTUAL VALUES | RANGE QUALIFIED ‘USED ( QW-360) | DIRECT / REMOTE VISUAL CONTROL DIRECT | DIRECT AUTOMATIC VOLTAGE CONTROL (GTAW ) NA. | NA. AUTOMATIC JOINT TRACKING NONE | ‘NONE WELDING POSITION (1G,5G,ECT.) 1G-FLAT | 1G-FLAT CONSUMABLES INSERT NONE ‘NONE BACKING ( METAL, WELD METAL, WELDED FROM. YES, | Only with backing BOTH SIDES, FLUX, ECT. ) CHANGE FROM AUTO. TO MACHINE MACHINE MACHINE EBW,LBW.FRW.NOT APPLICABLE TO THIS WPS GUIDED BEND TEST RESULTS GUIDED BEND TESTS TYPE ( ) QW-462.2 ( SIDE ) RESULTS () QW-46233 (a) (TRANS R&F) TYPE () Q! 623 (0) (LONG R&F ) RESULTS. ‘NOT APPLICABLE. VISUAL EXAMINATION RESULTS ( QW-302.4) : SATISFACTORY DYE PENETRANT INSPECTION SATISFACTORY MACRO EXAMINATION SATISFACTORY X 5 MAGNIFIED RADIOGRAPHIC TEST RESULTS ( QW-304 & QW-305 ): NONE eg (FOR ALTERNATIVE QUALIFICATION OF GROOVE WELDS BY RADIOGRAPHY ) oe Po! FILLET WELD FRACTURE TEST LENGTH AND PERCENT OF DEFECTS ‘avin MACRO TEST FUSION ——_FILLETLEG SIZE mm/in X —mm/in CONCAVITY/ CONVEXITY mmiin WELDING TEST CONDUCED BY ORION S.P.A. MECHANICAL TESTS CONDUCED BY : ORION S.P.A. Laboratory No/ WE CERTIFY THAT THE STATEMENTS IN THIS RECORDS ARE CORRECT AND THAT THE TEST COUPONS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF THE ASME CODE. DATE : 29JUNE 2007 BY: F.BRONZI Q.A. MgrORION S.p.A. WELDING PROCEDURE SPECIFICATION ( (WPS) _QW-482 ‘Page I of 2 Prepared by: F.BRONZI QA Manager WELDING PROCEDURE SPECIFICATION No. 18 Rev.6 SUPPORTING PQR: 18 Rev. No.6 WELDING PROCESS: __GTAW. TYPE: MACHINE Date: 26-06-2007 Date: 29-06-2007 JOINTS (QW-402) Joint Design — See sketch Backing (Yes) ....[ ] (No) Backing Material (Type) N.A. Metal [X] Nonmetallic [_] DIAMETER 270 +- Smm od sreuures Nonfusing Metal [ ] Other THICKNESS OF HARDFACING sari ol RLAY TO BE QUALIFIED 2mm & over 4mm DEPOSITED OVERLAY BASE METAL (QW-403) PNo. 8 Group.No. 1 To PNo. NA GroupNo. NA. Or | Specification type and grade- SA/ A 182 Gr.F316 | ‘To Specification type and grade - STELLITE No.6 ~ UNS R 30006 Or Chem. Analysis and Mech. Prop- SA/ A 182 Gr.F316 To Chem. Analysis and Mech. Prop~ _STELLITE No.6 ~ UNS R 30006 | Thickness Range: |Base Metal: 1 Inch & over Groove 1” to Unlimited Fillet: N.A. | Pipe Dia. Range: N.A. Groove Fillet: N.A. | | Ou.-c: None | FILLER METAL — (QW-404) Spec.No. (SFA) 5.21 AWS No. (Class) ERCoCrA F.No. nD | ANo. NA. | Size of Filler Metal 3.2 mm Dia. —<} Deposited Weld Metal ‘Thickness Range Overlay 2mm & over Groove NA. Fillet NA | Electrode — Flux (Class) NA. Electrode - Flux Trade Name MITSUBISHI HARD-FACING Consumable Insert ALLOY No.6 | NONE Ob Notes: Approved by: F, BRONZI Date: 26-06-2007SUPPORTING PQR: ] ORION S.p.A. ‘WELDING PROCEDURE SPECIFICATION pared by: F.BRONZI QA Manager WELDING PROCEDURE SPECIFICATION No. 18 Rev.6 WELDING PROCESS: GTAW, ‘Page 2 of 2 (WPS) _QW-482 Date: 29-06-2007 Date: 29-06-2007 TYPE: MACHINE 18 Rev. No.6 POSITION (QW-405) Postion (s) of Groove: 1G - CIRCULAR Welding Progression POST WELD HEAT TREATMENT (QW-407) TEMPERATURE RANGE: NONE. Time Range: N.A. Uphill: A. Downhill: N.A. Position (s) of Fillet: N.A. Minimum: N.A. Heating & Cooling Rate: N.A. | PREHEAT (QW-406) GAS (QW-408) | Preheat Temp. Min.: 30°C Percent Composition | Interoass Temp. Max.: 176°C Gas (es) (Mixture) Flow Rate | Pi atMaintenance: N.A. Shielding: 99.9% ARGON 14-16,5 LITRES /MIN | (Continuous or special heating where applicable) | Trailing: None _|Backing: None | ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC: DC Polarity: SP Amps (Range): 150-170 Volts (Range): 20-22 | Tungsten Electrode Size & Type: 4mm Diameter 2% throated (SIDERTIG TUNG) —_| Mode of Metal Transfer for GMAW: N.A. | Electrode Wire feed speed range: NOT MI __ | TECHNIQUE (QW-410) WEAVE | Orifice or Cup Size: 17mm DIAMETER Interpass / Initial and Interpass Cleaning: By Solvent & Brushing Method of Back Gouging: NA. Oscillation: 20 to.35 mm Contact Tube to Work Distance: NA. M “ple or Single Pass (per side): Multiple xo Re [\ Jusiple or Single Electrodes: Single xe 3 OF Travel Speed (Range) : 28 to 30 mm / minute [PAGE | Peening: Not permitted oo | Other: | Weld | Process | Filler | Filler | Current | Amp. | Volt | Tyavel Speed | Heat Input Layer Metal | Metal | AC/DC | Range | Range | Range J/mm | © Class | Diam Type (A) | cv) | (mm/min) __ polarity | 1 | GIAW | ERGoCrA | 32mm | DC/SP | 150-170 | 20-22 | 28730 7647 2 | GTAW | ERCoCrA | 3.2mm | DC/SP_ | 150-170 | 20-22 | 28/30 | 7647 max. | limited by I POR | REQUIRED TEST : 1. PTEXAM. ON OVERLAY AS PER ORION PROC. 1.002 -NO DEFECTS ALLOWED 2. VISUAL & MACRO EXAM. WITH 5X MAGNIFICATION on ETCHED SURFACE. NO CRACKS, LACK OF FUSION OR OTHER LINEAR DEFECTS ALLOWED ON BASE METAL AND. HEAT A. ZONE. HARDNESS TEST: HV 10-400 Min. in OVERLAY, 250 Max. in H.A.Z. & 250 Max. in base material DEPOSITED ANALISYS % : C=0,7-1,4 ; Co=Remaining ; Cr=25-32 ; Fe=5 Max. ; W=3.0 to 6,0; Mn=2.0 Max. ; Ni=3.0 Max. ; Si=2.0 Max.MUIREUIN Oop ef he (QR) Prepared by: QA Manager TYPE: MACHINE PROCEDURE QUALIFICATION RECORDS QW-483 PROCEDURE QUALIFICATION RECORDS No. 18 Rev.6 WELDING PROCEDURE SPECIFICATION No. WELDING PROCESS: GTAW 18 Rev.6 DETAILS JOINTS ( QW-402) Qc.ALIFIED THICKNESS : 2,0 mm minimum after machining 2+N LAYERS IST LAYER \ ‘chemical anatioys at2mm of fusion tine STELLITES: SAI EH eee door at | is BASE METAL ( QW-403 ) POST WELD HEAT TREATMENT (QW-407) Material Specification: SA 182 ‘Type or grade GrF316 Temperature : NONE P.No. 8 to PNo. NA. Time NA. Thickness of test coupon : 26 mm | Heating / Cooling rate : NA. Diameter of test coupon: 270 mm Other: NONE, Other: GAS (QW-408) PERCENT COMPOSITION GAS (MIXTURE) FLOW RATE Shielding: 99.9%ARGON + — 15 LITRES / MIN Trailing : NONE Backing_: NONE i FILLER METAL ( QW-404) GTAW ELECTRICAL CHARACTERISTIC (QW-409) SFA Specification 5.21 Curent — : DC AWS Classification ERCoCrA, Polarity: SP | Filler Metal Amps 185 (Average ) F-No. 2 | Volts : 21.5 (Average) Weld metal analysis A-No. NA. Tungsten electrode size : 4 mm Size of filler metal Other: Welded 2 passes with width of approx. 40 mm, Deposited approx. 6 mm_ thickness 2mm after machining, 3.2 mm Diam, Other: | Heat input : 6952 J/mm POSITION ( QW-405) Position of groove : 1G - CIRCULAR Weld progression ( uphill,downhill ) : N.A. PREHEAT ( QW-406) Pi tTemperature : 36°C Interpass Temperature : 176°C Other: TECHNIQUE (QW-410) | Travel speed 29 mm per minute | String or weave bead : WEAVE, scillation 26 mm gle or Multipass ( per side ) : MULTIPLE ingle or Multiple electrodes: SINGLE| ORION S.p.A. Page 2 of PROCEDURE QUALIFICATION RECORDS @QR) _QW-483 [Prepared by: QA Manager | PROCEDURE QUALIFICATION RECORDS No. 18 Rev.6 18 Rev. TENSILE TEST ( QW-150) SPECIMEN |WIDTH(mm) [THICKNESS [AREAmm2 ULTIMATE [ULTIMATE |TYPEOF x al TOTAL [ont teess Faron 2 | LOAD(N) Némm2 LOCATION i ~ 7 7 f f / GUIDED BEND TEST (QW160) i _ TYPE & FIGURE No. RESULTS _ _ ] ara a ‘TOUGHNESS TEST (QW-170) PAGE Ad_OF 2 | NOTCH NOTCHTVPE [TEST EAGT“ ERTERAL LATERAL LOCATION, TEMPERATURE | VALUES (J) | EXPANSIONS | EXPANSIONS. _| Yana ) een’ acs APPLICABLE PULET WELD TEST (QW-190) RFOILTS-SATISFACTORY YES[] NO[] _ PENETRATION INTOMETAL YES[] NO[] MACRO - RESULTS : VISUAL EXAMINATION x 5 MAGNIFIED, SATISFACTORY. OTHER TEST DEPOSITED ANALISYS % : C=0,9 ; Fe= 2,8 ; W=5,1 ; Co=59,91 ; Cr=26,6 ; Ni=2,26 ; Si CHEMICAL ANALYSIS PERFORMED at 2 mm from Fusion Line. ols Mr 57 ; Mo = 0,76 HARDNESS TEST= SATISFACTORY HV 10 BASE METAL (186 — 184-181) HV 10 HAZ :(227~226- 220 ) HVIO WELD METAL STELLITE6 (455-449-452 ) HV10 In accordance to NACE MR-O1-75 Ed.02 LIQUID PENETRAN’ ST = SATISFACTORY NAME OF WELDER: DARIS DAVIDE STAMP No.DD TEST CONDUCED BY : ORION S.p.A. LABORATORY TEST No. 5 WE CERTIFY THAT STATEMENTS IN THIS RECORDS ARE CORRECT AND THE TEST WELDS WERE PREPARED , WELDED AND TESTED IN ACCORDANCE WITH THE REQIREMENTS OF SECTION “IX” OF THE ASME CODE. 2 DATE: 29-06-2007 MANUFACTURER : ORION S.p.A. BY : F. BRONZIQ.A. MgrORION S.p.A. Page Tort RECORD OF WELDER OR WELDING OPERATOR QUALIFICATION TEST CWPQ) QW.-484 WELDER’S NAME : DARIS DAVIDE CLOCK No. STAMP No.:DD WELDING PROCESS (ES ) USED : GTAW—HARDFACING OVERLAY TYPE : MACHINE IDENTIFICATION OF WPS FOLLOWED BY WELDER DURING WELDING OF TEST COUPON : 05 Rev.1 BASE MATERIAL (S ) WELDED : SA182 Gr.F315 + S.P.A. 5.21 ERCoCr-A Stellite No.6 UNS R30006. BASE METAL THICKNESS = (26mm ) MANUAL OR SEMIAUTOMATIC VARIABLES [FOR EACH PROCESS ( QW-350 ) ~ ACTUAL VALUES RANGE QUALIFIED BACKING METAL, WELD METAL, WELDED FROM BOTH Weld Metal Only with backing SIDES, FLUX, ECT. ( QW-402) ASMEP.No. 8 TO P.No. NA. (QW-403) [X]PLATE [] PIPE FILLER METAL Spec.No.(SFA).......CLASS.(QW-404) FILLER METAL F-No. n nm FILLER METAL VARIETY SOLID SOLID CONSUMABLE INSERT FOR GTAW OR PAW ‘NONE. NONE WELD THICKNESS FOR EACH WELDING PROC. 1,6 mm 1,6 mm & OVER WF™ING POSITION ( 1G,5G,ECT. ) (QW-405 ) 1G FLAT Ph JRESSION ( UPHILL / DOWNHILL ) NA. NA. BACKING GAS FOR GTAW, PAW OR GMAW ( QW-408 ) ARGON ARGON GMAW TRANSFER MODE : ( QW-409) NA. NA. GTAW WELDING CURRENT TYPE / POLARITY, - DC/SP DC/SP MACHINE WELDING VARIABLES FOR THE PROCESS| ACTUAL VALUES | RANGE QUALIFIED USED ( QW-360) DIRECT / REMOTE VISUAL CONTROL DIRECT DIRECT AUTOMATIC VOLTAGE CONTROL (GTAW) NAL NA. AUTOMATIC JOINT TRACKING NONE NONE WELDING POSITION (1G,5G,ECT.) 1G-FLAT 1G-FLAT CONSUMABLES INSERT NONE NONE, BACKING ( METAL,WELD METAL, WELDED FROM ‘YES Only with backing BOTH SIDES, FLUX, ECT. ) CHANGE FROM AUTO. TO MACHINE MACHINE, MACHINE EBW.LBW,FRW,NOT APPLICABLE TO THIS WPS GUIDED BEND TEST RESULTS GUIDED BEND TESTS TYPE ( ) QW-462.2 ( SIDE ) RESULTS () QW-4623 (a) ( TRANS.R&F) TYPE () Q_ 62.3) (LONG R&F ) RESULTS. NOT APPLICABLE | VISUAL EXAMINATION RESULTS ( QW-302.4)_: SATISFACTORY DYE PENETRANT INSPECTION SATISFACTORY : MACRO EXAMINATION SATISFACTORY X 5 MAGNIFIED AL OF RADIOGRAPHIC TEST RESULTS ( QW-304 & QW-305 ) : NONE iP, AGE (FOR ALTERNATIVE QUALIFICATION OF GROOVE WELDS BY RADIOGRAPHY ) FILLET WELD FRACTURE TEST LENGTH AND PERCENT OF DEFECTS mm/in MACROTESTFUSION —_FILLETLEGSIZE mm/in X — mm/in CONCAVITY/ CONVEXITY mm/in WELDING TEST CONDUCED BY : ORION S.A. MECHANICAL TESTS CONDUCED BY : ORION 8.P.A. Laboratory No./ WE CERTIFY THAT THE STATEMENTS IN THIS RECORDS ARE CORRECT AND THAT THE TEST COUPONS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF THE ASME CODE. DATE : 29 JUNE 2007 BY: F. BRONZI Q.A. MgrORION S.p.A. Page Tot | ‘ ‘WELDING PROCEDURE SPECIFICATION | (WPS) QW-482 Prepared by: F.BRONZI QA Manager WELDING PROCEDURE SPECIFICATION No. 68 Rev.1 Date: 26-07-2007 SUPPORTING POR: 68 REV. No. 1 Date: 26-07-2007 WELDING PROCESS: _GMAW. TYPE: AUTOMATIC JOINTS (QW-402) Joint Design — See sketch Backing (Yes) ....[ ] (No) ....[X] Backing Material (Type) N.A. Metal [X] Nonmetallic [ ] ‘Nonfusing Metal [ ] Seatring SAI82 F316 Body SA A217 Gr.WC6 Other BASE METAL (QW-403) P-No. 4 Group.No. 1 To P-No. 8 GroupNo. 1 Or Specification type and grade - SA/A 217 Gr.WC6/WCSIWC4 To Specification type and grade- SA/ A 182 GrF316 (31600) Or Chem. Analysis and Mech. Prop - To Chem. Analysis and Mech. Prop — Thickness Range: Base Metal: Groove 4.8 -60 mm Fillet: All Pipe Dia. Range: N.A Groove 2 inch & Over Fillet: All Other: None FILLERMETAL —(QW-404) Spec.No. (SFA) A5.9 | AWS No. (Class) ER 309 LSI F-No. 6 ANo. 8 Size of Filler Metal 1.2mm | Sex ot Deposited Weld Metal e 4, © Thickness Range Corrosion resistant overlay NA. | e x Groove 60 mm MAX. | po Fillet ALL e Electrode ~ Flux (Class) NA. Electrode - Flux Trade Name SOGES - 309 LSI Consumable Insert NONE SOLID WIRE Other | Non Approved by: F.BRONZI Date 14-06-2005ORION S.p.A. | Pagez of WELDING PROCEDURE SPECIFICATION (WPS) _Qw-482 —__| - Prepared by: F.BRONZI QA Manager WELDING PROCEDURE SPECIFICATION No. 68 Rev. Date: 26-07-2007 SUPPORTING PQR: 68 Rev. No.1 Date: 26-07-2007 __ WELDING PROCESS:GMAW TYPE: AUTOMATIC | | POSITION (QW-405) POST WELD HEAT TREATMENT (QW-407) | Postion (5) of Groove: 1G - ROTATED TEMPERATURE RANGE: Not Applicable Welding Progression ‘Time Range: N.A. Uphill NAA. | Minimum: N.A. Minutes Max .N.A. Minutes Downhill: N.A. | Heating & Cooling Rate: N.A. Position (s) of Fillet: N.A. PREHEAT (QW-406) GAS (QW-408) Preheat Temp. Min. 20°C Percent Composition I pass Temp. Max.: N.A. Gas (es) (Mixture) Preheat Maintenance: N.A. Shielding: ( 98% ARGON + 2%02) (Continuous or special heating where applicable) | Flow Rate : 10-14 LITRES /MIN Trailing: None Backing: None ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC: DC Polarity: RP Amps (Range): 160 - 200 Volts (Range): 26 - 30 ‘Tungsten Electrode Size & Type: N.A. Mode of Metal Transfer for GMAW: PULSED ARC Electrode Wire feed speed range: 160 — 180 MILLIMETERS / MINUTES TECHNIQUE (QW-410) Weave Bead: String Orifice or Cup Size: 16 mm DIAMETER Interpass / Initial and Interpass Cleaning: brushing and/or grinding Method of Back Gouging: N.A. . lation: YES. e I Contact Tube to Work Distance: 12 ~ 14 mm Ab 0 Multiple or Single Pass (per side): Multiple GE Multiple or Single Electrodes: Single eh Travel Speed (Range) : N.A. Peening: not permitted Other: Weld | Process | Filler | Filler [ Current | Amp. | Volt | Travel Speed | Heat Input Layer Metal | Metal | AC/DC | Range | Range Range J/mm © Class | Diam. Type (|) | Gumiminy ___| _ poiarity 1 | GMAW /ER309LSI[ 12mm | DC/RP [160-200] 26-30 | 160-180 | Limited by 2 | GMAW |ER309LSI| 1.2mm | DC/RP |160-200| 26-30| 160-180 PQR 3 | GMAW |ER309LSI| 1.2mm | DC/RP |160-200| 26-30| 160-180 17379 n | GMAW |ER309LSI| 1.2mm | DC/RP |160-200| 26-30} 160-180 I/mm RFOUIRED TEST : \\_. TENSILE TEST 2. GUIDED SIDE BEND TEST 3. HARDNESS OF BASE MATERIALS & H.A.Z. (ACCORDING TO NACE MR-01-75 REQUIREMENTS )ORION S.p.A. Page Tf PROCEDURE QUALIFICATION RECORDS | (PQR) _QWw-483 _ | Prepared by: QA Manager PROCEDURE QUALIFICATION RECORDS No. 68 Rev.1 | WELDING PROCEDURE SPECIFICATION No. 68 Rev.1 WELDING PROCESS: GMAW TYPE: AUTOMATIC DETAILS | JOINTS ( QW-402) PAGE 15 OF At BASE METAL ( QW-403 ) POST WELD HEAT TREATMENT (QW-407) Material Specification : ASTM ‘Type or grade | Temperature 2 NA. P.No. 4 to P.No. 8 | Time : NA. Thickness of test coupon : 30mm Heating / Cooling rate DNA. Diameter of test coupon: N.A. Other Other: ‘GAS (QW-408 ) PERCENT COMPOSITION GAS (MIXTURE) Shielding : (98 % ARGON + 2%02) Flow rate: 11 LITRES / MIN Trailing : NONE Backing : NONE FILLER METAL ( QW-404) ELECTRICAL CHARACTERISTIC (QW-409) SFA Specification | aso Curent: DC AWS Classification ER309LSI- [Polarity — : RP FNo. 6 Amps 2 180 Weld metal analysis A-No. 8 Volts 2 28 Size of filler metal 1.2mm DIAM. | Tungsten electrode size : N.A. | Other: Other: | Travel speed range : 174 mm/min. | Heat input : 1737,9 J/mm | POSITION ( QW-405) TECHNIQUE (QW-410) Position of groove : 1G, ROTATED Travel speed NA. Weld progression ( uphill,downhill ) : N.A. String or weave bead : STRING | PREHEAT (QW-406) | Oscillation ‘YES |Pr“at Temperature: 20°C, Single or Multipass ( per side ) : MULTIPLE Ink..pass Temperature : N.A. Single or Multiple electrodes : SINGLE Other:ORION S.p.A. Page? of PROCEDURE QUALIFICATION RECORDS QR) _QW-483 Prepared by: QA Manager PROCEDURE QUALIFICATION RECORDS No. 68 Rev.1 WELDING PROCEDURE SPECIFICATION No. 68 Rev.1 WELDING PROCESS: GMAW L TYPE: AUTOMATIC TENSILE TEST (QW-150) SPECIMEN | WIDTH (mm) | THICKNE: AREA mm2 [ULTIMATE [ULTIMATE | TYPE OF No. (mm) TOTAL UNIT STRESS | FAILURE & | LOAD(N) | Nimm2 LOCATION es id | Outside weld 2 d 12.7mm 126.6 mm2 78239 618, Outside weld | | ( GUsDED BEND TEST (QW-160) _______TYPE & FIGURE No. — —__RESULTS SIDE BEND ~ QW-462.2 SATISFACTORY SIDE BEND ~ QW-462.2 SATISFACTORY, SIDE BEND ~ QW-462.2 SATISFACTORY SIDE BEND ~ QW-462.2 SATISFACTORY TOUGHNESS TEST ( QW-170) SPECIMEN | NOTCH ‘NOTCH TYPE | TEST IMPACT LATERAL [LATERAL No. LOCATION TEMPERATURE | VALUES (J) | EXPANSIONS | EXPANSIONS, JOULES % SHEAR _| MILS. NOT APPLICABLE FILLET WELD TEST (QW-180) RESULTS - SATISFACTORY YES[] NO[] _ PENETRATION INTOMETAL YES[] NO[] MACRO - RESULTS. OTHER TEST: VISUAL EXAMINATION = SATISFACTORY HARDNESS TEST= SATISFACTORY BASE METAL SA2I7WC6 _: ( 162-160-166 ) HB HAZ. (202 ~ 206 ~206 ) HB BASE METAL SA182GrF316 : (186-188-186) HB ‘NAME OF WELDER : STULLE STEFANO STAMP No.:/ TEST CONDUCED BY : ORION S.p.A. LABORATORY TEST No.: METALFAR S.A. WE CERTIFY THAT STATEMENTS IN THIS RECORDS ARE CORRECT AND THE TEST WELDS WERE PREPARED , WELDED AND TESTED IN ACCORDANCE WITH THE REQIREMENTS OF SECTION “IX” OF THE ASME CODE. DATE: 20 GIUGNO 2005 MANUFACTURER : ORION S.p.A. BY : FBRONZI QA. MjRECORD OF WELDER OR WELDING OPERATOR | | ORION S.p.A. ~ Page I of I | L | QUALIFICATION TEST { L (WPQ) QW-484 WELDER’S NAME : STULLE STEFANO. CLOCK No. STAMP No.:/ WELDING PROCESS (ES ) USED : GMAW TYPE : AUTOMATIC IDENTIFICATION OF WPS FOLLOWED BY WELDER DURING WELDING OF TEST COUPON : 68 Rev.1 BASE MATERIAL (S$) WELDED : SA/A 217 Gr.WC6 With SA/ A 182 Gr.F316 THICKNESS = 30 mm MANUAL OR SEMIAUTOMATIC VARIABLES. FOR EACH PROCESS ( QW-350 ) ‘ACTUAL VALUES RANGE QUALIFIED BACKING METAL,WELD METAL, WELDED FROM BOTH SIDES, FLUX, ECT. ( QW-402 ) ASMEP.No. 4 TO P.No. 8 (QW-403) []PLATE [X] PIPE (250mm ENTER DIAMETER ) FILLER METAL F-No, 6 6 FILLER METAL VARIETY Metal cored Metal cored CONSUMABLE INSERT FOR GTAW OR PAW NA. NA. WELD THICKNESS FOR EACH WELDING PROC. 30mm 60 mm,Max. to be welded WFDING POSITION (1G,5G,ECT. ) (QW-405 ) | 1G-ROTATED 1G- ROTATED |Pl_ 3RESSION ( UPHILL / DOWNHILL ) NA. NA. BACKING GAS FOR GTAW, PAW OR GMAW (QW-408)_| 98 % ARGON + 2% 02 98 % ARGON +2.% 02 | GMAW TRANSFER MODE : ( QW-409 ) PULSED ARC PULSED ARC GTAW WELDING CURRENT TYPE / POLARITY NA, NA MACHINE WELDING VARIABLES FOR THE PROCESS | ACTUAL VALUES [| RANGE QUALIFIED USED ( QW-360) | DIRECT / REMOTE VISUAL CONTROL DIRECT | DIRECT AUTOMATIC VOLTAGE CONTROL (GMAW ) YES | YES | AUTOMATIC JOINT TRACKING YES | YES WELDING POSITION (1G,5G,ECT.) 1G-ROTATED 1G-ROTATED CONSUMABLES INSERT NA. NA. | BACKING ( METAL, WELD METAL, WELDED FROM NA. NA. | BOTH SIDES, FLUX, ECT. GUIDED BEND TEST RESULTS GUIDED BEND TESTS TYPE ( X ) QW-462.2 ( SIDE ) RESULTS () QW-462.3 (a) (TRANS.R&F) TYPE () Q 162.3 (0) (LONG R&F ) RESULTS. __ SIDE BEND SATISFACTORY ‘SIDE BEND [SATISFACTORY —~SIDE BEND SATISFACTORY SIDE BEND SATISFACTORY — _[ VISUAL EXAMINATION RESULTS ( QW-302.4) : SATISFACTORY DYE PENETRANT INSPECTION NA. MACRO EXAMINATION NA RADIOGRAPHIC TEST RESULTS ( QW-304 & QW-305 ) : NONE. (FOR ALTERNATIVE QUALIFICATION OF GROOVE WELDS BY RADIOGRAPHY ) FILLET WELD FRACTURE TEST LENGTH AND PERCENT OF DEFECTS mm/in MACRO TESTFUSION —FILLETLEG SIZE mm/in X — mm/in CONCAVITY / CONVEXITY mm/in WELDING TEST CONDUCED BY ORION SP.A. MECHANICAL TESTS CONDUCED BY : METALFAR S.P.A. WE CERTIFY THAT THE STATEMENTS IN THIS RECORDS ARE CORRECT AND THAT THE TEST COUPONS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF THE ASME CODE. Do: BY: F.BRONZI Q.A. MgrORION S.p.A. eae soed RECORD OF WELDER OR WELDING OPERATOR QUALIFICATION TEST ( (WPQ) QW-484 WELDER’S NAME : UZZAL KHAN CLOCK No: STAMP No:/ WELDING PROCESS (ES) USED : GMAW TYPE: AUTOMATIC IDENTIFICATION OF WPS FOLLOWED BY WELDER DURING WELDING OF TEST COUPON : 68 Rev.1 BASE MATERIAL (S) WELDED: SA/A217Gr.WC6 With SA/ A 182 GrF316 ‘THICKNESS = 30 mm MANUAL OR SEMIAUTOMATIC VARIABLES FOR EACH PROCESS ( QW-350 ) BACKING METAL, WELD METAL, WELDED FROM BOTH SIDES, FLUX, ECT. ( QW-402 ) ASMEP.No. 4 TO PNo. 8 (QW-403) LJPLATE _[X] PIPE (250 mm ENTER DIAMETER ) FILLER METAL F-No, ‘ACTUAL VALUES | RANGE QUALIFIED 6 6 FILLER METAL VARIETY | Metal cored Metal cored CONSUMABLE INSERT FOR GTAW OR PAW NA. NA. WELD THICKNESS FOR EACH WELDING PROC. | 30 mm 60 mm,Max. to be welded WFDING POSITION ( 16, P(__3RESSION ( UPHILL / DOWNHILL ) | NA. NA. BACKING GAS FOR GTAW, PAW OR GMAW ( QW-408) | 98% ARGON +2.% 02 | 98% ARGON +2.% 02 GMAW TRANSFER MODE : ( QW-409 ) | PULSED ARC PULSED ARC GTAW WELDING CURRENT TYPE / POLARITY NA. NA | | | | JECT. ) ( QW-405 ) 1G- ROTATED | 1G- ROTATED | “MACHINE WELDING VARIABLES FOR THE PROCESS | ACTUAL VALUES | RANGE QUALIFIED USED ( QW-360) | DIRECT / REMOTE VISUAL CONTROL DIRECT DIRECT AUTOMATIC VOLTAGE CONTROL (GMAW ) YES | YES AUTOMATIC JOINT TRACKING YES YES WELDING POSITION (1G,5G,ECT.) 1G—ROTATED 1G -ROTATED (CONSUMABLES INSERT NA NA. BACKING ( METAL, WELD METAL, WELDED FROM. NA. NA. BOTH SIDES, FLUX, ECT. ) _ a | GUIDED BEND TEST RESULTS GUIDED BEND TESTS TYPE (X ) QW-462.2 ( SIDE ) RESULTS () QW-462.3 (a) (TRANS.R&F) TYPE () Q 162.3 (b) (LONG R&F ) RESULTS. E BEND. SATISFACTORY SIDE BEND SATISFACTORY SIDE BEND SATISFACTORY SIDE BEND ‘SATISFACTORY VISUAL EXAMINATION RESULTS ( QW-302.4)_: SATISFACTORY DYE PENETRANT INSPECTION NA. MACRO EXAMINATION NA. RADIOGRAPHIC TEST RESULTS ( QW-304 & QW-305 ) : SATISFACTORY (FOR ALTERNATIVE QUALIFICATION OF GROOVE WELDS BY RADIOGRAPHY ) FILLET WELD FRACTURE TEST LENGTH AND PERCENT OF DEFECTS munvin MACROTESTFUSION _FILLETLEGSIZE_ mm/in X — mm/in CONCAVITY / CONVEXITY min WELDING TEST CONDUCED BY : ORION S.P.A. MECHANICAL TESTS CONDUCED BY : METALFAR S.P.A. WE CERTIFY THAT THE STATEMENTS IN THIS RECORDS ARE CORRECT AND THAT THE TEST COUPONS WERE PREPARED,WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF THE ASME CODE. DATE : 06LUGLIO 2005ORION S.p.A. Page ofl | | RECORD OF WELDER OR WELDING OPERATOR | QUALIFICATION TEST | CWPQ) QW-484 WELDER’S NAME ; SCEK HENHET CLOCK No. STAMP No. WELDING PROCESS (ES ) USED : GMAW TYPE : AUTOMATIC IDENTIFICATION OF WPS FOLLOWED BY WELDER DURING WELDING OF TEST COUPON : 68 Rev.1 BASE MATERIAL (S) WELDED : SA/ A217 WC6 With SA/A 182 GrF316 ‘THICKNESS = 30 mm MANUAL OR SEMIAUTOMATIC VARIABLES. FOR EACH PROCESS ( QW-350) ‘ACTUAL VALUES RANGE QUALIFIED BACKING METAL,WELD METAL, WELDED FROM BOTH SIDES, FLUX, ECT. ( QW-402) ASMEP.No. 8 TO PNo. 8 (QW-403) []PLATE _[X] PIPE (250 mm ENTER DIAMETER ) FILLER METAL F-No. 6 6 FILLER METAL VARIETY Metal cored Metal cored CONSUMABLE INSERT FOR GTAW OR PAW NA, NA. WD THICKNESS FOR EACH WELDING PROC. 30mm 60 mm,Max. to be welded WEDING POSITION (1G,5G,ECT. ) (QW-405 ) 1G-ROTATED 1G- ROTATED PROGRESSION ( UPHILL / DOWNHILL ) NA. NA. BACKING GAS FOR GTAW, PAW OR GMAW (QW-408)_| 98 % ARGON +2%02 | 98 % ARGON +2% 02 GMAW TRANSFER MODE : ( QW-409) PULSED ARC PULSED ARC GTAW WELDING CURRENT TYPE / POLARITY NA, NA MACHINE WELDING VARIABLES FOR THE PROCESS | ACTUAL VALUES | RANGE QUALIFIED USED ( QW-360) DIRECT / REMOTE VISUAL CONTROL DIRECT DIRECT AUTOMATIC VOLTAGE CONTROL (GMAW ) YES YES AUTOMATIC JOINT TRACKING YES YES WELDING POSITION (1G,5G,ECT.) 1G—ROTATED 1G-ROTATED CONSUMABLES INSERT NA. NA. BACKING ( METAL, WELD METAL,WELDED FROM, NA. NA. BOTH SIDES, FLUX, ECT. ) G ED BEND TEST RESULTS GU.WED BEND TESTS TYPE (X ) QW-462.2 ( SIDE ) RESULTS () QW-462.3 (a) (TRANS.R&F) TYPE () QW-462.3 (b) (LONG R&F ) RESULTS. SATISFACTORY _ SIDE BEND SATI ‘ORY SATISFACTORY SIDE BEND SATISFACTORY VISUAL EXAMINATION RESULTS ( QW-302.4) : SATISFACTORY DYE PENETRANT INSPECTION NA MACRO EXAMINATION NA. RADIOGRAPHIC TEST RESULTS ( QW-304 & QW-305 ) : SATISFACTORY. (FOR ALTERNATIVE QUALIFICATION OF GROOVE WELDS BY RADIOGRAPHY ) FILLET WELD FRACTURE TEST LENGTH AND PERCENT OF DEFECTS mm/in MACROTESTFUSION —-FILLETLEGSIZE = mm/fin X — mm/in CONCAVITY/ CONVEXITY mmv/in WELDING TEST CONDUCED BY : ORION S.A. MECHANICAL TESTS CONDUCED BY : METALFAR S.P.A. WE CERTIFY THAT THE STATEMENTS IN THIS RECORDS ARE CORRECT AND THAT THE TEST COUPONS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF THE ASME met DATE : 06 LUGLIO 2005 BY: F.BRONZI_ Q.A. Mgr PAGE A OF AY E>orton INDEX OF WPS Pag 4 dil ‘TRIESTE ~ ITALY Data: 15/11/2007 WPS | BASE PROCESS |APPLICATION PQR NUMBER | MATERIAL NUMBER 69 rev.0 A494 CY-40 C1.2 SMAW Major repairs 69 rev.0 and Fillet 70 rev.0 A494 CUSMCuC SMAW Major repairs 70 rev.0 _ ee ___|__and Fillet | Eurosald INCOLOY 825 PAW Overlay on ES 02/2007 ES 02/2007 wedge and rev.0 rev.0 seats Eurosald INCONEL 625 PAW Overlay on ES 01/2007 ES 01/2007 wedge and rev.0 [revo | | “seats Cy 65 Rev.1 INCONEL 600 GMAW Overlay on 65 Rev.1 | wedge and l seats DICE DELLE REVISIONI / REVISION INDEX ISSUED VERIFIED | APPROVED REV. |DATE OGGETTO / SUBJECT BGO RCO. 0 | 1511/2007 |IsSUE~Pagelof2 | EUROSALD S.n.c. WELDING PROCEDURE SPECIFICATION (WPS) _Qw-482 Prepared by: QA Manager WPS No. ES 01/2007 _ Rev. 0 Date: 17/07/2007 SUPPORTING BY PQR No. ES 01A/2007 Rev. 0 Date: 17/07/2007 WELDING PROCESS: PAW ‘TYPE: MACHINE, JOINTS (QW-402) Joint Design — See sketch Backing (Yes) ....[ ] (No) ‘Backing Material (Type) N.A. Metal [X] Non metallic {_] [X] Non fusing Metal [J Other THICKNESS OF HARDFACING OVERLAY TO BE QUALIFIED : 2 mm & over DIAMETER 270 +- 5mm 2mm DEPOSITED OVERLAY sminimum SComonny Layer BASE METAL (QW-403) P-No. 43 Group. No. Specification type and grade - ‘To Specification type and grade - Chem. Analysis and Mech. Prop - To Thickness Range: Base Metal: Pipe Dia. Range: N.A Other: None Groove Groove To Or UNS N06600 - NO6625 — ASME/ASTM A494 Gr.CY-40 C12 COLMONOY 42 P-No. NAA. Group No. N.A. Or UNS NO06600 - N06625 ~ ASME/ASTM A494 Gr.CY-40 C12 Chem. Analysis and Mech. Prop COLMONOY 42 Fillet: N.A. Fillet: : 1” To Unlimited NA FILLER METAL Spee. No. (SFA) AWS No. (Class) F-No. ANo. Size of Filler Metal Deposited Weld Metal Thickness Range Hardfacing overlay Groove Fillet Electrode ~ Flux (Class) Electrode ~ Flux Trade Name Consumable Insert Other : Deposited Weld Metal (QW-404) 5.21 Colmonoy 42 / / 50-150 Micron 2 mm & over Colmonoy 42 Colmonoy 2mm minimum Notes: PAGE Qf OF 25EURCSAD orouwesuusrnu WELDING PROCEDURE SPECIFICATION EUROSALD S.n.c. Page 20f2 (WPS)_QW-482__ Prepared by: QA Manager WPS No. ES 01/2007 Rev. 0 Date: 17/07/2007 SUPPORTING BY PQR No. ES 01/2007 Rev. 0 Dat 1/07/2007 WELDING PROCESS: PAW_ TYPE: MACHINE Welding Progression Uphill: NAL Downhill: N.A. Position (s) of Fillet: POSITION (QW-405) | Minimum: N.A. -Max. N.A. Minutes Heating & Cooling Rate: N.A. NA. POST WELD HEAT TREATMENT (QW-407) Postion (s) of Groove: 1G - FLAT | TEMPERATURE RANGE: | Time Range: N.A. Hours / Inch Thickness PREHEAT (QW-406) GAS (QW-408) Preheat Temp. Min.: 50°C Percent Composition Interpass Temp. Max.: 200°C Gas (es) (Mixture) Flow Rate Preheat Maintenance: Preheat has been maintained | Shielding: ARGON 99,99% 0,5 Litre/Min Trailing: None Electrode Wire feed Orifice or Cup Size’ Oscillation: 18 mm Multiple or Single E! ‘Tungsten Electrode Size & Type: N.A. Mode of Metal Transfer for GMAW: N.A. speed range: N.A. TECHNIQUE (QW-410) Weave Bead: WEAVE NA. Interpass / Initial and Interpass Cleaning: brushing and/or grinding Method of Back Gouging: Contact Tube to Work Distance: 8 mm ‘Multiple or Single Pass (per side): SINGLE, ectrodes: SINGLE ‘Travel Speed (Range) : 50-60 mm/minute Peening: not permitted Backin; None ELECTRICAL CHARACTERISTICS (QW-409) | Current AC or DC: DC Polarity: RP | ‘Amps (Range): 95-110 Volts (Range): 26 - 28 Process | Filler | Filler ‘Current ‘Amp. Volt | Travel Speed | Heat Input Metal | Metal | AC/DC | Range | Range Range I} mm Class | Diam, Type (A) | (VY) | Gnminin) polarity PAW | Colmonoy | 50-150 DC? 27-—-| 95-110 50-60 3092.7 | 42 | Micron | Reverse Limited by | PQR REQUIRED TEST : a 1. PT EXAM. ON OVERLAY AS PER ORION PROC. L002 ~ NO DEFECTS ALLOWED 2. VISUAL & MACRO EXAM. WITH 5X MAGNIFICATION on ETCHED SURFACE. 3. NO CRACKS, LACK OF FUSION OR OTHER LINEAR DEFECTS ARE ALLOWED ON BASE, METAL AND HEAT A. ZONE. 4, HARDNESS TEST : HV 10 5. DEPOSITED ANALISYS : % PAGE 19 OF AEUROSALD S. Page 10f2 PROCEDURE QUALIFICATION RECORDS | I QR) __QW-483 __ Prepared by: QA Manager PQR No. ES 01A/2007 Rev. 0 Date: 17/07/2007 WPS No. ES 01/2007 Rev.0 Date: 17/07/2007 Ce WELDING PROCESS: PAW. TYPE: MACHINE, DETAILS soameney 2 Layer ‘CHEACAL ANALYSS at 2m FROM FUSONLINE INCONEL 625 JOINTS ( QW-402 ) QUALIFIED THICKNESS : 2.0 mm minimum of COLMONOY 42 BASE METAL ( QW-403) ‘POST WELD HEST TREATMENT ( QW-407) Material Specification : UNS N06600 - NO6625 —| ASME/ASTM A494 Gr. CY-40 C12 _ | Temperature : NONE ‘Type or grade N06625 Time : NONE P.No. 43 to P.No./ Heating / Cooling rate : NONE Thickness of test coupon : 26 mm Other: Diameter of test coupon. : 270 mm GAS (QW-408) Other: PERCENT COMPOSITION GAS (MIXTURE) FLOW RATE | Shielding: ARGON 99,99% 0,5 Litre / Minute | ‘Trailing -NONE C Backing :NONE _ FILLER METAL ( QW-404) ELECTRICAL CHARACTERISTIC (QW-409) SFA Specification 521 Current: DC AWS Classification Colmonoy 42 | Polarity REVERSE | F-No. ! ‘Amps 105 Weld metal analysis A-No. / Volts 27 Size of filler metal 50-150 Micron | Tungsten electrode size : 4 mm | Other: | Other: Heat input : 3092,7 Joule / mm POSITION ( QW-405) "TECHNIQUE ( QW-410) Position of groove : 1G - FLAT ‘Travel speed 55 mm/minute Weld progression ( uphill,downhill ) :N.A. String or weave bead : WEAVE PREHEAT (QW-406) ~~~ Oscillation 18 mm Preheat Temp. Min.: 50°C | Single or Multipass ( per side ) : SINGLI | Interpass Temp. Max.: 200°C | Single or Multiple electrodes: SINGLI ("Preheat Maintenance: Preheat has been maintained | Il PAGEQS OF 207EUROSALD S.n.c. 7 Page 2 0f2 EURSSALN | PROCEDURE QUALIFICATION RECORDS | womoursau een (PQR)_QW-483 Prepared by: QA Manager PQRNo. ES 01A/2007 Rev.0 Date: 17/07/2007 WPS No. ES 01/2007 Rev.0 Date: 17/07/2007 'S: PAW, ‘TYPE: MACHINE, WELDING PROC TENSILE TEST ( QW-150) SPECIMEN |WIDTH (mm) ]THICKNESS [AREAmm2 [ULTIMATE [ULTIMATE [TYPE OF No. (mm y TOTAL UNIT STRESS | FAILURE & LOAD(N) | Nimm2 LOCATION GUIDED BEND TEST (QW-160) TYPE & FIGURE No. TOUGHNESS TEST ( QW-170) SPECIMEN [NOTCH NOTCH [TEST “JIMPACT [LATERAL |LATEI No. LOCATION | TYPE | TEMPERATURE | VALUES (J) | EXPANSIONS | EXPANSIONS of JOULES —_|%SHEAR |Mms. | FILLET WELD TEST (QW-180) RESULTS—SATISFACTORY —-YES[] NO[] _ PENETRATION INTO METAL YES [] NO[] MACRO — RESULTS : SATIFACTORY, VISUAL EXAMINATION x 5 MAGNIFICATION, SATISFACTORY, SEE QUALITY CONTROL S.r.l. TEST REPORT NUMBER 1265RP101/07 OTHER TEST DEPOSITED ANALISYS %: SEE QUALITY CONTROL Srl. TEST REPORT NUMBER 1265RP101/07 CHEMICAL ANALYSIS PERFORMED At (2 & 1,6) mm from Fusion Line HARDNESS TEST = SATISFACTORY, SEE QUALITY CONTROL S.rl. TEST REPORT NUMBER 1265RP101/07 LIQUID PENETRANT TEST = SATISFACTORY ‘NAME OF WELDER: QUISINI IVAN STAMP No.: QL TEST CONDUCED BY : EUROSALD S.n. LABORATORY : QUALITY CONTROL S.r WE CERTIFY THAT STATEMENTS IN THIS RECORDS ARE CORRECT AND THE TEST WELDS WERE PREPARED , WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF ‘THE ASME CODE. DATE : 17/07/2007 MANUFACTURER : EUROSALD S.n.c. ISSUED BY : QUISINIIVANEUROSALD S.n.c. pose loel RECORD OF WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION CWPQ) QW-484 WELDER’S NAME : QUISINIIVAN CLOCK No.7 STAMP No: OF WELDING PROCESS (ES ) USED : PAW TYPE : MACHINE IDENTIFICATION OF WPS FOLLOWED BY WELDER DURING WELDING OF TEST COUPON: ES 01/2007 rev.0 BASE MATERIAL ($ ) WELDED : UNS N06625 Overlayed with COLMONOY 42 ‘THICKNESS = (26mm ) MANUAL OR SEMIAUTOMATIC VARIABLES FOR EACH PROCESS ( QW-350 ) BACKING METAL,WELD METAL, WELDED FROM BOTH SIDES, FLUX, ECT. ( QW-402) ASME P.No. 43 TO P.No. / ( QW-403) [X] PLATE [ ] PIPE FILLER METAL VARIETY CONSUMABLE INSERT FOR GTAW OR PAW WELD THICKNESS FOR EACH WELDING PROC. WEDING POSITION ( 1G,5G,ECT. ) (QW-405 ) PROGRESSION ( UPHILL / DOWNHILL ) BACKING GAS FOR GTAW, PAW OR GMAW ( QW-408 ) GMAW TRANSFER MODE : ( QW-409 ) PAW WELDING CURRENT TYPE / POLARITY ‘MACHINE WELDING VARIABLES FOR THE PROCESS USED ( QW-360) DIRECT / REMOTE VISUAL CONTROL. AUTOMATIC VOLTAGE CONTROL (PAW) AUTOMATIC JOINT TRACKING WELDING POSITION (16,5G,ECT.) CONSUMABLES INSERT BACKING ( METAL, WELD METAL, WELDED FROM BOTH SIDES, FLUX, ECT.) - GUIDED BEND TEST RESULTS GUIDED BEND TESTS TYPE ( ) QW-462.2 ( SIDE ) RESUL’ QW-462.3 (b) (LONG R&F ) RESULTS. ACTUAL VALUES | RANGE QUALIFIED COLMONOY 42 COLMONOY 42 I / 2mm 2mm & OVER IG-FLAT 1G-FLAT N. NA. ARGON 99,99% ARGON 99,99% DIRECT DIRECT YES YES YES ‘YES | 1G 1G TUNGSTEN TUNGSTEN NA. NA. TS () QW-462.3 (a) (TRANS.R&F) TYPE () NOT APPLICABLE NOT APPLICABLE. VISUAL EXAMINATION RESULTS ( QW-302.4)_: SATISFACTORY, QUALITY CONTROL S.r1 TEST REPORT NUMBER 1265RP101/07 DYE PENETRANT INSPECTION MACRO EXAMINATION SATISF, SATISFACTORY ‘ACTORY, QUALITY CONTROL rh TEST REPORT NUMBER 1265RP101/07 RADIOGRAPHIC TEST RESULTS ( QW-304 & QW-305 ): N (FOR ALTERNATIVE QUALIFICATION OF GROOVE WELI FILLET WELD FRACTURE TEST MACRO TESTFUSION —FILLETLEG SIZE mm/in WELDING TEST CONDUCED BY LENGTH AND PERCENT OF DEFECTS (ONE DS BY RADIOGRAPHY ) main xX mm/in CONCAVITY /CONVEXITY mm/in MECHANICAL TESTS CONDUCED BY : QUALITY CONTROL S.r1. WE CERTIFY THAT THE STATEMENTS IN THIS RECORDS 1S ARE CORRECT AND THAT THE TEST COUPONS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF SECTION “IX” OF THE ASME CODE. DATE : 17/07/2007 MANUFACTURER : EUROSALD S.n.c. ISSUED BY : QUISINIIVAN PRE OTE)a EUROSALD S.n.c. f EUROSAAD WELDING PROCEDURE SPECIFICATION | sates (WPS) _QW-482 | BROTOWERWUSESKI Prepared by: QA Manager WPS No. ES 02/2007 Rev. 0 Date: 02/10/2007 wacucaaee | SUPPORTING BY PQR No. ES 02A/2007 Rev. 0 Date: 02/10/2007 s WELDING PROCESS: PAW ___ TYPE: MACHINE JOINTS (QW-402) Joint Design — See sketch : DIAMETER 270 + Smm Backing (Yes) ...{ ] (No) ....X] 2mm DEPOSITED OVERLAY minimum Backing Material (Type) N.A. Metal [ X] Non metallic [ ] Laver Xcolmenoy 2 ‘Non fusing Metal [] Other THICKNESS OF HARDFACING OVERLAY TO BE QUALIFIED 2mm & over BASE METAL (QW-403) P-No. 45 Group. No. To P-No. NA. Group No. N.A. Or Specification type and grade - UNS N08825 ~ ASME/ASTM A494 Gr.CUSMCuC To Specification type and grade- _ COLMONOY 42 | Or ‘Chem, Analysis and Mech. Prop - UNS NO8825 — ASME/ASTM A494 Gr.CUSMCuC |To ‘Chem. Analysis and Mech. Prop ~ COLMONOY 42 | Thickness Range: | Base Metal: Groove: 1” To Unlimited Fillet: N.A. | Pipe Dia. Range: N.A Groove NA Fillet | Other: None FILLER METAL — (QW-404) Spec. No. (SFA) 5.21 AWS No. (Class) Colmonoy 42 F-No, / ANo. / Size of Filler Metal 50-150 Micron Deposited Weld Metal Thickness Range Hard facing overlay 2 mm & over Groove | Fillet | Electrode — Flux (Class) Colmonoy 42 | Electrode — Flux Trade Name Colmonoy Consumable Insert Other : Deposited Weld Metal 2mm minimum (Notes: PAGE 260F Jt Date:02-10-2007ovo ae sou I WPS) QW-482 | Prepared by: QA Manager WPS No. EUROSALD S.n.c. Page? of 2 ‘WELDING PROCEDURE SPECIFICATION 12/2007 Rev. 0 Date: 02/10/2007 SUPPORTING BY PQR No. ES 02/2007 Rev. 0 Date: 02/10/2007 WELDING PROCESS: PAW TYPE: MACHINE, POSITION (QW-405) POST WELD HEAT TREATMENT (QW-407) Position (s) of Groove: 1G - FLAT TEMPERATURE RANGE: Welding Progression ie Range: N.A. Hours / Inch Thickness Uphill NA. Minimum: N.A. — Max. N.A. Minutes Downhill: N.A. Heating & Cooling Rate: N.A. Position (s) of Fillet: N.A. _ | PREHEAT (QW-406) GAS (QW-408) | Preheat Temp. Min.: 50°C Percent Composition |Interpass Temp. Max.: 200°C Gas (es) (Mixture) Flow Rate Preheat Maintenance: Preheat has been maintained | Shielding: ARGON 99,99% 0,5 Litre/Min Trailing: None Backing: None Current AC of DC: Amps (Range): be ELECTRICAL CHARACTERISTICS (QW-409) Polarity: RP 95-110 Volts (Range): 26 - 28 ‘Tungsten Electrode Size & Type: N.A. Mode of Metal Transfer for GMAW: N.A. Electrode Wire feed speed range: N.A. | Ori ice or Cup Size: Oscillation: 18 mm Multiple or TECHNIQUE (QW-410) Weave Bead: WEAVE NA Inter pass / Initial and Inter pass Cleaning: brushing and/or grinding Method of Back Gouging: Contact Tube to Work Distance: 8 mm le or Single Pass (per side): SINGLE ile Electrodes: SINGLE Travel Speed (Range) : 50 - 60 mm/minute not permitted Other: : Weld | Process Filler | Curent | Amp. | Voit | Travel Speed | Heat Input | Layer Metal | Metal | AC/DC | Range | Range | — Range Jimm | () Class | Diam. Type (A) |) | Gnm/miny _ _ polarity T Coimonoy | 50-150 | DC/ 27 | 95-110 30-60 30927 | 42 Micron | Reverse Limited by | PQR | REQUIRED TEST : 1. PT EXAM. ON OVERLAY AS PER ORION PROC. L002 —NO DEFECTS ALLOWED 2. VISUAL & MACRO EXAM. WITH 5X MAGNIFICATION on ETCHED SURFACE. 3. NO CRACKS, LACK OF FUSION OR OTHER LINEAR DEFECTS ALLOWED ON BASE METAL AND HEAT A. ZONE. 4, HARDNESS TEST : HV 10 5. DEPOSITED ANALISYS :% [PAGE 24 OF 4¢