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QW - 483 PROCEDURE QUALIFICATION RECORD (PQR)
Procedure Qualification Record No.: 007 - 2005 WPS No.: 304-1 Rev. 3 + 003-1 Rev.6 Welding Process(es): FCAW+SMAW Type (Manual, Automatic, Semi-Auto): MANUAL JOINTS: (QW-402)
I

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THERMAX

J
Date: 05.04.2005

3 -4 mm. Root Face 0 1 mm. IncludedAngle - 600

Root Gap

~
.

)~-L[~~
) 1?~

BASE METALS (QW-403)

Material Spec. : SA 516 to SA 516 Type or Grade: Gr.70 to Gr.70 P. No. -1Gr. 2 to P.No. --1-Gr.-L Thickness of Test Coupon (mm) : 50 Dia. of Test coupon (mm): Nil Others: None

POST WELD HEAT TREATMENT Temperature C : ====

(QW-407)

Time: Others:

====

GAS: (QW-408) Gas(es)

%
Composition Mixture
SG-C

Flow
rate lit/min -

FILLER METALS: (QW-404) Process FCAW SMAW

Shielding Trailing Backing CO2 None None

as per

SFA- 5.32

18-20

Weld Metal Analysis A.No. 1 1 Size of Filler Metal mm 0 1.2 4 ~-iller Metal F.No. 6 4 -6FA Specification 5.20 5.1 AWS Specification E71T-1 E7018 Deposited Weld Metal (mm) 25 25 Pass Thickness(mm) 4 Max. 4 Max. Others: I) No addition of supplementary filler metal & Alloy Elements for FCAW. ii) Product form: Flux Cored for FCAW
I

POSITION :(QW-405)

ELECTRICAL CHARACTERISTICS:(QW-409) Current: DC Polarity: EP Amps: 160-180 for FCAW Volts 26-28 160-170 for SMAW - Volts: 23-24 Tungsten Electrode Type & Size: Not Applicable Others:TY"o"l'\sf'e'l M~dl. ~&\0 TECHNIQUE: (QW-410) Travel Speed (mm/min.):
For FCAW : 80-90 For SMAW: 55-60 String or Weave Bead: Strinq & Weave Oscillation:. Nil Single pass/ Multipass: Multipass Single/Multiple Electrode: Sinqle Others: Weavinq for SMAW 12mm Max. (3 times of Core Diameter of electrode.)

I I

Position of Groove: Welding Progression: Others: PREHEAT :(QW-406) Preheat Temp. (Min.) C : pass Temp. (Max.) C : Others: [Inter .

~
UQhili

(100) 250

Nil -

<>

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Specimen No. TT 1 Top TT 2 Top TT 1 Bottom TT 2 Bottom Width (mm) 19.30 19.02 18.90 19.28 QW 483 TENSILE TEST (QW-150) Area Ultimate Tensile Thickness load (ka.) (mm2) (mm) 31400 507.97 26.32 32000 525.52 27.63 31400 496.31 26.26 33200 506.67 26.28 PQR No. 007-2005 UTS (kg/mm2) 61.81 60.89 63.26 65.52
. -

THERMAX

Type of failure and location Ductile In PM Ductile In PM Ductile In PM Ductile In PM

.
,..-;;:; -...;

GUIDED BEND TESTS (QW160) Tvpe and Figure No. Side Bend QW-462.2 SB1
Side Bend QW-462.2 Side Bend QW-462.2 Side Bend QW-462.2 SB2 SB3 SB4

Results
Satisfactory Satisfactory Satisfactory Satisfactory

Specimen No.

Notch location

Notch

TOUGHNESS TESTS (QW 170) None Test Lateral Exp. Ava. Impact % Shear Mils Value Joules Temp. C Type

Drop Weiaht No Break Break

FILLET WELD TEST (QW 180) None Result: Not Applicable Macro Results: Micro:
/""

----None --

""'"

Type of Test:

Deposit Analysis: Others: Welder's Name: Test Conducted by:

OTHER TESTS Hardness (Hv-l 0) Weld: Top: 170.179,188 Middle 185,184,187 Bottom: 194.186.179 HAZ: Top: 160.159.157 Middle: 164.163.162 Bottom: 160.160.152 Parent Material-167. 157, 160 None Macro Test Satisfactorv. M. H. Ansari Weldinq Enqq Dept. T.No.: A2932 Stamp No.: WB 01 Lab Test No.: 226 dtd. 31.03.2005

We certify that the statements in this record are correct and that the test welds were prepared welded & tested in accordance with the requirement of ASME Sect.lX edition 2004. Test Witness By.: Vikas Neerai of

c-

Date: 05.04.2005

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cturer: THERMAXLTD. S

-..'V '-" e]L lloyd', Rcgist

AUDITED BY : S. A. VANCHINATH

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;...... By : V. K. SHENDRIKAR

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"""""

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QW - 483 PROCEDURE QUALIFICATION RECORD (PQR)

Procedure Qualification Record No.: 001 - 2005 WPS No.: 201-1 Rev. 5 Welding Process(es): GTAW Type (Manual, Automatic, Semi-Auto): MANUAL ,
I

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Date: 18.02.2005

THERMAX

JOINTS: (QW-402)

\(
RootGap RootFace2-3mm.
0 - 1.5 mm. IncludedAngle - 65 - 70

!6

mm

BASE METALS (QW-403) Material Spec. : SA 516 to SA 516 Type or Grade: r.70 to Gr.70

POST WELD HEAT TREATMENT

(QW-407) Nil -

TemperatureC: =
Time:

P. ,'-10. ....1.- Gr.

to P.No.-1-

Gr.

Others:

--------

--------

Thickness of Test Coupon (mm) : 16 Dia. of Test coupon (mm): Nil. Others: None

GAS: (QW-408)
% FILLER METALS: (QW-404)
I

Gas(es)

Composition

Mixture

Flow rate lit/rnin ---

Process Weld Metal Analysis A.No. Size of Filler Metal mm 0

--"'"

GTAW 1 2
6

Shielding GTAW Trailing Backing

Argon None None

As per SFA 5.32

10-11

----

-------,-

----

Filler Metal F.No.

SFA Specification . AWS Specification Deposited Weld Metal (mm) Pass Thickness(mm) Others
I

5.18 ER 70S-2 16 3 Max. No addition of flux to The face of weld joint

--. ELECTRICAL CHARACTERISTICS:(QW-409) Current: DC EN Polarity: 140-150 Volts N.A Amps: Tungsten Electrode Type & Size: EWTh-2. .,])2.4 Others: Nil TECHNIQUE: (QW-410) Travel Speed: String or Weave Bead: Oscillation: . I Single pass/ Multipass:

POSITION :(QW-405) Position of Groove: Welding Progression: Others: PREHEAT :(QW-406)

----StrinQ & Weave Nil Multipass SinQle

---------------

I Single/Multiple
Others:

Electrode:

PreheatTemp.(Min.)C : Interpass Temp.(Max.)C : Others:

RT (28) 250

Nil

Nil." -.I

'4'"> \( ...."' "...

; \.~ ,'& '-

I ~ I I ~

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,
Specimen No. Trans. Tensile 1 Trans. Tensile 2 Width (mm) 19.40 19.33 QW 483 TENSILE TEST (QW-150) Thickness Area Ultimate Tensile (mm2) load (ka.) (mm) 15.97 309.82 19800 311.02 16.09 19800 PQR No. 001-2005 UTS (kg/mm2) 63.91 63.66 Type of failure and location Ductile In PilJl Ductile In PM GUIDED BEND TESTS (QW 160) Type Face Bend Face Bend Root Bend Root Bend and FiQureNo. QW-462.3 (a) QW-462.3 (a) QW-462.3 (a) QW-462.3 (a) FB1 FB2 RB1 RB2 Results Satisfattory Satisfactory Satisfactory Satisfactory

THERMAX

..-

Specimen No. 1-3

1-3

Notch location
weld HAZ

Notch Type

TOUGHNESS TESTS (QW 170) Test Ava. Impact Lateral Exp. Mils Temp. C Value Joules % Shear
-29 110 28

Drop Weiaht Break No Break -

-29 Charpy

FILLET WELD TEST (QW 180) Result: Satisfactory Macro Results: Micro: Yes/No. None None

None

--

...... ..

i"ype of Test: Deposit Analysis: Others: Welder's Name: Test Conducted by:

OTHER TESTS Hardness (Hv10). Weld - 194, 198,186. Parent Material - 176,181,171. None
Macro

HAZ-199,197,185.

-Satisfactory

...-

M. H. Ansari WeldinQ EnQQDept.

T.No.: A2932 Stamp No.: WB01 Lab Test No.: 199 dtd. 10.02.2005

We certify that the statements in this record are correct and that the test welds were prepared welded & tested in accordance with the requirement of ASME SecUX edition 2004. Test Witness By.: Vikas Neerai of Date: 18.02.2005 LRS Manufacturer: THERMAX LTD.

AUDITED

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QW - 483 PROCEDURE QUALIFICATION RECORD (PQR)

Procedure QualificationRecordNo.: 005- 2004 201-1Rev.4 WPS No.:WeldingProcess(es): GTAW Type(Manual,Automatic,Semi-Auto): MANUAL JOINTS: (QW-402)

,r

THERMAX

Date: 14.05.2004

-~

+
3.0 to 3.5 mm. Root Gap ---RootFace--- 0 to 1mm. Included Angle- 70-75

\(

E74

mm

BASE METALS (QW-403) Material Spec.: SA 106 to SA 106 Type or Grade: Gr.B to Gr.B P No 1 Gr.Ato P.No. --L- Gr. .1.. 8.74 Thickness of Test Coupon (mm): Dia. of Test coupon (mm): 60.3. None Others:

POST WELD HEAT TREATMENT(QW-407) Nil Temperature DC: ------------------Time: ---------Others:

GAS: (QW-408)
% Gas(es) FILLER METALS: (QW-404) Process GTAW 1 2 6 5.18 ER 70S-2 8.74 3 Max. No addition of flux to The face of weld joint Shielding GTAW Trailing Backing Argon None None
Composition

Mixture As per SFA 5.32

Flow rate lit/min 8-10

r-...

Weld Metal Analysis A.No. Size of Filler Metal mm 0 Filler Metal F.No. SFA Specification AWS Specification Deposited Weld Metal (mm) Pass Thickness(mm) Others

----

----

ELECTRICAL CHARACTERISTICS:(QW-409) Current: DC EN Polarity: 100-120 N.A Volts Amps: Tungsten Electrode Type & Size: EWTh-2. g,2.j Others: Nil TECHNIQUE: (QW-410) Travel Speed: String or Weave Bead: Oscillation: Single pass/ Multipass Single/Multiple Electrode: Others:

POSITION :(QW-405) 1G Position of Groove: -----Welding Progression: --------Others: PREHEAT :(QW-406) Preheat Temp. DC: Interpass Temp. DC: Others:

----Strinq & Weave

WL
Multipass Sinqle Nil

_/

RT (39)
250 Nil 0 t-4.J-

JEj'cY.... ,

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Specimen No. TT-1 TT-2
19.35

THERMAX

QW 483 TENSILE TEST (QW-150) Area Ultimate Tensile mm2 load k . 159.00 7850 8.79 170.09 8250

PQR No. 005-2004

48.52

."""

Results Satisfacto Satisfacto Satisfacto Satisfacto

Specimen No.

Notch location

Notch Type

Dro Break

FILLET WELD TEST (QW 180)

~

None

Result: Satisfactory Macro Results: Micro: Type of Test: Deposit Analysis: Others: Welder's Name: Test Conducted by:

Yes/No. None None OTHER TESTS Hardness (Hv). Weld 180. 189. 199. HAZ- 193. 191. 186. Parent Material-197. 194. 193. None

M.H.Ansari Weldin!:! Ena!:! DeDI.

T.No.: A2932 Stamp No.: WB 01 Lab Test No.: 27 dtd. 14.05.2004

We certify that the statements in this record are correct and that the test welds were prepared welded & tested in accordance with the requirement of ASME SecUX edition 2001 including addenda 03. Test Witness By.: Surveyor of LRA Date: 14.05.20L\cturer: THERMAX LTD.

AUDITED BY : SA VANCHINATH

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By : A.H.Jadhav

-r

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QW - 483 PROCEDURE QUALIFICATION RECORD (PQR)
Procedure Qualification Record No.: 007 - 2005 WPS No.: 304-1 Rev. 3 + 003-1 Rev.6 Welding Process(es): FCAW+SMAW Type (Manual, Automatic, Semi-Auto): MANUAL JOINTS: (QW-402)
I

,r
THERMAX

J
Date: 05.04.2005

3 -4 mm. Root Face 0 1 mm. IncludedAngle - 600

Root Gap

~
.

)~-L[~~
) 1?~

BASE METALS (QW-403)

Material Spec. : SA 516 to SA 516 Type or Grade: Gr.70 to Gr.70 P. No. -1Gr. 2 to P.No. --1-Gr.-L Thickness of Test Coupon (mm) : 50 Dia. of Test coupon (mm): Nil Others: None

POST WELD HEAT TREATMENT Temperature C : ====

(QW-407)

Time: Others:

====

GAS: (QW-408) Gas(es)

%
Composition Mixture
SG-C

Flow
rate lit/min -

FILLER METALS: (QW-404) Process FCAW SMAW

Shielding Trailing Backing CO2 None None

as per

SFA- 5.32

18-20

Weld Metal Analysis A.No. 1 1 Size of Filler Metal mm 0 1.2 4 ~-iller Metal F.No. 6 4 -6FA Specification 5.20 5.1 AWS Specification E71T-1 E7018 Deposited Weld Metal (mm) 25 25 Pass Thickness(mm) 4 Max. 4 Max. Others: I) No addition of supplementary filler metal & Alloy Elements for FCAW. ii) Product form: Flux Cored for FCAW
I

POSITION :(QW-405)

ELECTRICAL CHARACTERISTICS:(QW-409) Current: DC Polarity: EP Amps: 160-180 for FCAW Volts 26-28 160-170 for SMAW - Volts: 23-24 Tungsten Electrode Type & Size: Not Applicable Others:TY"o"l'\sf'e'l M~dl. ~&\0 TECHNIQUE: (QW-410) Travel Speed (mm/min.):
For FCAW : 80-90 For SMAW: 55-60 String or Weave Bead: Strinq & Weave Oscillation:. Nil Single pass/ Multipass: Multipass Single/Multiple Electrode: Sinqle Others: Weavinq for SMAW 12mm Max. (3 times of Core Diameter of electrode.)

I I

Position of Groove: Welding Progression: Others: PREHEAT :(QW-406) Preheat Temp. (Min.) C : pass Temp. (Max.) C : Others: [Inter .

~
UQhili

(100) 250

Nil -

<>

~.

. ".f:JS ~ "'=-Pune Office lloyd's Register Asi..

-.

J "

..
~

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Specimen No. TT 1 Top TT 2 Top TT 1 Bottom TT 2 Bottom Width (mm) 19.30 19.02 18.90 19.28 QW 483 TENSILE TEST (QW-150) Area Ultimate Tensile Thickness load (ka.) (mm2) (mm) 31400 507.97 26.32 32000 525.52 27.63 31400 496.31 26.26 33200 506.67 26.28 PQR No. 007-2005 UTS (kg/mm2) 61.81 60.89 63.26 65.52
. -

THERMAX

Type of failure and location Ductile In PM Ductile In PM Ductile In PM Ductile In PM

.
,..-;;:; -...;

GUIDED BEND TESTS (QW160) Tvpe and Figure No. Side Bend QW-462.2 SB1
Side Bend QW-462.2 Side Bend QW-462.2 Side Bend QW-462.2 SB2 SB3 SB4

Results
Satisfactory Satisfactory Satisfactory Satisfactory

Specimen No.

Notch location

Notch

TOUGHNESS TESTS (QW 170) None Test Lateral Exp. Ava. Impact % Shear Mils Value Joules Temp. C Type

Drop Weiaht No Break Break

FILLET WELD TEST (QW 180) None Result: Not Applicable Macro Results: Micro:
/""

----None --

""'"

Type of Test:

Deposit Analysis: Others: Welder's Name: Test Conducted by:

OTHER TESTS Hardness (Hv-l 0) Weld: Top: 170.179,188 Middle 185,184,187 Bottom: 194.186.179 HAZ: Top: 160.159.157 Middle: 164.163.162 Bottom: 160.160.152 Parent Material-167. 157, 160 None Macro Test Satisfactorv. M. H. Ansari Weldinq Enqq Dept. T.No.: A2932 Stamp No.: WB 01 Lab Test No.: 226 dtd. 31.03.2005

We certify that the statements in this record are correct and that the test welds were prepared welded & tested in accordance with the requirement of ASME Sect.lX edition 2004. Test Witness By.: Vikas Neerai of

c-

Date: 05.04.2005

\J,\

'f III siil

""

cturer: THERMAXLTD. S

-..'V '-" e]L lloyd', Rcgist

AUDITED BY : S. A. VANCHINATH

-,,--er

N'

...
..... ./ -

;...... By : V. K. SHENDRIKAR

0::>

QW - 482 WELDING PROCEDURE SPECIFICATION (WPS)

Welding Procedure Specification No. : 201-2 Welding Process (es): GTAW JOINTS: (QW-402) Type(s): Manual Rev. Q Date Details As per equipment Drawinq & Refer to relevant WTS. 20.03.2008

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THERMAX

PQR No. : 001/2005, 005/2004

Joint Design:

Backing:

No for root pass, Yes for subsequent passes.

Backing Material (Type): Metal 0 Nonfusing Metal Nonmetallic 0 Others

Base metal of P1 / Weld metal.

::J

.-..

Retainers not permitted BASE METALS: (QW-403) to P.No. ------A.No. SFA No. nAWS(Class) --Product form (Solid/cored / Flux cored) GTAW / PAW Solid ER 70S-2 1 FILLER METAL: (QW-404) Process GTAW 6

P.NO. 1 Gr. 1 , 2
OR

1 Gr 1 , 2 .
F.No.

Specification Type & Grade To Specification Type & Grade OR

5.18

Chem. Analysis & Mech. Prop. To Chem. Analysis & Mech. Prop.

-GROOVE Base Metal thk.range (mm.) Pipe dia Range (mm.) Any Any 1.5 - 32 FillET Any

Size of Filler metal (mm) 0 Electrode-Flux (Class)

2.0, Not Applicable Not Applicable

Trade Name (Flux) Consumable Insert

None

Others:

This WPS is applicable for base metal

Deposited weld metal Thk. range (mm.) Pass Thk. (mm.)

Groove Fillet

32 Any :::;3

Without Notch Toughness requirements.

Others: No addition of flux to the face of weld joint.

,'~

QW

482
(QW-405) of Groove'

WPS No: Anv !JQJ.or' Vertical' Anv

Rev.: Q

Page 2 of 2

POSITION: Position(s)

POST WELD HEAT TREATMENT: (QW-407) None Temperature Range(OC) . Time Range(min)

Weld Progression Position(s) PREHEAT: of Fillet (QW-406)

GAS: (QW-408) . 15 T:s:25 mm 100 T >25 mm 250 None Shielding Trailing Backing Gas(es) % Comp Mixture Single Flow Rate (Iit/min) 5-12

Preheat_Temp. (Min.)OC

Interpass Temp.(Max.)OC' Preheat Maintenance

Argon None None

ELECTRICAL CHARACTRISTICS : (QW-409) Current Amps(Range) : DC : 80 - 180 (Ranqes) . Polarity' Volts.

<b

EN ==

TungstenElectrodeSize and Type'

Mode of Metal Transfer for GMAW
----,-...

2,4 mm As per SFA 5.12 EWTh - 2

Not Applicable Not Applicable

Electrode wire feed Speed Range Pulsing : TECHNIQUE: (QW-410) String or Weave Bead Orifice or Gas Cup Size 0 (mm) Initial and Interpass Cleaning Method of Back Gouging Oscillation Contact Tube to work distance (mm) Multiple or Single Pass (per side) Multiple or Single Electrode Closed to out chamber Electrode Spacing Travel Speed (Range) Peening Use of Thermal Process for P No. 11A & P No. 11B Others: Weld Layer (s) Process es GTAW
Filler Metal

~
Strinq / Weavinq of Max 6 mm 6 - 12.5 Wire Brushinq / Grindinq None None Not Applicable Multipass / Sinqle Sinqle Not Applicable Not AQQ.licable

--------------Not Allowed Not AQQ.licable

------

Surface to be welded shall be free from oil. dust. rust. scale, & other foreir
Current material.

Travel

Class

Dia.mm

Type & Polarit DCEN 80-180

Speed Range mm/min

Heatinput J/mm

As reqd.

ER 70S-2

2.0

Prepared By :

Approved By :

Welding Engg. Dept.

Mahadev Gochade

j4\
Date' 20.03.2008

v.K.Shendrik~4~~v

"""""

.,

..

QW - 483 PROCEDURE QUALIFICATION RECORD (PQR)

Procedure Qualification Record No.: 001 - 2005 WPS No.: 201-1 Rev. 5 Welding Process(es): GTAW Type (Manual, Automatic, Semi-Auto): MANUAL ,
I

,r
Date: 18.02.2005

THERMAX

JOINTS: (QW-402)

\(
RootGap RootFace2-3mm.
0 - 1.5 mm. IncludedAngle - 65 - 70

!6

mm

BASE METALS (QW-403) Material Spec. : SA 516 to SA 516 Type or Grade: r.70 to Gr.70

POST WELD HEAT TREATMENT

(QW-407) Nil -

TemperatureC: =
Time:

P. ,'-10. ....1.- Gr.

to P.No.-1-

Gr.

Others:

--------

--------

Thickness of Test Coupon (mm) : 16 Dia. of Test coupon (mm): Nil. Others: None

GAS: (QW-408)
% FILLER METALS: (QW-404)
I

Gas(es)

Composition

Mixture

Flow rate lit/rnin ---

Process Weld Metal Analysis A.No. Size of Filler Metal mm 0

--"'"

GTAW 1 2
6

Shielding GTAW Trailing Backing

Argon None None

As per SFA 5.32

10-11

----

-------,-

----

Filler Metal F.No.

SFA Specification . AWS Specification Deposited Weld Metal (mm) Pass Thickness(mm) Others
I

5.18 ER 70S-2 16 3 Max. No addition of flux to The face of weld joint

--. ELECTRICAL CHARACTERISTICS:(QW-409) Current: DC EN Polarity: 140-150 Volts N.A Amps: Tungsten Electrode Type & Size: EWTh-2. .,])2.4 Others: Nil TECHNIQUE: (QW-410) Travel Speed: String or Weave Bead: Oscillation: . I Single pass/ Multipass:

POSITION :(QW-405) Position of Groove: Welding Progression: Others: PREHEAT :(QW-406)

----StrinQ & Weave Nil Multipass SinQle

---------------

I Single/Multiple
Others:

Electrode:

PreheatTemp.(Min.)C : Interpass Temp.(Max.)C : Others:

RT (28) 250

Nil

Nil." -.I

'4'"> \( ...."' "...

; \.~ ,'& '-

I ~ I I ~

~J

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,
Specimen No. Trans. Tensile 1 Trans. Tensile 2 Width (mm) 19.40 19.33 QW 483 TENSILE TEST (QW-150) Thickness Area Ultimate Tensile (mm2) load (ka.) (mm) 15.97 309.82 19800 311.02 16.09 19800 PQR No. 001-2005 UTS (kg/mm2) 63.91 63.66 Type of failure and location Ductile In PilJl Ductile In PM GUIDED BEND TESTS (QW 160) Type Face Bend Face Bend Root Bend Root Bend and FiQureNo. QW-462.3 (a) QW-462.3 (a) QW-462.3 (a) QW-462.3 (a) FB1 FB2 RB1 RB2 Results Satisfattory Satisfactory Satisfactory Satisfactory

THERMAX

..-

Specimen No. 1-3

1-3

Notch location
weld HAZ

Notch Type

TOUGHNESS TESTS (QW 170) Test Ava. Impact Lateral Exp. Mils Temp. C Value Joules % Shear
-29 110 28

Drop Weiaht Break No Break -

-29 Charpy

FILLET WELD TEST (QW 180) Result: Satisfactory Macro Results: Micro: Yes/No. None None

None

--

...... ..

i"ype of Test: Deposit Analysis: Others: Welder's Name: Test Conducted by:

OTHER TESTS Hardness (Hv10). Weld - 194, 198,186. Parent Material - 176,181,171. None
Macro

HAZ-199,197,185.

-Satisfactory

...-

M. H. Ansari WeldinQ EnQQDept.

T.No.: A2932 Stamp No.: WB01 Lab Test No.: 199 dtd. 10.02.2005

We certify that the statements in this record are correct and that the test welds were prepared welded & tested in accordance with the requirement of ASME SecUX edition 2004. Test Witness By.: Vikas Neerai of Date: 18.02.2005 LRS Manufacturer: THERMAX LTD.

AUDITED

y'

4:

5,
~A~~ ,~.
~ \ 0 ~)/
, .

('
\.

V. K. SHENDRIKAR
n

<:)

~~i.ter

Asia

iF""

rr
I

....
t..
~

QW - 483 PROCEDURE QUALIFICATION RECORD (PQR)

Procedure QualificationRecordNo.: 005- 2004 201-1Rev.4 WPS No.:WeldingProcess(es): GTAW Type(Manual,Automatic,Semi-Auto): MANUAL JOINTS: (QW-402)

,r

THERMAX

Date: 14.05.2004

-~

+
3.0 to 3.5 mm. Root Gap ---RootFace--- 0 to 1mm. Included Angle- 70-75

\(

E74

mm

BASE METALS (QW-403) Material Spec.: SA 106 to SA 106 Type or Grade: Gr.B to Gr.B P No 1 Gr.Ato P.No. --L- Gr. .1.. 8.74 Thickness of Test Coupon (mm): Dia. of Test coupon (mm): 60.3. None Others:

POST WELD HEAT TREATMENT(QW-407) Nil Temperature DC: ------------------Time: ---------Others:

GAS: (QW-408)
% Gas(es) FILLER METALS: (QW-404) Process GTAW 1 2 6 5.18 ER 70S-2 8.74 3 Max. No addition of flux to The face of weld joint Shielding GTAW Trailing Backing Argon None None
Composition

Mixture As per SFA 5.32

Flow rate lit/min 8-10

r-...

Weld Metal Analysis A.No. Size of Filler Metal mm 0 Filler Metal F.No. SFA Specification AWS Specification Deposited Weld Metal (mm) Pass Thickness(mm) Others

----

----

ELECTRICAL CHARACTERISTICS:(QW-409) Current: DC EN Polarity: 100-120 N.A Volts Amps: Tungsten Electrode Type & Size: EWTh-2. g,2.j Others: Nil TECHNIQUE: (QW-410) Travel Speed: String or Weave Bead: Oscillation: Single pass/ Multipass Single/Multiple Electrode: Others:

POSITION :(QW-405) 1G Position of Groove: -----Welding Progression: --------Others: PREHEAT :(QW-406) Preheat Temp. DC: Interpass Temp. DC: Others:

----Strinq & Weave

WL
Multipass Sinqle Nil

_/

RT (39)
250 Nil 0 t-4.J-

JEj'cY.... ,

t~

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..

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Specimen No. TT-1 TT-2
19.35

THERMAX

QW 483 TENSILE TEST (QW-150) Area Ultimate Tensile mm2 load k . 159.00 7850 8.79 170.09 8250

PQR No. 005-2004

48.52

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Results Satisfacto Satisfacto Satisfacto Satisfacto

Specimen No.

Notch location

Notch Type

Dro Break

FILLET WELD TEST (QW 180)

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None

Result: Satisfactory Macro Results: Micro: Type of Test: Deposit Analysis: Others: Welder's Name: Test Conducted by:

Yes/No. None None OTHER TESTS Hardness (Hv). Weld 180. 189. 199. HAZ- 193. 191. 186. Parent Material-197. 194. 193. None

M.H.Ansari Weldin!:! Ena!:! DeDI.

T.No.: A2932 Stamp No.: WB 01 Lab Test No.: 27 dtd. 14.05.2004

We certify that the statements in this record are correct and that the test welds were prepared welded & tested in accordance with the requirement of ASME SecUX edition 2001 including addenda 03. Test Witness By.: Surveyor of LRA Date: 14.05.20L\cturer: THERMAX LTD.

AUDITED BY : SA VANCHINATH

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By : A.H.Jadhav

THERMAX LTD.
Chinchwad, Pune 411 019

Boller 8<Heater Group

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THERMA

QW 483 PROCEDURE QUALIFICATION RECORD POR

Procedure Qualification Record No.: 340/2007 WPS .No.: 60508 Welding Process(es): GTAW+ SMAW Types (Manual, Automatic, Semi-Auto): Manual
JOINTS (QW 406)

Date: 22.12.2007

1-

1.5mm'.J

-.J
r-;J

2.5-3 mm.

~
I+SMAW 8 02.5, 03.15 5
5.4
Weldfast 309L of Mis. Weldwell Electrodes Ltd.

18.26 mm.

BASEMETAL(QW-403) Material Spec.: SA 106 Type or Grade: B To Material Spec.: SA312 Type or Grade: 304 P No.: 1 To P No.: 8 Thickness of Test Coupon: 18.26 mm. Dia of Test Coupon: 168.3 mm. Others: None FILLER METAL GTAW

POSTWELD HEATTREATMENT(QW-407) Temperature: None Time: None Others: None

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W-404 Weld Metal 4naJysis (A No. Size of Filler Metal (mm. Filler Metal FNo. SFASpecification Trade Name
AWS Classification Deposited Weld 'Metal

8 02.0
6

Current: DC Polarity: EN (-) GTAW

EP (+) SMAW

Amps: 110 - 120 Amp. GTAW

75 -- 110 Amp. SMAW

5.9
SS Wire 309L of

Mis. Weldwell
Electrodes Ltd.

Volts: None Tungsten Electrode Size: EWTh-2,0 2.4 mm. Heat Input: None

ER309L

E309L-16

6mm.

12.26 mm.

Pass Thickness I 3 mm. (Max. POSITION (QW-405) Position of Groove: IG (Flat) Weld Progression: Not Applicable Others: Not Applicable
--

PREHEAT ~QW-405) Preheat Temp.: Ambient Temperature (32C) Inter-pass Temp.: 175e .Preheat Maintenance: None

TECHNIQUE(QW-410) Travel Speed (mm./minute): None String or Weave Bead: Weave Oscillation: Not Applicable Multi-pass or Single Pass (Per side): Multi-pass Single or ~~Itiple Electrodes: Single Others:

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Pune (lfl,cl \
Lloyd's RegisterAsia

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THERMAX

THERMAX LTD.
Chinchwad (pune)

- 411019
2

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Specimen No. Width (mm.)

340/2007

TESILE TEST Area Thickness (mm2) (mm.) 17.30 17.48 330.43 332.12

---==-===-_={Cnj-_of W-150 Ultimate Total Load (KN) 172

Ultimate Tensile Stregth M a 520.53 511\.87

Type of failure & Location

Transverse -1 Transverse -2

19.10 19.00

--

171

--

Ductile& In P. M. C. s. Ductile& In

--

P. M. C.S.

v
Specimen No. Notch Location Not,. Type

Results -Sati.sfactory Satisfactory .--.-.--.-..-.._.____atisfacto..!:Y_.. -'-' Satisfactorv -W-l T.) latlral Drop Weight Exp Break No Break Mils % Shear

QW-1____-------_.._-

----.

---

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----------

FILLET WELD TEST (QW-180) Result: None Penetration Into Parent Metal: None ---------------OTHER TESTS Macro Results: Satisfactory Hardness Test: Hardness (HV10 Scale) W. M. : 191, 194, 193, 193, 189 HAZ: (5.5.) 183, 186, 182, 185, 183 (C.S.) 168, 165, 167, 168, 167

----"- .-. -

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C.5. 142 144 145 T.No.: Welder's Name: D. R. Newase Test Conducted by: Welding Engg. (Thermax Ltd.)

P. M. : (5.5.) 173, 170, 171

.------..---Stamp No.: WD98 Lab Test No.: Perfect Lab. PLS__0307 _7/1/21.12.2007

We certify that the statements in this record are correct and test welds were prepared, welded & tested in accordance with requirement of section IX of ASME Code. Manufacturer: Date: 22.12.2007
Lie I 'L.""\ BY.:..6: E. fS.LISARriJ-

Thermax Ltd.

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THERMAX LTD.
Chinchwad,Pune 411019
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Bolle,& Heate, Group

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THERMAX

QW 483' PP:OCEOUREQUALIFICATION RrC;.E>ltb PQR'

Procedure Qualification Record No.: 341/2007 WPS No.: 61908 Welding Process(es): GTAW+ SMAW Types (Manual, Automatic, Semi-Auto): Manual JOINTS (QW406) Date: 22.12.2007

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18.26 mm.

~
POST WELD HEAT TREATMENT (QW-407)

BASE METAL (QW-403)

Material Spec.: SA312 Type or Grade: 304 To Material Spec.: SA312 Type or Grade: 304 PNo.:8 To PNo.:8 Thickness of Test Coupon: 18.26 mm.

Temperature: None Time: None Others: None

GTAW 8 02.0 6 5.9

i-ER308L of Mis. Venus Wires

SMAW 8 02.5, 03.15 5 5.4 OK61.30

(ESABIndia Ltd.) and Silvershine 308 (Mis. Honavar Electrodes P. Ltd.

Current: DC
Polarity: EN (-) GTAW EP (-+)SMAW Amps: 110 - 120 Amp. GTAW 70 - 110 Amp. SMAW Volts: None

Tungsten Electrode Size: EWTh-2,0 2.4 mm.

AWS I ER308L Classification 6mm. Deposited Weld Metal I 3 mm. (Max. Pass Thickness POSITION (QW-405) Position of Groove: 1G (Flat) Weld Progression: Not Applicable Others: Not Applicable

E308L-16

Heat Input: None

12.26 mm.

TECHNIQUE (QW-410)

Travel Speed (mm./minute): None String or Weave Bead: Weave Oscillation: NotApplicable Multi-pass or Single Pass(Per side): Multi-pass Single or.MultiDleElectrodes: Sinqle

PREHEAT(QW-405) Preheat Temp.: Ambient Temperature (32C) Inter-pass Temp.: 175C Preheat Maintenance: None

Others:-

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THERMAX LTD.
Chinchwad (pune)

IIIU?Mt,X

- 411019
--.-.--.-. Ultimate Tensile Stregth M a 622.11 615.06 _.__. Results
(contd.) 2 of 2

Specimen No.

Width (mm.)

- QR}o.: 3'\ 1/2007 ,-TESILE TEST (QW 150) Thickness Area Ultimate Total Load (mm.) (mm2) (KN) 17.18 17.20 324.70 326.80 202 201

Type or
failure & Location
Ductile & In Weld Ductile & In

Transverse -1 Transverse -2

18.90 19.00

---

Weld - ---

Satisfact_.._-- ?cllduclory
Sdl i.f iJclor

-'
Specimen No. Notch Location Notch Type -

-Drop Break

.---Weight No Break

Satisf<1ctor ,Exp. .Mils

-------

-----

-----.
- ._---.__._---.-.

._--- ... ._- - -.- ,--

FILLET WELD TEST (QW-180) Result: None Penetration into Parent Metal: None OTHER YESTS Macro Results: Satisfactory Hardness Test: Hardness (HV10 Scale) W. M. : 189, 192, 188, 188, 191 HAZ: (L. H. S.) 196,198,196,197,196 (R. H. S.) 196, 19/, 19'\, 19U, 19/ P. M. : (L. H. S.) 163, 164, 162 CR.H>-1.?2, 173, 175
St.unp No.: WI)')/

-------

'-

rfect Lab. PLS.,0301..1/1/21.12.2007 elds were prepared, welded &

tested in accordance with requirement of section IXofASME Code.

Manufacturer: Thermax Lld.

Date: 22.12.2007

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