Concast WPS - REV-01

Samay Project Services P Ltd.
Doc.No.: SPL/CSPL/AGECL/QA-002, Rev-01 DATE : 20.01.12 SUPPORTING PQR REF. No.: SPL/CSPL/AGECL/QA-001-01
Title :
Welding Procedure specification for all material specification
Page 1 of 28
WELDING PROCEDURE TYPE
: :
SMAW MANUAL
SYSTEM 1
TANKS
DETAILS OF EQUIPMENT COVERED 1. 2. 3. 300 Cu.m, DM water storage tank 300 Cu.m, make up water storage tank 60 Cu.m Over Head Surge tank
JOINTS (QW-402) : : Single 'V' Butt Nil
Joint Design Backing Material (type) 2 BASE METALS (QW-403)
Specification Type and Grade Thickness Range Base Metal
: : :
IS -2062, IS-1367, A-234 Gr.WPB, 4 mm to 10 mm Groove Single 'V' Fillet: All thickness Fillet: All Size
Client: M/s. CONCAST STEEL & POWER LTD., .
Consultant : Avant Garde Engineers and Consultants (P) ltd., PROJECT: 1 X 30 MW CAPTIVE POWER PLANT & 1 X 40 MW CPP
Samay Project Services P Ltd.,
Title :
Page 2 of 28
FILLER METALS (QW-404) : : : : : 5.1, E-6013 2 1 2.5mm Dia., 3.15 mm Dia
Specification No. (SFA) AWS NO. (Class) F-No. A-No. Size of the Filler Metals 4
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to E-6013 and Standard mfrs like ESAB, ADVANI and D & H.
Groove Fillet Electrode Flux Class Other
POSITION (QW-405) : : : NA Up-Hill All
Position of the Groove Welding Progression Position (s) of Fillet 6 PREHEAT (QW-406)
Preheat Temp. Min Interpass Temp Max Preheat maintenance 7
: : :
10 Deg. C 150 Deg. C to 250 Deg. C NA
POST WELD HEAT TREATMENT (QW- 407) : : NA NA
Temp Range Time Range 8 GAS (QW-408)
Shielding Trailing Backing

: : :
Percentage of Composition Gas Mixture Flow Rate NA NA NA NA NA NA NA NA NA
Title :
Page 3 of 28
ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 70-150 A 18-30 V Reverse NA NA NA
Current AC or DC Current Range Voltage Range Polarity Tungsten Electrode Size Mode of Metal Transfer for GTAW Electrode Wire Feed Speed Range
10
TECHNIQUE (QW-410) : : : : : : :
Process Filler Metal Class Dia 2.5mm 2.5mm 3.15mm
String or Weave Bead Initial Interpass and Cleaning Method of Back Gouging Multipass or Single pass per side Multiple or Single Electrode Travel Speed (Range) Other
Weld Layer (s)
String & Weave Both By Wire Brushing and Chipping Not applicable Multipass Single 65 to 75 mm per Minute N.A.
Current Type Polar Reverse Reverse Reverse Amp. Range 70-90 A 70-90 A 100-110 A Volt Range 18-30 V 18-30 V 18-30 V Travel Speed Range 50-65 mm 65-75 mm 65-75 mm
Root Filler Final (Basis on thick.)
SMAW SMAW SMAW
E6013 E6013 E6013
Title :
Page 4 of 28
: :
GTAW & SMAW MANUAL
SYSTEM 2
VESSELS
DETAILS OF EQUIPMENT COVERED ATM Flash tank
: : :
IS -2002 Gr.2 4 mm to 10 mm Groove Single 'V' Fillet: All thickness Fillet: All Size
FILLER METALS (QW-404) : : 5.18,5.1 ER70 S2 & E7018
Specification No. (SFA) AWS NO. (Class)

Title :
Page 5 of 28
F-No. A-No. Size of the Filler Metals 4 : : : 6,4 1 2.5mm Dia., 3.15 mm Dia. & 2.4mm Dia
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER70S2, E7018 and Standard mfrs like ESAB, ADVANI & D & H
POSITION (QW-405) : : : 6G Up-Hill All
Preheat Temp. Min Interpass Temp Max Preheat maintenance 7
: : :
10 Deg. C 150 Deg. C to 250 Deg. C NA
POST WELD HEAT TREATMENT (QW- 407) : : NA NA
Temp Range Time Range
GAS (QW-408) Percentage of Composition
Shielding Trailing Backing 9
: : :
Gas Argon NA NA
Mixture NA NA NA
Flow Rate 20cuft/hr NA NA
ELECTRICAL CHARACTERS (QW-409) : DC
Current AC or DC
Title :
Page 6 of 28
Current Range Voltage Range Polarity Tungsten Electrode Size Tungsten type Electrode Wire Feed Speed Range : : : : : : 90-100 A GTAW, 110-125 A SMAW 18-30 V Straight GTAW, Reverse - SMAW 2.4mm SFA5.12 EWTh-2 NA
10
TECHNIQUE (QW-410) : String & Weave Both(Less than three times of filler wire thickness)
String or Weave Bead
Initial Interpass and Cleaning Method of Back Gouging Multipass or Single pass per side Multiple or Single Electrode Travel Speed (Range) Other Weld Layer (s) Precess
: : : : : : Filler Metal Class Dia
By Wire Brushing and Chipping Not applicable Multipass Single 65 to 75 mm per Minute N.A. Type Polar Current Amp. Range 100-125 A 90-100 A 90-100 A Volt Range Travel Speed Range inch/min 2 3.5 5-6 5-6
GTAW SMAW SMAW
ER70S2 E7018 E7018
2.4mm 2.5mm 3.15m m
Straight Reverse Reverse
18-30 V 18-30 V 18-30 V
Title :
Page 7 of 28
SYSTEM : 3. 1. Critical piping carbon steel material 2. Critical piping stainless steel material 3. Critical piping low alloy steel material GR.P11, GR.P12 4. Critical piping low alloy steel material GR.P22 5. Non critical piping carbon steel material 6. Piping less than 6mm wall thick carbon steel material 7. Piping less than 6mm wall thick stainless steel material 1. Critical piping system carbon steel material
: :
GTAW & SMAW MANUAL
Joint Design Backing Material (type)

Title :
Page 8 of 28
BASE METALS (QW-403) : : SA 106 Gr.B 8mm and above
Specification Type and Grade Thickness Range
Base Metal
Groove Single 'V' Socket weld (fittings less than 50NB) Fillet: All Thickness Fillet: All Size
Pipe Dia Range
15NB to 1200 NB
FILLER METALS (QW-404) : : : : : 5.18,5.1 ER70S2, E7018 6, 4 1 2.5mm Dia., 3.15 mm Dia. & 2.4mm Dia.
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER70S2, E7018 and Standard mfrs like ESAB, ADVANI & D & H.
Preheat Temp. Min Interpose Temp Max

: :
Min 10 Deg. C 150 Deg. C to 250 Deg. C
Title :
Page 9 of 28
Preheat maintenance 7 : NA
POST WELD HEAT TREATMENT (QW--407) : : NA NA
: : :
Gas Argon NA NA
Mixture NA NA NA
ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 90-100 A GTAW, 110-125 A SMAW 18-30 V Straight GTAW, Reverse - SMAW 2.4mm SFA5.12 EWTh-2 NA
Current AC or DC Current Range Voltage Range Polarity Tungsten Electrode Size Tungsten type Electrode Wire Feed Speed Range
10
Initial Interpass and Cleaning Method of Back Gouging Multipass or Single pass per side Multiple or Single Electrode Travel Speed (Range) Other
: : : : : :
By Wire Brushing and Chipping Not applicable Multipass Single 65 to 75 mm per Minute N.A.
Title :
Page 10 of 28
Weld Layer (s)
Precess
Filler Metal Class Dia
Type Polar
Current Amp. Range 100-125 A 90-100 A 90-100 A
Volt Range
GTAW SMAW SMAW
ER70S2 E7018 E7018
2.4mm 2.5mm 3.15m m
18-30 V 18-30 V 18-30 V
Travel Speed Range inch/min 2 3.5 5-6 5-6
Title :
Page 11 of 28
2. Critical piping system stainless steel material

WELDING PROCEDURE TYPE : : GTAW & SMAW MANUAL
: : :
SA 312 TP 304 7.11mm and above Groove Single 'V' Socket weld (fittings less than 50NB) Fillet: All Thickness Fillet: All Size
Pipe Dia Range
15NB to 1200 NB
Title :
Page 12 of 28
3 FILLER METALS (QW-404) : : : : : 5.4 & 5.9 ER347, E347 5&6 8 2.5mm Dia., 3.15 mm Dia & 2.4 mm Dia.
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER347, E347 and Standard mfrs like ESAB, ADVANI & D & H.
Preheat Temp. Min Interpose Temp Max Preheat maintenance 7
: : :
Min 10 Deg. C 150 Deg. C to 250 Deg. C NA

: : :
Gas Argon NA Argon
Mixture NA NA NA
Flow Rate 20cuft/hr NA 10 to 12 LPM
Title :
Page 13 of 28
ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 90-100 A GTAW, 110-125 A SMAW 18-30 V Straight GTAW, Reverse - SMAW 2.4mm SFA5.12 EWTh-2 NA
10
GTAW SMAW SMAW
ER347 E347 E347
2.4mm 2.5mm 3.15mm
18-30 V 18-30 V 18-30 V
Title :
Page 14 of 28 3. Critical piping low alloy steel material GR.P11, GR.P12

: : 8mm and above
Base Metal
Pipe Dia Range
15NB to 1200 NB
FILLER METALS (QW-404)

Title :
Page 15 of 28
: : : : :
5.28, 5.5 ER 80S B2, E8018B2 6, 4 3 2.5mm Dia., 3.15 mm Dia. & 2.4mm Dia.
WELD METAL THICKNESS RANGE : : : : 14.22mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER80SB2, E8018B2 and Standard mfrs like ESAB, ADVANI & D & H.
: : :
: : :
Gas Argon NA NA
Mixture NA NA NA
ELECTRICAL CHARACTERS (QW-409)

Title :
Page 16 of 28
: : : : : : :
DC 90-100 A GTAW, 110-125 A SMAW 18-30 V Straight GTAW, Reverse - SMAW 2.4mm SFA5.12 EWTh-2 NA
10
Initial Interpass and Cleaning Method of Back Gouging Multipass or Single pass per side Multiple or Single Electrode Travel Speed (Range) Other Weld Layer (s) Process
GTAW SMAW SMAW
ER 80SB2 E8018B2 E8018B2
2.4mm 2.5mm 3.15m m
18-30 V 18-30 V 18-30 V
Title :
Page 17 of 28 4. Critical piping low alloy steel material GR.P22

: : 8mm and above
Base Metal
Pipe Dia Range
15NB to 1200 NB
FILLER METALS (QW-404) : : 5.28, 5.5 ER 90S B3, E9018B3
Specification No. (SFA) AWS NO. (Class)

Title :
Page 18 of 28
F-No. A-No. Size of the Filler Metals 4 : : : 6, 4 4 2.5mm Dia., 3.15 mm Dia. & 5 mm Dia.
WELD METAL THICKNESS RANGE : : : : 56 mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER90SB3, E9018B3 and Standard mfrs like ESAB, ADVANI & D & H.
: : :
: : :
Gas Argon NA NA
Mixture NA NA NA
ELECTRICAL CHARACTERS (QW-409) : : DC 90-100 A GTAW, 125-135 A SMAW
Current AC or DC Current Range

Title :
Page 19 of 28
Voltage Range Polarity Tungsten Electrode Size Tungsten type Electrode Wire Feed Speed Range : : : : : 18-30 V Straight GTAW, Reverse - SMAW 2.4mm SFA5.12 EWTh-2 NA
10
Initial Interpass and Cleaning Method of Back Gouging Multipass or Single pass per side Multiple or Single Electrode Travel Speed (Range) Other Weld Layer (s) Process
By Wire Brushing and Chipping Not applicable Multipass Single 65 to 75 mm per Minute N.A. Type Polar Current Amp. Range 75-100A 90-100 A 100-140 A 100-140 A Volt Range Travel Speed Range inch/min 2 3.5 5-6 5-6 5-6
Root Filler Filler Final (Basis on thick.)
GTAW SMAW SMAW SMAW
ER 90SB3 E9018B3 E9018B3 E9018B3
2.4mm 2.5mm 3.15m m 3.15 mm
Straight Reverse Reverse Reverse
18-30 V 18-30 V 18-30 V 18-30 V
Title :
Page 20 of 28
5. Non Critical piping system carbon steel material

WELDING PROCEDURE TYPE : : SMAW MANUAL
: : :
IS1239 Pt. I & II, IS2062, IS3589 8mm and above Groove Single 'V' Socket weld (fittings less than 50NB) Fillet: All Thickness Fillet: All Size
Pipe Dia Range

15NB to 1200 NB
Title :
Page 21 of 28
FILLER METALS (QW-404) : : : : : 5.1 E6013 2 1 2.5mm Dia., 3.15 mm Dia
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to E6013, and Standard mfrs like ESAB, ADVANI & D & H.
: : :

: : :
Gas NA NA NA
Mixture NA NA NA
Flow Rate NA NA NA
Title :
Page 22 of 28
ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 110-125 A 18-30 V Reverse NA NA NA
Current AC or DC Current Range Voltage Range Polarity Tungsten Electrode Size Mode of Metal Transfer for GTAW Electrode Wire Feed Speed Range
10
TECHNIQUE (QW-410) : : : : : : : Precess Filler Metal Class Dia String & Weave Both By Wire Brushing and Chipping Not applicable Multipass Single 65 to 75 mm per Minute N.A. Type Polar Current Amp. Range 100-125 A 100-125 A 100-125 A Volt Range Travel Speed Range inch/min 2 3.5 5-6 5-6
String or Weave Bead Initial Interpass and Cleaning Method of Back Gouging Multipass or Single pass per side Multiple or Single Electrode Travel Speed (Range) Other Weld Layer (s)
SMAW SMAW SMAW
E6013 E6013 E6013
2.5mm 2.5mm 3.15mm
Reverse Reverse Reverse
18-30 V 18-30 V 18-30 V
Title :
Page 23 of 28
6. Piping less than 6mm wall thickness carbon steel piping

WELDING PROCEDURE TYPE : : GTAW MANUAL
: :
IS1239 Pt. I & II, IS2062, IS3589, SA 106 Gr.B 3.68mm and above
Base Metal
Title :
Page 24 of 28
Pipe Dia Range : 15NB to 1200 NB
FILLER METALS (QW-404) : : : : : 5.18 ER70S2 6 1 2.4mm dia.
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER70S2, and Standard mfrs like ESAB, ADVANI & D & H.
: : :
GAS (QW-408) Percentage of Composition Gas Mixture Flow Rate
Title :
Page 25 of 28
Shielding Trailing Backing 9 : : : Argon NA NA NA NA NA 20cuft/hr NA NA
ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 90-100 A 18-30 V Straight 2.4mm SFA5.12 EWTh-2 NA
Current AC or DC Current Range Voltage Range Polarity Tungsten Electrode Size Tungsten Type Electrode Wire Feed Speed Range
10
TECHNIQUE (QW-410) : String & Weave Both(Less than four times of filler wire thickness)
GTAW GTAW GTAW
ER70S2 ER70S2 ER70S2
2.4mm 2.4mm 2.4mm
Straight Straight Straight
18-30 V 18-30 V 18-30 V
Title :
Page 26 of 28
7. Piping less than 6mm wall thickness stainless steel piping

WELDING PROCEDURE TYPE : : GTAW MANUAL
: :
SA 312 TP 304 3.05mm and above
Base Metal
Title :
Page 27 of 28
Pipe Dia Range : 15NB to 1200 NB
FILLER METALS (QW-404) : : : : : 5.9 ER347 6 8 2.4mm Dia.
WELD METAL THICKNESS RANGE : : : : 9.6mm Max / 2 times thk qualified All thk Rutile Electrode Shall be used confirming to ER347, and Standard mfrs like ESAB, ADVANI & D & H.
: : :
Shielding
Gas Argon
Mixture NA
Flow Rate 20cuft/hr
Title :
Page 28 of 28
Trailing Backing 9 : : NA Argon NA NA NA 10 to 12 LPM
ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 90-100 A 18-30 V Straight 2.4mm SFA5.12 EWTh-2 NA
Current AC or DC Current Range Voltage Range Polarity Tungsten Electrode Size Tungsten Type Electrode Wire Feed Speed Range
10
GTAW GTAW GTAW
ER347 ER347 ER347
2.4mm 2.4mm 2.4mm
Straight Straight Straight
18-30 V 18-30 V 18-30 V

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Samay Project Services P Ltd.

Welding Procedure specification for all material specification

WELDING PROCEDURE TYPE

JOINTS (QW-402) : : Single 'V' Butt Nil

Joint Design Backing Material (type) 2 BASE METALS (QW-403)

Specification Type and Grade Thickness Range Base Metal

Client: M/s. CONCAST STEEL & POWER LTD., .

Samay Project Services P Ltd.,

Welding Procedure specification for all material specification

FILLER METALS (QW-404) : : : : : 5.1, E-6013 2 1 2.5mm Dia., 3.15 mm Dia

Groove Fillet Electrode Flux Class Other

POSITION (QW-405) : : : NA Up-Hill All

Preheat Temp. Min Interpass Temp Max Preheat maintenance 7

10 Deg. C 150 Deg. C to 250 Deg. C NA

POST WELD HEAT TREATMENT (QW- 407) : : NA NA

Temp Range Time Range 8 GAS (QW-408)

Shielding Trailing Backing

Percentage of Composition Gas Mixture Flow Rate NA NA NA NA NA NA NA NA NA

Samay Project Services P Ltd.,

Welding Procedure specification for all material specification

ELECTRICAL CHARACTERS (QW-409) : : : : : : : DC 70-150 A 18-30 V Reverse NA NA NA

Root Filler Final (Basis on thick.)

SMAW SMAW SMAW

E6013 E6013 E6013

Client: M/s. CONCAST STEEL & POWER LTD., .

Samay Project Services P Ltd.,

Welding Procedure specification for all material specification

WELDING PROCEDURE TYPE

GTAW & SMAW MANUAL

DETAILS OF EQUIPMENT COVERED ATM Flash tank

JOINTS (QW-402) : : Single 'V' Butt Nil

Joint Design Backing Material (type) 2 BASE METALS (QW-403)

Specification Type and Grade Thickness Range Base Metal

FILLER METALS (QW-404) : : 5.18,5.1 ER70 S2 & E7018

Specification No. (SFA) AWS NO. (Class)

Samay Project Services P Ltd.,

Welding Procedure specification for all material specification

Groove Fillet Electrode Flux Class Other

POSITION (QW-405) : : : 6G Up-Hill All

Preheat Temp. Min Interpass Temp Max Preheat maintenance 7

10 Deg. C 150 Deg. C to 250 Deg. C NA

POST WELD HEAT TREATMENT (QW- 407) : : NA NA

Temp Range Time Range

GAS (QW-408) Percentage of Composition

Shielding Trailing Backing 9

Flow Rate 20cuft/hr NA NA

ELECTRICAL CHARACTERS (QW-409) : DC

Samay Project Services P Ltd.,

Welding Procedure specification for all material specification

String or Weave Bead

: : : : : : Filler Metal Class Dia

Root Filler Final (Basis on thick.)

GTAW SMAW SMAW

ER70S2 E7018 E7018

2.4mm 2.5mm 3.15m m

Straight Reverse Reverse

18-30 V 18-30 V 18-30 V

Client: M/s. CONCAST STEEL & POWER LTD., .

Samay Project Services P Ltd.,