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QW - 483
PROCEDURE QUALIFICATION RECORD I

(PQR)
J

Procedure Qualification Record No.: 007 - 2005 Date: 05.04.2005

WPS No.: 304-1 Rev. 3 + 003-1 Rev.6
Welding Process(es): FCAW+SMAW
Type (Manual, Automatic, Semi-Auto): MANUAL

JOINTS: (QW-402)

~ Root Gap
Root Face -
- 3 -4 mm.
-
0 1 mm.
~ )~-L[~~
IncludedAngle - 600
) 1?~

BASE METALS (QW-403) . POST WELD HEAT TREATMENT (QW-407)

Material Spec. : SA 516 to SA 516 Temperature °C : ====
Type or Grade: Gr.70 to Gr.70 Time: : ====
P. No. -1- Gr. 2 to P.No. --1-Gr.-L Others:
Thickness of Test Coupon (mm) : 50
Dia. of Test coupon (mm): Nil
Others: None GAS: (QW-408) -
% Flow
Gas(es) I Composition rate
FILLER METALS: (QW-404) Mixture lit/min
-
Process FCAW SMAW SG-C as per 18-20
Shielding CO2 SFA- 5.32
Weld Metal Analysis A.No. 1 1 Trailing None
I
Size of Filler Metal mm 0 1.2 4 Backing None
~-iller Metal F.No. 6 4
-6FA Specification 5.20 5.1
AWS Specification E71T-1 E7018 ELECTRICAL CHARACTERISTICS:(QW-409)
Deposited Weld Metal (mm) 25 25 Current: DC
Pass Thickness(mm) 4 Max. 4 Max. Polarity: EP
Others: I) No addition of supplementary filler metal & Amps: 160-180 for FCAW Volts 26-28
Alloy Elements for FCAW. 160-170 for SMAW - Volts: 23-24
ii) Product form: Flux Cored for FCAW Tungsten Electrode Type & Size: Not Applicable I
I

Others:TY"o"l'\sf'e'l M~dl. ~&\0

POSITION :(QW-405) TECHNIQUE: (QW-410)
For FCAW : 80-90
Position of Groove: ~ Travel Speed (mm/min.): For SMAW: 55-60
Welding Progression: UQhili String or Weave Bead: Strinq & Weave
Others: Oscillation:. Nil
Single pass/ Multipass: Multipass
PREHEAT :(QW-406) Single/Multiple Electrode: Sinqle
Preheat Temp. (Min.) °C : (100) Others: Weavinq for SMAW 12mm Max. (3 times
pass Temp. (Max.) °C : 250 of Core Diameter of electrode.)
Others:

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

GUIDED BEND TESTS (QW160)

Tvpe and Figure No. Results
. Side Bend QW-462.2 SB1 Satisfactory
Side Bend QW-462.2 SB2 Satisfactory
-...;
,..-;;:;
Side Bend QW-462.2 SB3 Satisfactory
Side Bend QW-462.2 SB4 Satisfactory

TOUGHNESS TESTS (QW 170) None

Specimen Notch Notch Test Ava. Impact Lateral Exp. Drop Weiaht
No. location Type Temp. °C Value Joules % Shear Mils Break No Break

FILLET WELD TEST (QW 180) None

Result: Not Applicable
Macro Results: ------
Micro: None --

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OTHER TESTS -
Type of Test: 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
Deposit Analysis: None
Others: Macro Test Satisfactorv.

Welder's Name: M. H. Ansari T.No.: A2932 Stamp No.: WB 01

Test Conducted by: Weldinq Enqq Dept. 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

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Date: 05.04.2005 \J,\ 'f I S "" cturer: THERMAX
S LTD.
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By : V. K. SHENDRIKAR
AUDITED BY : S. A. VANCHINATH N'
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QW - 483
PROCEDURE QUALIFICATION RECORD
(PQR)
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THERMAX

Procedure Qualification Record No.: 001 - 2005 Date: 18.02.2005

WPS No.: 201-1 Rev. 5
Welding Process(es): GTAW
Type (Manual, Automatic, Semi-Auto): MANUAL

JOINTS: (QW-402)
,

\( !6 mm

RootGap - 2-3mm.
RootFace- 0 - 1.5 mm.
IncludedAngle - 65 - 70°
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BASE METALS (QW-403) POST WELD HEAT TREATMENT (QW-407) Nil -

Material Spec. : SA 516 to SA 516 Temperature°C: =
Type or Grade: r.70 to Gr.70 Time: ---------
....1.- Gr.
P. ,'-10. 2 to P.No.-1- Gr. 2 Others: ---------
Thickness of Test Coupon (mm) : 16
Dia. of Test coupon (mm): Nil.
Others: None
GAS: (QW-408)
% Flow
Gas(es) Composition rate
l Mixture lit/rnin
FILLER METALS: (QW-404) I ---
Process GTAW Shielding As per 10-11
GTAW Argon SFA 5.32
Weld Metal Analysis A.No. 1 Trailing None ---- ----
Size of Filler Metal mm 0 2 Backing None ---- ----
Filler Metal F.No. 6 -,-
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I SFA Specification 5.18 --.
. AWS Specification ER 70S-2 ELECTRICAL CHARACTERISTICS:(QW-409)
Deposited Weld Metal (mm) 16 Current: DC
Pass Thickness(mm) 3 Max. Polarity: EN
Others No addition of flux to Amps: 140-150 Volts N.A
The face of weld joint Tungsten Electrode Type & Size: EWTh-2. .,])2.4
Others: Nil
-
POSITION :(QW-405) TECHNIQUE: (QW-410)
Position of Groove: Travel Speed: -----
Welding Progression: ------- String or Weave Bead: StrinQ & Weave
Others: --------- Oscillation: Nil
. I Single pass/ Multipass: Multipass
PREHEAT :(QW-406) I Single/Multiple Electrode: SinQle -
PreheatTemp.(Min.)°C : RT (28) Others: Nil
InterpassTemp.(Max.)°C : 250
Others:

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THERMAX

QW 483 PQR No. 001-2005

TENSILE TEST (QW-150)
Width Thickness Area Ultimate Tensile UTS Type of failure
Specimen No. (mm) (mm2) load (ka.)
(mm) (kg/mm2) and location -
Trans. Tensile 1 19.40 15.97 309.82 19800 63.91 Ductile In PilJl
Trans. Tensile 2 19.33 16.09 311.02 19800 63.66 Ductile In PM

GUIDED BEND TESTS (QW 160)

Type and FiQureNo. Results
Face Bend QW-462.3 (a) FB1 Satisfattory
Face Bend QW-462.3 (a) FB2 Satisfactory
Root Bend QW-462.3 (a) RB1 Satisfactory
..-
Root Bend QW-462.3 (a) RB2 Satisfactory

TOUGHNESS TESTS (QW 170)

Specimen Notch Notch Test Ava. Impact Lateral Exp. Drop Weiaht
No. location Type Temp. °C Value Joules % Shear Mils Break No Break
-
1-3 weld -29 110

HAZ
1-3
} Charpy
-29 28

FILLET WELD TEST (QW 180) None

Result: Satisfactory Yes/No.
Macro Results: None
Micro: None --

........ OTHER TESTS

i"ype of Test: Hardness (Hv10). Weld - 194, 198,186. HAZ-199,197,185.
Parent Material - 176,181,171.
Deposit Analysis: None
Others: Macro -Satisfactory ...-

Welder's Name: M. H. Ansari T.No.: A2932 Stamp No.: WB01

Test Conducted by: WeldinQ EnQQDept. 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 LRS

Date: 18.02.2005 Manufacturer: THERMAX LTD.

AUDITED y' 4: 5, ('

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V. K. SHENDRIKAR

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QW - 483 THERMAX
PROCEDURE QUALIFICATION RECORD
(PQR)

ProcedureQualificationRecordNo.: 005- 2004 Date: 14.05.2004

WPS No.:- 201-1Rev.4
WeldingProcess(es): GTAW
Type(Manual,Automatic,Semi-Auto): MANUAL

JOINTS: (QW-402)

-~
+ \( E74 mm

Root Gap ---- 3.0 to 3.5 mm.

RootFace--- 0 to 1mm.
IncludedAngle- 70-75°

BASE METALS (QW-403) POST WELD HEAT TREATMENT(QW-407) Nil

Material Spec.: SA 106 to SA 106 Temperature DC: ----------
Type or Grade: Gr.B to Gr.B Time: ----------
P No 1 Gr.A- to P.No. --L- Gr. .1.. Others: ----------
Thickness of Test Coupon (mm): 8.74
Dia. of Test coupon (mm): 60.3.
Others: None
GAS: (QW-408)
% Flow
Gas(es) Composition rate
FILLER METALS: (QW-404) Mixture lit/min
Process GTAW Shielding Argon As per 8-10
GTAW SFA 5.32
r-... Weld Metal Analysis A.No. 1 Trailing None ---- ----
Size of Filler Metal mm 0 2 Backing None - -
Filler Metal F.No. 6
SFA Specification 5.18
AWS Specification ER 70S-2 ELECTRICAL CHARACTERISTICS:(QW-409)
Deposited Weld Metal (mm) 8.74 Current: DC
Pass Thickness(mm) 3 Max. Polarity: EN
Others No addition of flux to Amps: 100-120 Volts N.A
The face of weld joint Tungsten Electrode Type & Size: EWTh-2. g,2.j
Others: Nil

POSITION :(QW-405) TECHNIQUE: (QW-410)

Position of Groove: 1G Travel Speed: -----
Welding Progression: ------ String or Weave Bead: Strinq & Weave
Others: ---------- Oscillation: WL
Single pass/ Multipass Multipass
PREHEAT :(QW-406) Single/Multiple Electrode: Sinqle
Preheat Temp. DC: RT (39) Others: Nil
_/ 250
Interpass Temp. DC:
Others: Nil

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THERMAX

QW 483 PQR No. 005-2004

TENSILE TEST (QW-150)
Specimen Area Ultimate Tensile
No. mm2 load k .
TT-1 159.00 7850

TT-2 19.35 8.79 170.09 8250 48.52

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Results
Satisfacto
Satisfacto
Satisfacto
Satisfacto

Specimen Notch Notch Dro

No. location Type Break

FILLET WELD TEST (QW 180) None

~
Result: Satisfactory Yes/No.
Macro Results: None
Micro: None
OTHER TESTS
Type of Test: Hardness (Hv). Weld 180. 189. 199. HAZ- 193. 191. 186.
Parent Material-197. 194. 193.
Deposit Analysis: None
Others:

Welder's Name: M.H.Ansari T.No.: A2932 Stamp No.: WB 01

Test Conducted by: Weldin!:! Ena!:! DeDI. 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: 14.05.20°L\- cturer: THERMAX LTD.

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AUDITED BY : SA VANCHINATH
By : A.H.Jadhav

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THERMAX
QW - 483
PROCEDURE QUALIFICATION RECORD I

(PQR)
J

Procedure Qualification Record No.: 007 - 2005 Date: 05.04.2005

WPS No.: 304-1 Rev. 3 + 003-1 Rev.6
Welding Process(es): FCAW+SMAW
Type (Manual, Automatic, Semi-Auto): MANUAL

JOINTS: (QW-402)

~ Root Gap
Root Face -
- 3 -4 mm.
-
0 1 mm.
~ )~-L[~~
IncludedAngle - 600
) 1?~

BASE METALS (QW-403) . POST WELD HEAT TREATMENT (QW-407)

Material Spec. : SA 516 to SA 516 Temperature °C : ====
Type or Grade: Gr.70 to Gr.70 Time: : ====
P. No. -1- Gr. 2 to P.No. --1-Gr.-L Others:
Thickness of Test Coupon (mm) : 50
Dia. of Test coupon (mm): Nil
Others: None GAS: (QW-408) -
% Flow
Gas(es) I Composition rate
FILLER METALS: (QW-404) Mixture lit/min
-
Process FCAW SMAW SG-C as per 18-20
Shielding CO2 SFA- 5.32
Weld Metal Analysis A.No. 1 1 Trailing None
I
Size of Filler Metal mm 0 1.2 4 Backing None
~-iller Metal F.No. 6 4
-6FA Specification 5.20 5.1
AWS Specification E71T-1 E7018 ELECTRICAL CHARACTERISTICS:(QW-409)
Deposited Weld Metal (mm) 25 25 Current: DC
Pass Thickness(mm) 4 Max. 4 Max. Polarity: EP
Others: I) No addition of supplementary filler metal & Amps: 160-180 for FCAW Volts 26-28
Alloy Elements for FCAW. 160-170 for SMAW - Volts: 23-24
ii) Product form: Flux Cored for FCAW Tungsten Electrode Type & Size: Not Applicable I
I

Others:TY"o"l'\sf'e'l M~dl. ~&\0

POSITION :(QW-405) TECHNIQUE: (QW-410)
For FCAW : 80-90
Position of Groove: ~ Travel Speed (mm/min.): For SMAW: 55-60
Welding Progression: UQhili String or Weave Bead: Strinq & Weave
Others: Oscillation:. Nil
Single pass/ Multipass: Multipass
PREHEAT :(QW-406) Single/Multiple Electrode: Sinqle
Preheat Temp. (Min.) °C : (100) Others: Weavinq for SMAW 12mm Max. (3 times
pass Temp. (Max.) °C : 250 of Core Diameter of electrode.)
Others:

[Inter .
Nil
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<>
. ".f:JS
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"'=--
Pune Office
lloyd's Register Asi..
-.

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THERMAX

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

GUIDED BEND TESTS (QW160)

Tvpe and Figure No. Results
. Side Bend QW-462.2 SB1 Satisfactory
Side Bend QW-462.2 SB2 Satisfactory
-...;
,..-;;:;
Side Bend QW-462.2 SB3 Satisfactory
Side Bend QW-462.2 SB4 Satisfactory

TOUGHNESS TESTS (QW 170) None

Specimen Notch Notch Test Ava. Impact Lateral Exp. Drop Weiaht
No. location Type Temp. °C Value Joules % Shear Mils Break No Break

FILLET WELD TEST (QW 180) None

Result: Not Applicable
Macro Results: ------
Micro: None --

""'"
/""

OTHER TESTS -
Type of Test: 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
Deposit Analysis: None
Others: Macro Test Satisfactorv.

Welder's Name: M. H. Ansari T.No.: A2932 Stamp No.: WB 01

Test Conducted by: Weldinq Enqq Dept. 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 I S "" cturer: THERMAX
S LTD.
-..'V
lloyd','-"Rcgist
e]L III
siil 0::>
-,,--er ... ;......
By : V. K. SHENDRIKAR
AUDITED BY : S. A. VANCHINATH N'
.....-./
 \ QW - 482
WELDING PROCEDURE SPECIFICATION
(WPS)
,r
THERMAX

Welding Procedure Specification No. : 201-2 Rev. Q Date 20.03.2008

Welding Process (es): GTAW Type(s): Manual PQR No. : 001/2005, 005/2004

JOINTS: (QW-402) Details

Joint Design: As per equipment Drawinq & Refer to relevant WTS.

Backing: No for root pass, Yes for subsequent passes.

Backing Material (Type): Base metal of P1 / Weld metal.

::J Metal 0 Nonfusing Metal

.-.. Nonmetallic 0 Others
Retainers not permitted
BASE METALS: (QW-403) FILLER METAL: (QW-404)
Process GTAW
P.NO. 1 Gr. 1 , 2 to P.No. 1 Gr 1 , 2 .
OR F.No. 6
-------
Specification Type & Grade
To A.No. 1

Specification Type & Grade

OR SFA No. 5.18

Chem. Analysis & Mech. Prop. n-

To AWS(Class) ER 70S-2
---
Chem. Analysis & Mech. Prop.
Product form (Solid/cored / Solid
Flux cored) GTAW / PAW
-- Size of Filler metal (mm) 0 2.0,

GROOVE FillET Electrode-Flux (Class) Not

Base Metal 1.5 - 32 Any Applicable
thk.range (mm.) Trade Name (Flux) Not

Pipe dia Any Any Applicable

Range (mm.) Consumable Insert None

Others: This WPS is applicable for base metal Deposited weld Groove 32

Without Notch Toughness requirements. metal Thk. range Fillet Any

(mm.)
Pass Thk. (mm.) :::;3
Others: No addition of flux to the face of weld joint.

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