Supporting PQR No

Welding process(es)

: SMAW

Type

: Manual

Scope

: This welding procedure specification is applicable for repair welding of P No.1.

Materials without PWHT.

JOINTS: -(QW 402)

Joint Design
Root gap
Root land
Bevel Angle
Backing
Base material
Retainer
Base material

: Single V Groove Joint or as per approved drawing

: 1.5-3.0 mm or as per approved drawing
: 1.5-3.0 mm or as per approved drawing
: 65 5 C
: Nil
: NA
: Nil
: 10 mm

JOINT DESIGN (TYPICAL)

BASE METALS (QW 403)

P.No. / Group No.

: P.No. 1 Group No 2 to P.No.1 Group No 2

Specification Type & Grade

:-

Chemical Analysis

:-

Mechanical Properties

:-

Thickness Range Base Metal

Fillet

: 1.50 20 mm
: All

Weld pass thk < 13 mm

: Yes

FILLER METALS (QW 404)

Specification No. (SFA)

: A5.1

AWS No. Classification

: E7018

F.No.

:4

A.No.

:1

Size of Electrode/Filler metal

: 3.15 & 4.00 mm dia

Filler metal product from

: Electrode

Weld metal Thickness Range

: 20 mm Max.

Electrode Flux

: NA

Supplemental Filler Metal: NA

Fillet: NA
Consumable insert: NA

Change of alloy element

: NA

Brand Name / Trade Name

: NA

Power Feed rate: NA

POSITIONS (QW 405)

Position of Groove
Welding Progression

: All
: NA

Position of Fillet: All

PREHEAT (QW 406)

Preheat Temperature Min.
Inter pass Temperature Max.

: 30 C
: 300 C

Preheat Maintenance: NA

POST WELD HEAT TREATMENT (QW 407)

Type

: None

Temperature Range

: None

Rate of heating / cooling

: None

Time Range

: None

Loading / unloading (max)

: None

GAS (QW 408)

Flow Rate (lpm)

Gas

Shielding gas

: NA

Trailing

: NA

Backing

%Composition / Mixture

: NA

ELECTRICAL CHARACTERISTICS (QW 409)

Weld Pass

Process

Filler metal
Classification

Root Pass
Fill up &
Cap

SMAW
SMAW

E-7018
E-7018

Pulsing Current

Diameter
(mm)
3.15
3.15
4.00

Current
Type &
Polarity

Amps
(Range)

DC/EP
DC/EP
DC/EP

100-140
100-140
140-180

Volt
Travel Speed
Heat Input
(Range) Range (mm/min) K.I/mm (max)

24-28
24-28
24-28

150-200
150-200
200-250

: N.A

Heat Input (max)(KJ/mm)

: Refer table above

Tungsten Electrode Size & Type

: NA

Mode of metal transfer

: NA

Electrode wire feed speed range

: NA

TECHNIQUE (QW 410)

String or weave Bead

: Both (Weave not more than 3 times dia of electrode)

Office, Nozzle or Gas cup Size

: NA

Initial and Inter pass Cleaning

: Wire Brushing and Grinding

Method of back gouging

: Grinding if required

Oscillation

: N.A

Contact tube to work distance

: NA

Multiple or Single pass (per side)

: Multiple pass

Multiple or Single electrode

: Single

Electrode spacing

: N.A

Travel Speed (Range)

: Refer table above

Peening

: Not allowed

Use of thermal process

: Nil

Transfer mode

: NA

Torch orifice dia

Filler metal delivery

: NA
: NA

1.57
1.57
1.51

JOINTS: -(QW 402)

Joint Design
given
Root gap (A)
Root land (B)
Bevel angle
Backing
Base Material
Retainer
Base material thickness (t)

: Single V Groove Joint as per Sketch

Joint design (refer sketch encl)

: 1.5-2.0 mm
: 1.5-2.0 mm
: 65 5 C
: Nil
: NA
: NA
: 10 mm

BASE METALS (QW 403)

PREHEAT (QW 406)

Material Specification

: ASTM A216

Preheat Temperature

Type or Grade

: WCB

Inter pass Temperature : 300 C

P.No. Gr.No.

: P.No. 1 Gr.No.2

Thickness of Test Coupon

: 10 mm

Diameter of Test Coupon

: N.A

Size (mm) (l x w x t)

: 300 x 150 x 10 Thk

: 30 C

Others

: N.A
POST WELD HEAT TREATMENT (QW 407)

Temperature
Time Range

: None
: None

Cooling

: None

Rate of heating / cooling

: None

Loading / Unloading
FILLER METALS (QW 404)
Flow Rate (lpm)

: None

GAS (QW 408)

Gas

Shielding Gas

%Composition

SFA Specifications

: A5.1

: NA

AWS Classification

: E7018

Filler Metal F.No.

:4

Backing Gas

Weld Metal Analysis A.No.

:1

ELECTRICAL CHARECTERISTICS (QW 409)

Size of Filler Metal

: 3.15 mm dia

Current (A.C. or D.C.)

Filler Metal product from

(EP)

: Electrode

Polarity

Weld metal thickness (t)

: 10 mm

Amps

: 130 A

Trade name / brand name

: (ESAB 36H of M/s ESAB

Volts

: 27 V

Trailing Gas

India ltd Chennai, Ref TC Enclosed)

: NA
: NA

: D.C.
: Reverse (Electrode +ve)

Tungsten Electrode size

: NA

SIZE 3.15mm

Others: Heat Input

SIZE 4.00mm

Mode of metal transfer : NA

POSITION (QW 405)

( Refer Attached Welding Parameter Sheet)

Position of Groove

: 1G

Weld Progression

: N.A

: 1.40 KJ/mm

TECHNIQUE (QW 410)

Travel Speed

: 150 160 mm /min (for all pass / all layer)

String or weave Bead

: Both (Weave width not more than 3 times dia of electrode)

Oscillation

: N.A

Multi pass or Single pass (pre side)

: Multi pass

Single or Multiple electrodes

: Single

Method of back gauging

: None

Change of process

Orifice / nozzle size

: N.A

Peening

Gas cup size

: N.A

Transfer mode

Method of cleaning

: Wire brushing, Grinding

: N.A

: Nill

Torch orifice dia

: N.A
: N.A

Filler metal delivery

: NA

TENSILE TEST (QW 150): Report Ref:

Specimen
No
T1
T1

Width (mm)

Thickness (mm)Area (mm)

18.71
18.73

10.01
9.66

187.29
180.93

Ultimate Load (KN)

Ultimate Stress (Mpa)

Type of fracture &
location

99.15
97.90

529.39
541.09

Ductile & base

Ductile & base

GUIDED BEND TEST (QW 160):

Specimen size (mm) ( l x w x t ): 300 x 10 x 10
Specimen ID
FB1
FB2
FB1
FB2

Nature of Bend
Face Bend
Face Bend
Root Bend
Root Bend

Angle of Bend (Deg)

180
180
180
180

Dia of Roller (mm)(4t)

38.1
38.1
38.1
38.1

Free
Free
Free
Free

from
from
from
from

Result
defects. Satisfactory
defects. Satisfactory
defects. Satisfactory
defects. Satisfactory

TOUGHNESS TESTS (QW-170) : NA

FILLET-WELD TEST (QW-180)
Results

: N.A

Penetration into Parent metal: Yes/No

: N.A

Macro Results

: N.A

OTHER TESTS
SI. NO Type of ExaminationAcceptance standard/ Requirement
1 Visual Examination QW-302.4 of ASME Section IX
2 Liquid Penetrate Testing
As per ASME Sec. VIII Div. 1.A.8
3 Radiography
QW-191.2. of ASME Section IX
Acceptable Refer Lab Report
4 Hardness (HV10)
As per NACE MR 0175 / ISO 15156-2
Hardness survey as per sketch enclosed in report
:2003
Base
200 HV max
Base
: Average 158 HV
Weld
200 HV max
Weld
: Average 199 HV
HAZ
200 HV max
HAZ
: Average 191 HV
Acceptable Refer Lab Report
5 Macro examination Shall be free from defects
Free from crack, pin hole, porosity and other abnormalities.
Fusion Satisfactory.
Acceptable Refer Lab Report

We certify that statement in this record are correct and that the test welds were prepared, welded and tested in accordance
with the