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QW -482 WELDING PROCEDURE SPECIFICATION

(WPS)
(SEE QW 201.1, SECTION IX, ASME BOILER
AND PRESSURE VESSEL CODE
SHEET 1 OF 2
Company Name DCMS ENGINEERING CO.
Welding Procedure Specification No DCMS/WPS/099 Rev-0
Date : 19/04/2012
Supporting PQR no. (S)
DCMS/PQR/099 Rev - 0 Date : 7.05.2012
Welding Process (es)
GTAW
Type (s)
Manual
(Automatic, Manual, Machine or semi Automatic)
JOINTS (QW-402)
Joints Design Single V Groove Joint
Backing Yes ___________ No ____X______
Backing Material (Type) _ARGON GAS______
(Refer to both backing & retailers).
Metal
Nonfusing Metal
Non Metallic

Other

DETAILS

Plates ASTM-A240-Gr 304L


(S.S. to S.S.)

* BASE METAL (QW 403)


P.No. 8
Group no. 1
to P.no.
8
Group no. 1
OR
Specification type and grade
Plates ASTM-A-240 Gr 304L
To specification type and grade
Plates ASTM-A-240 Gr 304L
OR
Chem. Analysis and Mech. Prop ___________NA___________________________
To Chem Analysis and Mech. Prop ________NA___________________________
Thickness Range :Base Metal :- Groove 1.6 to 12 mm
Fillet All thickness, all sizes & all diameters
Other WPS shall be applicable for both without and with backing (Stainless Steel Material)
FILLER METALS (QW-404)
Spec No. (SFA)
AWS No. (Class)
F-No.
A-No
Size of Filler Metals
Weld Metal
Thickness Range
Groove
Fillet
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert

SFA-5.9
ER-308L
6
8
1.6mm

1.6 mm to 12mm
All thicknesses
N.A.
N.A.
N.A.
N.A.
POSITION (QW-405)
POST WELD HEAT TREATMENT (QW-407)
Position (s) of Groove All Positions(Test piece 1G)
Temperature Range ____NA_____
Welding Progression : Up Uphill Down NA
Time Range
_____NA____
Position (s) of Fillet
All Positions

QW-482

WPS NO : DCMS/WPS/099 Dated 19/4/2012


REV : 0
SHEET 2 OF 2
PREHEAT (QW-406)
Preheat Temp. Min
NA__________
Interpass Temp. Max _________1250C________
Preheat maintenance _________NA__________
(Continuous or special heating where applicable should
be recorded)
ELECTRICAL CHARCTERISTICS (QW-409)
Current AC or DC _DC_
Amp (Range)
65-85 Amp

Polarity,
Volts (Range)

GAS (QW-408)
Percent Composition
Shielding (Mixtures) Flow Rate
Shielding
Argon
99.99% Pure 12-15Ltr./min
Trailing
Argon
-Backing
Argon
99.99% Pure 5-10Ltr./min

DCEN (STRAIGHT)
10-12 Volts

(Amp and volts range should be recorded for each electrode size, positions and thickness etc.)

Tungsten Electrodes Size & Type

1.6mm, 2.4mm, 2% Thoriated Tungsten Electrodes

Mode to metal transfer for GMAW

____________ NA ________________________
(Spray arc short circulating arc etc.)
____________ NA ________________________

(Pure tungsten 2% Thoriated etc.)

Electrodes Wire feed speed range

TECHNIQUE (QW-410)
String or weave bead
Root (stringer) & Final (weaving).
Orifice or Gas Cup Size
ceramic nozzle of
Initial and Inter pass (Cleaning Brushing, Grinding etc.)Degreasing with acetone, wire brushing, if required grinding of all pass.
Method of Back Gouging
_____NA ______________
Oscillation
2.5 times of size of filler wire_____________
Contact Tube to Work Distance _____NA______________
Single Pass (per side) __ Multiple____________
Multiple or Single Electrode
__Single_____________
Travel Speed (Range)
40-65 mm/min.__
Peening
Not Allowed
Other
_NA__________________
FILLER METAL
WELD
LAYER(S)

CURRENT

AMP
RANGE

VOLT
RANGE

TRAVEL
SPEED
RANGE
(mm/min)

PROCESS

CLASS

DIAMETER

TYPE /
POLARITY

Root
(1st Pass)

GTAW

ER 308-L

1.6mm

DCEN

65-75

10-12

40-50

2nd Pass

GTAW

ER 308-L

1.6mm

DCEN

75-85

10-12

55-65

3rd &
Subsequent
Passes

GTAW

ER 308-L

1.6mm

DCEN

75-85

10-12

55-65

OTHER

QW-483PROCEDURE QUALIFICATION RECORD

(PQR)
(SEE QW200.2, SECTION IX ASME BOILER AND
PRESSURE VESSEL CODE)
RECORD ACTUAL CONDITION USED TO WELD TEST
COUPON
Company Name
M/S. DCMS Engineering Ltd. Mumbai
Procedure Qualification Record No. DCMS / PQR/099 Date : 7/5/2012
WPS No.
DCM/WPS/099
Date : 19/4/2012
Welding Process(es)
GTAW
Types (Manual, Automatic, Semi-Automatic) Manual

SHEET 1 OF 3

Rev 0
Rev. 0

JOINTS (QW-402)

Plates ASTM - A -240 Gr. 304L to Plate ASTM A - 240 Gr. 304L
Groove Design of Test Coupon

BASE METAL (QW-403)


Material Spec. SA - 240
Type of Grade 304 L
P.No. ________8________ to P. No. ______8_________
Thickness of Test Coupon
6mm
Diameter of Test Coupon
NA
Other
Weld thickness range qualified 1.6 mm to 12 mm

POST WELD HEAT TREATMENT (QW-407)


Temperature ___NA_______
Time
___NA_______
Other
___NA_______

FILLER METALS (QW-404)


SFA Specification
AWS Classification
Filler Metal F-No

GAS (QW-408)

Weld Metal Analysis A-No


Size of Filler Metal

5.9
ER 308-L
6

Percent Composition
Shielding (Mixtures) Flow Rate
Shielding
Argon
99.99% Pure 12-15Ltr./min
Trailing
---Backing Argon
99.99% Pure 12-15Ltr./min

8
1.6mm &
2mm

ELECTRICAL CHARACTERISTICS (QW-409)


Current __________DC_____________
Polarity STRAIGHT (DCEN)
Amps.
85-90 Amp.
Volts 12 (Refer Annexure)
Tungsten Electrode Size ________2.4mm ___________
Other
NA____

Other
Weld Metal Thickness
6mm
POSITION (QW-405)
Position of Groove __________1G___________
Weld Progression (Uphill, Downhill) N.A.
Others __________________N.A.___________
PREHEAT (QW-406)
Preheat Temperature (Minimum) __N.A _
InterpassTemperature (Maximum) 1250 C
Other ________________N.A._______________

TECHNIQUE (QW-410)
Travel Speed
48.8 to 66.7 mm /min (Refer Annexure)
String or Weave Bead _Root(stringer) ,Final(weave)
Oscillation final pass weaving not exceeding 2.5 times dia of filler
wire.
Multipass or Single Pass (Per Side) ___Multipass____
Single or Multiple Electrodes _________Single ______
Other -------------------------------------

PQR No. DCMS/WPS/099


Dt. 8/5/2012 Rev - 0

2007 SECTION IX
QW -483

PQR
Tensile Test (QW 150)
Specimen
No.
T-1
T-2

Width
mm
19
18.80

Thickness
mm
5.90
5.94

Area
mm2
112.10
99.75

Ultimate
Total Load N
70400
62400

Page 2 of 3

Ultimate Unit
Stress N/mm2
628.01
625.56

Type of Failure and


Location
weld metal
weld metal

Guided Bend Tests (QW-160) Mandrel dia 24 mm (4t)


Type and Figure No.
Root Bend
RB -1
Root Bend
RB -2
Face Bend
FB -1
Face Bend
FB -2

Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory

Toughness Tests (QW-170)


Specimen
No.

Notch
Location

Specimen
Size

Test
Temperature

Impact Values
ft.lb

% Shear

Drop Weight Break (Y/N)


Mills

NA

Comments ________________________________________NA__________________________________

Fillet Weld Test (QW-180)


Result Satisfactory Yes _________No. _________ Penetration into Parent Metal Yes ______ No. ___
Macro Results_________________ NA ___________________________________________________
Other Tests
Type of Test ___________________________________________________________________________
Deposit Analysis _________ _______________ NA __________________________________________
Other _________________________________________________________________________________
Welders Name

N. MADHAVAN

Stamp/ID: NMV

Test Conducted by Geo Chem Lab(P)Ltd. Laboratory Test No. M LD /12/04/2012 dt.4.5.2012

We Certify that the statement in this record are correct and that the test welds were prepared, welded, and
tested in accordance with the requirements of Section IX of the ASME BOILER AND PRESSURE VESSEL
CODE.
Manufacture By DCMS Engg. Co.
Date:7.05.2012
Details of record of tests are illustrative only and may be modified to confirm to the type and number of tests
required by the Code.

Page 3 of 3
Annexure to PQR No. DCMS/PQR/099 Date: 7/5/2012 Rev: 0
Name of Welder: N. MADHAVAN

Numbers
of Runs /
Weld
Passes

Stamp/ID: NMV

Electrode
Th 2%

Filler Wire

(Tungsten)

st

1
(Root)
2nd pass

rd

3 pass

4th pass

Prepared By

Abhishek Nag
(QC Engineer)

Process: GTAW

Gas

Backing

Shielding

Gas

ltrs / min

Ltrs./min

2.4 mm

1.6 mm dia
ER 308-L

14

12

2.4mm

1.6 mm dia
ER 308-L

14

12

2.4mm

1.6 mm dia
ER 308-L

14

12

14

12

2.4mm

1.6 mm dia
ER 308-L

Reviewed By

P.V.Khambatkone
(Ex-NPCIL QA)

Current
Volts

11

12

12

12

Amp

Speed
mm/min

72

48.8

87

66.7

87

53.04

87

49.4

Accepted By

Client

QW-484 MANUFACTURERS RECORD OF WELDER OR


WELDING OPERATOR PERFORMANCE
QUALIFICATION TESTS (SEE QW-301, SECTION XI,
ASME BOILER AND PRESSURE VESSEL CODE)

WELDER NAME PURAN SINGH


Welding process(es) used
GTAW

Stamp/ID: PN

Identification of WPS followed by welder during welder during welding of test coupon : DCMS/WPS/099Rev-0 dt.15.09.11

Base material(s) welded

SA-240 Gr 304L

Thickness

6mm Thick Plate

Manual for Each Process (QW-350)


Backing (Metal, weld metal, welded from both sides, flux etc.)
(QW-402)
ASME P.No. 8 to ASME P.No. 8 (QW-403)
( ) Plate (X ) Pipe (enter diameter, if pipe)
Filler metal specification (SFA) : 5.9 and 5.1 Classification
(QW-404)
Filler metal F No.
Filler Metal variety for GTAW, PAW (QW 404)
Consumable insert for GTAW or PAW
Weld deposit thickness for each welding process
Welding position (1G,5G, etc) (QW-405)
Progression (uphill/downhill)
Backing gas for GTAW, PAW or GMAW : Fuel gas for QFW
(QW-408)
GMAW transfer mode (QW-409)
GTAW welding current type / polarity

Actual Values
Without

Range Qualified
with or without

6 mm thk plate
ER-308L
A No.8
6
NA
NA
1.6mm GTAW
1G
N.A.
Argon Gas
99.995%
N.A.
DCEN (GTAW)

1.6 to 12mm Plate


ER-308L
A.No.8
6
N.A.
N.A.
1.6 mm (GTAW)

Machine Welding Variables for the Process Used (QW-360)


Direct / remote visual control
Automatic voltage control (GTAW)
Automatic joint tracking
Welding position (1G, 5G, etc)
Consumable insert
Backing (metal, weld metal, welded from both sides, flux etc.)

Actual Values

Range Qualified

1G & all fillet welds

N.A.
Argon Gas
99.995%
N.A.
DCEN (GTAW)

NA

GUIDED BEND TEST RESULTS


Guided Bend Tests Type ( ) QW- 462.2 (Side) Results ( ) QW 462.3 (a) (Trans. R & F) Type ( ) QW-462.3
(b) (Long, R & F) Results
FB-1
Satisfactory
RB-1
Satisfactory
FB-2
Satisfactory
RB-2
Satisfactory

Visual examination results (QW-302.4):


Satisfactory
Radiographic test results (QW-304 and QW-305):
Satisfactory
(For alternative qualification of groove welds by radiography)
Fillet Weld Fracture test N.A. Length and percent of defects
NA
Macro test fusion NA Fillet leg size NA in X inch Concavity / convexity NA in.
Welding test conduced by DCMS Engineering Co. Ltd.
Radiographic tests conducted by M/s. Geo chem Lab, Mumbai. Laboratory Test No. MLD/11/08/06896
DT.17.9.2011
We certify that the statements in this record are correct and that the test coupons were prepared
welded and tested in accordance with the requirements of Section IX of the ASME Code
DCMS Engineering Co.
Date

__________

CLIENT
Date

_________________

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