NUCLEAR POWER CORPORATION OF INDIA LTD.
(A Government of India Enterprise)
NPCIL WELDING PROCEDURE SPECIFICATIONS
AND
PROCEDURE QUALIFICATIO RECORDS
( PP-P-2049 R-2 )
DIRECTORATE OF QUALITY ASSURANCE
AND
DIRECTORATE OF TEHNOLOGY DEVELOPMENT,
R&D CENTRE, TARAPUR
NUCLEAR POWER CORPORATION OF INDIA LTD.
(A Government of India Enterprise)
NPCIL
WELDING PROCEDURE SPECIFICATIONS
(WPS)
PP-P-2049 R-2
DIRECTORATE OF QUALITY ASSURANCE
AND
DIRECTORATE OF TECHNOLOGY DEVELOPMENT,
R&D CENTRE, TARAPUR
Foreword
The complexity of requirements, diversity of applications and compelling tighter
schedules demand standardization. Standardization and continual improvement are of
paramount importance to any company to attain new heights.
At a time when NPCIL is expecting a significant growth rate, it is important to put
standardized systems in place and to continually upgrade the same, so that the twin objectives
of quality and pace of activities are fulfilled.
Welding is a significant activity during site construction and during plant
maintenance. In the Nuclear industry, the quality of welds is one of the many features
ensuring safety and hence weld quality has been treated seriously since beginning.
In any process, the main contributors to good work are the men and materials
involved. Welding is no exception. Welding Procedures are effective tools to utilise welders
and materials.
Since long, it is strongly felt that in our organization, standardized welding
Procedures satisfying the requirements of Section IX of the ASME Boiler & Pressure Vessel
Code was used so that the construction and maintenance agencies do not encounter initial
difficulties in qualifying the welding procedures etc.
During the decades of its existence, NPCIL has accumulated experience in welding.
The Quality Assurance Directorate (QAD) and R&D centre, TMS under the Directorate of
Technology Development (DTD) has prepared and compiled these standard Welding
Procedures along with the supporting Procedure Qualification Records.
The efforts put by QAD and DTD in preparing these Welding Procedures and
Procedure Qualification Records are praiseworthy and it is expected that this compilation
will be of immense use to all our projects and stations.
Date : 27-05-2016
Place : Mumbai
K.C. PUROHIT
Chairman and Managing Director
NPCIL
Preface
Since long it was strongly felt by NPCIL to develop NPCIL WPS in-house for
application on NPCIL jobs, namely projects, stations and contractor/vendor shops. In NPCIL
contract documents wherever welding is one of the activities to be performed by the
contactor/manufacture, to satisfy the requirements of ASME Boiler & Pressure Vessel code
Section IX. Every manufacturer or contractor is required to prepare relevant Welding
Procedure Specifications (WPS) and qualify the same by carrying out necessary tests after
welding a test coupon and submit relevant Procedure Qualification Records (PQR) to the
departmental agencies i.e. NPCIL for their approval. Even writing of WPS, obtaining
approval from NPC and its qualification is repeat job which consumes lot of man-hour and
delay in start of manufacturing / fabrication activities.
As per ASME Section IX, there are provisions to use “AWS Standard Welding
Procedure specification/s (WPS) listed in Appendix E of ASME Sec. IX, by adoption by
manufacturer or contactor in accordance with Article V.” These Standard WPSs are
developed by AWS and are recognized by ASME. These Std WPSs are to be utilized within
the stipulated conditions laid down in the code. Which includes:
a)
Standard WPSs can not be utilized where impact-testing requirements are specified.
b)
Only AWS Standard WPSs are permitted for adoption by manufacturers / contractors.
Therefore, necessary approval for the following was obtained from Director (T)
c)
Approved NPCIL Welding Procedure Specification/s can be adopted by
manufacturers/contractors engaged for NPCIL jobs and used after necessary
qualification.
d)
NPCIL qualified Std. WPSs can be used by manufacturers/contractors without
elaborate re-qualification on jobs which are non-critical in nature.
(Non
critical
area
/
application
shall
be
identified
by
indentors/projects/stations/Users and shall be reviewed and approved by QA and
FE/TSS/Design Group based on safety and component application, subject to
satisfactory bend test results)
As a step towards standardization, a set of 19 WPSs has been prepared by QAD and
DTD. Out of these most commonly used 11 procedures had been qualified at R&D Centre
and 09 Nos. are declared as standard qualified WPS. Accordingly PP-P-2049 R-1 has been
revised to PP-P-2049 R-2 and procedure qualification records are added.
Guidelines for applicability of WPS and PQR shall be:
1.
NPCIL Qualified WPS and PQR can be used at ongoing project sites/ stations for
departmental use without further qualification. (In cases where work is executed directly
by NPCIL).
2.
NPCIL Standard WPS (09 Nos.) can be adopted by manufacturer or contractor
engaged for NPCIL jobs without elaborate re-qualification for jobs which are not critical
in nature. These can be used by manufacturer or contractor after performing necessary
bend tests as per Article II of ASME Section IX.
For critical applications PQR shall
be made.
3.
WPS, other than Standard WPS can be adopted by Contractor / Manufacturer and shall
be used after qualification as per ASME Section - IX.
4.
User shall check respective applicable specifications, drawings for suitability of
welding procedure(s) for the use and shall obtain necessary approval prior to start
of work.
In addition, WPS for Aluminum welding and BPS for Copper Tube brazing, commonly
used in NPCIL’s NPPs are also prepared and annexed as Annexure-A for reference. These
WPS can be used with necessary qualification as per ASME section-IX.
Associate Director (Quality Assurance)
Date : 25-05-2016
Place : Mumbai
NUCLEAR POWER CORPORATION OF INDIA LIMITED
A GOVERNMENT OF INDIA ENTERPRISE
DIRECTORATE OF QUALITY ASSURANCE
AND
DIRECTORATE OF TECHNOLOGY DEVELOPMENT
NPCIL
WELDING PROCEDURE SPECIFICATIONS
(WPS)
PP-P-2049 R-2
REF. – ASME B & PV CODES, Sections- II, III & IX, NPC Specifications PB-P-452 & PC-P-285 R0.
1
REVISION CONTROL SHEET
Sl.
No.
Révision
Rev. Details
Date of
Approval
Approved by
01
R0
First Issue
21-05-2002
CE (QA-2)
QA Directorate
02
R1
Complete
Document
Revised
15-07-2008
Exécutive Director (QA)
03
R2
PQR added
25-05-2016
Associate Director (QA)
2
INDEX
Sl. No.
Description
Page Nos.
01
Approval Sheet
01
02
Revision Control Sheet
02
03
Index
03
04
General Notes
04-07
05
WPS at a Glance
08
06
Applicability of WPS and PQR
09
07
Welding Procedure Specifications (WPS) and
procedure qualification records (PQR)
10-104
08
(Al welding & Cu brazing)
09
Document (WPS) Acceptance Note
10
Standard Joint Configurations
Table QW 451.1,
11
ASME Sec IX
(Thickness limits)
12
Test Reports
Annexure – A
(5 Pages)
Annexure-B
(1 Page)
Annexure – C
(2 Pages)
Annexure – D
(1 Page)
Annexure – E
(8 Pages)
3
NOTES ON STANDARD WELDING PROCEDURE SPECIFICATIONS
Total 19 Nos. Welding Procedure Specifications (WPS) are prepared. Out of 19,
11 Procedures are qualified at R&D centre, TMS as listed. WPS & PQR are compiled
for the materials commonly used during Construction and Maintenance activities in
NPCIL.
In addition to this, WPS for Aluminium welding and BPS for Copper Tube
brazing, commonly used in NPCIL’s NPPs are also prepared and annexed.
Agencies involved in Fabrication, Construction or Maintenance activities on
NPCIL jobs can use any of these WPS & PQR found suitable to the job to be executed
by them subject to the conditions laid down. Applicability of WPS & PQR shall be
checked with reference to the requirements specified in applicable documents like
design documents and contract documents. If required, job specific WPS & PQR shall
be prepared.
General Notes given below shall be referred before deciding on application of
any of the WPS and PQR. For requirements such as edge preparation, fit-up, weld
surface cleaning, limitation on arc initiation, use of special device like High Frequency
unit, inert gas purging Dam, welding sequence, weld reinforcement, weld identification,
NDT, etc. applicable codes along with design/ contract documents shall be referred.
Applicability of WPS and PQR for repair of welds shall be confirmed with
engineer.
GENERAL NOTES:
Note 1:
a. NPCIL Qualified WPS and PQR can be used at ongoing project sites/ stations and made
available to all stations & sites for departmental use without further qualification after
approval of Document (WPS) acceptance note (Refer Annexure –B). (In cases where
work is executed directly by NPCIL).
b. All the Qualified NPCIL Standard WPS (09 Nos. out of 11 Nos.) can be adopted by
manufacturer or contractor engaged for NPCIL jobs without elaborate re-qualification on
jobs which are non-critical in nature (For details see Table 1 and Table 2). These can be
used by manufacturer or contractor by adopting the WPS and after performing
necessary bend test as per ASME Section IX. For critical applications PQR shall be
made. See Document (WPS) acceptance note attached as Annexure-B.
c. Other NPCIL Qualified WPS (02 Nos.) can be adopted by manufacturer or contractor
engaged for NPCIL jobs (For details see Table 1 and Table 2). These can be used by
manufacturer or contractor after performing necessary qualification as per ASME
Section IX. (See Document (WPS) acceptance note attached as annexure-B)
d. User shall check respective applicable specifications, drawings for suitability of
welding procedure(s) for the use and shall obtain approval. (See Document (WPS)
acceptance note attached as annexure-B)
4
Note 2:
For all Gas Tungsten Arc Welding, shielding gas shall be Argon having purity of
99.967 % or better (as per IS 5760) Gas flow rate shall be in the range of 6-10
liter per minute depending on nozzle size and amperage. Exact flow rate shall be
established during welding procedure qualification.
Note 3:
Purging with Argon is required during Gas Tungsten Arc Welding so as to
protect the backside of the weld from oxidation. Initial purging rate shall be in
the range of 5-25 lpm, depending on volume to be purged. Initial Purge flow rate
& duration shall be adequate to provide purging at least 6 times the volume to be
purged. In no case, however, initial purge shall be less than 10 minutes before
starting of welding.
After initial purge is completed as stipulated above, flow rate can be reduced to a
level, which is just sufficient to maintain a slight +ve pressure inside. Exact flow
rates shall be established during welding procedure qualification.
The above purging shall be maintained at least during root pass & stabilizing
passes or until 5 mm weld metal thickness is obtained.
Argon used for purging shall also be of 99.967 % purity (IS 5760). For welding
high Nickel material e.g. INCONEL 600 Argon used for purging shall be of
99.997 % purity (Grade II of IS 5760)
For automatic tube welding high purity Argon gas (99.9993%) shall be used.
Note 4:
Only NPC approved brands of welding consumables shall be used.
In case of SS covered electrodes, filler wires & consumable inserts, delta ferrite
shall be between 5-9.2%.
For Submerged Arc welding only NPCIL approved Flux- Wire combination shall
be used.
Certificates showing compliance with AWS specification shall be provided for
each batch of welding consumables.
Covered Electrodes shall be kept in their original sealed containers stored in dry
conditions (50% max. relative humidity). Particular care shall be taken in case of
Coastal areas having very high humidity. As covered electrodes coatings are
hygroscopic in nature, all efforts are to be made to ensure that they do not pick
up moisture.
Covered Electrodes shall be taken out from their original sealed containers just
before use and baked in Baking/Drying ovens in accordance with manufacturer’s
instructions.
5
After baking, electrodes shall be taken out and kept in holding oven/field ovens
(maintained at around 60 oC) until finally consumed. Welding consumables shall
be kept identifiable and traceable until finally consumed.
Note 5:
Pre-heat & inter-pass temperatures affect notch toughness properties of weld and
heat affected zones. Therefore Pre-heat & inter-pass temperature shall be
maintained as indicated in WPS. Relevant design specification/ code shall be
referred for deciding on these temperatures. Induction heating coils, resistance
heating coils or gas burners may be used for preheating. Temperature indicating
crayons, calibrated thermocouple with display system or calibrated portable laser
sensor may be used for checking pre-heat temperature and inter pass
temperature.
Note 6:
Test coupons shall be subjected to Post Weld Heat Treatment (PWHT) as
indicated in WPS. Relevant design specification/ code as called for shall also be
referred for deciding on PWHT Temperature and Time ranges.
Approved applicable PWHT procedure shall be followed.
Note 7:
Thickness ranges mentioned in these WPS covers broader range. Actual qualified
range will depend upon thickness of test coupon. In other words for covering full
thickness range of a WPS multiple test coupons may be required (Refer table
QW451.1of ASME Section IX).
Note 8:
There are limitations on thickness qualified in view of Notch Toughness property
requirements (Refer QW451.1 of ASME Section IX); Pre-heat and Post-weld heat
treatment requirements. These shall be taken into account when qualifying a
WPS for an application.
Note 9:
Parameters such as group No under a P-No, inter-pass temperature, heat input
(function of amperage, voltage, travel speed) affect Notch Toughness property.
Hence these parameters shall be taken into account while qualifying a WPS for
particular application.
Note 10:
Inter-pass Cleaning:
Welds shall be cleaned between passes to remove all traces of slag and flux using
brushes & grinders etc. before successive beads or layers are deposited. For SS
welds, wire brushes & chisels used for cleaning shall be of stainless steel.
Similarly only Al oxide grinding wheels shall be employed for cleaning SS welds
so as to avoid iron contamination. Grinding wheels, wire brushes and chisels
used on other base metal shall not be used on SS.
6
Note 11:
Auto Tube Welding:
Welding and testing requirements for this work are different from all other
Welding Procedures written and compiled. For Auto Tube Welding detailed
procedure has been prepared, for specific welding set-up. For qualifying this
procedure Auto Tube Welding M/c manufacturer’s recommendations on various
parameters should be taken into account and recorded in qualification record.
Note 12:
Aluminum Welding:
WPS for Aluminum welding has been prepared for welding of Aluminum Bus
bar at PHWR project sites for electrical applications.
Note 13:
Cu- tube brazing:
BPS for copper brazing has been prepared for brazing of Copper tubes at PHWR
project sites for electrical/ instrumentation applications.
LEGENDS USED:
SM
Shielded Metal Arc Welding
GT
Gas Tungsten Arc Welding
SAW
Submerged Arc Welding
GT SM
Combination of GT and SM welding processes
SMSAW
Combination of SM and SAW welding processes
A-T-T
Automatic Tube to Tube
IS
Indian Standards
H
Post Weld Heat Treated
11
For welding of P1 to P1 or equivalent materials
88
For welding of P8 to P8 materials
18
For welding of P1 or equivalent to P8 materials
1:43
For welding of P1 or equivalent to P43 materials
8:43
For welding of P8 or equivalent to P43 materials
5A: 5A
For welding of P5A to P5A materials.
23:23
For welding of P23 to P23 materials.
107:107
For brazing of P107 to P107 materials.
7
TABLE 1
WELDING PROCEDURES AT A GLANCE
MAX QUALIFIED
THICKNESS
BASE METAL WELDMENT
2T MAX 19
2T
5.1
E-7018,7018-1
MIN.
PWHT
PREHEAT
(Deg C)
(Deg C)
10
NA
2T
5.1
E-7018,7018-1
121
595-675
2T
5.18
ER 70 S2,ER 70 S6
10
NA
2T
2T
5.4
E 308 L -16
10
NA
2T
2T MAX 19
2T
2T
5.9
5.4
ER 308 L
E 309 L -16
NA
10 (P1)
NA
NA
19.0 ≤ T < 38
2T
2T
5.4
E 309 L -16
121 (P1)
Ref Design Spec’n
1.50 ≤ T < 19
2T MAX 19
2T
5.9
ER 309 L
10(P1)
NA
P1 Gr1/2 – P1 Gr1/2
1.50 ≤ T < 19
2TMAX19
2t/2t
5.18+5.1
ER 70 S2/S6+ E-7018,7018-1
10
NA
GTAW+SMAW
P1 Gr1/2 – P1 Gr1/2
19.0 ≤ T < 38
2T
2t/2t
5.18+5.1
ER 70 S2/S6+ E-7018,7018-1
121
595-675
GTAW+SMAW
P1 Gr1/2 – P8 Gr1
1.50 ≤ T < 19
2T MAX 19
2t/2t
5.9 +5.4
ER 309 L+ E 309 L -16
10(P1)
NA
GTSM - 18H
GTAW+SMAW
P1 Gr1/2 – P8 Gr1
19.0 ≤ T < 38
2T
2t/2t
5.9 +5.4
ER 309 L+ E 309 L -16
121 (P1)
Ref Design Spec’n
13
STD GTSM - 88
GTAW+SMAW
P8 Gr1 – P8Gr1
1.50 ≤ T < 19
2T
2t/2t
5.9 +5.4
ER 308 L+ E 308 L -16
NA
NA
14
GT- 1 :43
GTAW
P1 Gr1/2 – P 43
1.50 ≤ T < 19
2T MAX 19
2T
5.14
ER-NiCr 3
NA
NA
15
GT-8 :43
GTAW
P8 Gr1 – P 43
1.50 ≤ T < 19
2T MAX 19
2T
5.14
ER-NiCr 3
NA
NA
16
GTSM 5A5A
GTAW+SMAW
P5Gr1 – P5 Gr1
1.50 ≤ T < 19
2TMAX19
2t/2t
5.28+5.5
ER 90 S B3 + E-9018 B3
200
NA
17
GTSM
5A 5A H
SMSAW-11
GTAW+SMAW
P5Gr1 – P5 Gr1
1.50 ≤ T < 38
2T
2t/2t
5.28+5.5
ER 90 S B3 + E-9018 B3
200
700-760
GMAW+SAW
P1 Gr1/2 – P1 Gr1/2
1.50 ≤ T < 19
2TMAX19
2t/2t
5.1+5.17
E7018-1+F 7 A2 EH 14
10
NA
NPCIL GT-88
(A-T-T)
GTAW
P. No. 8( S.S 304L
Tube) to P. No. 8
( S.S 304L Tube)
Ø6mm1.2thk
Ø10mm1.2thk
Ø12mm1.5thk
Same as PQR
Same as PQR
Not
applicable
Autogenous welds
Not
applicable
Not applicable
SL.
NO
WPS NO
MATERIAL
COMBINATION
‘T’ RANGE
1
STD SM - 11
SMAW
P1 Gr1/2 – P1 Gr1/2
1.50 ≤ T < 19
2
3
SM -11H
SMAW
P1 Gr1/2 – P1 Gr1/2
19.0 ≤ T < 38
2T
STD GT - 11
GTAW
P1 Gr1/2 – P1 Gr1/2
1.50 ≤ T < 19
2T MAX 19
4
STD SM - 88
SMAW
P8 Gr1 – P8Gr1
19.0 ≤ T ≤ 38
5
6
STD GT - 88
STD SM - 18
GTAW
SMAW
P8 Gr1 – P8Gr1
P1 Gr1/2 – P8 Gr1
1.50 ≤ T < 19
1.50 ≤ T < 19
7
SM -18H
SMAW
P1 Gr1/2 – P8 Gr1
8
STD GT - 18
GTAW
P1 Gr1/2 – P8 Gr1
9
STD GTSM - 11
GTAW+SMAW
10
GTSM - 11H
11
STD GTSM - 18
12
18
19
PROCESS
SFA.NO
AWS NO (FILLER)
Legend:
STD Qualified
Qualified up to 4.5 mm.
To be qualified.
PQR to be made.
NOTE:
1)
2)
ALL QUALIFICATIONS ARE CONSIDERED WITH FULL THICKNESS WELDMENT.
FOR APPLICATIONS REQUIRING INSERTS, REF RESPECTIVE WPS.
SEPARATE RE QUALIFICATION MAY BE CONDUCTED IF CALLED BY DESIGN SPECIFICATION.
3) FOR GTAW, WITHOUT BACKING GAS/PURGING, RE QUALIFICATION IS REQUIRED.
8
TABLE 2
Applicability of WPS and PQR
SL.
NO
WPS NO
1
STD SM - 11
2
Supporting
PQR
Application
NPCIL
Contractor /
Supplier
A
Note (i)
Note (ii)
SM -11H
------
Note (iii)
Note (iii)
3
STD GT - 11
C
Note ( i)
Note (ii)
4
STD SM - 88
D
Note ( i)
Note (ii)
5
STD GT - 88
E
Note ( i)
Note (ii)
6
STD SM - 18
F
Note ( i)
Note (ii)
7
SM -18H
----
Note (iii)
Note (iii)
8
STD GT - 18
H
Note ( i)
Note (ii)
9
STD GTSM - 11
C+A
Note ( i)
Note (ii)
10
GTSM - 11H
----
Note (iii)
Note (iii)
11
STD GTSM - 18
H+F
Note (i)
Note (ii)
12
GTSM - 18H
----
Note (iii)
Note (iii)
13
STD GTSM - 88
E+D
Note (i)
Note (ii)
14
GT- 1 :43
L*
Note (i)
Note (iii)
15
GT-8 :43
M*
Note (i)
Note (iii)
16
GTSM 5A5A
---
Note (iii)
Note (iii)
17
GTSM 5A 5A H
---
Note (iii)
Note (iii)
18
SMSAW-11
---
Note (iii)
Note (iii)
19
NPCIL GT-88 (A-T-T)
---
Note (iii)
Note (iii)
Remarks
* Qualified up to
4.5 mm only
Note:
(i) WPS can be used by NPCIL without further qualification.
(ii) STD WPS can be used by contractor on non-critical areas after necessary bend test as per
article II of ASME section–IX .
For critical applications PQR shall be made with all the tests as per ASME section - IX.
(iii) WPS can be adopted and shall be used only after qualification (PQR) as per section IX.
For all the above cases approval shall be obtained through Document (WPS) acceptance note
(Refer Annexure–B).
9
NPCIL-STD-SM-11 (QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT TEST REQUIREMENT
Page 1 of 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate & DTD, R&D CENTER
WPS No.
NPCIL-STD-SM-11
Date
Supporting PQR
No(s).
A
Date
07.07.2014
Type(s)
MANUAL
Welding process (as)
SMAW
07.07.2014
Rev. No.
R-1
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type)
As per design
(Refer to both backing and
retainers)
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
document.
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
Sketches, production drawings, weld symbols or written description should show the general arrangement of
the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified. (At
the option of the mfg., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g.
for notch toughness procedure, for multiple process procedures, etc.)
Base Metals (QW-403) •
P.No:
OR
1
*Group No:
1/2
Specification, Type & Grade to Specification, type
& grade
OR
TO
P.No:
1
*Group No:
1/2
IS 2062 or IS1239 or equivalent to IS 2062 or IS1239
or equivalent or P1.
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
NA
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
Fillet
All Thickness
* When Notch Toughness properties are called for refer QW 403.5, ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT requirement. Please check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness, Ref: QW 403.6 (16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T <
6mm) or by respective design document.
10
NPCIL-STD -SM-11
(Page 2 of 3)
Filler metals (QW-404) .
Specification 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
Other
SFA 5.1
E-7018 or E7018-1
2 or 4
1
2.5mm, 3.15mm, 4 mm
Max 2T# (limited to 19 mm)
All sizes
NA
NA
NA
…….
 Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
Positions (QW-405)
Post Weld Heat Treatment
(QW-407)
Position(s) of Groove
$All
Temp. range
NA
Weld Progression
Vertical Uphill
Time range
NA
Position(s) of Fillet
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
Inter pass temp.
(max.)
*10 degree C
* $$NA
Preheat maintenance
(Continuous or
special heating,
where applicable,
should be recorded)
With or
Without
Gas(es)
(Mixture)
Flow rate
Shielding
NA
NA
NA
Trailing
NA
NA
NA
Backing
NA
NA
NA
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature
above the minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature
achieved shall be Recorded and IP temperature more than recorded (in PQR) + 55 deg.
C calls for re-qualification.
11
NPCIL-STD-SM-11
(Page 3 of 3)
Electrical Characteristics (QW-409)
DC
Current AC or DC
Amps (Range)
Weld
layer(s)
Process
Root
1st
2nd
3rd
Balance
SMAW
‘’
‘’
‘’
‘’
Polarity
Refer table below
Filler metal
Volts (range)
Current
Class
Dia.
Type
polarity
Amp
range+
SFA5.1
‘’
‘’
‘’
‘’
2.5
2.5
3.15
3.15
4.0
DC-EP
‘’
‘’
‘’
‘’
70-100
70-100
100-140
100-140
150-190
Volt
range+
22-40
‘’
‘’
‘’
‘’
Electrode Positive
(EP)
Refer table below
Travel
speed
range
mm/min+
40-80
‘’
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Not applicable
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
NA
Brushing or Grinding, joint shall be dry prior to
welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of
2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR, Calls
for re-qualification (Ref QW409.1)
QUALIFIED
REFER TABLE-2 FOR FURTHER
ACTION
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY
OF THIS WELDING PROCEDURE FOR THE
APPLICATION AND SHALL HAVE THE
APPROVAL AS PER DOCUMENT (WPS)
ACCETANCE NOTE ATTACHED.
(SEE Annexure-B.
12
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No. : A
Page: 1of 2
Date: 07.07.2014
WPS No.: NPCIL-STD- SM-11
Welding Process (es) / Type(s) SMAW / Manual
Joints (QW-402)
Weld Type
: Groove weld, Single-bevel
Backing
: NA
Root Opening : 2.8 mm Root Face 1.6
Groove Angle : 37.5o
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407 )
Material Spec., Type or Grade
: ASTMA 516, Grade 70 to
ASTM 516, Grade 70
P-NO.: 1 Group No: 2 to P-NO : 1 Group NO.: 2
Thickness of Test Coupon (mm) : 10.0
Type
: NA
Temperature
: NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification:
: 5.1
Shielding
: None
AWS Classification:
: E-7018
Trailing
: None
: 4
Backing
: None
Filler Metal F-No:
Weld Metal Analysis A-No : NA
Size of Filler Metal (mm)
: 2.4 & 3.15
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP
Weld Deposit’ t’ (mm)
: 10.0
Amps
: 85 - 135
Pass Greater Than ½"
: No
Volts
: 22-28
Filler Metal Product Form
: Covered electrode
Tungsten Type / Size
: NA
Supplemental Filler Metal
: None
Transfer Mode
: NA
Wire Feed Speed (mm/min) : NA
Positions (QW-405)
Heat Input
Position of Joint
: 3G - Vertical
Weld Progression
: Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C (Ambient)
Interpass Temp.
: 150°C (Max.)
Preheat Maintenance : NA
: --
Technique (QW-410)
Travel Speed (mm/min)
: 75
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
: 3 times of filler metal size max.
Oscillation
Multi /Single Pass (per side ) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: NA
Contact Tube to Work Dist. : NA
13
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No.: A
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
ROOT
FILL
FILL
CAP
SMAW
SMAW
SMAW
SMAW
Filler Metal
AWS
Size (mm)
Classification
E-7018
E-7018
E-7018
E-7018
Current
Type / Polarity Amperage
Range
2.4
2.4
3.15
3.15
DCEP (reverse)
DCEP (reverse)
(reverse)
DCEP
(reverse)
DCEP (reverse)
90-95
85-90
130-135
125-128
Voltage
Range
22 -28
22 28
22 -28
22 -28
Travel
Speed
Range
(mm/min)
72
80
68
62
Tensile Test (QW-150)
Specimen
No.
Width (mm)
Thickness
(mm)
Area (mm2)
1A
1B
12.58
12.60
9.92
9.94
124.79
125.24
Ultimate
Total Load,
N
72840
73680
Ultimate
Unit Stress,
N/mm2
583.68
588.29
Type of
Failure &
Location
Ductile-Weld
Ductile-PM
Result
satisfactory
satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen Size
(mm)
Test Temp.
(0C)
Impact Values
Joule
Comments:
%
Shear
Drop Weight
Break (Y/N)
Result
Mils
Test results were acceptable. (Test Report no. : 44079 dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Awadh Bihari
Liquid penetration test
RT
None
None
ID: ………………………….. Stamp: …………………….
PQR was done and welding of coupon was witnessed by:
Test conducted by: NPCIL
Test ID: A
Manish J. Chauhan
We certify that the statements in the record are correct and that the test welds were prepared welded
and tested in accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
14
WITH PWHT
NPCIL-SM-11H
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate
WPS No.
NPCIL-SM-11 H
Date
Supporting PQR No(s).
TO BE MADE BY USER
ORGANIZATION
Date
7-3-2007
Welding process (es)
SMAW
Type(s)
Rev. No.
R-0
MANUAL
(Automatic, Manual, Machine, or SemiAuto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type)
As per design
document.
(Refer to both backing and
retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
** # 19 ≤ T (thickness of test coupon) < 38
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)
P.No:
1
*Group No:
1/2
TO
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
IS 2062 or IS1239 or equivalent to IS 2062 or IS1239 or
equivalent or P1.
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
5 mm to 2T
NA
Fillet
All Thickness
* When Notch Toughness properties are called for refer QW 403.5, ASME Sec-IX for Group. No.
restriction.
** When Notch Toughness properties are called for, minimum thickness qualified is governed by test coupon
thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or respective
design document. For lower thickness range in PHT system (presently 12mm to 16mm) additional test
coupon is required.
15
NPCIL-SM-11H
(Page 2 of 3)
Filler metals (QW-404) •
Specification 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
Other
SFA 5.1
E-7018 or E7018-1
4
1
2.5mm, 3.15mm,4 mm,5 mm
Max 2T#
All sizes
NA
NA
NA
NIL
 Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
Positions (QW-405)
Post Weld Heat Treatment (QW-407)
(Reference taken from PB-P-452; user to check applicable Specification.)
Position(s) of Groove
$All
Temp. range
595-675 Deg C
Weld Progression
Vertical
Uphill
Time
range(hold)
A)T up to 25 mm -1Hr;
B)25< T
<50 -1Hr+25min for each addition of 1cm beyond 25mm C)50< T
<125-2Hr+6min for each addition of 1cm beyond 50 mm.
Position(s) of Fillet
All
PWHT Procedure shall be referred for Temp range, heating and cooling rates.
Ref applicable Specn, change in parameters calls for re qualification.
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
Inter pass temp. (max.)
Preheat maintenance
(Continuous or special heating,
where applicable, should be
recorded)
$$ 121 degree C
^ NA
With or Without
Shielding
Tracing
Gas(es)
NA
NA
Backing
NA
(Mixture)
NA
NA
Flow rate
NA
NA
NA
NA
$$ For T > 30 mm and C ≤ 0.3% or T > 20 mm and C > 0.3% ; Preheat to 121 Deg C For T > 12 mm in
PHT and T > 19mm in Steam lines irrespective of C% and weld zone temp shall be min 93 Deg C
throughout the welding process.(Ref:PB-P-452)
1.
In any case min metal temp shall not be below 10 Deg C.(when preheat is not applied )
2.
Decrease of preheats by more than 55Deg C, calls for re qualification.
^ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall
be Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
16
NPCIL-SM-11H
(Page 3 of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Filler metal
Polarity
Volts (range)
Reverse (EP)
Refer table below
Current
Travel speed
Other
Volt
range
Class
Dia.
Type polarity Amp range
Process
range
mm/min
.
SMAW SFA5.1 2.5
DC-EP
70-100
22-40
40-80
‘’
‘’
2.5
‘’
70-100
‘’
‘’
‘’
‘’
3.15
‘’
100-140
‘’
‘’
‘’
‘’
3.15
‘’
100-140
‘’
‘’
‘’
‘’
4.0
‘’
150-190
‘’
‘’
‘’
‘’
5.0
‘’
200-250
‘’
‘’
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Weld
layer(s)
Root
1st
2nd
3rd
Balance
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Not applicable
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
NA
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR,
calls for requalification (Ref : QW409.1)
17
NPCIL - STD- GT-11 (QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT
TEST REQUIREMENT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
WPS No.
NPCIL
NPCIL-STD-GT-11
Supporting PQR No(s).
C
Welding process (es)
GTAW
Prepared by
QA Directorate & DTD, R&D CENTER
Date
07.07.2014
Date
07.07.2014
Rev. No.
R-1
MANUAL
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
TO
P.No:
1
*Group No:
1/2
IS 2062 or IS1239 or equivalent to IS 2062 or IS1239 or
equivalent or P1.
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
NA
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5, ASME Sec-IX for Group. No.
restriction.
** a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT. Please check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or
by respective design document.
18
NPCIL-GT-11
(Page 2 of 3)
Filler metals (QW-404) •
Specification 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
Other
SFA 5.18; SFA 5.30 (FOR INSERT)
ER 70 S2 or ER 70 S6
6
1
1.6mm, 2.4mm, 3.2 mm
Max 2T#(limited to 19 mm)
All sizes
NA
NA
# # With or Without
NIL
 Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
## Inserts when used, shall confirm to SFA 5.30(Mild Steel)
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
$All
Temp. range
NA
Weld Progression
Vertical Uphill
Time range
NA
Position(s) of Fillet
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
* 10 degree C
Inter pass temp. (max.)
* $$NA
Shielding
99.95%
Argon
NA
6-10 LPM
Preheat maintenance
With or Without
Trailing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture
)
Flow rate
See Gen Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature
above the minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved
shall be Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for requalification.
19
NPCIL-GT-11
(Page 3 of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Filler metal
Class
Weld
layer(s)
Process
Root
1st
2nd
3rd
Balance
GTAW
‘’
‘’
‘’
‘’
SFA5.30
SFA5.18
‘’
‘’
‘’
Polarity
Volts (range)
Straight (EN)
Refer table below
Current
Dia.
Type polarity
INSERT
2.4
2.4
3.2
3.2
DC-EN
‘’
‘’
‘’
‘’
Amp
range+
55-90
60-100
60-100
70-120
70-120
Volt
range+
Travel speed
range
mm/min+
10-20
10-30
‘’
‘’
‘’
40-80
‘’
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness,
etc. This information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Stringer for Root, Weave for subsequent passes
Orifice or gas cup size
Standard sizes
Initial & inter pass cleaning
Method of back gouging
Oscillation
Brushing or Grinding
Grinding
3 times of filler metal size (max)
Contact Tube to work Distance
NA
Multiple or single pass (per side)
Either, All pressure retaining weld shall be minimum of 2 passes
Multiple or single electrode
Travel speed (range)
Single
40 – 80 mm per minute
Peening
Not allowed
Other
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR, calls for
requalification (Ref QW409.1)
QUALIFIED
REFER TABLE-2 FOR FURTHER
ACTION
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
APPLICATION
AND
SHALL
HAVE
THE
APPROVAL
AS
PER
DOCUMENT
(WPS)
ACCETANCE NOTE ATTACHED. (SEE Annexure-B.)
20
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
WPS No. NPCIL-STD-GT-11
PQR No.: C
Date:
07.07.2014
Page:
1 of 2
GTAW / Manual
Welding Process (es) / Type(s)
Joints (QW-402)
Weld Type
: Groove weld
Single-bevel Vee
Backing
: NA
Root Opening : 2.8 mm Root Face 1.8
Groove Angle : 37.5o
SINGLEVEEGROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407
Material Spec., Type or Grade
: ASTM A 516, Grade 70
to ASTM 516, Grade 70
Type
: NA
Temperature : NA
P-NO.: 1 Group No: 2 to P-NO. : 1 Group NO.: 2
Time
Thickness of Test Coupon (mm) : 10.0
Gas (QW-408)
Filler Metals (QW-404)
Gas Composition / Flow Rate
: NA
SFA Specification
: 5.1
Shielding
: 99.95% argon / 7 LPM
AWS Classification
: ER 70 S2
Trailing
: None
Filler Metal F-No
: 6
Backing
: 99.95% argon / 14 LPM
Weld Metal Analysis A-No : NA
Size of Filler Metal (mm)
Weld Deposited’ (mm)
: 1.6 & 2.4
: 11.50
Pass Greater Than ½"
: No
Filler Metal Product Form
: Bare electrode
Supplemental Filler Metal : None
Positions (QW-405)
Position of Joint
: 3G - Vertical
Weld Progression : Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C
Inter-pass Temp.
: NA°C
Preheat Maintenance : NA
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP (reverse)
Amps
: 72-110
Volts
: 12-27
Tungsten Type / Size
: EW Th-2 / 2.4 mm
Transfer Mode
: NA
Wire Feed Speed (mm/min) : NA
Heat Input
:
Technique (QW-410)
Travel Speed (mm/min)
String/ Weave Bead
: 75
: Stringer for Root, Weaves for subsequent
passes
Oscillation
: 3 times of filler metal size
Multi / Single pas )per side) : Multi pass
Multi / Single Electrode
: Single
Nozzle / Gas Cup Size
: Standard Size
Contract Tube to Work Dist : NA
21
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. C
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
ROOT
Process
Current
Type / Polarity Amperage
Range
DCEP (reverse)
90-100
Voltage
Range
SMAW
Filler Metal
AWS
Size
Classification
(mm)
ER 70 S2
2.4
20-25
Travel
Speed Range
(mm/min)
72
FILL
FILL
CAP
SMAW
SMAW
SMAW
ER 70 S2
ER 70 S2
ER 70 S2
DCEP (reverse)
DCEP (reverse)
DCEP (reverse)
20-25
25-35
25-35
80
80
62
2.4
3.2
3.2
90-100
95-115
95-115
Tensile Test (QW-150)
Specimen No.
Width (mm)
Thickness
(mm)
Area
(mm2 )
Ultimate Total
Load, N
Ultimate Unit
Stress, N/mm2
3A
3B
12.54
12.54
9.86
9.84
123.64
123.39
63880
63760
516.64
516.72
Type of
Failure &
Location
Ductile-PM
Ductile-PM
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Speci
men
No.
1
Notch
Location
Specimen
Size (mm)
Test Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight Break
(Y/N)
Mils
Comments : Test results were acceptable. (Test Report no : 44079-B dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Santosh Pagdhare
Liquid penetration test
RT
ID :
----------------
Stamp :
None
None
----------------------------
PQR was done and welding of coupon was witnessed by: Manish J. Chauhan
Test conducted by : NPCIL
Test ID:
C
We certify that the statements in the record are correct and that the test welds were prepared welded and
tested in accordance with the requirements of section IX of the ASME Code
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
22
NPCIL-STD-SM-88(QUALIFIED)
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate & D, R&D CENTRE
Supporting PQR No(s).
D
Date
Date
7-7-2014
7-7-2014
Welding process (es)
SMAW
Type(s)
WPS No.
NPCIL-STD-SM-88
Rev. No.
R-1
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type)
As per design
document.
(Refer to both backing and
retainers)
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1. 5 ≤ T (thickness of test coupon) ≤ 38
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)
P.No:
8
Group No:
1
TO
P.No: 8
Group No:
1
OR
Specification, Type & Grade to Specification,
type & grade
NA
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
* Groove
1.5 mm to 200 mm
Fillet
All Thickness
* For 1.5 < T ≤ 10 Range Qualified : 1.5 - 2T
For 10 < T < 38 Range Qualified : 5.0 - 2T
For
T = 38 Range Qualified : 5.0 – 200 mm Also Refer Table QW-451.1
23
NPCIL-STD-SM-88
(Page 2 of 3)
Filler metals (QW-404) •
Specification 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
Other

#
SFA 5.4
E-XXX(X)-15,16,17 eg;E308L-16
5
8
2.5mm, 3.15mm,4 mm,5 mm
Max 2T#
All sizes
NA
NA
NA
NA
Each base metal-filler metal combination should be recorded individually.
Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
All
Weld Progression
Vertical Uphill
Position(s) of Fillet
All
Preheat (QW-406)
Temp. range
NA
Time range(hold)
NA.
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
NA
Inter pass temp. (max.)
* < 150 Deg C
Shielding
Preheat maintenance
NA
(Continuous or special
heating, where applicable,
should be recorded)
Gas(es)
(Mixture)
Flow rate
NA
NA
NA
Tracing
NA
NA
NA
Backing
NA
NA
NA
* Preheat and inter pass temperature must be sufficient to prevent crack
formation. Temperature above the minimum shown may be required for highly
restrained welds.
24
NPCIL-STD-SM-88
(Page 3 of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Filler metal
Weld
layer(s)
Root
1st
2nd
3rd
Balance
Process
SMAW
‘’
‘’
‘’
‘’
‘’
Polarity
Volts (range)
Reverse (EP)
Refer table below
Current
Class
Dia.
Type polarity
Amp range
SFA5.4
‘’
‘’
‘’
‘’
‘’
2.5
2.5
3.15
3.15
4.0
5.0
DC-EP
‘’
‘’
‘’
‘’
‘’
60-80
60-80
80-120
80-120
110-160
150-200
Volt
range
22-40
‘’
‘’
‘’
‘’
‘’
Travel speed
range
mm/min
40-80
‘’
‘’
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Not applicable
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
NA
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
REFER TABLE-2 FOR FURTHER APPLICATION AND SHALL HAVE THE APPROVAL
ACTION
AS PER DOCUMENT (WPS) ACCETANCE NOTE
ATTACHED. (SEE Annexure-B.)
QUALIFIED
25
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
WPS No. NPCIL-STD-SM-88
PQR No : D
Welding Process (es) / Type(s) :
Date:
07.07.2014
Page: 1 of 2
SMAW / Manual
Joints (QW-402)
Weld Type
: Groove weld, Single-bevel
Backing
: Back welded
Root Opening : 3.0 mm
Root Face: 2.1 mm
Groove Angle : 75°
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407 )
Material Spec., Type or Grade
: ASTM A 240, SS304 to
ASTM A 240, SS304
P-No.: 8, Group No.: 1 to P-No. : 8 Group No.: 1
Type
: NA
Temperature : NA
Time
: NA
Thickness of Test Coupon (mm) : 20.0
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
: 5.4
Shielding
: None
AWS Classification
: E-308 L
Trailing
: None
Filler Metal F-No
: 5
Backing
: None
SFA Specification
Weld Metal Analysis A-No : NA
Electrical Characteristics (QW-409)
Size of Filler Metal (mm)
: 2.5 &
3.15
Current / Polarity
: DCEP (reverse)
Weld Deposited’ (mm)
: 21.30
Amps
: 70-120
Pass Greater Than ½"
: No
Volts
: 22-30
Filler Metal Product From
: Royal Arc
Tungsten Type / Size : NA
Supplemental Filler Metal : None
Transfer Mode
Positions (QW-405)
Wire Feed Speed (mm/min): NA
Position of Joint
Heat Input : --
: 3G - Vertical
Weld Progression : Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C
Interpass Temp.
: 120°C
Preheat Maintenance : NA
: NA
Technique (QW-410)
Travel Speed (mm/min)
: 50
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size
Multi /Single Pass (per side) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
:
NA
Contact Tube to Work Dist.:
NA
26
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. – D
Page: 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
Filler Metal
AWS
Size
Classification
(mm)
Current
Type /
Amperage
Polarity
Range
Voltage
Range
2.5
2.5
2.5
3.15
3.15
DCEP
DCEP
DCEP
DCEP
DCEP
65-80
65-80
70-80
80-110
85-115
30-40
‘’
‘’
20-30
‘’
Travel
Speed
Range
(mm/min)
40
62
46
62
40
ROOT
FILL
FILL
FILL
FILL
SMAW
SMAW
SMAW
SMAW
SMAW
E-308 L
E-308 L
E-308 L
E-308 L
E-308 L
FILL
CAP
SMAW
SMAW
E-308 L
E-308 L
2.5
2.5
DCEP
DCEP
70-80
70-80
30-40
‘’
40
40
Specimen
No.
Width (mm)
Thickness
(mm)
Area (mm2)
1A
1B
12.56
12.50
20.12
20.30
252.71
253.75
Tensile Test (QW-150)
Ultimate
Total Load,
N
145760
145440
Ultimate Unit
Stress, N/mm2
Type of Failure
& Location
576.79
573.16
Ductile - PM
Ductile - PM
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Side bend at 4t (SB1)
QW-462.2 Side bend at 4t (SB2)
Result
Satisfactory
Satisfactory
Toughness Test (QW-170) - Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments: Test results were acceptable. ( Test report no. : 44081 dated 21.11.2012)
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder's Name : Awadh Bihari
Liquid penetration test
RT
ID: ..................
PQR was done & welding of coupon witnessed by:
Test conducted by:
NPCIL
None
None
Stamp: ...............................................
Manish J. Chauhan
Test ID:
D
We certify that the statements in the record are correct & that the test welds were prepared,
welded and tested in
accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
27
NPCIL-STD-GT-88 (QUALIFIED)
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
WPS No.
NPCIL-STD-GT-88
Supporting PQR No(s).
E
Prepared
by
Date
Date
Welding process (es)
GTAW
Type(s)
Company Name
NPCIL
QA Directorate & DTD, R&D Centre
MANUAL
7-7-2014
7-7-2014
Rev. No.
R-1
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type)
As per design
document.
(Refer to both backing and
retainers)
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1. 5 ≤ T (thickness of test coupon) < 19
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
8
Group No:
1
TO
P.No: 8
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
* Groove
1.5 mm to 2 T
Group No:
1
NA
NA
Fillet
All Thickness
* 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range qualified.
28
NPCIL-STD-GT-88
(Page 2 of 3)
Filler metals (QW-404) •
Specification 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
Other

#
^
SFA 5.9,SFA 5.30(for insert)
ER-XXX(X) eg; ER 308 L
6
8
1.6mm, 2.4mm,3.2mm
Max 2T#
All sizes
NA
NA
^With or Without
NA
Each base metal-filler metal combination should be recorded individually.
Weldment is full thickness of test coupon.
Insert when used shall confirm to SFA 5.30 e.g.: IN 308 L class 1, style A
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
All
Weld Progression
Vertical Uphill
Position(s) of Fillet
All
Preheat (QW-406)
Preheat temp. (min.)
NA
Inter pass temp. (max.)
* < 150 Deg C, Record in
Temp. range
NA
Time range(hold)
NA.
Gas (QW-408
Percentage composition
Gas(es)
(Continuous or special
heating, where applicable,
should be recorded)
NA
Flow rate
Shielding
99.95%
Argon
NA
6-10 LPM
Tracing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
PQR
Preheat maintenance
(Mixture)
See Gen.
Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation.
Temperature above the minimum shown may be required for highly restrained welds.
29
NPCIL-STD-GT-88
(Page 3 of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
Weld
layer(s)
Process
Root
1st
2nd
3rd
Balance
GTAW
‘’
‘’
‘’
‘’
DC
Refer table below
Polarity
Volts (range)
Filler metal
Current
Class
Dia.
SFA5.30
SFA5.9
‘’
‘’
‘’
INSERT
2.4
2.4
3.2
3.2
Type
polarity
DC-EN
‘’
‘’
‘’
‘’
Amp range
55-90
60-100
60-100
70-120
70-120
Straight (EN)
Refer table below
Volt
range
10-20
10-30
‘’
‘’
‘’
Travel
speed
range
mm/min
40-80
‘’
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
QUALIFIED
REFER TABLE-2 FOR FURTHER
ACTION
Stringer, except for final pass
Standard sizes
Brushing or Grinding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
APPLICATION AND SHALL HAVE THE APPROVAL
AS PER DOCUMENT (WPS) ACCETANCE NOTE
ATTACHED. (SEE Annexure-B.)
30
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No.:
WPS No.: NPCIL-STD-GT-88
E
Date: 07.07.2014
Page:
1of 2
GTAW / Manual
Welding Process (es) / Type(s):
Joints (QW-402)
Weld Type
: Groove weld , Single-bevel
Backing
: NA
Root Opening
: 2.6
Groove Angle
: 75
mm Root Face
1.8 mm
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407)
Material Spec., Type or Grade
: ASTMA A 240, SS 304
to ASTM A 240, SS 304
Type:
NA
Temperature:
NA
P-NO.: 8 Group No: 1 to P-NO.: 8 Group NO.: 1
°C
Thickness of Test Coupon (mm)
Time:
: 10.0
NA
Hr
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification
: 5.9
Shielding:
99.95 Argon / 6 LPM
AWS Classification
: ER 308 L
Trailing:
None
: 6
Backing:
99.95 Argon / 12 LPM
Filler Metal F-No
Weld Metal Analysis A-No : NA
Electrical Characteristics (QW-409)
Size of Filler Metal (mm)
: 2.0 & 3.20
Current / Polarity
: DCEN (straight)
Weld Deposit ’t’ (mm)
: 11.50
Amps
: 55-115
Pass Greater Than ½"
: No
Volts
: 12-30
Filler Metal Product Form
: Bare electrode
Tungsten Type / Size : EW Th-2
Supplemental Filler Metal : None
Transfer Mode
Positions (QW-405)
Wire Feed Speed (mm/min) : NA
Position of Joint
: 3G - Vertical
: NA
Heat Input
: --
Weld Progression : Uphill
Technique (QW-410)
Preheat (QW-406)
Preheat Temp.
: 20 °C
Inter pass Temp.
: 145°C
Preheat Maintenance : NA
Travel Speed (mm/min)
: 50-75
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size ( max. )
Multi /Single Pass (per side) : Multi pass
Multi /Single Electrode
:
Single
Nozzle/Gas Cup Size
:
NA
Contact Tube to Work Dist. : NA
31
NPCIL, R&D CENTRE
Procedure Qualification Record (PQR)
PQR No. – E
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
ROOT
FILL
FILL
CAP
GTAW
GTAW
GTAW
GTAW
Filler Metal
AWS
Size (mm)
Classification
ER-308L
ER-308L
ER-308L
ER-308L
Current
Type /
Amperage
Polarity
Range
Voltage
Range
DCEP
DCEP
DCEP
DCEP
25-28
25-28
20-25
20-25
2.4
2.4
3.2
3.2
60-65
60-80
100-115
100-115
Travel
Speed
Range
(mm/min)
50
65
75
60
Tensile Test (QW-150)
Specime
n No.
Width
(mm)
Thickne
ss (mm)
Area
(mm2)
Ultimate
Total Load, N
Ultimate Unit
Stress, N/mm2
T1
T2
12.42
12.44
9.80
9.84
121.72
122.41
70800
71520
581.68
584.27
Type of
Failure &
Location
Ductile-PM
Ductile-PM
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) - Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments : Test Results were acceptable. ( Test Report No. : 44081 –A dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Santosh Pagdhare
Liquid penetration test
RT
ID:
-----
Stamp:
None
None
----------
PQR was done and welding of coupon was witnessed by: Manish J. Chauhan
Test conducted by:
NPCIL
Test ID: E
We certify that the statements in the record are correct and that the test welds were prepared
welded and tested in accordance with the requirements of section IX of the ASME Code
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
32
NPCIL-STD-SM-18 (QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT
TEST REQUIREMENT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
WPS No.
NPCIL-STD-SM-18
Supporting PQR No(s).
F
Prepared
by
Date
Date
Welding process (es)
SMAW
Type(s)
Company Name
NPCIL
QA Directorate & DTD R&D Centre
7-7-2014
7-7-2014
Rev. No.
R-1
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer to
As per design
document.
both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
TO
P.No:
8
*Group No:
1
IS 2062 or IS1239 or equivalent to P8 Gr1.
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT. Please check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness,
Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by respective design
document.
33
NPCIL-STD-SM-18
(Page 2of 3)
Filler metals (QW-404) •
Specification 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
Other

#
SFA 5.4
E-XXX(X)-15,16,17; eg:E-309 (L)-16
5
8
2.5mm, 3.15mm,4 mm
Max 2T# (limited to 19 mm)
All sizes
NA
NA
NA
Each base metal-filler metal combination should be recorded individually.
Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
$All
Temp. range
NA
Weld Progression
Vertical Uphill
Time range
NA
Position(s) of Fillet
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification..
Preheat (QW-406)
Gas (QW-408) Percentage composition
Preheat temp. (min.)
* 10 degree C
Inter pass temp. (max.)
* $$NA
Shielding
Preheat maintenance
With or Without
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
NA
NA
NA
Trailing
NA
NA
NA
Backing
NA
NA
NA
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above the
minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall be
Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
34
NPCIL-STD-SM-18
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
Weld
layer(s)
Process
Root
1st
2nd
3rd
Balance
SMAW
‘’
‘’
‘’
‘’
DC
Refer table below
Filler metal
Class
Dia.
SFA5.4
‘’
‘’
‘’
‘’
2.5
2.5
3.15
3.15
4.0
Polarity
Volts (range)
Current
Type
polarity
DC-EP
‘’
‘’
‘’
‘’
Amp
range+
60-80
60-80
80-120
80-120
110-160
Reverse (EP)
Refer table below
Volt
range+
Travel speed
range mm/min+
22-40
‘’
‘’
‘’
‘’
40-80
‘’
‘’
‘’
‘’
Other
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Not applicable
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
NA
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t
requalification(Ref QW409.1)
PQR , calls for
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
REFER TABLE-2 FOR FURTHER APPLICATION AND SHALL HAVE THE APPROVAL
ACTION
AS PER DOCUMENT (WPS) ACCETANCE NOTE
ATTACHED. (SEE Annexure-B. )
QUALIFIED
35
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
WPS No. NPCIL-STD-SM-18
PQR No : F
Date:
07.07.2014
Page 1 of 2
SMAW / Manual
Welding Process (es) / Type(s) :
Joints (QW-402)
Weld Type
: Groove weld, Single-bevel Vee
Backing
: NA
Root Opening : 3.0mm Root Face: 1.6
mm
Groove Angle : 37.5
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407)
Material Spec., Type or Grade
: ASTM A 516, Grade 70
to ASTM A 240, SS
304
P-No.: 1 Group No. 2 to P-No.:8
Group No. : 1
Thickness of Test Coupon (mm) : 10.0
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification
: 5.4
AWS Classification
: E-309 L
Filler Metal F-No
: 5
Weld Metal Analysis A-No: NA
Size of Filler Metal (mm) : 2.5 & 3.15
Weld Deposit’ t’ (mm)
Pass Greater Than ½"
: Full thickness
: No
Filler Metal Product Form : Covered Electrode
Supplemental Filler Metal : None
Shielding : None
Trailing
: None
Backing
: None
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP
Amps
: 55-85
Volts
: 19-29
Tungsten Type / Size : NA
Transfer Mode
: NA
Wire Feed Speed (mm/min) : NA
Positions (QW-405)
Position of Joint
Heat Input
: --
: 3G - Vertical
Weld Progression : Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C
Interpass Temp.
: NA
Preheat Maintenance : NA
Technique (QW-410)
Travel Speed (mm/min)
: 45-80
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size max.
Multi /Single Pass (per side) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: NA
Contact Tube to Work Dist.
: NA
36
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No.: F
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
ROOT
FILL
FILL
CAP
Process
Filler Metal
AWS
Size
Classification
(mm)
E-309 L
2.5
E-309 L
2.5
E-309 L
3.15
E-309 L
2.5
SMAW
SMAW
SMAW
SMAW
Current
Type /
Amperage
Polarity
Range
DCEP
65-75
DCEP
65-75
DCEP
95-110
DCEP
95-110
Voltage
Range
28-35
28-35
22-30
22-30
Travel Speed
Range
(mm/min)
50
55
45
40
Tensile Test (QW-150)
Specimen
No.
Width
(mm)
Thickness
(mm)
Area
(mm2 )
1A
1B
12.42
12.58
9.76
9.76
119.48
122.78
Ultimate
Total Load,
N
71120
71840
Ultimate
Unit Stress,
N/mm2
595.24
585.11
Type of
Failure &
Location
Ductile - PM
Ductile - PM
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen Size
(mm)
Test
Temp. (0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments: Test results were acceptable ( Test Report no. : 44080 dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Awadh Bihari
Liquid penetration test
RT
ID: ……………….. Stamp : …………….
PQR was done and welding of coupon was witnessed by:
Test conducted by:
NPCIL
None
None
Test ID:
Manish J. Chauhan
F
We certify that the statements in the record are correct and that the test welds were
prepared welded and tested in accordance with the requirements of section IX of the ASME
Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
37
NPCIL-SM-18H
WITH PWHT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
WPS No.
NPCIL
Prepared by
Supporting PQR No(s).
NPCIL-SM-18 H
To be made by user
organisation
Date
Date
Welding process (es)
SMAW
Type(s)
QA Directorate & DTD R&D Centre
7-3-2007
Rev. No.
R-0
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer to
As per design
document.
both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
** # 19 ≤ T(thickness of test coupon) < 38
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
5 mm to 2T
TO
P.No:
8
*Group No:
1
IS 2062 or IS2002 or IS1239 or equivalent to P8 Gr 1..
NA
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
** When Notch Toughness properties are called for, minimum thickness qualified is governed by test coupon
thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by
respective design document. For lower thickness range in PHT system (presently 12mm to 16mm)
additional test coupon is required.
38
NPCIL-SM-18H
(Page 2of 3)
Filler metals (QW-404) •
Specification 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
Other

#
SFA 5.4
E-XXX(X)-15,16,17 e.g.; E-309(L)-16
5
8
2.5mm, 3.15mm,4 mm,5 mm
Max 2T#
All sizes
NA
NA
NA
NA
Each base metal-filler metal combination should be recorded individually.
Weldment is full thickness of test coupon.
Positions (QW-405)
Post Weld Heat Treatment (QW-407)
Position(s) of Groove
$All
Temp. range
Ref applicable Design document and PWHT procedure.
Change in parameter calls for re qualification
Weld Progression
Vertical
Uphill
Time
range(hold)
Ref applicable Design document and PWHT procedure.
Change in parameter calls for re qualification
Position(s) of Fillet
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions, for all position qualification.
Preheat (QW-406)
Gas (QW-408) Percentage composition
Preheat temp. (min.)
* $$ 121 degree C
Inter pass temp. (max.)
^ NA
Shielding
Preheat maintenance
With or Without
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
NA
NA
NA
Tracing
NA
NA
NA
Backing
NA
NA
NA
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
$$ Preheat is to be applied on P1 material and for T > 30 mm and C ≤ 0.3% or T > 20 mm and C > 0.3% ;
Preheat For T > 12 mm in PHT and T > 19mm in Steam lines irrespective of C %. (Requirements from
PB-P-452)
1. In any case min metal temp shall not be below 10 Deg C.(when preheat is not applied )
2 . Decrease of preheat by more than 55Deg C, calls for re qualification.
^ When Notch Toughness properties are called for , maximum Inter Pass (IP) temperature achieved shall
be Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
39
NPCIL-SM-18H
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or
DC
Amps (Range)
Weld
layer(s)
Process
Root
1st
2nd
3rd
Balance
Balance
SMAW
‘’
‘’
‘’
‘’
‘’
DC
Polarity
Refer table below
Filler metal
Class
Dia.
SFA5.4
‘’
‘’
‘’
‘’
‘’
2.5
2.5
3.15
3.15
4.0
5.0
Volts (range)
Current
Type
polarity
DC-EP
‘’
‘’
‘’
‘’
‘’
Reverse (EP)
Amp range+
60-80
60-80
80-120
80-120
110-160
150-200
Refer table below
Volt
range+
Travel speed
range mm/min+
22-40
‘’
‘’
‘’
‘’
‘’
40-80
‘’
‘’
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Not applicable
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
NA
Brushing or Grinding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t
requalification(Ref QW409.1)
PQR, calls for
40
NPCIL-STD-GT-18(QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT
TEST REQUIREMENT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
WPS No.
NPCIL
Supporting PQR No(s).
NPCIL-STD-GT-18
H
Welding process (es)
GTAW
Prepared by
Date
Date
QA Directorate & DTD, R&D Centre
7-7-2014
7-7-2014
Rev. No.
R-1
MANUAL
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
OR
TO
P.No:
8
*Group No:
1
IS 2062 or IS2002 or IS1239 or equivalent to P8 Gr 1.
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
NA
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT. Please check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness,
Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by respective design
document.
41
NPCIL-STD-GT-18
(Page 2of 3)
Filler metals (QW-404) •
SFA 5.9; SFA 5.30 (FOR INSERT)
Specification No. (SFA)
AWS No. (class)
ER-XXX(X) eg:ER 309 L
F-no.
6
A-no
8
Size of filler metals
1.6mm, 2.4mm, 3.2 mm
Weld metal thickness range:
Groove
Max 2T#(limited to 19 mm)
Fillet
All sizes
Electrode-Flux (Class)
NA
Flux trade name
NA
Consumable insert
# # With or Without
Other
NIL
 Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
## Inserts when used, shall confirm to SFA 5.30(e.g.: IN 310, Class 1, Style A)
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
$All
Weld Progression
Vertical Uphill
Temp. range
NA
Position(s) of Fillet
All
Time range
NA
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification..
Preheat (QW-406)
Gas (QW-408) Percentage composition
Preheat temp. (min.)
* 10 degree C
Inter pass temp. (max.)
* $$NA
Shielding
99.95%
Argon
NA
6-10 LPM
Preheat maintenance
With or Without
Trailing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture
)
Flow rate
See Gen Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall be
Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
42
NPCIL-STD-GT-18
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
Weld
layer(s)
DC
Refer table below
Process
Filler metal
Class
Root
GTAW
1st
2nd
3rd
Balance
‘’
‘’
‘’
‘’
Polarity
Volts (range)
SFA5.30
/ SFA
5.9
SFA 5.9
‘’
‘’
‘’
Current
Dia.
Insert /
Filler wire
2.4
2.4
3.2
3.2
Straight (EN)
Refer table below
Type
polarity
DCEN
Amp range
+
55-90
Volt
range
+
10-20
Travel
speed range
mm/min +
40-80
‘’
‘’
‘’
‘’
60-100
60-100
70-120
70-120
10-30
‘’
‘’
‘’
‘’
‘’
‘’
‘’
Othe
r
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2
passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR , calls for requalification (Ref QW409.1)
QUALIFIED
REFER TABLE-2 FOR FURTHER
ACTION
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
APPLICATION
AND
SHALL
HAVE
THE
APPROVAL
AS
PER
DOCUMENT
(WPS)
ACCETANCE NOTE ATTACHED. (SEE Annexure-B. )
43
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No.:
H
WPS No.: NPCIL-STD-GT-18
Welding Process (es) / Type(s):
Date 07.07.2014
Page
1of 2
GTAW / Manual
Joints (QW-402)
Weld Type
: Groove weld Single-bevel Vee
Backing
: NA
Root Opening
: 2.6 mm Root Face: 1.8
Groove Angle
: 75°
mm
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407 )
Material Spec., Type or Grade
P-No.:1
: ASTM SA 516, Grade
70 to ASTM SA
240,SS 304
Group No.: 2 to P-No. : 8 Group No.:1
Thickness of Test Coupon (mm)
: 10.0
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification
: 5.9
AWS Classification
: ER 309 L
Filler Metal F-No
: 6
Shielding : 99.95 Argon / 7 LPM
Trailing
: None
Backing
: 99.95 Argon / 9 LPM
Weld Metal Analysis A-No : NA
Electrical Characteristics (QW-409)
Size of Filler Metal (mm)
: 1.6 & 2.0
Current / Polarity
: DCEN
Weld Deposited’ (mm)
: 11.50
Amps
: 60-115
Pass Greater Than ½"
: No
Volts
: 15-25
Filler Metal Product From
:
Tungsten Type / Size
: EW Th-2 /2 mm
Transfer Mode
: NA
Supplemental Filler Metal :
None
Wire Feed Speed (mm/min) : NA
Positions (QW-405)
Position of Joint:
3G - Vertical
Weld Progression:
Uphill
Preheat (QW-406)
Preheat Temp.
: 20 °C
Inter pass Temp.
: NA
Preheat Maintenance : NA
Heat Input
:
Technique (QW-410)
Travel Speed (mm/min)
: 51 - 73
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size Max.
Multi /Single Pass (per side) :
Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: Standard sizes
Contact Tube to Work Dist. : NA
44
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. –
H
Layers(s)
and/or
Pass (es)
ROOT
FILL
FILL
CAP
Process
Page :- 2 of 2
Additional Welding Parameters
Filler Metal
AWS
Size
Classification
(mm)
ER-309 L
1.6
ER-309 L
1.6
ER-309 L
2.4
ER-309 L
2.4
GTAW
GTAW
GTAW
GTAW
Current
Type /
Amperage
Polarity
Range
DCEN
65-70
DCEN
65-70
DCEN
80-90
DCEN
80-90
Voltage
Range
15-25
15-25
28
23
Travel Speed
Range
(mm/min)
64
73
63
51
Tensile Test (QW-150)
Specimen
No.
Width
(mm)
Thickness
(mm)
Area
(mm2)
3A
3B
12.60
12.52
10.06
10.22
126.76
127.95
Ultimate
Total
Load, N
70960
70720
Ultimate
Unit Stress,
N/mm2
559.82
552.70
Type of
Failure &
Location
Ductile-PM
Ductile-PM
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test
Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments : Test results are acceptable. ( Test Report no. : 44080 – B dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Liquid penetration test
RT
None
None
Welder’s Name : Santosh Pagdhare
ID: - - - --------- Stamp: - - ----------- - - - - - - PQR was done and welding of Coupon was witnessed by : Manish J. Chauhan
Test conducted by : NPCIL
Test ID:
H
.
We certify that the statements in the record are correct and that the test welds were prepared
welded and tested in accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
45
NPCIL-STD-GTSM-11(QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT
TEST REQUIREMENT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Prepared by
Company Name
NPCIL
WPS No.
NPCIL-STD-GTSM-11
Date
Supporting PQR No(s).
C+A
Date
Welding process (es)
GTAW+SMAW
Type(s)
QA Directorate & DTD, R&D Centre
7-7-2014
Rev. No.
R-1
7-7-2014
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
TO
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
IS 2062 or IS2002 or IS1239 or equivalent to IS 2062 or
IS2002 or IS1239 or equivalent or P1.
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
NA
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT. Please check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or
by respective design document.
46
NPCIL-STD-GTSM-11
(Page 2of 3)
Filler metals (QW-404) •
Specification 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
Other
GTAW
SMAW
SFA 5.18; SFA 5.30 (FOR INSERT)
ER 70 S2 or ER 70 S6
SFA 5.1
E-7018 or E7018-1
6
1
1.6mm, 2.4mm, 3.2 mm
4
1
2.5mm, 3.15mm,4 mm
Max 2t # #
All sizes
NA
NA
^ With or Without
NA
Max 2t # #
All sizes
NA
NA
NA
 Each base metal-filler metal combination should be recorded individually.
^ Inserts when used, shall confirm to SFA 5.30(Mild Steel)
# # ‘t’ is weldment thickness by respective process(Ref PQR),cumulative thickness limited to 19 mm.
# Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
$All
Temp. range
NA
Weld Progression
Vertical Uphill
Time range
NA
Position(s) of Fillet
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification..
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
* 10 degree C
Inter pass temp. (max.)
* $$NA
Shielding
Preheat maintenance
With or Without
(Continuous or special
heating, where
applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
99.95%
Argon
NA
6-10 LPM
Trailing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
See Gen
Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature
above the minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall
be recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
47
NPCIL-STD-GTSM-11
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
DC
Amps (Range)
Polarity
Refer table below
Current
Filler metal
Weld
layer(s)
Root
Process
GTAW
1st
2nd
3rd
Balance
‘’
‘’
SMAW
‘’
Class
Dia.
SFA5.30/
SFA 5.18
Insert /
Filler
wire
2.4
2.4
3.15
4.0
SFA5.18
‘’
SFA 5.1
‘’
Volts (range)
Straight (EN)/Reverse
(EP)
Refer table below
Other
Type
polarity
DCEN
Amp
range +
55-90
Volt
range +
10-20
Travel speed
range
mm/min +
40-80
‘’
‘’
DCEP
‘’
60-100
60-100
100-140
150-190
10-30
‘’
22-40
‘’
‘’
‘’
‘’
‘’
.
Min 5
mm BY
GTAW
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t
requalification(Ref QW409.1)
QUALIFIED
REFER TABLE-2 FOR FURTHER
ACTION
PQR, calls for
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
APPLICATION
AND
SHALL
HAVE
THE
APPROVAL
AS
PER
DOCUMENT
(WPS)
ACCETANCE NOTE ATTACHED. (SEE Annexure-B. )
48
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No.: C
WPS No. NPCIL-STD-GT-11
Welding Process (es) / Type(s)
Date:
07.07.2014
Page:
1 of 2
GTAW / Manual
Joints (QW-402)
Weld Type
: Groove weld
Single-bevel Vee
Backing
: NA
Root Opening : 2.8 mm Root Face 1.8
Groove Angle : 37.5o
SINGLEVEEGROOVE
Base Metals (QW-403)
Material Spec., Type or Grade
: ASTM A 516, Grade 70
to ASTM 516, Grade 70
P-NO.: 1 Group No: 2 to P-NO. : 1 Group NO.: 2
Thickness of Test Coupon (mm) : 10.0
Filler Metals (QW-404)
SFA Specification
: 5.1
AWS Classification
: ER 70 S2
Filler Metal F-No
: 6
Weld Metal Analysis A-No : NA
Size of Filler Metal (mm) : 1.6 & 2.4
Weld Deposited’ (mm)
: 11.50
Pass Greater Than ½"
: No
Filler Metal Product Form : Bare electrode
Supplemental Filler Metal : None
Positions (QW-405)
Position of Joint : 3G - Vertical
Weld Progression : Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C
Inter-pass Temp.
: NA°C
Preheat Maintenance : NA
Post weld Heat Treatment (QW-407
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Shielding
: 99.95% argon / 7 LPM
Trailing
: None
Backing
: 99.95% argon / 14 LPM
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP (reverse)
Amps
: 72-110
Volts
: 12-27
Tungsten Type / Size
: EW Th-2 / 2.4 mm
Transfer Mode
: NA
Wire Feed Speed (mm/min) : NA
Heat Input
:
Technique (QW-410)
Travel Speed (mm/min)
String/ Weave Bead
Oscillation
: 75
: Stringer for Root, Weaves for subsequent
passes
: 3 times of filler metal size
Multi / Single pas )per side) : Multi pass
Multi / Single Electrode
: Single
Nozzle / Gas Cup Size
: Standard Size
Contract Tube to Work Dist : NA
49
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. C
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
ROOT
Process
Current
Type / Polarity Amperage
Range
DCEP (reverse)
90-100
Voltage
Range
SMAW
Filler Metal
AWS
Size
Classification
(mm)
ER 70 S2
2.4
20-25
Travel
Speed Range
(mm/min)
72
FILL
FILL
CAP
SMAW
SMAW
SMAW
ER 70 S2
ER 70 S2
ER 70 S2
DCEP (reverse)
DCEP (reverse)
DCEP (reverse)
20-25
25-35
25-35
80
80
62
2.4
3.2
3.2
90-100
95-115
95-115
Tensile Test (QW-150)
Specimen No.
Width (mm)
Thickness
(mm)
Area
(mm2 )
Ultimate Total
Load, N
Ultimate Unit
Stress, N/mm2
3A
3B
12.54
12.54
9.86
9.84
123.64
123.39
63880
63760
516.64
516.72
Type of
Failure &
Location
Ductile-PM
Ductile-PM
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Speci
men
No.
1
Notch
Location
Specimen
Size (mm)
Test Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight Break
(Y/N)
Mils
Comments : Test results were acceptable. (Test Report no : 44079-B dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Santosh Pagdhare
Liquid penetration test
RT
ID :
----------------
Stamp :
None
None
----------------------------
PQR was done and welding of coupon was witnessed by: Manish J. Chauhan
Test conducted by : NPCIL
Test ID:
C
We certify that the statements in the record are correct and that the test welds were prepared welded and
tested in accordance with the requirements of section IX of the ASME Code
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
50
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No. : A
WPS No.: NPCIL-STD- SM-11
Page: 1of 2
Date: 07.07.2014
Welding Process (es) / Type(s) SMAW / Manual
Joints (QW-402)
Weld Type
: Groove weld, Single-bevel
Backing
: NA
Root Opening : 2.8 mm Root Face 1.6
Groove Angle : 37.5o
SINGLE VEE GROOVE
Base Metals (QW-403)
Material Spec., Type or Grade
: ASTMA 516, Grade 70 to
ASTM 516, Grade 70
P-NO.: 1 Group No: 2 to P-NO : 1 Group NO.: 2
Thickness of Test Coupon (mm) : 10.0
Filler Metals (QW-404)
SFA Specification:
AWS Classification:
Filler Metal F-No:
Weld Metal Analysis A-No
Size of Filler Metal (mm)
: 5.1
: E-7018
: 4
: NA
: 2.4 & 3.15
Weld Deposit’ t’ (mm)
Pass Greater Than ½"
Filler Metal Product Form
Supplemental Filler Metal
: 10.0
: No
: Covered electrode
: None
Positions (QW-405)
Position of Joint
: 3G - Vertical
Weld Progression
: Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C (Ambient)
Interpass Temp.
: 150°C (Max.)
Preheat Maintenance : NA
Post weld Heat Treatment (QW-407 )
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Shielding : None
Trailing
: None
Backing
: None
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP
Amps
: 85 - 135
Volts
: 22-28
Tungsten Type / Size
: NA
Transfer Mode
: NA
Wire Feed Speed (mm/min) : NA
Heat Input
: -Technique (QW-410)
Travel Speed (mm/min)
String/Weave Bead
: 75
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size max.
Multi /Single Pass (per side ) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: NA
Contact Tube to Work Dist. : NA
51
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No.: A
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
ROOT
FILL
FILL
CAP
SMAW
SMAW
SMAW
SMAW
Filler Metal
AWS
Size (mm)
Classification
E-7018
E-7018
E-7018
E-7018
Current
Type / Polarity Amperage
Range
2.4
2.4
3.15
3.15
DCEP (reverse)
DCEP (reverse)
(reverse)
DCEP
(reverse)
DCEP (reverse)
Voltage
Range
90-95
85-90
130-135
125-128
Travel
Speed
Range
(mm/min)
72
80
68
62
22 -28
22 28
22 -28
22 -28
Tensile Test (QW-150)
Specimen
No.
Width (mm)
Thickness
(mm)
Area (mm2)
1A
1B
12.58
12.60
9.92
9.94
124.79
125.24
Ultimate
Total Load,
N
72840
73680
Ultimate
Unit Stress,
N/mm2
583.68
588.29
Type of
Failure &
Location
Ductile-Weld
Ductile-PM
Result
satisfactory
satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen Size
(mm)
Test Temp.
(0C)
Impact Values
Joule
Comments:
%
Shear
Drop Weight
Break (Y/N)
Result
Mils
Test results were acceptable. (Test Report no. : 44079 dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Awadh Bihari
Liquid penetration test
RT
None
None
ID: …………………………….. Stamp: …………………….
PQR was done and welding of coupon was witnessed by:
Test conducted by: NPCIL
Test ID: A
Manish J. Chauhan
We certify that the statements in the record are correct and that the test welds were prepared welded
and tested in accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
52
NPCIL-GTSM-11H
WITH PWHT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
NPCIL
Prepared by
QA Directorate
WPS No.
NPCIL-GTSM-11 H
TO BE MADE BY USER
ORGANIZATION
Date
Date
Rev. No.
Supporting PQR No(s).
Welding process (es)
GTAW+SMAW
Company Name
21-3-2007
R-0
MANUAL
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
** # 19 ≤ T (thickness of test coupon) < 38
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
5 mm to 2T
TO
P.No:
1
*Group No:
1/2
IS 2062 or IS2002 or IS1239 or equivalent to IS 2062 or
IS2002 or IS1239 or equivalent or P1.
NA
Fillet
All Thickness
* When Notch Toughness properties are called for refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
** When Notch Toughness properties are called for, minimum thickness qualified is governed by test coupon
thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by
respective design document. For lower thickness range in PHT system (presently 12mm to 16mm)
additional test coupon is required.
53
NPCIL-GTSM-11H
(Page 2of 3)
Filler metals (QW-404)
GTAW
SFA 5.18; SFA 5.30 (FOR INSERT)
ER 70 S2 or ER 70 S6
Specification 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
Other
SMAW
SFA 5.1
E-7018 or E7018-1
4
1
2.5mm, 3.15mm,4 mm,5 mm
6
1
1.6mm, 2.4mm, 3.2 mm
Max 2t # #
All sizes
NA
NA
^ With or Without
NIL
Max 2t # #
All sizes
NA
NA
NA
•
^
Each base metal-filler metal combination should be recorded individually.
Inserts when used, shall confirm to SFA 5.30(Mild Steel)
# # ‘t’ is weldment thickness by respective process (Ref PQR).
#
Weldment is full thickness of test coupon.
Positions (QW-405)
Post Weld Heat Treatment (QW-407)
(Reference taken from PB-P-452; user to check applicable Specification.)
Position(s) of Groove
Weld Progression
Position(s) of Fillet
$All
Vertical
Uphill
All
Temp. range
595-675 Deg C
Time
A)T up to 25 mm -1Hr;
range(hold)
B)25< T <50 -1Hr+25min for each addition of 1cm beyond 25mm
C)50< T <125-2Hr+6min for each addition of 1cm beyond 50 mm.
PWHT Procedure shall be referred for Temp range, heating and cooling rates. Ref
applicable Specn, change in parameters calls for re qualification.
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions, for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
$$ 121 degree C
Inter pass temp. (max.)
^ NA
Shielding
99.95% Argon
NA
6-10 LPM
Preheat maintenance
With or Without
Tracing
NA
NA
NA
Backing
99.95% Argon
NA
5-25 LPM
See Gen Notes
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture
)
Flow rate
$$ For T > 30 mm and C ≤ 0.3% or T > 20 mm and C > 0.3% ; Preheat to 121 Deg C For T > 12 mm in PHT
and T > 19mm in Steam lines irrespective of C% and weld zone temp shall be min 93 Deg C throughout
the welding process.
1. In any case min metal temp shall not be below 10 Deg C.(when preheat is not applied )
2. Decrease of preheats by more than 55Deg C, calls for re qualification.
^ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall be
Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
54
NPCIL-GTSM-11H
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Filler metal
Weld
layer(s)
Root
1st
2nd
3rd
4th
Balance
Class
Dia.
Process
GTAW
‘’
‘’
SMAW
‘’
‘’
SFA5.30
SFA5.18
‘’
SFA 5.1
‘’
‘’
INSERT
2.4
2.4
3.15
4.0
5.0
Polarity
Volts (range)
Straight (EN)/Reverse (EP)
Refer table below
Current
Type
polarity
Amp
range +
DC-EN
‘’
‘’
DC-EP
‘’
‘’
55-90
60-100
60-100
100-140
150-190
200-250
Volt
range +
10-20
10-30
‘’
22-40
‘’
‘’
Travel
speed
range
mm/min +
40-80
‘’
‘’
‘’
‘’
‘’
Other
.
Min 5
mm
BY
GTAW
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR ,calls for
requalification(Ref QW409.1)
55
NPCIL-STD-GTSM-18(QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT
TEST REQUIREMENT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Prepared by
QA Directorate & DTD, R&D Centre
Company Name
NPCIL
WPS No.
NPCIL-STD-GTSM-18
Date
7-7-2014
Supporting PQR No(s).
H+F
Date
7-7-2014
Welding process (es)
GTAW+SMAW
Rev. No.
R-1
MANUAL
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Joint Design
Backing :
Backing Material (Type) (Refer
to both backing and retainers)
□ Metal Thickness
□ Non-metallic
Details
GROOVE
With OR Without
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
As per design
document.
□ Non-fusing metal
□ Other
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
TO
P.No:
8
*Group No:
1
IS 2062 or IS2002 or IS1239 or equivalent to P8 Gr 1.
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT. Please check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness,
Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by respective design
document.
56
NPCIL-STD-GTSM-18
(Page 2of 3)
Filler metals (QW-404)
Specification 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
Other
GTAW
SFA 5.9; SFA 5.30 (FOR INSERT)
SMAW
SFA 5.4
ER-XXX(X) eg:ER 309 L
E-XXX(X)-15,16,17; eg:E-309 (L)-16
6
8
1.6mm, 2.4mm, 3.2 mm
5
8
2.5mm, 3.15mm,4 mm
Max 2 t # #
All sizes
NA
NA
^ With or Without
Max 2 t # #
All sizes
NA
NA
NA
NIL
 Each base metal-filler metal combination should be recorded individually.
^ Inserts when used, shall confirm to SFA 5.30(Mild Steel)
# # ‘t’ is weldment thickness by respective process (Ref PQR).
# Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment (QW-407)
$All
Temp. range
NA
Weld Progression
Vertical Uphill
Time range
NA
Position(s) of Fillet
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification..
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
* 10 degree C
Inter pass temp. (max.)
* $$NA
Shielding
99.95%
Argon
NA
6-10 LPM
Preheat maintenance
With or Without
Trailing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture
)
Flow rate
See Gen Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall
be recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
57
NPCIL-STD-GTSM-18
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or
DC
Amps (Range)
Weld
layer(s)
Process
Root
GTAW
1st
2nd
3rd
4th
Balance
‘’
‘’
SMAW
‘’
‘’
DC
Polarity
Straight (EN)
Refer table below
Volts
(range)
Refer table below
Filler metal
Current
Class
Dia.
SFA5.30 /
SFA 5.9
SFA 5.9
‘’
SFA5.4
‘’
‘’
INSERT /
filler wire
2.4
2.4
2.5
3.15
4.0
Type
polarity
DCEN
Amp
range +
55-90
‘’
‘’
DCEP
‘’
‘’
60-100
60-100
60-80
80-120
110-160
Volt
range
+
Travel
speed range
mm/min +
Other
10-20
40-80
10-30
‘’
22-40
‘’
‘’
‘’
‘’
40-80
‘’
‘’
Min 5
mm by
GTAW
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2
passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR, calls for
requalification(Ref QW409.1)
QUALIFIED
REFER TABLE-2 FOR
FURTHER ACTION
NOTE: USER SHALL CHECK RESPECTIVE
SPECIFICATIONS, DRGS FOR SUITABILITY OF
THIS
WELDING
PROCEDURE
FOR
THE
APPLICATION AND SHALL HAVE THE APPROVAL
AS PER DOCUMENT (WPS) ACCETANCE NOTE
ATTACHED. (SEE Annexure-B.)
58
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No.:
H
WPS No.: NPCIL-STD-GT-18
Welding Process (es) / Type(s):
Date 07.07.2014
Page
1of 2
GTAW / Manual
Joints (QW-402)
Weld Type
: Groove weld Single-bevel Vee
Backing
: NA
Root Opening
: 2.6 mm Root Face: 1.8
Groove Angle
: 75°
mm
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407 )
Material Spec., Type or Grade
P-No.:1
: ASTM SA 516, Grade
70 to ASTM SA
240,SS 304
Group No.: 2 to P-No. : 8 Group No.:1
Thickness of Test Coupon (mm)
: 10.0
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification
: 5.9
AWS Classification
: ER 309 L
Filler Metal F-No
: 6
Shielding : 99.95 Argon / 7 LPM
Trailing
: None
Backing
: 99.95 Argon / 9 LPM
Weld Metal Analysis A-No : NA
Electrical Characteristics (QW-409)
Size of Filler Metal (mm)
: 1.6 & 2.0
Current / Polarity
: DCEN
Weld Deposited’ (mm)
: 11.50
Amps
: 60-115
Pass Greater Than ½"
: No
Volts
: 15-25
Filler Metal Product From
:
Tungsten Type / Size
: EW Th-2 /2 mm
Transfer Mode
: NA
Supplemental Filler Metal :
None
Wire Feed Speed (mm/min) : NA
Positions (QW-405)
Position of Joint:
3G - Vertical
Weld Progression:
Uphill
Preheat (QW-406)
Preheat Temp.
: 20 °C
Inter pass Temp.
: NA
Preheat Maintenance : NA
Heat Input
: --
Technique (QW-410)
Travel Speed (mm/min)
: 51 - 73
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size Max.
Multi /Single Pass (per side) :
Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: Standard sizes
Contact Tube to Work Dist. : NA
59
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. –
H
Layers(s)
and/or
Pass (es)
ROOT
FILL
FILL
CAP
Process
Page :- 2 of 2
Additional Welding Parameters
Filler Metal
AWS
Size
Classification
(mm)
ER-309 L
1.6
ER-309 L
1.6
ER-309 L
2.4
ER-309 L
2.4
GTAW
GTAW
GTAW
GTAW
Current
Type /
Amperage
Polarity
Range
DCEN
65-70
DCEN
65-70
DCEN
80-90
DCEN
80-90
Voltage
Range
15-25
15-25
28
23
Travel Speed
Range
(mm/min)
64
73
63
51
Tensile Test (QW-150)
Specimen
No.
Width
(mm)
Thickness
(mm)
Area
(mm2)
3A
3B
12.60
12.52
10.06
10.22
126.76
127.95
Ultimate
Total
Load, N
70960
70720
Ultimate
Unit Stress,
N/mm2
559.82
552.70
Type of
Failure &
Location
Ductile-PM
Ductile-PM
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test
Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments : Test results are acceptable. ( Test Report no. : 44080 – B dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Liquid penetration test
RT
None
None
Welder’s Name : Santosh Pagdhare
ID: - - - --------- Stamp: - - ----------- - - - - - - PQR was done and welding of Coupon was witnessed by : Manish J. Chauhan
Test conducted by : NPCIL
Test ID:
H
.
We certify that the statements in the record are correct and that the test welds were prepared
welded and tested in accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
60
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
WPS No. NPCIL-STD-SM-18
PQR No : F
Date:
07.07.2014
Page 1 of 2
SMAW / Manual
Welding Process (es) / Type(s) :
Joints (QW-402)
Weld Type
: Groove weld, Single-bevel Vee
Backing
: NA
Root Opening : 3.0mm Root Face: 1.6
mm
Groove Angle : 37.5
SINGLE VEE GROOVE
Base Metals (QW-403)
Post weld Heat Treatment (QW-407)
Material Spec., Type or Grade
: ASTM A 516, Grade 70
to ASTM A 240, SS
304
P-No.: 1 Group No. 2 to P-No.:8
Group No. : 1
Thickness of Test Coupon (mm) : 10.0
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification
: 5.4
Shielding : None
AWS Classification
: E-309 L
Trailing
: None
Filler Metal F-No
: 5
Backing
: None
Weld Metal Analysis A-No: NA
Size of Filler Metal (mm) : 2.5 & 3.15
Weld Deposit’ t’ (mm)
: Full thickness
Pass Greater Than ½"
: No
Filler Metal Product Form : Covered Electrode
Supplemental Filler Metal : None
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP
Amps
: 55-85
Volts
: 19-29
Tungsten Type / Size : NA
Transfer Mode
: NA
Wire Feed Speed (mm/min) : NA
Positions (QW-405)
Position of Joint
Heat Input
: --
: 3G - Vertical
Weld Progression : Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C
Interpass Temp.
: NA
Preheat Maintenance : NA
Technique (QW-410)
Travel Speed (mm/min)
: 45-80
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size max.
Multi /Single Pass (per side) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: NA
Contact Tube to Work Dist.
: NA
61
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No.: F
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
ROOT
FILL
FILL
CAP
Process
Filler Metal
AWS
Size
Classification
(mm)
E-309 L
2.5
E-309 L
2.5
E-309 L
3.15
E-309 L
2.5
SMAW
SMAW
SMAW
SMAW
Current
Type /
Amperage
Polarity
Range
DCEP
65-75
DCEP
65-75
DCEP
95-110
DCEP
95-110
Voltage
Range
28-35
28-35
22-30
22-30
Travel Speed
Range
(mm/min)
50
55
45
40
Tensile Test (QW-150)
Specimen
No.
Width
(mm)
Thickness
(mm)
Area
(mm2 )
1A
1B
12.42
12.58
9.76
9.76
119.48
122.78
Ultimate
Total Load,
N
71120
71840
Ultimate
Unit Stress,
N/mm2
595.24
585.11
Type of
Failure &
Location
Ductile - PM
Ductile - PM
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen Size
(mm)
Test
Temp. (0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments: Test results were acceptable ( Test Report no. : 44080 dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Awadh Bihari
Liquid penetration test
RT
ID: ……………….. Stamp : …………….
PQR was done and welding of coupon was witnessed by:
Test conducted by:
NPCIL
None
None
Test ID:
Manish J. Chauhan
F
We certify that the statements in the record are correct and that the test welds were
prepared welded and tested in accordance with the requirements of section IX of the ASME
Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
62
NPCIL-GTSM-18H
WITH PWHT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
WPS No.
NPCIL-GTSM-18 H
Date
Supporting PQR No(s).
To be made by use
organisation
Date
Welding process (es)
GTAW+SMAW
Type(s)
QA Directorate & DTD, R&D Centre
7-3-2007
Rev. No.
R-0
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer to
As per design
document.
both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
** # 19 ≤ T(thickness of test coupon) < 38
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
TO
P.No:
8
*Group No:
1
IS 2062 or IS2002 or IS1239 or equivalent to P8 Gr 1..
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
5 mm to 2T
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
** When Notch Toughness properties are called for, minimum thickness qualified is governed by test coupon
thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by
respective design document. For lower thickness range in PHT system (presently 12mm to 16mm)
additional test coupon is required. Pl. check applicable specification.
63
NPCIL-GTSM-18H
(Page 2of 3)
Filler metals (QW-404) •
GTAW
SMAW
SFA 5.9; SFA 5.30 (FOR INSERT)
Specification No. (SFA)
SFA 5.4
E-XXX(X)-15,16,17 e.g.; E-308(L)-16
AWS No. (class)
ER-XXX(X) eg:ER 309 L
F-no.
6
5
A-no
8
8
Size of filler metals
1.6mm, 2.4mm, 3.2 mm
2.5mm, 3.15mm,4 mm,5 mm
Weld metal thickness range:
Groove
Max 2 t # #
Max 2 t # #
Fillet
All sizes
All sizes
Electrode-Flux (Class)
NA
NA
Flux trade name
NA
NA
Consumable insert
NA
^ With or Without
Other
NA
 Each base metal-filler metal combination should be recorded individually.
^ Inserts when used, shall confirm to SFA 5.30(e.g.: IN 310 Class 1,Style A)
# # ‘t’ is weldment thickness by respective process(Ref PQR).
# Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Weld Progression
Position(s) of Fillet
Post Weld Heat Treatment (QW-407)
$All
Vertical
Uphill
Temp. range
Ref applicable Design document and PWHT
procedure. Change in parameter calls for re
qualification
Time
Ref applicable Design document and PWHT
procedure. Change in parameter calls for re
qualification
range(hold)
All
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions, for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
* $$ 121 degree C
Inter pass temp. (max.)
^^ NA
Shielding
Preheat maintenance
With or Without
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
99.95%
Argon
NA
6-10 LPM
Tracing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
See Gen Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
$$ Preheat is to be applied on P1 material and for T > 30 mm and C ≤ 0.3% or T > 20 mm and C > 0.3% ;
Preheat For T > 12 mm in PHT and T > 19mm in Steam lines irrespective of C %. (Requirements from
PB-P-452)
1. In any case min metal temp shall not be below 10 Deg C.(when preheat is not applied )
2. Decrease of preheat by more than 55Deg C, calls for re qualification.
^^ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved
shall be recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for requalification.
64
NPCIL-GTSM-18H
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
Weld layer(s)
DC
Refer table below
Process
Filler metal
Class
Dia.
Polarity
Volts (range)
Current
Type polarity
Amp
range+
Straight (EN)/Reverse (EP)
Refer table below
Volt range
+
Travel speed
range
mm/min +
Other
Min 5
mm by
GTAW
Root
GTAW
SFA5.30
INSERT
DC-EN
55-90
10-20
40-80
1st
2nd
3rd
4th
Balance
‘’
‘’
SMAW
‘’
‘’
SFA 5.9
‘’
SFA 5.4
‘’
‘’
2.4
2.4
3.15
4.0
5.0
‘’
‘’
DC-EP
‘’
‘’
60-100
60-100
80-120
110-160
150-200
10-30
‘’
22-40
‘’
‘’
‘’
‘’
‘’
‘’
‘’
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes EW Th2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2
passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR, calls for
requalification (Ref QW409.1)
65
NPCIL-STD-GTSM-88(QUALIFIED)
WITHOUT PWHT AND WITHOUT IMPACT
TEST REQUIREMENT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate & DTD, R&D Centre
WPS No.
NPCIL-GTSM-88
Date
7-7-2014
Supporting PQR No(s).
E+D
Date
7-7-2014
Welding process (es)
GTAW+SMAW
Type(s)
Rev. No.
R-1
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type)
As per design
document.
(Refer to both backing and
retainers)
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1. 5 ≤ T (thickness of test coupon) < 19
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
8
Group No:
1
TO
P.No: 8
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
* Groove
1.5 mm to 2 T
* For 1.5 < T ≤ 10 Range Qualified : 1.5 - 2T
For 10 < T < 19 Range Qualified : 5.0 - 2T
Group No:
1
NA
NA
Fillet
All Thickness
66
NPCIL-GTSM-88
(Page 2of 3)
Filler metals (QW-404) •
Specification 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
Other
GTAW
SFA 5.9,SFA 5.30(for insert)
SMAW
SFA 5.4
ER-XXX(X) eg; ER 308 L
E-XXX(X)-15,16,17 eg;E308L-16
6
8
1.6mm, 2.4mm,3.2mm
5
8
2.5mm, 3.15mm,4 mm,5 mm
Max 2 t # #
All sizes
NA
NA
^ With or Without
NA
Max 2 t # #
All sizes
NA
NA
NA
 Each base metal-filler metal combination should be recorded individually.
^ Inserts when used, shall confirm to SFA 5.30(eg: IN 310 Class 1,Style A)
# # ‘t’ is weldment thickness by respective process(Ref PQR).
# Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
All
Weld Progression
Vertical Uphill
Position(s) of Fillet
All
Preheat (QW-406)
Temp. range
NA
Time range(hold)
NA.
Gas (QW-408)
Preheat temp. (min.)
NA
Inter pass temp. (max.)
* < 150 Deg C, Record in
Gas(es)
(Continuous or special
heating, where applicable,
should be recorded)
NA
(Mixture)
Flow rate
Shielding
99.95%
Argon
NA
6-10 LPM
Tracing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
PQR
Preheat maintenance
Percentage composition
See Gen
Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
67
NPCIL-GTSM-88
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
Weld
layer(s)
Process
Root
1st
2nd
3rd
3rd
4th
Balance
GTAW
‘’
‘’
SMAW
‘’
‘’
‘’
DC
Refer table below
Filler metal
Class
Dia.
SFA5.30
SFA5.9
‘’
SFA 5.4
‘’
‘’
‘’
INSERT
2.4
2.4
3.15
3.15
4.0
5.0
Polarity
Volts
(range)
Straight (EN)/Reverse(EP)
Refer table below
Current
Type
polarity
DC-EN
‘’
‘’
DC-EP
‘’
‘’
‘’
Amp
range
55-90
60-100
60-100
80-120
80-120
110-160
150-200
Volt
range
Travel
speed range
mm/min
Other
10-20
“
‘’
22-40
‘’
‘’
‘’
40-80
‘’
‘’
‘’
‘’
‘’
‘’
Min 5
mm by
GTAW
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes EW Th2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
68
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No.:
WPS No.: NPCIL-STD-GT-88
E
Date: 07.07.2014
Page:
1of 2
GTAW / Manual
Welding Process (es) / Type(s):
Joints (QW-402)
Weld Type
: Groove weld , Single-bevel
Backing
: NA
Root Opening
: 2.6
Groove Angle
: 75
mm Root Face
1.8 mm
SINGLE VEE GROOVE
Post weld Heat Treatment (QW-407)
Base Metals (QW-403)
Material Spec., Type or Grade
: ASTMA A 240, SS 304
to ASTM A 240, SS 304
P-NO.: 8 Group No: 1 to P-NO.: 8 Group NO.: 1
Thickness of Test Coupon (mm)
Type:
NA
Temperature:
NA
Time:
NA
: 10.0
Gas (QW-408)
Filler Metals (QW-404)
SFA Specification
Gas Composition / Flow Rate
: 5.9
Shielding:
99.95 Argon / 6 LPM
AWS Classification
: ER 308 L
Trailing:
None
Filler Metal F-No
: 6
Backing:
99.95 Argon / 12 LPM
Weld Metal Analysis A-No : NA
Size of Filler Metal (mm)
: 2.0 & 3.20
Electrical Characteristics (QW-409)
Weld Deposit ’t’ (mm)
: 11.50
Current / Polarity
: DCEN (straight)
Pass Greater Than ½"
: No
Amps
: 55-115
Filler Metal Product Form
: Bare electrode
Volts
: 12-30
Supplemental Filler Metal : None
Transfer Mode
Positions (QW-405)
Position of Joint
Tungsten Type / Size : EW Th-2
: 3G - Vertical
Weld Progression : Uphill
: NA
Wire Feed Speed (mm/min) : NA
Heat Input
: --
Technique (QW-410)
Preheat (QW-406)
Preheat Temp.
: 20 °C
Inter pass Temp.
: 145°C
Preheat Maintenance : NA
Travel Speed (mm/min)
: 50-75
String/Weave Bead
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size (
max. )
Multi /Single Pass (per side) :
Multi pass
Multi /Single Electrode
:
Single
Nozzle/Gas Cup Size
:
NA
Contact Tube to Work Dist. : NA
69
NPCIL, R&D CENTRE
Procedure Qualification Record (PQR)
PQR No. – E
Page 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
ROOT
FILL
FILL
CAP
GTAW
GTAW
GTAW
GTAW
Filler Metal
AWS
Size (mm)
Classification
ER-308L
ER-308L
ER-308L
ER-308L
Current
Type /
Amperage
Polarity
Range
Voltage
Range
DCEP
DCEP
DCEP
DCEP
25-28
25-28
20-25
20-25
2.4
2.4
3.2
3.2
60-65
60-80
100-115
100-115
Travel
Speed
Range
(mm/min)
50
65
75
60
Tensile Test (QW-150)
Specime
n No.
Width
(mm)
Thickne
ss (mm)
Area
(mm2)
Ultimate
Total Load, N
Ultimate Unit
Stress, N/mm2
T1
T2
12.42
12.44
9.80
9.84
121.72
122.41
70800
71520
581.68
584.27
Type of
Failure &
Location
Ductile-PM
Ductile-PM
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB1)
QW-462.2 Face bend at 4t (FB2)
QW-462.2 Root bend at 4t (RB1)
QW-462.2 Root bend at 4t (RB2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) - Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments : Test Results were acceptable. ( Test Report No. : 44081 –A dated 21.11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder’s Name: Santosh Pagdhare
Liquid penetration test
RT
ID:
-----
Stamp:
None
None
----------
PQR was done and welding of coupon was witnessed by: Manish J. Chauhan
Test conducted by:
NPCIL
Test ID: E
We certify that the statements in the record are correct and that the test welds were prepared
welded and tested in accordance with the requirements of section IX of the ASME Code
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
70
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No : D
WPS No. NPCIL-STD-SM-88
Welding Process (es) / Type(s) :
Date:
07.07.2014
Page: 1 of 2
SMAW / Manual
Joints (QW-402)
Weld Type
: Groove weld, Single-bevel
Backing
: Back welded
Root Opening : 3.0 mm Root Face: 2.1 mm
Groove Angle : 75°
SINGLE VEE GROOVE
Base Metals (QW-403)
Material Spec., Type or Grade
: ASTM A 240, SS304 to
ASTM A 240, SS304
P-No.: 8, Group No.: 1 to P-No. : 8 Group No.: 1
Thickness of Test Coupon (mm) : 20.0
Filler Metals (QW-404)
SFA Specification
: 5.4
AWS Classification
: E-308 L
Filler Metal F-No
: 5
Weld Metal Analysis A-No : NA
Size of Filler Metal (mm) : 2.5 & 3.15
Weld Deposited’ (mm)
: 21.30
Pass Greater Than ½"
: No
Filler Metal Product From : Royal Arc
Supplemental Filler Metal : None
Positions (QW-405)
Position of Joint : 3G - Vertical
Weld Progression : Uphill
Preheat (QW-406)
Preheat Temp.
: 20°C
Interpass Temp.
: 120°C
Preheat Maintenance : NA
Post weld Heat Treatment (QW-407 )
Type
: NA
Temperature : NA
Time
: NA
Gas (QW-408)
Gas Composition / Flow Rate
Shielding
: None
Trailing
: None
Backing
: None
Electrical Characteristics (QW-409)
Current / Polarity
: DCEP (reverse)
Amps
: 70-120
Volts
: 22-30
Tungsten Type / Size : NA
Transfer Mode
: NA
Wire Feed Speed (mm/min): NA
Heat Input : -Technique (QW-410)
Travel Speed (mm/min)
String/Weave Bead
: 50
: Stringer for Root, weaves for
subsequent passes
Oscillation
: 3 times of filler metal size
Multi /Single Pass (per side) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: NA
Contact Tube to Work Dist.: NA
71
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. – D
Page: 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
Filler Metal
AWS
Size
Classification
(mm)
Current
Type /
Amperage
Polarity
Range
Voltage
Range
2.5
2.5
2.5
3.15
3.15
DCEP
DCEP
DCEP
DCEP
DCEP
65-80
65-80
70-80
80-110
85-115
30-40
‘’
‘’
20-30
‘’
Travel
Speed
Range
(mm/min)
40
62
46
62
40
ROOT
FILL
FILL
FILL
FILL
SMAW
SMAW
SMAW
SMAW
SMAW
E-308 L
E-308 L
E-308 L
E-308 L
E-308 L
FILL
CAP
SMAW
SMAW
E-308 L
E-308 L
2.5
2.5
DCEP
DCEP
70-80
70-80
30-40
‘’
40
40
Specimen
No.
Width (mm)
Thickness
(mm)
Area (mm2)
1A
1B
12.56
12.50
20.12
20.30
252.71
253.75
Tensile Test (QW-150)
Ultimate
Total Load,
N
145760
145440
Ultimate Unit
Stress, N/mm2
Type of Failure
& Location
576.79
573.16
Ductile - PM
Ductile - PM
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Side bend at 4t (SB1)
QW-462.2 Side bend at 4t (SB2)
Result
Satisfactory
Satisfactory
Toughness Test (QW-170) - Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments: Test results were acceptable. ( Test report no. : 44081 dated 21.11.2012)
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder's Name : Awadh Bihari
Liquid penetration test
RT
ID: ..................
PQR was done & welding of coupon witnessed by:
Test conducted by:
NPCIL
None
None
Stamp: ..............................................
Manish J. Chauhan
Test ID:
D
We certify that the statements in the record are correct & that the test welds were prepared,
welded and tested in
accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
72
NPCIL-GT-1:43
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate & DTD, R&D Centre
WPS No.
NPCIL-GT-1:43
Date
7-7-2014
Supporting PQR No(s).
L
Date
7-7-2014
Welding process (es)
GTAW
Type(s)
Rev. No.
R-1
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
TO
OR
Specification, Type & Grade to Specification,
type & grade
P.No:
43(Inconel 600)
*Group No:
NA
NA.
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 4.5 mm)
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5 ,ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range qualified.
b) Maximum qualified thickness is restricted for PHT system (presently to 12 mm) due to Preheat &
PWHT(P1). Pl. check applicable specification.
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness,
Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by respective design
document.
73
NPCIL-GT-1:43
(Page 2of 3)
Filler metals (QW-404) •
SFA 5.14; SFA 5.30 (FOR INSERT)
Specification 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
Other
ER-NiCr 3
43
NA
1.6mm, 2.4mm, 3.2 mm
Max 2T#(limited to 19 mm)
All sizes
NA
NA
# # With or Without
NIL
 Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
## Inserts when used, shall confirm to SFA 5.30(e.g. :Gr E IN 82)
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
$All
Weld Progression
Vertical Uphill
Temp. range
NA
Position(s) of Fillet
All
Time range
NA
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions for all position qualification..
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
* 10 degree C
Inter pass temp. (max.)
* $$NA
Shielding
99.997%
Argon
NA
6-10 LPM
Preheat maintenance
With or Without
Trailing
NA
NA
NA
Backing
99.997%
Argon
NA
5-25 LPM
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture
)
Flow rate
See Gen Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
$$ When Notch Toughness properties are called, maximum Inter Pass (IP) temperature achieved shall be
recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
74
NPCIL-GT-1:43
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or
DC
Amps (Range)
DC
Polarity
Straight (EN)
Refer table below
Volts
(range)
Refer table below
Filler metal
Current
Travel
speed
range
mm/min +
Class
Dia.
Type
polarity
Amp
range +
Volt
range
+
GTAW
IN 82 / ER
Ni Cr 3
1.6X3.2 /
2.4
DC-EN
55-90
10-20
40-80
‘’
‘’
‘’
‘’
ER Ni Cr 3
2.4
2.4
3.2
3.2
‘’
‘’
‘’
‘’
60-100
60-100
70-120
70-120
10-30
‘’
‘’
‘’
‘’
‘’
‘’
‘’
Weld
layer(s)
Process
Root
1st
2nd
3rd
Balance
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2
passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increment in heat input w.r.t PQR, calls for
requalification(Ref QW409.1)
75
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
WPS No.: NPCIL-GT -1.43
PQR No.: L
Date 07.07.2014
Page
1of 2
GTAW / Manual
Welding Process (es) / Type(s):
Joints (QW-402)
Weld Type : Groove weld
Square
Butt joint without bevel edge
Backing : NA
Root Opening : 1.5 mm Root Face : 0.2 mm
Groove Angle:
NA
Base Metals (QW-403)
Post weld Heat Treatment (QW-407)
Material Spec., Type or Grade:
Type:
: NA
Temperature
: NA
P-No.:1 Group No.:1 to P-No.:43 Group No.: A
Time
:
Thickness of Test Coupon (mm):
Gas (QW-408)
ASTM A 516 GR-70 to
ASTM B168 Inconel 600
2.3
NA
Gas Composition / Flow Rate
Filler Metals (QW-404)
SFA Specification:
5.14
Shielding:
99.95% Argon / 6 LPM
AWS Classification:
ER - NiCr 3
Trailing :
None
Filler Metal F-No:
43
Backing::
99.95% Argon / 13 LPM
Weld Metal Analysis A-No:
NA
Electrical Characteristics (QW-409)
Size of Filler Metal (mm):
1.6 & 2.4
Current / Polarity:
DCEN (Straight)
Weld Deposited’ (mm):
2.38
Amps:
60-72
Pass Greater Than ½":
No
Volts:
15-19
Filler Metal Product From : Bare electrode
Tungsten Type / Size:
NA
Supplemental Filler Metal
Transfer Mode:
NA
:
None
Wire Feed Speed (mm/min): NA
Heat Input:
Positions (QW-405)
Position of Joint:
3G - Vertical
Technique (QW-410)
Weld Progression:
Uphill
Travel Speed (mm/min): 58-63
String/Weave Bead: Stringer for Root, weaves for subsequent passes
Preheat (QW-406)
Preheat Temp.:
20°C
Oscillation:
3 times of filler metal size Max.
Interpass Temp.:
NA°C
Multi /Single Pass (per side): Multi pass
Preheat Maintenance:
NA
Multi /Single Electrode:
Single
Nozzle/Gas Cup Size:
NA
Contact Tube to Work Dist.: NA
76
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. – L
Page: 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
ROOT
FILL
CAP
Process
GTAW
GTAW
GTAW
Filler Metal
AWS
Size
Classification
(mm)
ER Ni Cr 3
1.6
ER Ni Cr 3
1.6
ER Ni Cr 3
1.6
Specime
n No.
Width
(mm)
Thickness
(mm)
Area
(mm2)
3A
25.40
2.30
3B
25.20
2.38
Type /
Polarity
DCEP
DCEP
DCEP
Current
Amperage
Range
60-65
65-72
60-65
Voltage
Range
Travel Speed
Range
(mm/min)
58
64
63
15-17
17-19
15-17
Tensile Test (QW-150)
166.83
Ultimate
Total
Load, N
91240
Ultimate
Unit Stress,
N/mm2
546.91
170.54
89160
522.81
Type of Failure
& Location
Result
Ductile – PM
(CS)
Ductile – PM
(CS)
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t ( FB 1 )
Result
Satisfactory
QW-462.2 Face bend at 4t ( FB 2 )
QW-462.2 Root bend at 4t ( RB 1 )
QW-462.2 Root bend at 4t ( RB 2 )
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test
Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments : Test results were acceptable. ( Test report no. : 44081 – B dated 21.11.2012 )
Other Tests
Deposit Analysis
Macro examination test
Visual examination
None
None
Good
Welder's Name: Santosh Pagdhare Id-
_______
Liquid penetration test
RT
None
None
Stamp : _______
PQR was done & welding of coupon witnessed by Manish J. Chauhan
Test conducted by: NPCIL
Test ID : L
We certify that the statements in the record are correct & that the test welds were prepared, welded and tested in
accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
77
NPCIL-GT-8:43
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
WPS No.
NPCIL
NPCIL-GT-8:43
Supporting PQR No(s).
M
Prepared by QA Directorate & DTD, R&D Centre
Date
7-7-2014
Rev. No.
R-1
Date
7-7-2014
Welding process (es)
GTAW
Type(s)
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No: 8
Group No:
1
TO
P.No:43(Inconel 600)
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove*
1.5 mm to 2T(max 4.5 mm)
Group No:
NA
NA.
NA
Fillet
All Thickness
* 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range qualified.
78
NPCIL-GT-8:43
(Page 2of 3)
Filler metals (QW-404) •
SFA 5.14; SFA 5.30 (FOR INSERT)
Specification 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
Other
ER-NiCr 3
43
NA
2.0mm, 3.2 mm
Max 2T#(limited to 19 mm)
All sizes
NA
NA
# # With or Without
NIL
 Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
## Inserts when used, shall confirm to SFA 5.30(e.g. :Gr E IN 82)
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment
(QW-407)
All
Weld Progression
Vertical Uphill
Temp. range
NA
Position(s) of Fillet
All
Time range
NA
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
Inter pass temp. (max.)
Preheat maintenance
(Continuous or special heating,
where applicable, should be
recorded)
NA
Gas(es)
(Mixture) Flow rate
To
be Record in PQR.
Shielding
99.997%
Argon
NA
6-10 LPM
With or Without
Trailing
NA
NA
NA
Backing
99.997%
Argon
NA
5-25 LPM
* <150 Deg C,
See Gen Notes
* Preheat and inter pass temperature must be sufficient to prevent crack formation. Temperature above
the minimum shown may be required for highly restrained welds.
79
NPCIL-GT-8:43
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Polarity
Volts
(range)
Filler metal
Current
Class
Weld
layer(s)
Root
1st
Process
GTAW
‘’
2nd
3rd
Balance
‘’
‘’
‘’
IN 82
ER Ni Cr
3
‘’
‘’
‘’
Straight (EN)
Refer table below
Dia.
Type
polarity
Amp
range +
1.6X3.2
2.0
DC-EN
‘’
70-100
80-110
Volt
range
+
10-30
10-30
‘’
‘’
‘’
80-110
80-130
80-130
‘’
‘’
‘’
2.0
3.2
3.2
Travel
speed
range
mm/min +
40-80
‘’
‘’
‘’
‘’
Other
.
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes, EW Th-2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2
passes
Single
40 – 80 mm per minute
Not allowed
Nil
+ When notch toughness properties are called for, any increment in heat input w.r.t PQR, calls for
requalification(Ref QW409.1)
80
Nuclear Power Corporation of India Limited
R&D Centre, TMS Tarapur
Procedure Qualification Record (PQR)
PQR No.:
WPS No.: NPCIL-GT – 8: 43
M
Date 07.07.2014
Page
1of 2
GTAW / Manual
Welding Process (es) / Type(s):
Joints (QW-402)
Weld Type
: Groove weld , Square butt
Backing
: NA
Root Opening : 1.5mm
Root Face : 0.5 mm
Butt weld without bevel edge
Groove Angle : NA
Base Metals (QW-403)
Post weld Heat Treatment (QW-407)
Material Spec., Type or Grade : ASTM SA 240, SS304 to
ASTM SB 168 Incoloy 600
P-No.:8Group No.:1 to P-No.:43 Group No. : NA
Thickness of Test Coupon (mm) :
Type
: NA
Temperature : NA
Time
: NA
2.40
Gas (QW-408)
Filler Metals (QW-404)
Gas Composition / Flow Rate
SFA Specification
: 5.14
Shielding
: 99.95% Argon / 6 LPM
AWS Classification
: ER - NiCr 3
Trailing
: None
Filler Metal F-No
: 43
Backing
: 99.95% Argon / 12 LPM
Weld Metal Analysis A-No : NA
Size of Filler Metal (mm)
: 1.6
Electrical Characteristics (QW-409)
Weld Deposited’ (mm)
: 2.40
Current / Polarity
: DCEN (Straight)
Pass Greater Than ½"
: No
Amps
:
Filler Metal Product From :
Volts
:
Supplemental Filler Metal :
Tungsten Type / Size :
NA
Transfer Mode
:
Spray arc
Wire Feed Speed
(mm/min)
:
NA
Positions (QW-405)
Position of Joint
Heat Input
:
None
: 3G - Vertical
61-85
21-27
Weld Progression : Uphill
Technique (QW-410)
Preheat (QW-406)
Preheat Temp.
: 20°C
Inter pass Temp.
: NA°C
Preheat Maintenance : NA
Travel Speed (mm/min)
: 50
String/Weave Bead
: Stringer for Root, weaves
for subsequent passes
Oscillation
: 3 times of filler metal size
Multi /Single Pass (per side) : Multi pass
Multi /Single Electrode
: Single
Nozzle/Gas Cup Size
: NA
Contact Tube to Work Dist. : NA
81
NPCIL, R&D CENTRE
Procedure Qualification Records (PQR)
PQR No. –
M
Page: 2 of 2
Additional Welding Parameters
Layers(s)
and/or
Pass (es)
Process
ROOT
FILL
CAP
GTAW
GTAW
GTAW
Filler Metal
AWS
Size
Classification
(mm)
Type /
Polarity
ER Ni Cr 3
ER Ni Cr 3
ER Ni Cr 3
DCEP
DCEP
DCEP
1.6
1.6
1.6
Current
Amperage
Range
Voltage
Range
70-76
73-80
80-83
Travel
Speed
Range
(mm/min)
50
45
58
14-18
16-22
20-25
Tensile Test (QW-150)
Specimen
No.
O.D.
(mm)
Thickness
(mm)
Area
(mm2)
174.07
Ultimate
Total Load,
N
95800
Ultimate
Unit Stress,
N/mm2
550.35
4A
25.16
2.44
4B
25.18
2.40
171.67
89840
523.33
Type of
Failure &
Location
Ductile - PM
(SS)
Ductile - PM
(SS)
Result
Satisfactory
Satisfactory
Guide-Bend Test (QW-160)
Type and Figure No.
QW-462.2 Face bend at 4t (FB 1)
QW-462.2 Face bend at 4t (FB 2)
QW-462.2 Root bend at 4t (RB 1)
QW-462.2 Root bend at 4t (RB 2)
Result
Satisfactory
Satisfactory
Satisfactory
Satisfactory
Toughness Test (QW-170) – Not applicable
Specimen
No.
Notch
Location
Specimen
Size (mm)
Test
Temp.
(0C)
Impact Values
Joule
% Shear
Drop Weight
Break (Y/N)
Mils
Comments : Test results were acceptable. ( Test report no. : 44081 – C dated 21…11.2012)
Other Tests
Deposit Analysis
Macro examination test
Visual examination
Welder's Name:
None
None
Good
Santosh Pagdhare
Liquid penetration test
RT
ID: ..................
None
None
Stamp : ........
PQR was done & welding of coupon witnessed by Manish J. Chauhan
Test conducted by: NPCIL
Test ID : M
We certify that the statements in the record are correct & that the test welds were prepared, welded and tested in
accordance with the requirements of section IX of the ASME Code.
Signature
Name
Date
Manish J. Chuahan
SO/E(R&D)
07.07.2014
82
NPCIL-GTSM-5A:5A
WITHOUT PWHT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate
WPS No.
NPCIL-GTSM5A:5A
Date
Rev. No.
Supporting PQR No(s).
TO BE MADE BY
USER
ORGANIZATION
Date
Welding process (es)
GTAW+SMAW
28-3-2007
R-0
MANUAL
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 1.5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
5A
Group No: 1(e.g. SA 387 Gr22)
TO
P.No: 5A
Group No: 1(e.g. SA 387 Gr22)
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove*
1.5 mm to 2T(Max19 mm)
Fillet
All Thickness
* 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range qualified.
* When Notch Toughness properties are called for, minimum thickness qualified is governed by test coupon
thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or check
respective design document.
83
NPCIL-GTSM-5A:5A
(Page 2of 3)
Filler metals (QW-404) •
GTAW
Specification 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
Other
SMAW
SFA 5.28
SFA 5.5
ER90S B3
6
4
2.4mm, 3.2 mm
E 9018-B3
4
4
2.5mm, 3.15mm, 4 mm,5 mm
Max 2 t # #
All sizes
NA
NA
With or Without
NA
Max 2 t # #
All sizes
NA
NA
NA
 Each base metal-filler metal combination should be recorded individually.
# # ‘t’ is weldment thickness by respective process (Ref PQR).
# Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment (QW-407)
$All
Weld Progression
Vertical
Uphill
Position(s) of Fillet
All
Temp. range
NA
Time range(hold)
NA
$ When Notch Toughness properties are called for, test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions, for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
$$ 200degree C
Inter pass temp. (max.)
^^300 degree C
Shielding
99.95%
Argon
NA
6-10 LPM
Preheat maintenance
Yes
(Ref. Design
Specification)
Tracing
NA
NA
NA
Backing
99.95%
Argon
NA
(Continuous or special
heating, where applicable,
should be recorded)
Gas(es)
(Mixture)
Flow rate
5-25 LPM
See Gen Notes
$$ Decrease of preheats by more than 55Deg C, calls for re qualification.
^^ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall be
Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
84
NPCIL-GTSM-5A:5A
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Polarity
Volts (range)
Straight (EN)/Reverse (EP)
Refer table below
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes EW Th2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
40 – 80 mm per minute
Not allowed
Nil
Filler metal
Weld layer(s)
Process
Root
GTAW
1st
2nd
3rd
4th
,,
SMAW
‘’
‘’
Class
Dia.
Type polarity
Current
Amp range+
Volt
range +
Travel speed
range mm/min
+
ER 90S B3
ER 90S B3
E9018-B3
E9018-B3
E9018-B3
2.4
2.4
2.4
3.15
3.15
DC-EN
‘’
DC-EP
,,
‘’
55-90
55-90
60-100
100-140
100-140
10-30
10-30
20-40
20-40
‘’
40-80
‘’
‘’
‘’
‘’
Other
.
Min 5 mm
by GTAW
+ When notch toughness properties are called for, any increase in heat input w. r. t PQR, calls for
requalification, (Ref QW409.1)
85
NPCIL-GTSM-5A:5AH
WITH PWHT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate
WPS No.
NPCIL-GTSM-5A:5A H
Date
Rev. No.
Supporting PQR No(s).
TO BE MADE BY USER
ORGANIZATION
Date
Welding process (es)
GTAW+SMAW
Type(s)
28-3-2007
R-0
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
**# 19 ≤ T (thickness of test coupon) < 38
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
5A
Group No: 1(e.g. SA 387 Gr22)
TO
P.No: 5A
Group No: 1(e.g. SA 387 Gr22)
OR
Specification, Type & Grade to Specification,
type & grade
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove*
5 mm to 2T
Fillet
All Thickness
* When Notch Toughness properties are called for, minimum thickness qualified is governed by test coupon
thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or by
respective design document.
86
NPCIL-GTSM-5A:5AH
(Page 2of 3)
Filler metals (QW-404) •
GTAW
Specification 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
Other
SMAW
SFA 5.28
SFA 5.5
ER90S B3
6
4
2.4mm, 3.2 mm
E 9018-B3
4
4
2.5mm, 3.15mm, 4 mm,5 mm
Max 2 t # #
All sizes
NA
NA
With or Without
NA
Max 2 t # #
All sizes
NA
NA
NA
 Each base metal-filler metal combination should be recorded individually.
# # ‘t’ is weldment thickness by respective process (Ref PQR).
# Weldment is full thickness of test coupon.
Positions (QW-405)
Position(s) of Groove
Post Weld Heat Treatment (QW-407)
$All
Weld Progression
Vertical
Uphill
Position(s) of Fillet
All
*700 to 760
Temp. range
Time range(hold)
*1 Hr for every 25 mm (Minimum 1hr)
* Values are taken from Secondary Cycle Piping Pkg. Of TAPP 3&4. Refer design
document.
$ When Notch Toughness properties are called for test coupon should be welded in vertical up- hill
progression e.g. 3G, 5G or 6G positions, for all position qualification.
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
$$ 200degree C
Inter pass temp. (max.)
^^300 degree C
Shielding
Preheat maintenance
Yes (Ref Design
Specification)
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
99.95%
Argon
NA
6-10 LPM
Tracing
NA
NA
NA
Backing
99.95%
Argon
NA
5-25 LPM
See Gen
Notes
$$ Decrease of preheats by more than 55Deg C, calls for re qualification.
^^ When Notch Toughness properties are called for, maximum Inter Pass (IP) temperature achieved shall be
recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
87
NPCIL-GTSM-5A:5AH
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or DC
Amps (Range)
DC
Refer table below
Polarity
Volts (range)
Straight (EN)/Reverse (EP)
Refer table below
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
Standard sizes EW Th2
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
Grinding
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
3 times of filler metal size (max)
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
Travel speed (range)
Peening
Other
Weld
layer(s)
Filler metal
Process
Root
GTAW
1st
,,
nd
SMAW
‘’
‘’
2
3rd
4th
Balance
40 – 80 mm per minute
Not allowed
Nil
Current
Class
Dia.
Type polarity
ER 90S B3
ER 90S B3
2.4
2.4
DC-EN
‘’
E9018-B3
E9018-B3
E9018-B3
‘’
2.4
3.15
4.0
5.0
DC-EP
,,
‘’
‘’
Volt
range +
Travel speed
range mm/min +
Other
55-90
55-90
10-30
40-80
10-30
‘’
Min 5
mm by
GTAW
60-100
100-140
110-160
150-200
20-40
20-40
‘’
‘’
‘’
‘’
‘’
‘’
Amp range+
.
+ When notch toughness properties are called for, any increase in heat input w.r.t PQR, calls for
requalification (Ref QW409.1)
88
NPCIL-SMSAW-11
WITHOUT PWHT
Page 1 OF 3
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
QA Directorate
WPS No.
NPCIL-SMSAW-11
Date
Rev. No.
Supporting PQR No(s).
TO BE MADE BY USER
ORGANIZATION
Date
3-4-2007
R-0
MANUAL
Welding process (es)
SMAW + SAW
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
With OR Without
Backing Material (Type) (Refer
As per design
document.
to both backing and retainers)
□ Metal Thickness
□ Non-fusing metal
□ Non-metallic
□ Other
SEE STANDARD JOINT
CONFIGURATIONS ATTACHED.
# 5 ≤ T (thickness of test coupon) < 19
Sketches, production drawings, weld symbols or written description should show the general
arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld
groove may be specified. (At the option of the mfg., sketches may be attached to illustrate joint
design, weld layers and bead sequence, e.g. for notch toughness procedure, for multiple process
procedures, etc.)
Base Metals (QW-403)•
P.No:
1
*Group No:
1/2
OR
Specification, Type & Grade to Specification,
type & grade
TO
P.No:
1
*Group No:
1/2
IS 2062 or IS2002 or IS1239 or equivalent to IS 2062 or
IS2002 or IS1239 or equivalent or P1.
OR
Chem. Analysis & Mech. Properties
NA
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
Groove**
1.5 mm to 2T(max 19 mm)
Fillet
All Thickness
* When Notch Toughness properties are called for, refer QW 403.5, ASME Sec-IX for Group. No.
restriction.
**a) 10 mm thick test coupon qualifies full range, otherwise see table QW 451.1(attached) for range
qualified.
b) Any pass deposit is restricted to 13mm. (Refer QW 403.9)
c) When Notch Toughness properties are called for, minimum thickness qualified is governed by test
coupon thickness, Ref: QW 403.6(16 mm for T≥ 16 mm, T for 6 mm < T ≤ 16 mm, T/2 for T < 6mm) or
by respective design document.
89
NPCIL-SMSAW-11
(Page 2of 3)
Filler metals (QW-404) •
SMAW
Specification No. (SFA)
AWS No. (class)
F-no.
A-no
Size of filler metals
Weld metal thickness range:
Groove
Fillet
Electrode-Flux (Class)
SFA 5.1
4
1
2.5mm
Max 2t # #
All sizes
NA
Max 2t # #
All sizes
F 7 A2 EH 14 ^
Eg:Auto melt Gr 4 Flux ,Use NPC
approved.
NA
NA
Consumable insert

SFA 5.17
F 7 A2 EH 14
6
1
3.15
E-7018 or E7018-1
Flux trade name
Other
SAW
NA
SMAW IS ONLY FOR PROVIDING
BACKING FOR SAW
Each base metal-filler metal combination should be recorded individually.
# # ‘t’ is weldment thickness by respective process(Ref PQR), cumulative thickness limited to 19 mm.
# Weldment is full thickness of test coupon.
^ Change in Flux- Wire combination calls for re- qualification.
Positions (QW-405)
Post Weld Heat Treatment
(QW-407)
Position(s) of Groove
FLAT
Temp. range
NA
Weld Progression
NA
Time range
NA
Position(s) of Fillet
All
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
10 degree C
Inter pass temp. (max.)
$$NA
Shielding
Preheat maintenance
With or Without
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
NA
NA
NA
Trailing
NA
NA
NA
Backing
NA
NA
NA
$$ When Notch Toughness properties are called, maximum Inter Pass (IP) temperature achieved shall be
Recorded and IP temperature more than recorded (in PQR) + 55 deg. C calls for re-qualification.
90
NPCIL-SMSAW-11
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or
DC
Amps (Range)
DC
Polarity
Refer table below
Reverse (EP)
Volts (range)
Refer table below
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular
form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
NA
Not applicable
2.5-2.8 mtr/min
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer
NA
Brushing or grinding, Joint shall be dry prior to welding
Grinding
NA
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
400-500 mm per minute
Not allowed
Nil
Filler metal
Weld
layer(s)
Root
1st
2nd
Process
SMAW
SAW
“
Current
2.5
3.15
Type
polarity
DC-EP
DC-EP
Amp
range +
70-100
300-400
Volt
range
+
22-40
22-40
Travel speed
range +
40-80 mm/min
2.5-2.8 mtr/min
“
“
“
“
“
Class
Dia.
E-7018-1
F7A2EH14
“
Other
.
+ When notch toughness properties are called for, any increment in heat input w.r.t PQR, calls for
requalification, (Ref QW409.1)
91
WELDING PROCEDURE SPECIFICATION
NPCIL GT-88 (A-T-T)
PROCEDURE FOR WELDING OF SS TUBE TO SS TUBE WITH
PULSED AUTO TUBE WELDING MACHINE
92
CONTENTS
1.0
INTRODUCTION
2.0
PURPOSE
3.0
APPLICABILITY
4.0
REFERENCE DOCUMENT
5.0
RESPONSIBILITY
6.0
PRE-REQUISITES
7.0
EQUIPMENTS & ACCESSORIES
8.0
DESCRIPTION
8.1
VARIABLES
8.2
PREPARATION OF THE BASE METAL
8.3
ELECTRODES
8.4
SEQUENTIAL ACTIONS
9.0
IMPORTANT PARAMETERS
10.0
TESTING
10.1
TEST FOR QUALIFICATION OF EQUIPMENTS
10.2
QUALIFICATION OF WELDING OPERATOR
10.3
TEST PRIOR TO, DURING AND AT THE END OF THE PRODUCTION
WELDING
11.0
ACCEPTANCE CRITERIA
11.1
EXTERNAL VISUAL EXAMINATION
11.2
INTERNAL VISUAL EXAMINATION
11.3
TENSILE TEST
11.4
BEND TEST
115
WELDING PARAMETERS
12.0
RECORD
13.0
PRECAUTION / SAFETY
14.0
WELDING PROCEDURE SPECIFICATION FOR TUBE TO TUNE
WELDING BY AUTO TUBE WELDING MACHINE
93
1.0
INTRODUCTION:
This procedure is evolved for the qualification of microprocessor based Auto Tube
Welding Machine for welding SS tube to SS tube by auto GTAW process without
filler metal. This procedure can be applied for Welder qualification and production
welding of main plant instrumentation/process tubing.
2.0
PURPOSE:
This procedure gives step by step guide lines for Joining by welding two tube sections
of instrumentation sensing / process lines using Pulsed Auto Tube Welding Machine
by Tungsten Inert Gas welding with out using filler metal.
3.0
APPLICABILITY:
This procedure is applicable to welding of SS tubing work size from 6mm to 25mm
OD. This procedure can be applied for Welder qualification and production welding of
main plant instrumentation/process tubing.
4.0
REFERENCE DOCUMENT:
 Section IX of Boiler pressure vessel code.
 PB-M-17 Rev. 1 Technical specification for seamless austenitic stainless steel
tubing for 500 MW PHWR.
 Machine Manufacturer’s user manuals.
5.0
RESPONSIBILITY:
Responsibility of implementation of this procedure lies with performer.
6.0
PRE-REQUISITES:

High purity (99.9993%) Argon Gas confirming to IS-5760-1998, Gr -1.

Welding program, power supply.

Seamless austenitic bright-annealed tube.

Swagelok make Stainless Steel Flux(for 20/25 mm tube).
7.0
EQUIPMENTS & ACCESSORIES:
Auto tube welding machine along with its accessories viz. Thoriated Tungsten
Electrode, Centering Gauge, Arc Gap Gauge, Tube Fixtures / collets, Welding Head,
Tube Cutter, Tube Squaring machine & Bits, thermal paper, pressure regulators, purge
tubing, dial caliper or micrometer, pressure gauge, flow meter for purging & shielding.
8.0
DESCRIPTION:
Automatic butt welding of SS-304L tubes without the use of filler wire is done by
placing two sections of tubes in welding heads connected to an Automatic Tube
welding Machine. Rotary welding electrode is aligned. Purging of tube ID and
welding head, initiation of the welding arc and completion of welding is done as per a
welding program, stored in the memory of welding machine.
Mode of qualification: As per ASME Section IX; Boiler and pressure vessel code.
94
8.1
VARIABLES:
8.1.1

Process:
Single Pass Pulsed Automatic Gas Tungsten Arc welding without adding filler
metal by means of a rotating electrode.
8.1.2

Base metal
8.1.3

Thickness and Dia of tube:
O.D
6mm
10mm
12mm
20mm
25mm
8.1.4

Filler metal
:
NIL
8.1.5

Position
:
ALL
8.1.6

Pre-heating & PWHT
8.1.7

Shielding and purging:
Shielding & Purging gas shall confirm to IS-5760-1998, Gr -1 (Argon of
99.9993% pure (min)).
8.1.8

ELECTRICAL CHARACTERISTICS:
The process works on DC straight polarity.
Electrode
-VE ; Work Piece +VE (Also see parameters : 9 00 )
8.1.9

Technique: Pulsed orbital Automatic TIG welding without addition of
filler metal.
8.2

PREPARATION OF THE BASE METAL:
: P. No. 8( S.S 304L Tube) to P. No. 8( S.S 304L Tube)
:
WALL THICKNESS
1.2mm
1.2mm
1.5mm
2.5mm
3.0mm
NA
The tube shall be handled throughout carefully so that there are no injurious marks on
the tubing. The tube end shall be square cut only with hand operated tube
cutter/squiring machine. After cutting, burrs should be removed by burr removing tool,
keeping the tube face inclined downwards. Both the tube end shall be cleaned
thoroughly using acetone or any other approved solvent just before assembling the
tubes in the weld head.
For 20mm and 25mm OD SS Tube welding:
For welding higher sizes/ wall thickness SS tubes, penetration is not achievable
without applying Flux A wet paste of Swagelok welding Flux (Swagelok Part No.
SWS-FLUX-1) and Acetone shall be prepared. The quantity of Flux used shall be
minimum. Application of flux has been accepted by NPCIL vide DCR NO. TICB/BF01.
For 20mm dia tube the wet paste shall be applied on outer surface of the tubes on
either side of the joint and allowed to dry.
For 25 mm tube the paste shall be applied both on the outer surface and the cross
section of the joints.
Note: For size up to 6mm to 12mm no Swagelok Flux shall be applied.
95
8.3
ELECTRODES :
2% thoriated or cereated tungsten electrode of size as recommended by manufacture
of machine, as per figure given below.
3d
Included Angle
8.3.1
d
0.3 d
Grinding Direction Parallel to
Fig:1
Electrode Axis
Different length electrodes for different size of SS tube must be used as per guidance
given by manufacturer. As per Swagelok manufacturer, electrode of size 27.94 mm x
1.57 mm is standard size for use on tube size from 6mm up to 25 mm. Electrode shall
be replaced after 25 welds or immediately after contamination/ deformation.
8.4
SEQUENTIAL ACTIONS:
8.4.1
ELECTRODE FIT UP:
Select the proper electrode for the job to be performed. Without fixture block attached,
press WELD Then press HOME. Verify the rotor is in correct position, to install the
electrode.
On the real panel, turn off the circuit breaker. Loosen the two electrode clamping
screws.
Insert the desired electrode with sharp tip pointing out. Tighten the electrode clamping
screws slightly to temporarily hold in place.
8.4.2
SETTING THE ARC GAP:
Select the arc gap value from the following table.
Tube Size
ARC gap
6
0.64 mm
10
0.64 mm
12
1.02 mm
20
1.39 mm
25
1.39 mm
Insert the arc gap gage in to the rotor. Tilt the weld head upward. Loosen the electrode
screw allowing the electrode to drop onto the gauge surface.
Tighten the electrode clamping screws just enough to secure the electrode. Remove the
arc gap gauge. Restore the power to the SWS by turning the circuit breaker ON.
Press HOME to return the rotor to home position and visually inspect the rotor smooth
position/motion.
8.4.3
INSTALLING THE COLLETS IN TUBE FIXTURE BLOCK:
Install proper collets for the diameter of tube being welded. Release both levers of
fixture and open the tube fixture block. Align the collets halves in both the top and
bottom side plates and tighten the collets screws. Make sure that the collets shoulder is
flushed against the fixture side plate.
96
8.4.4
ALIGNING THE WORK PIECES IN THE TUBE FIXTURE BLOCK:
Place the centering gauge on one side of the tube fixture block. The centering gauge
must span the width of the collets. Butt one tube against the centering gauge. Lock
down the topside plates. Remove the centering gauge. Butt the second tube against the
first, and lock down the topside plate. Inspect 360 deg around the joint for fit and
alignment.
8.4.5
MATING THE WELD HEAD TO THE FIXTURE BLOCK:
Rotate the locking lever on the weld headcounter – clockwise until it stops. Insert the
weld head in to the fixture block. Rotate the locking lever clockwise to secure the weld
head. Examine the fixture indicator light. Verify that it is off.
8.4.6
SETTING THE SHIELD GAS FLOW:
Verify the shielding and the purge gas connection to the work pieces as per figure 2
Set the shielding gas flow meter to setting between 4.7 to 9.4L/mm
Set PURGE to operate the shielding gas solenoid valve and to start the shielding gas
flow. Allow the system to purge for several minutes on initial setup to clear the
shielding gas system of oxygen. Press purge again to close the shielding gas solenoid
valve.
8.4.7
Set Shielding and purging parameter are as follows:
Tube
Size
6 mm
Wall
Thickness
1.2mm
Minimum ID
Purged Rate
2.5 std L/min
10m
m
12m
m
1.2mm
2.5 std L/min
1.5mm
7 std L/min
20m
m
25m
m
2.5mm
14 std L/min
3.0mm
14 std L/min
Pressure
71 to 86
mmwc
38 to 64
mmwc
25 to
383
mmwc
13 to 28
mmwc
13 to 28
mmwc
Swagelok Head
Purge Rate
5 to 10 std
L/min
5 to 10 std
L/min
5 to 12 std
L/min
Restrictor
Size
3mm
7 to 14 std
L/min
7 to 14 std
L/min
6mm
3mm
6mm
6mm
Above Parameters are for general idea, actual Parameter shall be as per orbital tube
welding machine manufacturer.
97
8.4.8
NOTE: ARGON GAS WITH 99.9993 % PURITY WITH THE FOLLOWING THE
FOLLOWING IMPURITY LIMITS.
O2
---
0.50
MOISTURE
CO2
CO
H2
N2
HYDROCARBON
SULPHER COMP
MERCURY
CHLORINE
-------------------
2.00
NIL
NIL
0.20
2.00
2.00
NIL
NIL
NIL
PPM BY
VOLUME
-DO-DO-DO-DO-DO-DO-DO-DO-DO-
TO ATMOSPHERE
S. S.
TUBE
V2
V1
TEE
S. S.
TO ATMOSPHERE
WATER
PURGING GAS
CYL
(ARGON)
FIG:2
INTERNAL PURGING BACK PRESSURE SETUP
8.4.9
Connect a purge gas pressure control valve V2 at the outlet end of the tube being
welded and keep it in full open position. Open the purge gas cylinder valve V1 and
pressure regulator valve slowly to achieve the required flow rate as mentioned in the
table. Adjust the valve V2 so that the required height of water column is indicated in
the manometer / flow meter.
NOTE:
In case where backing gas pressure cannot be achieved due to design configuration of
the system, the internal purge flow shall be determined by means of Trail/Mock up. In
case of short tube welded to a pipe the manometer pressure setting is ineffective.
8.4.10
STARTING AND COMPLETING THE WELDS:
LOAD the weld program / for welding the desired size of SS tube. Check the
following before starting the weld.
All the rear panel connection is complete. Shielding and the purge gas lines are
properly connected. The inert gas source is on. Correct gas flow rates are set.
98
Tubes are properly aligned and clamped to the fixture block. The proper arc gap is
set. The weld head is connected to the fixture block. Proper weld procedure program
has been selected and entered. Internal purge gas is flowing.
Press START and wait till completion of the welding process.
Wait for machine to return to ready state. Check the fixture block has cooled enough
to be safely handled. Release the locking lever on the weld head housing. Remove the
weld head from the fixture block. Remove the internal purge gas line from the welded
assembly. Release the lever on the fixture block. Open the side plates on the fixture
block. Remove the welded assembly.
9.0
IMPORTANT PARAMETERS: (Refer enclosed annexure)
Machine parameters need to be identified based on guidelines given by auto tube
welding M/C manufacturers and based on trials to suit to the tube material in use.
Once finalized, these parameters shall be followed without change for qualification /
production welds. Any change in parameters calls for re qualification of the procedure.
Some of the important parameters are listed here, which are required to be established
w.r.t each diameter of SS tube.
1. Head rotation delay.
2. Shielding and purging gas purity and flow rate.
3. Low pulse current, pulse width/time and voltage for each level/segment.
4. High pulse current, pulse width/time and voltage for each level/segment.
5. Head rotation/speed..
6. Down slope timing.
7. Each segment timings and total weld time.
In addition to the above, any parameters that affect weld and identified by the auto
tube welding M/C manufacturer on control panel are also to be recorded.
ALL THE ABOVE PARAMETERS NEED TO BE RECORDED DURING
QUALIFICATION AND SHALL BECOME PART OF PQR.
10.0
TESTING:
10.1
TEST FOR QUALIFICATION OF EQUIPMENTS:
After the machine has been commissioned, 15 welds for each size of tubing and each
position (2G & 5G) shall be made in one un-interrupted sequence and examined as
following.

All welds shall be examined visually.

Six welds shall be sectioned for internal examination.

Three welds shall be subjected to tensile test.

Six welds shall be subjected to bend test and examined.
99
10.2
QUALIFICATION OF WELDING OPERATOR:
To ascertain that the operator is familiar with the connection and the operation of the
equipment, printer and interpretation of graphs, trade test as follows shall be
conducted.
 The operator must have knowledge of material and material handling,
knowledge of purging requirements and machine parameter settings.
 For each position and size of tubing the operator shall make three test pieces.
 Two of these shall be cut open and subjected to internal examination and bend
test.
10.3
TEST PRIOR TO, DURING AND AT THE END OF THE DAY:
Daily test prior to production welding i.e., Daily machine Qualification.
The welder shall produce three satisfactory weld samples in each position for planed
size of tubing before start of work.

Test welds shall be longitudinally sectioned for internal examination. This will
be the part of daily machine qualification.

Also whenever argon cylinder is changed, three sample welds will be made
before starting production weld.
Testing during production:
No test will be made during production. Consistency of welding machine performance
can be checked from hard copy of the welding parameters. Also uniformity on quality
of production weld can thus be inferred. However weld shall be visually checked
(externally) for

Weld bead width to ascertain proper fusion.

Centering of the bead to ascertain arc wandering, if at all it has taken place.

Bulging or depression in the weld bead.
In case of repeated observations, re-qualification of the machine may be called for.
Testing at the end of the day:
At the end of the day three samples welds will be made. This will be required if total
production welds are more than 30 Nos. in a day. Otherwise end samples may be
waved off. Test welds shall be longitudinally sectioned for internal examination.
11.0
ACCEPTANCE CRITERIA:
11.1
EXTERNAL VISUAL EXAMINATION:
 The weld must be free from cracks, porosity, undercuts, concavity &convexity
(indicating the proper pressure of internal purge has been applied), encroachment.

The tube shall not be misaligned (axial and angular misalignment) beyond the
tolerance given under “fit up” indicating that the tube ends were straight and the
weld head clamps were clamped properly.

It must not have excessive oxidation indicating inert gas coverage until the molten
puddle has sufficiently cooled.
Note: It is noted that use of FLUX in the welding process result in a Thin Blackish
Layer on inside and outside of the tube in about 5mm band.

The weld bead shall have uniform width indicating that the current was
100
programmed properly maintaining requisite heat input for at least 360 deg of
electrode rotation.

The current is tapered out during the overlapping phase, where smooth tapered end
prevents crater due to arc extinguishing. This can be further verified with hard
copy of the weld parameter, which will be produced at the time of weld inspection.

The weld bead evenly centered, ensuring complete fusion of both the tube ends
and absence of arc wander.
The bead shall be smooth and uniform indicating correct electrode travel speed
11.2
INTERNAL VISUAL EXAMINATION:
The sample shall be cut open longitudinally thought the weld joint and examined

The weld shall have complete penetration. However there shall not be
penetration, which results in reduction of the internal diameter (drop in
through) as detailed below:
For 6mm Tube
-No internal reinforcement is permitted
For 10mm Tube
-0.127 mm maximum internal reinforcement
For 12 mm Tube -0.153 mm maximum internal reinforcement
Note: With Tubes welded in the horizontal position; gravity may cause a concave
weld at the top and convex weld at the bottom. This is acceptable as long as the
reduction in internal diameter is not more than 20% of the wall thickness. For
6mm tubes, no reduction in internal diameter is permitted.
11.3

Internal bead width is nearly equal to the external bead width.

There shall not be any visible sign of tool marks.
TENSILE TEST:
To pass this test the specimen shall have tensile strength not less than tube material
strength (4925 kg/cm2). If the specimen breaks in the base metal outside of the weld
or fusion lines the strength should not be less than 95 % of tube material strength
(4675 kg/cm2). (See also specification for requirements)
11.4
BEND TEST:
Sample for bend test, both full tube and longitudinally sectioned tube, shall be at last
150mm long with weld in center. The tube shall be bent 180 Deg around a mandrel
having diameter equal to 8 times the OD of the tube in such a way that face/ root of
the weld is tension. Weld should not open up in the process.
11.5
12.0
WELDING PARAMETERS:

The current variation should not be greater than +2A for time period more than
5% of the weld time.

Current variation between tow successive peaks (in plus mode) should not be
grater than +0.5A.

The weld speed is in concurrence with the approved value.
RECORD:
The recorder shall record all the parameter used during the welding. The printout of
recorded parameters shall be identified with joint number and shall be examined for
acceptability of its values.
101
13.0
PRECAUTION / SAFETY:
Follow all the basic of welding safety practice.

Provide adequate ventilation when insert gas is used for shielding and purging
for fumes to escape.

Do not expose the welding machine to water, as it is not waterproof.

Do not store / use hazardous material nearby.

Do not unplug by pulling on the cord.

Disconnect the weld head completely from the power supply prior to servicing.

Initially and after any extended period of interruption in work, the gas hoses
have to be purged with a minimum of 3 times of contained volume or for 2 to 3
minutes which ever is greater, to remove air from the hoses.
102
14.0
WELDING PROCEDURE SPECIFICATION FOR TUBE TO TUBE WELDING
BY AUTO TUBE WELDING M/C USING IMPULSE CURRENT
Parameters for Swagelok Auto Tube Welding Machine
Sl.
PARAMETER
No
1 Joint Type
For 6 mm Tube
For 10 mm Tube
For 12 mm Tube
Tube to Tube
Square Butt
P-8, SS-304L
1.2 mm
SWS-10H-B
CWS-C.062-1.105P
0.89 mm
Tube to Tube
Square Butt
P-8, SS-304L
1.2 mm
SWS-10H-B
CWS-C.0621.105-P
0.89 mm
Tube to Tube
Square Butt
P-8, SS-304L
1.5 mm
SWS-10H-B
CWS-C.0621.105-P
1.02 mm
Argon of
99.9993% (min)
purity (Gr –1of IS5760-1998).
3 lit / min.
Argon of
99.9993% (min)
purity (Gr –1of IS5760-1998).
7 lit / min
Argon of
99.9993% (min)
purity (Gr –1of
IS-5760-1998).
3 lit / min.
Argon of
99.9993% (min)
purity (Gr –1of IS5760-1998).
7 lit / min
Argon of
99.9993% (min)
purity (Gr –1of
IS-5760-1998).
3 lit / min.
Argon of
99.9993%(min)pur
ity (Gr–1of
IS-5760-1998).
7 lit / min
165-167 mm of
Water Column
2.75 mm/sec
85-88 mm of
Water Column
2.50mm/sec
75-77 mm of
Water Column
2.56 mm/sec
2
3
4
5
Material Type
Wall Thickness in Millimeters
Weld Head Model No.
Electrode Part No.
6
Arc Gap in mm
7
ID Purging:
Gas & Flow rate
8
Shielding:
Gas & Flow rate
9
ID Purging Gas Pressure
10
Travel speed
11
Rotor speed in rpm for all levels 8.75 RPM
(Travel speed / Circumference) x
60
4.78 RPM
4.07 RPM
12
Start power (Low / Norm)
Norm
Norm
Norm
13
Maintenance amps for all
Levels
19.85 Amps
19.85 Amps
24.82 Amps
14
Start Current =
(Imp Level 1 x % Imp Width) +
(Maint. X (1 - % Imp Width)
33.75 Amps
33.75 Amps
42.19 Amps
15
Impulse amps for level-1
66.19 mps
66.19 mps
82.74 Amps
16
Level Factor =
(Impulse Amps Level 1 x 0.15) /
(Number of Levels-1)
3.31 Amps
3.3 Amps
4.14 Amps
17
Impulse Amps for level 2 =
Impulse Amps Level 1 – Level
Factor
62.88 Amps.
62.89 Amps.
78.6 Amps.
103
Sl.
PARAMETER
No
18 Impulse Amps for level 3 =
Impulse Amps Level 2 – Level
Factor
19
For 10 mm Tube
For 12 mm Tube
59.57 Amps.
59.59 Amps.
74.46 Amps.
Impulse amps for level 4 =
Impulse Amps Level 3 – Level
Factor
Pulse Rate =
(Travel speed x 60) / (30 x wall
thickness)
56.26 Amps.
56.29 Amps.
70.32 Amps.
4.58 cycle / sec
4.16 cycle / sec
3.41 cycle / sec
21
Impulse width
30 %
30 %
30 %
22
Pre-purge time in seconds
20 sec.
20 sec.
20 sec.
23
Rotor delay time
0.87 sec.
0.96 sec.
1.17 sec.
24
Total weld time single pass in
seconds =
Second per Revolution + Weld
Overlap time
Where,
Seconds per revolution = 60 /
rpm, and
Weld over lap time = Wall
Thickness x 2 / Travel Speed
Weld time for each level =
Total Weld Time / Number of
Levels
Down Slope Time =Total Weld
Time x 0.2
Post-purge time in seconds
7.73 sec.
13.51 sec.
15.91 sec.
1.9 sec.
3.38 sec.
3.98 sec.
1.55 sec.
2.7 sec.
3.18 sec.
20 sec.
20 sec.
20 sec.
20
25
26
27
For 6 mm Tube
104
Annexure A
 Aluminum Welding
 Copper Brazing
1
1
1
NPCIL-GT-23:23
(Page 1of 3)
WELDING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
WPS No.
NPCIL-GT-23:23
Date
Supporting PQR No(s).
TO BE MADE BY USER
ORGANIZATION
Date
Welding process (es)
GTAW
Type(s)
QA Directorate
7-3-2007
Rev. No.
R-0
MANUAL
(Automatic, Manual, Machine, or Semi-Auto)
Joints (QW-402)
Details
Joint Design
GROOVE
Backing :
*With
Backing Material (Type) (Refer to
both backing and retainers)
Same as parent
material.
Gap 6mm
350 to 400
Sleeve
□ Metal Thickness –Min 3 mm
□ Non-fusing
metal
□ Non-metallic
□ Other
C/L of pipe
(100 dia.)
Sketches, production drawings, weld symbols or written description should show the general arrangement
of the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified. (At
the option of the mfg., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g. for
notch toughness procedure, for multiple process procedures, etc.)
Base Metals (QW-403)•
P.No:
23
Group No:
-
TO
OR
Specification, Type & Grade to Specification,
type & grade
P.No:
Groove
Group No:
-
IS 5082 to IS 5082
OR
Chem. Analysis & Mech. Properties
to Chem. Analysis & Mech. Properties
Thickness range
Base metal
23
NA
5 mm to 2T
Fillet
All Thickness
* Procedure without backing requires re-qualification (NPCIL Practice).
1
2
2
NPCIL-GT-23:23
(Page 2of 3)
Filler metals (QW-404) •
Specification No. (SFA)
SFA 5.10
AWS No. (class)
ER 4043
F-no.
23
A-no
-
Size of filler metals
5 mm
Weld metal thickness range:
Groove
Max 2T#
Fillet
All sizes
Electrode-Flux (Class)
NA
Flux trade name
NA
Consumable insert
NA
Other
NA
Each base metal-filler metal combination should be recorded individually.
# Weldment is full thickness of test coupon.
Positions (QW-405)
Post Weld Heat Treatment (QW-407)
All
Temp. range
NA
Weld Progression
Vertical
Uphill
Time
range(hold)
NA
Position(s) of Fillet
All
Position(s) of Groove
Preheat (QW-406)
Gas (QW-408)
Percentage composition
Preheat temp. (min.)
-
Inter pass temp. (max.)
NA
Shielding
Preheat maintenance
Without
(Continuous or special heating,
where applicable, should be
recorded)
Gas(es)
(Mixture)
Flow rate
99.95%
Argon
NA
14-20 LPM
Tracing
NA
NA
NA
Backing
NA
NA
NA
1
3
3
NPCIL-GT-23:23
(Page 3of 3)
Electrical Characteristics (QW-409)
Current AC or
DC
Amps (Range)
AC
Polarity
Refer table below
Filler metal
Weld
layer(s)
Root
1st
2nd
3rd
Balance
-
Volts (range)
Refer table below
Current
Process
Class
Dia.
Type polarity
Amp range
Volt
range
GTAW
‘’
‘’
‘’
‘’
‘’
ER 4043
‘’
‘’
‘’
‘’
‘’
5
‘’
‘’
‘’
‘’
‘’
AC
‘’
‘’
‘’
‘’
‘’
200-260
‘’
‘’
‘’
‘’
‘’
25-30
‘’
‘’
‘’
‘’
‘’
Travel speed
range
mm/min
75-100
‘’
‘’
‘’
‘’
‘’
Other
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below.)
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW
Electro Wire feed speed range
4 mm 2% Zr EWZR
Not applicable
Not applicable
Technique (QS-410)
Stringer or weave bead
Orifice or gas cup size
Initial & inter pass cleaning
Method of back gouging
Oscillation
Contact Tube to work Distance
Multiple or single pass (per
side)
Multiple or single electrode
Travel speed (range)
Peening
Other
Stringer for Root, Weave for subsequent passes
Standard sizes
Brushing or grinding, Joint shall be dry prior to welding
NA
NA
NA
Either, All pressure retaining weld shall be minimum of 2 passes
Single
75 – 100 mm per minute
Not allowed
Nil
1
4
4
NPCIL-TB-107:107
(Page 1of 1)
BRAZINGING PROCEDURE SPECIFICATION
Company Name
NPCIL
Prepared by
BPS No.
NPCIL-TB-107:107
Supporting BQR No(s).
TO BE MADE BY USER
ORGANIZATION
Date
Date
QA Directorate
7-3-2007
Rev. No.
R-0
MANUAL
Brazing process (es)
Torch Brazing
Type(s)
(Automatic, Manual, Machine, or Semi-Auto)
JOINT DESIGN (QB – 408)
Joint Design:
Type: Tube # Tube Lap Joint
Joint Clearance: 0.05 to 0.13mm
Overlap: Minimum: 3 T
Maximum: ……
BASE METAL (QB-402)
BRAZING FILLER METAL (QB-403)
P/ S-Number: 107 (SB 111/12000)
to P/ S-Number: 107 (SB 11/12000)
Other:
NA
Specification Number: SFA 5.8
AWS Classification: B Cu-P5 (Chemical Analysis of filler Wire: Ag
BASE METAL THICKNESS- T ≤ 3 mm
Minimum - 1 / 2 T
F-Number: 103
Filler Metal Product Form: SOLID 1.6mm
BRAZING TEMPERATURE ( QB-404)
Maximum- 2 T
POST-BRAZE-HEAT TREATMENT
(QB-409)
Temperature Range:
Time Range:
14.5 to 15.5, P 4.8 to 5.2, Other 0.15
& Cu Reminder)
NA
NA
FLOW POSITION ( QB-407)
Brazing Temperature Range: 718 C to 816 C
BRAZING FLUX, FLUX GAS, OR ATMOSPHERE (QB-406)
Flux (AWS Class, Composition or Trade Name): RUPATAM A
TYPE OF “ESSAB” MADE
Fuel Gas: OXYGEN & ACCETYLENE using Neutral Flame
Furnace Temperature:
N/A
Atmosphere Type:
N/A
Other : Nil
Positions Permitted : VERTICAL
DOWN FLOW
Flow Direction : FACE FEEDING
TECHNIQUE (QB-410) AND OTHER INFORMATION
(
Initial
cleaning : By Cotton Cloth, Wire Brush & by using Acetic Acid with 5% Con, Prior to
brazing the surface of tube and header should appear as bright as possible.
Brazing operation shall be done a separate clean areas (clean room) to avoid
contamination during brazing.
Flux Application: Flux Applied on filler wire
Nature of Flame (Oxidizing , Neutral, Reducing): Neutral flame
Torch Tip sizes: Use suitable number size nozzle.
Post braze cleaning: Wire brush/Acid picking/By water quenching or washing.
1
5
5
Annexure - B
Nuclear Power Corporation of India Ltd.
(A Government Of India Enterprise)
DOCUMENT (WPS) ACCEPTANCE NOTE
Project/Station:
Proposed by : NPCIL execution group ( for departmental job):
: Contractor/Manufacturer (for job through contract):
Work Order No ( If applicable) :
Name of Work :
Area of Work /Application:
Applicable NPCIL Specification:
WPS No:
PQR No:
It is proposed that above WPS shall be adopted by us for the mentioned works. This is meeting the
specification requirements for the application. Further it is proposed to accept above mentioned(Strike out which is not applicable)
1.
WPS and PQR without further qualification (For NPCIL use Only)
2.
Standard WPS and PQR for noncritical application with bend test.
3.
Standard WPS for critical areas. PQR to be made as per ASME Section IX (all tests).
4.
WPS only. PQR to be made as per ASME Section IX (all tests).
Proposed by
( NPCIL engineer ) in case of departmental use
Head of Contractor / Manufacturer
We Accept full responsibility for application of WPS
for the mentioned work as above.
Category :
Critical
/ Non critical
(Based on system safety, impact test and PWHT requirement)
Following applications are suggested to be considered under the non-critical category.
a) All Carbon Steel applications other than PHT, ECCS, Reactor Auxiliary and critical structural applications.
b) All Stainless Steel applications other than Main Moderator, Calandria Vault, Reactor Protective & Control and critical structural applications.
c) Fabrication/ Manufacturing of other than critical components and equipments.
Pl see Table 2 of this PP-P-2049 R-2 (Page 9 for details regarding applicability.
Above needs to be further reviewed/ modified and finalized by Designer/FE/TSS.
Reviewed By
NPCIL QA
EIC
FE /TS
Approved By
SME/PE/Execution I/C
Number of bend test conducted
(Applicable for Sr. no. 2 only) ;
Result of bend test :
Reviewed by
Approved By
(Contractor/ Executing agency)
(NPCIL QA)
1
1
1
Annexure – C
STANDARD WELD JOINT CONFIGURATION
FOR WELDING PROCEDURE SPECIFICATION
(For 't' 3 to 6 mm)
SQUARE GROOVES:
4 to 6 mm
t/2
t
t
BACKING STRIP
SINGLE V GROOVE:
(For 't' up to 16 mm)
37.5° ± 2.5° (Typ.)
22° ± 2° (Typ.)
t
1.5 to 2.5 mm
BACKING STRIP
5 to 7 mm
1.5 to 3 mm
DOUBLE V GROOVE:
(For 't' from 16 mm to 40 mm)
37.5° ± 2.5° (Typ.)
t/2 or 2t/3
10° - 15°
t/2 or 2t/3
6R
t
1.5 to 2.5
1.5 to 3 mm
1.5 to 2.5 mm
1.5 to 3 mm
1
2
2
STANDARD WELD JOINT CONFIGURATION
FOR WELDING PROCEDURE SPECIFICATION
SINGLE V GROOVE
:
(Reduced Angle for 't' > 40
mm)
37.5° ± 2.5° (Typ.)
10° to 15°
1.5 to 2.5
mm
20
mm
1.5 to 3
mm
SINGLE V
GROOVE:
(With Weld
Inserts)
37.5° ± 2.5° (Typ.)
0 to.8
mm
INSER
T
1.5 to 2.5
mm
0.8 mm
(Max.)
37.5°± 2.5° (Typ.)
0.8 mm
(Max.)
0.5 mm
(Max.)
0.8 to 1.5
mm
INSERT
NOTE: Insert Details also apply to 'Single V-Groove, Reduced
Angle'
3
Annexure - D
Annexure -QW – 450 SPECIMENS (ASME SECTION- IX)
QW – 451 PROCEDURE QUALIFICATIONS
THICKNESS LIMITS AND TEST SPECIMENS
QW – 451.1
GROOVE-WELD TENSION TESTS AND TRASVERSE-BEND TESTS
Thickness T of Test coupon,
Welded, in. (mm)
Range of Thickness T of
Base Metal, Qualified, in.
(mm)
[(Notes (1) and (2) ]
Min.
Less than 1/16 (1.5)
1/16 to 3/8 (1.5 to 10), incl.
T
1/16
(1.5)
Over 3/8 (10), but less than ¾ (19) 3/16(5)
¾ (19) to less than 1 ½ (38)
3/16(5)
Maximum thickness t of
Deposited Weld Metal,
Qualified, in. (mm)
[(Notes (1) and (2) ]
Type and Number of Tests Required
(Tension and Guided-bend Tests) [Note (2)]
Tension,
QW-150
Max.
Side
Bend,
QW-160
Face
Bend,
QW160
Root
Bend,
QW160
2T
2T
2t
2t
2
2
….
Note (5)
2
2
2
2
2T
2T
2t
2t when t < ¾ (19)
2
2 [Note (4)]
Note (5)
4
2
2
¾ (19) to less than 1 ½ (38)
3/16(5) 2 T
2Twhen t < ¾ (19)
2 [Note (4)]
4
1 ½ (38) and over
3/16(5) 8 (200) [Note
(3)]
3/16(5) 8 (200) [Note
(3)]
2 t when t < ¾ (19)
2 [Note (4)]
4
8(200) [Note (3)] when t < ¾
(19)
2 [Note (4)]
4
½ (38) and over
(1)
(2)
(3)
(4)
NOTES :
The following variables further restrict the limits shown in his table when they are referenced in QW-250 for the process under
consideration : QW-403.9, QW-403.10, QW-404.32 and QW-407.4. also, QW-202.2, QW-202.3, QW-202.4 provide exemptions that
supersede the limits of this table.
For combination of welding procedures, see QW-200.4.
For the welding processes of QW-403.7 only; otherwise per Note (1) or 2 T, or 2 t whichever is applicable.
See QW-151.1, QW-151.2 and QW-151.3 for details on multiple specimens when coupon thicknesses are over 1 in. (25 mm).
Four side-bend tests may be substituted for the required face-and root-bend tests, when thickness T is 3/8 in. (10 mm) and over.
1
Annexure - E
1
2
3
4
5
6
7
8