concast wps - rev-01

Samay Project Services P Ltd.,

Doc.No.: SPL/CSPL/AGECL/QA-002, Rev-01DATE : 20.01.12

SUPPORTING PQR REF. No.: SPL/CSPL/AGECL/QA-001-01

Title : Welding Procedure specification for all material specification

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WELDING PROCEDURE : SMAW

TYPE : MANUAL SYSTEM 1 : TANKS

DETAILS OF EQUIPMENT COVERED

1. 300 Cu.m, DM water storage tank

2. 300 Cu.m, make up water storage tank

3. 60 Cu.m Over Head Surge tank

1 JOINTS (QW-402)

Joint Design : Single 'V' Butt

Backing Material (type) : Nil 2 BASE METALS (QW-403) Specification Type and Grade : IS -2062, IS-1367, A-234 Gr.WPB,

Thickness Range : 4 mm to 10 mm

Base Metal : Groove Single 'V' Fillet: All thickness

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

Consultant : Avant – Garde Engineers and Consultants (P) ltd., PROJECT: 1 X 30 MW CAPTIVE POWER PLANT & 1 X 40 MW CPP





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Fillet: All Size

3 FILLER METALS (QW-404) Specification No. (SFA) : 5.1,

AWS NO. (Class) : E-6013

F-No. : 2

A-No. : 1

Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia

4 WELD METAL THICKNESS RANGE

Groove : 9.6mm Max / 2 times thk qualified

Fillet : All thk

Electrode Flux Class : Rutile

Other : Electrode Shall be used confirming to E-6013 and Standard mfrs like ESAB, ADVANI and D & H.

5 POSITION (QW-405) Position of the Groove : NA

Welding Progression : Up-Hill

Position (s) of Fillet : All

6 PREHEAT (QW-406) Preheat Temp. Min : 10 Deg. C

Interpass Temp Max : 150 Deg. C to 250 Deg. C

Preheat maintenance : NA

7 POST WELD HEAT TREATMENT (QW- 407) Temp Range : NA

Time Range : NA

8 GAS (QW-408) Percentage of Composition

Gas Mixture Flow RateShielding : NA NA NA







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Trailing : NA NA NA

Backing : NA NA NA

9 ELECTRICAL CHARACTERS (QW-409) Current AC or DC : DC

Current Range : 70-150 A

Voltage Range : 18-30 V

Polarity : Reverse

Tungsten Electrode Size : NA

Mode of Metal Transfer for GTAW : NA

Electrode Wire Feed Speed Range : NA

10 TECHNIQUE (QW-410) String or Weave Bead : String & Weave Both

Initial Interpass and Cleaning : By Wire Brushing and Chipping

Method of Back Gouging : Not applicable

Multipass or Single pass per side : Multipass

Multiple or Single Electrode : Single

Travel Speed (Range) : 65 to 75 mm per Minute

Other : N.A.

Weld Layer (s) Process Filler Metal Current Amp. Volt Travel

Class Dia Type Polar

Range Range Speed Range

Root SMAW E6013 2.5mm Reverse 70-90 A 18-30 V 50-65 mm

Filler SMAW E6013 2.5mm Reverse 70-90 A 18-30 V 65-75 mm

Final(Basis on thick.)

SMAW E6013 3.15mm Reverse 100-110 A 18-30 V 65-75 mm







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WELDING PROCEDURE : GTAW & SMAW

TYPE : MANUAL SYSTEM 2 : VESSELS

DETAILS OF EQUIPMENT COVERED

ATM Flash tank

1 JOINTS (QW-402)


Backing Material (type) : Nil 2 BASE METALS (QW-403) Specification Type and Grade : IS -2002 Gr.2

Thickness Range : 4 mm to 10 mm

Base Metal : Groove Single 'V' Fillet: All thickness

Fillet: All Size

3 FILLER METALS (QW-404)







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Specification No. (SFA) : 5.18,5.1

AWS NO. (Class) : ER70 S2 & E7018

F-No. : 6,4

A-No. : 1

Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia. & 2.4mm Dia



Fillet : All thk


Other : Electrode Shall be used confirming to ER70S2, E7018 and Standard mfrs like ESAB, ADVANI & D & H

5 POSITION (QW-405) Position of the Groove : 6G



6 PREHEAT (QW-406) Preheat Temp. Min : 10 Deg. C

Interpass Temp Max : 150 Deg. C to 250 Deg. C


7 POST WELD HEAT TREATMENT (QW- 407) Temp Range : NA

Time Range : NA

8 GAS (QW-408)

Percentage of Composition

Gas Mixture Flow Rate







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Shielding : Argon NA 20cuft/hr Trailing : NA NA NA Backing : NA NA NA

9 ELECTRICAL CHARACTERS (QW-409)

Current AC or DC : DC

Current Range : 90-100 A GTAW, 110-125 A SMAW


Polarity : Straight – GTAW, Reverse - SMAW

Tungsten Electrode Size : 2.4mm

Tungsten type : SFA5.12 EWTh-2


10 TECHNIQUE (QW-410) String or Weave Bead : String & Weave Both(Less than three times

of filler wire thickness)






Other : N.A.

Weld Layer (s) Precess Filler Metal Current VoltRange

TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER70S2

2.4mm Straight 100-125 A 18-30 V 2 – 3.5

Filler SMAW E7018 2.5mm Reverse 90-100 A 18-30 V 5 - 6

Final (Basis on thick.)

SMAW E7018 3.15mm

Reverse 90-100 A 18-30 V 5 - 6







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SYSTEM : 3. 1. Critical piping carbon steel material 2. Critical piping stainless steel material 3. Critical piping low alloy steel material GR.P11, GR.P12 4. Critical piping low alloy steel material GR.P22 5. Non critical piping carbon steel material 6. Piping less than 6mm wall thick carbon steel material 7. Piping less than 6mm wall thick stainless steel material

1. Critical piping system carbon steel material

WELDING PROCEDURE : GTAW & SMAW TYPE : MANUAL







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1 JOINTS (QW-402)


Backing Material (type) : Nil

2 BASE METALS (QW-403)

Specification Type and Grade : SA 106 Gr.B

Thickness Range : 8mm and above

Base Metal : Groove Single 'V'

Socket weld (fittings less than 50NB)

Fillet: All Thickness

Fillet: All Size

Pipe Dia Range : 15NB to 1200 NB








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Specification No. (SFA) : 5.18,5.1

AWS NO. (Class) : ER70S2, E7018

F-No. : 6, 4

A-No. : 1

Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia. & 2.4mm Dia.



Fillet : All thk


Other : Electrode Shall be used confirming to ER70S2, E7018 and Standard mfrs like ESAB, ADVANI & D & H.




6 PREHEAT (QW-406)

Preheat Temp. Min : Min 10 Deg. C

Interpose Temp Max : 150 Deg. C to 250 Deg. C








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7 POST WELD HEAT TREATMENT (QW--407) Temp Range : NA

Time Range : NA

8 GAS (QW-408)


Gas Mixture Flow Rate Shielding : Argon NA 20cuft/hr Trailing : NA NA NA Backing : NA NA NA 9 ELECTRICAL CHARACTERS (QW-409)















Other : N.A.







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TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER70S2

2.4mm Straight 100-125 A 18-30 V 2 – 3.5



SMAW E7018 3.15mm

Reverse 90-100 A 18-30 V 5 - 6







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2. Critical piping system stainless steel material


1 JOINTS (QW-402)










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Specification Type and Grade : SA 312 TP 304

Thickness Range : 7.11mm and above




Fillet: All Size



Specification No. (SFA) : 5.4 & 5.9

AWS NO. (Class) : ER347, E347

F-No. : 5 & 6

A-No. : 8

Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia & 2.4 mm Dia.



Fillet : All thk







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Other : Electrode Shall be used confirming to ER347, E347 and Standard mfrs like ESAB, ADVANI & D & H.




6 PREHEAT (QW-406)





Time Range : NA

8 GAS (QW-408)


Gas Mixture Flow Rate Shielding : Argon NA 20cuft/hr Trailing : NA NA NA Backing : Argon NA 10 to 12 LPM










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Other : N.A.


TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER347 2.4mm Straight 100-125 A 18-30 V 2 – 3.5



SMAW E347 3.15mm Reverse 90-100 A 18-30 V 5 - 6

3. Critical piping low alloy steel material GR.P11, GR.P12







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1 JOINTS (QW-402)




Specification Type and Grade :











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Fillet: All Size



Specification No. (SFA) : 5.28, 5.5

AWS NO. (Class) : ER 80S B2, E8018B2

F-No. : 6, 4

A-No. : 3

Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia. & 2.4mm Dia.



Fillet : All thk


Other : Electrode Shall be used confirming to ER80SB2, E8018B2 and Standard mfrs like ESAB,

ADVANI & D & H. 5 POSITION (QW-405) Position of the Groove : 6G









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6 PREHEAT (QW-406)





Time Range : NA

8 GAS (QW-408)

















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Other : N.A.

Weld Layer (s) Process Filler Metal Current VoltRange

TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER 80SB2 2.4mm Straight 75-100 A 18-30 V 2 – 3.5

Filler SMAW E8018B2 2.5mm Reverse 90-100 A 18-30 V 5 - 6


SMAW E8018B2 3.15mm

Reverse 100-140 A 18-30 V 5 - 6

4. Critical piping low alloy steel material GR.P22








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1 JOINTS (QW-402)




Specification Type and Grade :





Fillet: All Size



Specification No. (SFA) : 5.28, 5.5

AWS NO. (Class) : ER 90S B3, E9018B3







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F-No. : 6, 4

A-No. : 4

Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia. & 5 mm Dia.


Groove : 56 mm Max / 2 times thk qualified

Fillet : All thk


Other : Electrode Shall be used confirming to ER90SB3, E9018B3 and Standard mfrs like ESAB,

ADVANI & D & H. 5 POSITION (QW-405) Position of the Groove : 6G



6 PREHEAT (QW-406)





Time Range : NA







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8 GAS (QW-408)

















Other : N.A.

Weld Layer (s) Process Filler Metal Current VoltRange

TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER 90SB3 2.4mm Straight 75-100A 18-30 V 2 – 3.5







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Filler SMAW E9018B3 2.5mm Reverse 90-100 A 18-30 V 5 - 6

Filler SMAW E9018B3 3.15mm

Reverse 100-140 A 18-30 V 5 - 6


SMAW E9018B3 3.15 mm

Reverse 100-140 A 18-30 V 5 - 6

5. Non Critical piping system carbon steel material

WELDING PROCEDURE : SMAW TYPE : MANUAL







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1 JOINTS (QW-402)




Specification Type and Grade : IS1239 Pt. I & II, IS2062, IS3589





Fillet: All Size



Specification No. (SFA) : 5.1

AWS NO. (Class) : E6013

F-No. : 2

A-No. : 1







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Size of the Filler Metals : 2.5mm Dia., 3.15 mm Dia



Fillet : All thk


Other : Electrode Shall be used confirming to E6013, and Standard mfrs like ESAB, ADVANI & D & H.




6 PREHEAT (QW-406)





Time Range : NA

8 GAS (QW-408)


Gas Mixture Flow Rate Shielding : NA NA NA







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Trailing : NA NA NA Backing : NA NA NA 9 ELECTRICAL CHARACTERS (QW-409)




Polarity : Reverse

Tungsten Electrode Size : NA

Mode of Metal Transfer for GTAW : NA


10 TECHNIQUE (QW-410) String or Weave Bead : String & Weave Both






Other : N.A.


TravelSpeed Range

inch/min


Amp. Range

Root SMAW E6013 2.5mm Reverse 100-125 A 18-30 V 2 – 3.5



SMAW E6013 3.15mm Reverse 100-125 A 18-30 V 5 - 6







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6. Piping less than 6mm wall thickness carbon steel piping

WELDING PROCEDURE : GTAW TYPE : MANUAL

1 JOINTS (QW-402)










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Specification Type and Grade : IS1239 Pt. I & II, IS2062, IS3589, SA 106 Gr.B





Fillet: All Size




AWS NO. (Class) : ER70S2

F-No. : 6

A-No. : 1

Size of the Filler Metals : 2.4mm dia.



Fillet : All thk







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Other : Electrode Shall be used confirming to ER70S2, and Standard mfrs like ESAB, ADVANI & D & H.




6 PREHEAT (QW-406)





Time Range : NA

8 GAS (QW-408)






Polarity : Straight







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Tungsten Type : SFA5.12 EWTh-2


10 TECHNIQUE (QW-410) String or Weave Bead : String & Weave Both(Less than four times







Other : N.A.


TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER70S2

2.4mm Straight 90-100 A 18-30 V 2 – 3.5

Filler GTAW ER70S2

2.4mm Straight 90-100 A 18-30 V 5 - 6


GTAW ER70S2

2.4mm Straight 90-100 A 18-30 V 5 - 6

7. Piping less than 6mm wall thickness stainless steel piping

WELDING PROCEDURE : GTAW TYPE : MANUAL







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1 JOINTS (QW-402)




Specification Type and Grade : SA 312 TP 304





Fillet: All Size








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AWS NO. (Class) : ER347

F-No. : 6

A-No. : 8

Size of the Filler Metals : 2.4mm Dia.



Fillet : All thk


Other : Electrode Shall be used confirming to ER347, and Standard mfrs like ESAB, ADVANI & D & H.




6 PREHEAT (QW-406)







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Time Range : NA

8 GAS (QW-408)


Gas Mixture Flow Rate Shielding : Argon NA 20cuft/hr Trailing : NA NA NA Backing : Argon NA 10 to 12 LPM





Polarity : Straight


Tungsten Type : SFA5.12 EWTh-2










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Other : N.A.


TravelSpeed Range

inch/min


Amp. Range

Root GTAW ER347 2.4mm Straight 90-100 A 18-30 V 2 – 3.5

Filler GTAW ER347 2.4mm Straight 90-100 A 18-30 V 5 - 6


GTAW ER347 2.4mm Straight 90-100 A 18-30 V 5 - 6



concast wps - rev-01

Documents

joints qw

filler metals qw

temp range

nil2 base metals qw

natime range

na8 gas qw

na10 technique qw

specification type