QW -482 WELDING PROCEDURE SPECIFICATION (WPS) (SEE QW 201.

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

* BASE METAL (QW 403) P.No. 8 Group no. 1 to P.no. 8 Group no. 1 OR Specification type and grade Plates ASTM-A-240 Gr 304L To specification type and grade Plates ASTM-A-240 Gr 304L OR Chem. Analysis and Mech. Prop ___________NA___________________________ To Chem Analysis and Mech. Prop ________NA___________________________ Thickness Range :Base Metal :- Groove 1.6 to 12 mm Fillet All thickness, all sizes & all diameters Other WPS shall be applicable for both without and with backing (Stainless Steel Material) FILLER METALS (QW-404) Spec No. (SFA) AWS No. (Class) F-No. A-No Size of Filler Metals Weld Metal Thickness Range Groove Fillet Electrode-Flux (Class) Flux Trade Name Consumable Insert

Plates ASTM-A240-Gr 304L (S.S. to S.S.)

SFA-5.9 ER-308L 6 8 1.6mm

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

QW-482

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

REV : 0 SHEET 2 OF 2
PREHEAT (QW-406) Preheat Temp. Min NA__________ Interpass Temp. Max _________1250C________ Preheat maintenance _________NA__________ (Continuous or special heating where applicable should be recorded) ELECTRICAL CHARCTERISTICS (QW-409) Current AC or DC _DC_ Amp (Range) 65-85 Amp Tungsten Electrodes Size & Type Mode to metal transfer for GMAW Electrodes Wire feed speed range Polarity, Volts (Range) GAS (QW-408) Percent Composition Shielding (Mixtures) Flow Rate Shielding Argon 99.99% Pure 12-15Ltr./min Trailing Argon -Backing Argon 99.99% Pure 5-10Ltr./min

DCEN (STRAIGHT) 10-12 Volts

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

1.6mm, 2.4mm, 2% Thoriated Tungsten Electrodes

(Pure tungsten 2% Thoriated etc.)

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

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

CLASS

DIAMETER

TYPE / POLARITY

AMP RANGE

OTHER

Root (1st Pass) 2nd Pass 3rd & Subsequent Passes

GTAW GTAW GTAW

ER 308-L ER 308-L ER 308-L

1.6mm 1.6mm 1.6mm

DCEN DCEN DCEN

65-75 75-85 75-85

10-12 10-12 10-12

40-50 55-65 55-65

QW-483PROCEDURE QUALIFICATION RECORD

(PQR)
(SEE QW200.2, SECTION IX ASME BOILER AND PRESSURE VESSEL CODE) RECORD ACTUAL CONDITION USED TO WELD TEST COUPON
Company Name M/S. DCMS Engineering Ltd. Mumbai Procedure Qualification Record No. DCMS / PQR/099 Date : 7/5/2012 WPS No. DCM/WPS/099 Date : 19/4/2012 Welding Process(es) GTAW Types (Manual, Automatic, Semi-Automatic) Manual JOINTS (QW-402) Rev 0 Rev. 0

SHEET 1 OF 3

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

BASE METAL (QW-403) Material Spec. SA - 240 Type of Grade 304 L P.No. ________8________ to P. No. ______8_________ Thickness of Test Coupon 6mm Diameter of Test Coupon NA Other Weld thickness range qualified 1.6 mm to 12 mm

POST WELD HEAT TREATMENT (QW-407) Temperature ___NA_______ Time ___NA_______ Other ___NA_______

FILLER METALS (QW-404) SFA Specification AWS Classification Filler Metal F-No

GAS (QW-408)
5.9 ER 308-L 6

Percent Composition Shielding (Mixtures) Flow Rate Shielding Argon 99.99% Pure 12-15Ltr./min Trailing ---Backing Argon 99.99% Pure 12-15Ltr./min
ELECTRICAL CHARACTERISTICS (QW-409) Current __________DC_____________ Polarity STRAIGHT (DCEN) Amps. 85-90 Amp. Volts 12 (Refer Annexure) Tungsten Electrode Size ________2.4mm ___________ Other NA____ TECHNIQUE (QW-410) Travel Speed 48.8 to 66.7 mm /min (Refer Annexure) String or Weave Bead _Root(stringer) ,Final(weave) Oscillation final pass weaving not exceeding 2.5 times dia of filler wire. Multipass or Single Pass (Per Side) ___Multipass____ Single or Multiple Electrodes _________Single ______ Other -------------------------------------

Weld Metal Analysis A-No Size of Filler Metal Other

8 1.6mm & 2mm

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

2007 SECTION IX QW -483

PQR No. DCMS/WPS/099 Dt. 8/5/2012 Rev - 0 Page 2 of 3 Type of Failure and Location weld metal weld metal

PQR
Tensile Test (QW 150) Specimen No. T-1 T-2 Width mm 19 18.80 Thickness mm 5.90 5.94 Area mm2 112.10 99.75 Ultimate Total Load N 70400 62400 Ultimate Unit Stress N/mm2 628.01 625.56

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

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

Toughness Tests (QW-170)

Specimen No. Notch Location Specimen Size Test Temperature ft.lb Impact Values % Shear Mills Drop Weight Break (Y/N)

NA

Comments ________________________________________NA__________________________________

Fillet Weld Test (QW-180)

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

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

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

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

Numbers of Runs / Weld Passes

Electrode Th 2% (Tungsten) Filler Wire

Gas Shielding ltrs / min

Backing Gas Ltrs./min Volts

Current Amp

Speed mm/min

1 (Root) 2nd pass

st

2.4 mm

1.6 mm dia ER 308-L

14

12

11

72

48.8

2.4mm

1.6 mm dia ER 308-L

14

12

12

87

66.7

3 pass

rd

2.4mm

1.6 mm dia ER 308-L

14

12

12

87

53.04

4th pass

2.4mm

1.6 mm dia ER 308-L

14

12

12

87

49.4

Prepared By

Reviewed By

Accepted By

Abhishek Nag (QC Engineer)

P.V.Khambatkone (Ex-NPCIL QA)

Client

QW-484 MANUFACTURERS RECORD OF WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION TESTS (SEE QW-301, SECTION XI, ASME BOILER AND PRESSURE VESSEL CODE)

WELDER NAME PURAN SINGH Welding process(es) used GTAW

Base material(s) welded SA-240 Gr 304L Thickness

Stamp/ID: PN
6mm Thick Plate Actual Values Without Range Qualified with or without

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

Manual for Each Process (QW-350) Backing (Metal, weld metal, welded from both sides, flux etc.) (QW-402) ASME P.No. 8 to ASME P.No. 8 (QW-403) ( ) Plate (X ) Pipe (enter diameter, if pipe) Filler metal specification (SFA) : 5.9 and 5.1 Classification (QW-404) Filler metal F No. Filler Metal variety for GTAW, PAW (QW 404) Consumable insert for GTAW or PAW Weld deposit thickness for each welding process Welding position (1G,5G, etc) (QW-405) Progression (uphill/downhill) Backing gas for GTAW, PAW or GMAW : Fuel gas for QFW (QW-408) GMAW transfer mode (QW-409) GTAW welding current type / polarity Machine Welding Variables for the Process Used (QW-360) Direct / remote visual control Automatic voltage control (GTAW) Automatic joint tracking Welding position (1G, 5G, etc) Consumable insert Backing (metal, weld metal, welded from both sides, flux etc.)

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

1.6 to 12mm Plate ER-308L A.No.8 6 N.A. N.A. 1.6 mm (GTAW)

1G & all fillet welds

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

NA

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

Visual examination results (QW-302.4): Satisfactory Radiographic test results (QW-304 and QW-305): Satisfactory (For alternative qualification of groove welds by radiography) Fillet Weld Fracture test N.A. Length and percent of defects NA Macro test fusion NA Fillet leg size NA in X inch Concavity / convexity NA in. Welding test conduced by DCMS Engineering Co. Ltd. Radiographic tests conducted by M/s. Geo chem Lab, Mumbai. Laboratory Test No. MLD/11/08/06896 DT.17.9.2011 We certify that the statements in this record are correct and that the test coupons were prepared welded and tested in accordance with the requirements of Section IX of the ASME Code DCMS Engineering Co. Date __________ Date CLIENT _________________