SWATHI INDUSTRIES

A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032

[QW – 483 PROCEDURE QUALIFICATION RECORD (PQR)]
Procedure Qualification Record No.: SI-107 DATE.: 08.10.2010
WPS No.: SI-007
Welding Process (es): GMAW
Type (Manual; Automatic; Semi Automatic): Semi-Automatic
JOINT (QW 402)

Groove Design of Test Coupon

BASE METALS ( QW – 403 ) POST WELD HEAT TREATMENT (QW – 407 )
Material specification. : SA 516-70 Temperature : 620 Deg C
Type or Grade : GR -70 Time / Soaking: As per UCS 56
P. No. : 1 Gr. 2 To P. No. : 1 Gr. 2 Other : SR.Cycle.No: 131/2010, Date: 29‐09‐2010.
Thickness of Test Coupon: 40 mm SR Carried out at M/s Vijay Engineering Industires
Diameter of Test Coupon : ‐‐
Other :
FILLER MATERIALS (QW – 404 ) GAS ( QW – 408 )
SFA Specification : 5.1 Percentage Composition
AWS Classification : ER 70S‐6 Gas (es) Mixture Flow rate
Filler Metal F. No. : 6 Shielding CO2 100% 12‐20 LPM
Weld Metal Analysis A No. : 5.1 Trailing ‐‐ ‐‐ ‐‐
Size of Filler Metal : Ø 1.2mm Backing ‐‐ ‐‐ ‐‐
Weld Metal Thickness : 40mm ELECTRICAL CHARACTERISTICS ( QW– 409 )
Current : DC Polarity : Electrode positive
Other :
Amps : 140‐ 350A Volts : 20 – 32V
POSITION ( QW – 405 ) Tungsten Electrode size : ……
Position of Groove : 2G, Vertical Other ……
Weld Progression : Uphill TECHNIQUE ( QW – 410 )
Other : Travel Speed : ‐‐‐
PREHEATING (QW – 406 ) String / Weave Bead : String & Weave Bead
Preheat Temp. : 10° C Upto 30mm
31-100mm - 100° C Multi pass / Single pass ( per side ) : MULTI PASS
Above 100mm - 150° C
Interpass Temp. : 350° C max. Single or Multiple Electrodes : SINGLE

Other : ……. Other : Clean each layer before start welding new passes/
layers. Weaving Maximum 3 times the diameter of Electrode.

Contd page 2
 Page 2 of 2

QW‐ 483 ( Back )

PQR No: SI-107.
Tensile Test ( QW – 150 )

Ultimate Total Load. Ultimate Unit Stress. Type of Failure

Specimen No Width (mm) Thickness Area mm²
kN Mpa (410 Min) & Location
Broken away
SAMPLE‐1 19.00 18.00 mm 342.00 170 497.08
from weld
Broken away
SAMPLE‐2 19.00 17.60 mm 334.4 167 499.40
from weld
Broken away
SAMPLE‐3 19.00 17.20 mm 326.80 165 504.90
from weld
Broken away
SAMPLE‐4 19.00 18 mm 342.00 169 494.15
from weld

Guide – Bend Tests (QW – 160)

Type and Figure No. Result

Side Bend test 4 No’s‐ 180o , 4T Satisfactory

Welder’s Name : MUNNA KUMAR SINGH Clock No : ‐‐ Stamp No. : MKS‐01

The Welding tests are conducted and supervised by M/s. SWATHI INDUSTRIES, R.C.Puram and Mechanical Tests carried out by
M/s. SMS METALLURGICAL SERVICES, Vide TEST REPORT NO:10‐11/0198, DT:08.10.10 Welding test and Mechanical Tests are
Witnessed by M/s. BHEL , HPEP, Hyderabad, Quality control Department.
We certifies that the statement in this record are correct and the weld test coupons were prepared, welded, and tested in
accordance with the requirements of Section IX of ASME code.

Witnessed / Certified By. Manufacturer :

Signature : Signature :

Date :
Date :
 SWATHI INDUSTRIES
A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032

QW – 482 WELDING PROCEDURE SPECIFICATION (WPS)

Welding Procedure Specification No. SI-007 Date. 26.08.2010 Supporting PQR No. SI-107
Revision No. : 00 Date.: –– Welding Process (es): GMAW Type(s): Semi Automatic
(Automatic; Manual; Machine or Semi Automatic)

JOINTS ( QW‐ 402 ) :

Joint Design : As per Manufacturers Drawing (Groove / Fillet)
Backing ( Yes) For Double side and backing strip groove welds
(No.) For Single side Groove welds
Backing Material (Type): Base metal / weld metal
Metal : Yes Non fusing Metal : No
Retainer : No

BASE METALS ( QW ‐ 403 )

P No. : 1 Group No. : 1&2 To P No. : 1 Group No. : 1 &2
OR
Specification Type and Grade : SA 516‐70 To Specification Type and Grade : SA516‐70

OR
Chemical Analysis and Mech. Properties: ‐‐ To Chemical Analysis and Mech. Properties: ‐‐
THICKNESS RANGE :
Base Metal Groove : 4.75 to 200 mm Fillet : All Sizes
Pipe Dia
Groove : All Dia Fillet : All Sizes
Range Root spacing for backing strip joints : 8 - 10 mm
Other :
For others : 1-3 mm
(403.13 : not applicable)

FILLER MATERIALS (QW – 404 )

Specification No. : ( SFA ) : 5.18
A W S No .: ER70S‐6
F . No. : 6
A. No. : 1
Size of Filler Materials : Ø 1.2, 1.6
Deposited weld metal :
Thickness Range : Groove : 5.0 to 200 mm Fillet : All Sizes
Electrode Flux ( Class ) : Basic
Consumable Insert. : No
Max. Bead Thickness : 4mm

Contd page 2
 Page 2 of 2

WQ – 482 (BACK) WPS No: SI-007.Rev.00

POSITIONS. ( QW – 405) POST WELD HEAT TREATMENT (QW – 407 )
Position of groove : All Position Temperature Range : 600° C- 650° C
Welding Progression : Up Hill , Vertical Down Hill: ‐‐ Time Range : UCS 56
Position (s) of Fillet : ALL (As per UCS 56 )

PRE‐HEAT ( QW – 406 ) GAS ( QW – 408 )

10° C Up to 30 mm Percentage Composition
PRE Heating Temperature Min.: 100° C max.above 30 mm Gas (es) Mixture Flow rate
Above 100mm - 150° C
Shielding CO2 100% 12‐20 LPM
Inter pass Temperature Max. : 250° C max.
Trailing ‐‐ ‐‐ ‐‐
Pre‐heat Maintenance. : NIL Backing ‐‐ ‐‐ ‐‐
ELECTRICAL CHARACTERTISTICS I QW – 409 )
Current ( AC or DC ) : DIRECT CURRENT Polarity ( +ve or _ve ) : ELECTRODE POSITIVE
Amperes (Range ) : 150 to 350 A Volts. ( Range ) : 20 - 30 V
Tungston Electrode Size and Type. : NA
Mode of Metal Transfer for GMAW. : GMAW SPRAY
Electrode Wire Feed Speed Range : ‐‐‐‐
TECHNIQUE ( QW – 410 )
String or Weave Bead : string and weave
Orifice or Gas Cup Size : 20mm (ID)
Initial & Inter pass cleaning : By Brushing / Grinding. / Chipping Etc. (use stainless steel tools)
Method of Back Gouging : Grinding
Oscillation : ‐‐‐‐‐‐‐‐‐ x ‐‐‐‐‐‐‐‐‐‐‐
Contact tube to work distance : 25 to 40mm
Multiple / Single Pass ( per side ) : Multiple Passes
Multiple / Single Electrode : Single Electrode.
Peening : Not allowed.
Travel speed (Range) : 150‐200mm/min
Min 1” on either side of the weld area to be cleaned and free from Dirt, rust, paints,
Other ( Weld Discipline ) :
Oil, grease, etc. ( Before start the welding ).

Weld Filler Metal Current Remarks

Process
Layers Class Dia (mm) Type polar Amps
Root run GMAW ER70S‐6 1.2 DC + 150-200

2 ‐n GMAW ER70S‐6 1.6 DC + 250-350 STRING & WEAVE

Approved By :
Date :
 SWATHI INDUSTRIES
A-2/1, B.H.E.L, AIE, Ramachandrapuram, Hyderabad-032
{QW – 484 A MANUFACTURER’S RECORD OF WELDER PERFORMANCE QUALIFICATION ( WPQ )}

Welder’s Name : MUNNA KUMAR SINGH Identification No. MKS‐01

Test Description
Identification of WPS followed SI-007 Test Coupon: Yes Production Weld. No
Specification of Base metal ( s ) SA516‐70 to SA516‐70 Thickness : 40 mm
Testing Conditions and Qualification Limits.
Welding variables ( QW – 350 ) Actual Values Range of Qualified
Welding Process(es): GMAW GMAW
Type ( Manual, Semi, Auto ) : MANUAL MANUAL
Backing ( metal, weld metal, double welded etc. WITHOUT WITH / WITHOUT
Plate Pipe (enter Ø if pipe or tube) PLATE 40 mm Plate Max to be welded & pipe Ø73 and above
Base Metal P‐ or S‐ Number to P or S –Number : P1 P1
Filler metal or electrode specification(s) (SFA) 5.18 5.18
Filler metal or electrode Classification(s) ER70S‐6 ER70S‐6
Filler metal F‐ Number(s) : F6 F6
Consumable insert ( GTAW or PAW ) : ‐‐‐‐‐‐ ‐‐‐‐
Filler Type ( Solid/metal or flux cored / powder ( GTAW
SOLID SOLID
or PAW ) )
Deposit Thickness for each Process.
Process 1: GMAW 3 layers min. Yes / No 40 mm Maximum to be welded
Process 2: 3 layers min. Yes / No ‐‐‐‐ ‐‐‐‐
Position qualified ( 2G,6G,3F etc.) 2G 1G , 2G, 1F, 2F & 3F
PLATE & PIPE OD > 610mm – F & V
Groove
FLAT POSITION FOR PIPE OD 73mm to < OD 610mm
Fillet PLATE & PIPE – F, H & V
Vertical progression (Up/ Down hill) UPHILL UPHILL
Inert gas backing ( GTAW, PAW, GMAW ) NA NA
Transfer mode (spray / globular or pulse to short circuit –
NA NA
GMAW ))
GTAW current type / Polarity ( AC, DCEP, DCEN ) NA NA

RESULTS
Visual Examination of Completed Weld ( QW – 302.4 ) : SATISFACTORY
Bend Test; SATISFACTORY Transverse root and face ( QW – 462.3 (a) ); Longitudinal root and face ( QW – 462.2)
Pipe bend specimen, Corrosion – resistant Overlay ( QW 462c) Plate bend specimen, corrosion –resistant overlay (QW – 462.5 (d) )
Macro test for fusion ( QW – 462.5(b) Macro test for fusion ( QW – 462.5(e)

Type Result Type Result Type Result

Tensile Satisfactory Side bend Satisfactory

The Welding tests are conducted and supervised by M/s. SWATHI INDUSTRIES, R.C.Puram and Mechanical Tests carried
out by M/s. SMS METALLURGICAL SERVICES, Vide TEST REPORT NO:10‐11/0198, DT:08.10.10 Welding test and Mechanical
Tests are Witnessed by M/s. BHEL , HPEP, Hyderabad, Quality control Department.
We certify that the statement s in this record and that coupon were prepared, welded, and tested in accordance with the requirements of section IX of the
ASME Boiler and Pressure Vessel Code.

Certified / Witnessed By.

Date : Organization :