WELDING PROCEDURE SPECIFICATION (WPS)

QUALIFIED TO:ASME SEC IX

WPS NO:TFEPL PROJECT NO : S110001 REV NO :0

PQR NO: 04/06/2015 TFEPL INSPECTION : DATE:06/03/2016
BASE METEL & JOINT DETAIL:
TUBE SHEET MATERIAL : SA515 Gr.70 P NO:1 TUBE PITCH :79.4mm
TUBE MATERIAL : SA 192 P NO:1 PATTERN :TRIANGLE
PROJECT NO :S110001 PROJECTION OF TUBE :0
TUBE SHEET O.D(mm) :2270 T/TS JOINT TYPE :GROOVE
TUBE SHEET THK(mm) :40
LIGAMENT :21.74
TUBE OD/THK(mm) :57.2/4.57
HOLE ID :57.66

WELDING DETAIL:
WELDING PROCESS :GTAW (Manual) SHIELDING GAS :Argon (Single gas)
FILLER AWS CLASS. :ER 70S2 / SFA.5.18 F NO:6 PREHEAT TEMP :100˚C
SIZE OF FILLER WIRE :ø 1.6, ø 2 & ø 2.4 mm A NO:1 INTERPASS TEMP :250˚C
MANUFACTURER,BRAND: PWHT :YES
POSITION :T/S VERTICAL AND TUBE HORIZONTAL TUBE EXPANSION :Expansion after welding
PROGRESSION :UPHILL METHOD OF CLEANING:Wire brush
ELECTRODE TYPE & SIZE :2% Th and 3 mm POST HEATING :NA
CURRENT & POLARITY :DCEN
SKETCH:

WELDING PARAMETERS:

WELDING AWS CLASS CURRENT(Amps) VOLTAGE(VOLTS) TRAVEL SPEED GAS FLOW

Min Heat Input(KJ)
SEQUENCE (mm/min) RATE(Ipm)
& SIZE
ROOT RUN ER 70S2 / 1.6 mm 230-240 15-16 Minimum.75 10 to 12 3.10
SECOND PASS ER 70S2 / 2 mm 230-240 15-16 Minimum.85 10 to 12 2.71
BALANCE RUN ER 70S2 / 2.4 mm 230-240 15-16 Minimum.85 10 to 12 2.71

PREPARED BY: APPROVED BY

S.V GHATE
PAWAN BARIK
06.03.2016
06.03.2016
Procedure Qualificattion Record (PQR)

WPS NO : dated on 6/3/2016 TFEPL DATE: 6/4/2015

ASME SEC.IX EDITION 2013,
PQR NO : PQR 04/06/2015 TFEPL APPLICABLE CODES: ASME SEC VIII Div.1 ASNE SEC
I.

BASE METEL & JOINT DETAIL:

MOCKUP BLOCK MATERIAL : SA515 Gr.70 P NO: 1 TUBE PITCH :79.4mm
MOCKUP BLOCK SIZE : 500 x 500 x 42 THK PATTERN :Tringular
TUBE MATERIAL :SA 192 P NO: 1 HOLE ID :57.66 mm
TUBE SHEET O.D & THICKNESS :57.2mm & 4.572 mm T/TS JOINT TYPE :G
PROJECTION OF TUBE :0 LIGAMENT :21.74
Expansion :Light Expansion after Welding METHOD OF CLEANING :wire brush

WELDING DETAIL:
WELDING PROCESS :GTAW (Manual) CURRENT & POLARITY :DCEN
FILLER AWS CLASS. :ER 70S2 / SFA.5.18 F NO:6 SHIELDING GAS :Argon gas 99.995
SIZE OF FILLER WIRE :1.6mm & 2.00mm A NO:1 PREHEAT TEMP :100˚C
ELECTRODE TYPE & SIZE :2% Th and 3 mm INTERPASS TEMP :250˚C
POSITION :T/S VERTICAL AND TUBE HORIZONTAL POST HEATING :NA
WELDING PROGRESSION:UPHILL PWHT :YES
HEAT TREATMENT DETAIL:
SOAKING TEMPERATURE :610+10˚C SOAKING TIME :120 Minutes>
RATE OF COOLING :20˚C/Hr. MAX. Up to 300˚C RATE OF HEATING :20˚C/Hr. MAX. Above 300˚C
ALL DIMENSION ARE IN MM
WELDER DETAIL:
Welder Name/ Sal Code Tubes Welded Welder Name / Sal Code Welder Name / Sal Code Tubes Welded
(5)5 .1,5.2,5.3,5.4 (8)8.1,8.2,8.3,8.4
(6)6.1,6.2,6.3,6.4 (9)9.1,9.2,9.3,9.4
(7)7.1,7.2,7.3,7.4

SKETCH:

WELDING PARAMETERS:

VOLTAGE
AWS CLASS CURRENT(Amps) TRAVEL SPEED GAS FLOW
WELDING SEQUENCE (VOLTS) Min Heat Input(KJ)
(mm/min) RATE(Ipm)
& SIZE
FIRST RUN ER 70S2 / 1.6 mm 230-240 15-16 Minimum.75 10 to 12 3.10
SECOND TO FINAL RUN ER 70S2 / 2.0 mm 230-240 15-16 Minimum.85 10 to 12 2.71

We certify that statements In this record are correct and the test were prepared, welded and tested in accordance with the requirements of section ix oh the ASME Code
PREPARED BY: WITNESSED BY

PAWAN BARIK

06.03.2016
PQR NO. 15-174

Report No: M-13701.1

PROJECT No. : S110001 S110001/QC/15-174/MOCKUP/VISUAL/01-02
S110001/QC/PT/15-174/01-02
1. Visual Examination, Report no :- S110001/QC/15-
174/MOCKUP/VISUAL/01-02

Visual examination is acceptable as per ASME Section IX , QW-193.1.1

Observation
Complete Penetration
No Suck back or Burn through observed
No porosity or Crack observed
No Tube edge Burn
2. Liquid penetrant (PT) examination Report no :- S110001/QC/PT/15-174/01-02

PT examination is acceptable as per ASME Section IX , QW-193.1.1

Observation
No any relevent indication found

3. MACRO EXAMINATION
TUBE No. LOC-NO 1 LOC-NO 2 LOC-NO 3 LOC-NO 4
5 Acceptable Acceptable Acceptable Acceptable
6 Acceptable Acceptable Acceptable Acceptable
7 Acceptable Acceptable Acceptable Acceptable
8 Acceptable Acceptable Acceptable Acceptable
9 Acceptable Acceptable Acceptable Acceptable

Macro examination as per ASME SectionIX QW193

Magnification ofMacro Examination is 10X-20X

Observation
1. No cracking,
2.Complete fusion of the weld deposit into the tube-sheet and tube wall face,
3.Complete penetration
4.No Defect observe on Weld and HAZ.

PREPARED BY: WITNESSED BY

PAWAN BARIK

06.03.2016
PQR NO. 15-174

PROJECT No. : S110001 Report No: M-13701.1

4. MINIMUM LEAK PATH
TUBE No. LOC-NO 1 LOC-NO 2 LOC-NO 3 LOC-NO 4
5 2.2 5.1 0.7 5.1
6 5.6 1.5 5.4 4.2
7 4.4 4.8 5.3 1.4
8 1.7 4.5 5.5 3.5
9 5.0 1.0 4.7 5.3

REMARKS
Tube wall Thickness= 4.508 mm

MLP = 14.1mm > 4.51 Satisfactory Result

MLP is found greater than wall thickness. Hence Satisfactory.

PREPARED BY: WITNESSED BY

PAWAN BARIK

06.03.2016
PQR NO. 15-174

PROJECT No. : S110001 Report No: M-13701.1

5. Pull Out Load Calculation
TUBE No. 1 2 4
Location Surrounded By Welded Tubes
LOAD (KN)
FRACTURE

CALCULATION OF Fr VALUE

MINIMUM BREAKING STRESS

Fr VALUE = ………………………………………………..
MINIMUM SPECIFIED TENSILE STRENGTH OF TUBE MATERIALS

MINIMUM BREAKING LOAD (KN)

MIN BREAKING STRESS = ………………………………………………..
AREA OF TUBE MATERIAL (MM2)

MIN BREAKING LOAD =

AREA OF TUBE MATERIA =

MIN BREAKING STRESS =

MINIMUM SPECIFIED TENSILE STRENGTH OF TUBE MATERIALS =

Fr VALUE = Fr VALUE > 1

PREPARED BY: WITNESSED BY

PAWAN BARIK

06.03.2016