/

G'

COMTECH METALS PVT LTD.

QW-482 WELDING PROCEDURE SPECIFICATION (WPS)

(AS per QW-200.2 Section IX ASME Boiler and Pressure Vessel Code)

Company Name:

COMTECH METALS PVT LTD

WPS No.

CMPLIWPS/12/12-13

Rev. no. :- 0

IDate:- 9/8/2012

PQR No.

CMPLI PQR/12/12-13

Rev. No. :- 0

IDate:- 9/8/2012

Welding Process

GTAW+SMAW

Type

11;:i:i1';;if,<

Manual

'ii/lt:.>'>;>:

';'j.;'i.i.<?ii[(r01,;r;

'1ii;:12\\:!Yl':e"Pt~TS(QW~(j~ "~l~~;:~;t \~ ,',~';;'

.,iiY""?:",i;I!:>

fil
Specific Joint Details

As per Drawing

Joint Design

Yes

Backing

For GTAW - NIL & SMAW - Weld metal

Backing Material

AS PER DRAWING
Retainers

No

Retainer Material

NA

BAse~ETAL (Q~-40~)

."i}'\

.;';0(,\U;!i

"'ii~,r' i t

'?~;\~'i ;';ii~~~'j.!'

iX5iii/,i ;'i\iiiI'i}'iikl!i>.,.. . ,.:"ii';:I'. .j\{W:;~1

..'i;ii;hi

Material Spec. I P no. I

Group no.

From P No. 1 Group 1 to P no. 1 Group No.2 OR P No. 1 Group 1 to P no. 1 Group No. 1 OR P
No.1 Group 2 to P no. 1 Group No.2

Thickness of Test Coupon

16 MM

Thickness Range

Groove

t pass> 13 mm
iiii ;..... 3.'1111

16 to 32 mm

Fillet

All

NO, t pass < 13 mm

. :;g

'"

',,;l~\j'

!!";\\~It,lI;i~;tiIIETill:l,f;Nlib~.i_

'i'

~.ll;J;'Vii(.

Welding Process

GTAW

SMAW

F No.

ANo.

11

11

Diameter

2.4 MM DIA

2.5 MM DIA & 3.15 MM DIA

SFA No.

5.28

5.5

With or Without Filler

With filler only

NA

Filler metal product form

Solid

NA

Supplemental Filler Metal

NA

NA

Alloy Elements

NA

NA

Flux Design

NA

NA

Deposit of Weld Metal

Thickness

Upto 8 mm

Upto 24 mm

Classification

ER-80SD2

E-8018 G

Brand Name

D&H,ESAB,GEE,HONAVER,ADOR

D&H

iii

0",
#~ "0

( ~')(~fi,~; '
'--f\~~

"..",

COMTECH METALS PVT LTD.

QW 482 (Back)

WPS No.

CMPL!WPS/12/12-13 Rev. no. :- 0 Dated 09.08.12

POSITION QW-405
Position of Groove

.,,\
All

3G uphill

Welding Progression
Position of fillet

All

:).:'0};f",:,f"~;~~,\:},,fii\01;s>::1,~f;;j/' ,t;t~"T:f~8~-407)J~!:
Temp. :

NA

Time Range:

NA

Holding Time (Min)

PREHEAT (QW-406),,\,:,\;I~;lf!)i/1]i;~4:!;;~\!:{;;;jf

Preheat Temp. (min)

16 C

Interpass Temp.

250' C

Preheat Maintenance:
Others

,\

Flow Rate

Shielding

ARGON

SINGLE

10-12 mm

NA

Trailing

NA

NA

NA

Nil

Backing

NA

NA

NA

Polarity

<;i"\,,.JECHNICtf.ft;;/(QW-41 0"

i"<'.

.,!

Stringer I Weave (Weaving shall not be greater

.
.
than 3 times of the electrode diameter)

Orrifice Cup Size

10 mm

G'nn d'mg I W'Ire brus h'mg I Ch'Ippmg

.

Grinding, if applicable

Methode of Back Gouging:

Amp.

NA

2.4 mm dia.& Osciliation:

o'

2 Vo thonated

Contact Tube to Work Distance:

NA

Mode of Metal Transfer

NA

Multiple or Single Pass(Per side)

Multiple

Heat Input Maximum

aII owa bl e

3.5 J/mm
.
MaXlmum

Multiple or Single Electrode:

T
I S pee d
rave

Single
Referbei ow tabl e

Other

QW-410.11 & QW-41 0.64 - Not applicable

FILLER METALS

WELD LAYER

CURRENT

PROCESS
AWS CLASS

DIA MM

POLARITY

AMPS

VOLTS

TRAVEL
SPEED IN
MM 1MIN

ROOT

GTAW

ER-80SD2

2.4

DCEN

90 to 110

16 TO 22 60 TO 90

HOT PASS

GTAW

ER-80SD2

2.4

DCEN

95 to 120

16 TO 22 60 TO 90

FILL UP

SMAW

E-8018G

3.15

DCEP

85 to 125

22T030 60T090

FINAL

SMAW

E-8018G

2.5

DCEP

85 to 125

22 TO 30 60 TO 90

PREPARED BY
NAME:

~~~(Q,o..!Q~~)~

~.V\;S \, \).

SIGNATURE'

..

)'.

DATE: 09/08/2012

REVIEWED BY

,. Al.$A

\~

~v~

.~,

... /~
~AI~>\?J;:
-

APPROVED BY

~~'i)~,t:~'

NAME:X'>~I\i'~ ~~h~~i.~~

SIGNATURE:
DATE:

. F' ,

, ...... )

,0

..

)~w~. :U-'

OC1.() ~\1.9l'

NAME:

-III
.r::" 11

O,-)--..____ .-:;.(\"V-)
'~~fH~ ~

")"""'1

.
W
N d
Stnng or eave ea:

Methode
. of initial and interpass
See Table CI
eamng:

Tungsten Electrode

(qW~(j8)jf' ';1:';

Percentage Compositions

DC

V oItage

Ct.

NA

Gases

ElE;CTRICA'C!tlATA (QW-409)
Current AC I DC

. 1!!'9AS

;YilfY,,>,iit,lliV'\!\'i

SIGNATURE:

....._-...

UV~V(~O
. ~~.;;-. . .;'V <5>%
lie ~1Q: _.

q\~(~:f

DATE:.

~~\f\

~~\ /

COMTECH METALS PVT LTO.

QW-483, Procedure Qualification Record
(AS per QW-200.2 Section IX ASME Boiler and Pressure Vessel Code)
CMPLI PQR/12/12-13

REV:O

Prepared By

Mr. Santsharan Parmar

CMPLlWPS/12/12-13

REV:O

Welder Name

Mr. Bapi Ruidas

Location

CMPL

GTAW+SMAW

75 5deg.
16mm
2 0.5 mm
21mm
None

Material Spec.

SA 516 GR 60 TO SA516 GR 70

NA
NA

HAET No.
P no. 1 Group No.2

NA

5.28

5.5

Type

Gas (es)

Mixures

Flow Rate

ER 80 S 02

E-8018 G

Shielding

ARGON

SINGLE

10-12 MM

Trailing

NA

NA

NA

11

11

Backing

NA

NA

NA

Size of filler Metal

2.4 MM OIA

2.5 MM & 3.15 MM OIA

Weld Metal Thickness

8mm

24 mm

Trade Name

GEE

O&H

Metal Analysis A No.

ing Progression

Interpass Temprature(Max)
Others

Up Hill

Polarity

None.

Amps

250 C

Refer Annexure 01
Grinding & Wire brush
Multipass
No Peening

COMTECH METALS PVT LTD.

QW-483 ( Back)
PQRNo.

Date:- 09/08/2012

CMPLI PQRl12/12-13 Rev-O

T-1

15.6

20.8

I 324.48

190000

585.5

Parent Metal

T-2

15.55

20.9

192000

590.7

Parent Metal

325

SB-1

SIDE BEND

180

38mm

Satisfactory

SB-2

SIDE BEND

180

38mm

Satisfactory

SB-3

SIDE BEND

180

38mm

Satisfactory

SB-4

SIDE BEND

180

38mm

Satisfactory

---1

Ductile Fracture
Ductile Fracture

90-RQ/2012 DTD:-19/7/12

Mark

I HAZ(GR-60) r

1OX1 0

-46'C

20

32

20

10X10
10X10

-46'C
-46'C

22
38

30
42

34
30

VISUAL TEST

Type of Test (Other)

28.67
36.67

376
Refer report no.
R/2012 Dt: 20.07.12

: Found Satisfactory

RADIOGRAPHIC TEST:- Fount satisfactory. REPORT No-NRS-REP/1124/12-13 DTD:9n112

HARDNESS TEST

:NA

CORROSION TEST

: NA

PWHT TEST
vvr:::Lur:::r;o NAME:

Mr. Bapi Ruidas

CONDUCTED BY:

Met Heat Engineers Pvt. Ltd.

: NA
CLOCK NO.

STAMP NO. w-19

LABORATORY TEST NO.: 90-RQ/2012 DTD:-19/7/12

CERTIFY THAT THE STATEMENT IN THIS RECORD ARE CORRECT AND THAT THE TEST WELDS WERE PREPARED
VVt:LUt:U

AND TESTED IN ACCORDANCE WITH THE REQUIREMENT OF SECTION IX OF THE ASME CODE.

~~.

NAME:
SIGN:
DATE:

.rr.----------------------------------

COMTECH METALS PVT LTD.

PQR No.

CMPLI PQR/12/12-13 REV-O DATED 09.08.12

WPS No.

CMPLIWPS/12/12-13 REV-O DATED 09.08.12

ANNEXURE -1
FILLER METALS
WELD LAYER

CURRENT

JTRAVEL SPEED

I PROCESS

liN MM 1 MINUTE
AWSCLASS

DIAMM

POLARITY

AMPS

VOLTS

ROOT

GTAW

ER-80SD2

2.4

DCEN

90 TO 105

20 TO 22

60 TO 90

HOT PASS

GTAW

ER-80SD2

2.4

DCEN

95 TO 113

20 TO 24

60 TO 90

FILL UP &
SUB-SEQUENT
RUNS

SMAW

IE-8018G

13. 15

IDCEP

187T0115

123 TO 31

160 TO 90

FINAL

SMAW

IE-8018G

12.5

IDCEP

185 TO 111

125 TO 30

160 TO 90

PREPARED BY

REVIEWED BY

OVEDBY

NAME:I
SIGNATURE:

SIGNATURE:

DATE: 09/08/2012

DATE:

,"

(.

(~)

r!imay Raiio9f'aphic Sef'vice:1

O~

(fonne(y Iqwwn as CBaroaa lnaustrialX-ray Services)

Radiographic & Other NOT Testing of Welds, Casting & Piping

43/8, G.I.D.C., Makarpura, VADODARA - 390010.
Ph. : (0265) 2632808, 2642456 Fax: (0265) 3042854 e-mail: nimay-rs@hotmail.com

Mis
Report No' NRS-Repl 1124 f12-13

Comtech Metals Pvt . Ltd

Plot No-111, Near Gujarat Engg.Co.

Jarod - Samlaya Road,

Vadodara

Date: 9-Jul-12
RADIOGRAPHIC INSPECTION REPORT

Source:
Iridium 192
Source Size:
2.95 mm
Strength:
14.00 Ci
IQI hole type: ASTMwire type: ASTM - 1 B 11
Total No of Exposures:
. Acceptance Crieteria: ASME Sec IX
SeNo.

,SOD:
OFO from SSO:
,E~posure Type:
Viewing:
Exposure Time:
Material: SA 516

Film:
AGFA - 0 7
Lead front:
0.1 mm
Screen back:
0.1 mm
Weldi~g Tech.:

Film per
cassette:

490.00 mm
18 mm
sin~le wall
single image
"'

9 min

,nil

In'

uln

Identification Marks

Film Size

Observation

CMPL PQR-1iV\119 XR-1 SAP] RUIOAs

15" x 3"

NSD

Remarks

mlJ

..

I)

'"

~.

It)

It I

I'

.'
YNY

_Ny

,,,,',,y

Note: Films Marked as C.S(gheck SurfacEl) must be viewed cmd these films will be

('

I2L

Inspection Agency

accept~d

accordingy

Page_of_

......

'

.,

--------~--

MET:t~ENGINEERS PVT. LTD.

IMHEPLH/F-wt7]
857/2, G.I.D.C.
INDUSTRIAL ESTATE, MAKARPURA,
VADODARA - 390 010.
TELEFAX: 0265-2632374, 2643655, 2648026,
6548715,6548716
E-mail: info@metheat.com
Website : www.metheat.com

METALLURGICAL LABORATORY
ON APPROVED LIST OF VARIOUS GOVT. DEPART~ENTS
& PUBLIC SECTOR UNDERTAKINGS
'
(SINCE 1975)

TEST REPORT (PHYSICAL)

Ie of The Customer

wo:e7/734SrHo.l PI/

COMTECH METALS PVT LTD

PLOT NO:111~
NR.GUJARAT ENGG. CO.
VILLAGE-VADADALA

PTR No.
Date

3&-Cr-Hol'

90-RQ/2012
19/07/2012

Date of Receipt: 13/07/2012

omer's Reference N0'i REF: CMPL/CMO-58/MET-HEAT /21

!rial Specification

SA-516 GRADE-60:2010 TO SA-516 GRADE-70:2010

...

Identification

Description
of Material

Dia-Width
mm

Thick
mm

Cross
Sectional
Area
mm 2

Yield
Strength

Yieid
Load

Required
Minimum

Welded Test
PIl:CE 16M'! nil(
PLATE

stamped ...

29.80

is. fill

324.46

'TWO
Of TW..H(R)

Gauge
Length
mm

Required
Minimum

'. 1'F'a
f.

41S

Elong
ation %

Final
Length
mm

Required
Minimum

l'F'a

"
I

Tensile
Strength

Ultimate
Load

1'ii1IIIIHCt.

lSSS.,s i3t'0keR -ParMt MiKal

Fr a.c::tI.lre-Ouctil.
,
(SA-S16 ClR-filI)

--

ID: CK"L/CI'Il-SSI
PCFVl2/12-13
\IPS. NO : OPl/llPSl

12/2912-13

NO:OPL/PI'.V

12/2012-13

T-l

do

29.',;0

do T-2

lS.SS

192H11iS9C1 .,

32S._

Fr acture;-DuctU.
(SAi-S16 OR-tA)
38._ . . Ar'I<ill. Of 'BIr!d' 1ar1.II'

do

do

SEI-l

SIDE BEHO rtsT SaUaf.ctory

MilndrU Oia

do

do 00-2

SIDE BEND TEST Satiafactory

Kandril Oia

38.011 . . I!n'iIle Of fland lfl111 ,

do

do 00-3

SIDE BEND TEST Sa.tiafactory

Mandril Oia

:sa.

111M

AAgl. Of ElllndlE111

do

doSB-4

SIDE eEHO TEST Satisfactory

Mandril Oia

:sa."

I11III

An<ille Of 8end U'0.0

':~.

. _ - - - _ _ _........ _ _ ........ _ _ _ _ _ _ _ _ ... _ _ _ _ ... _ _ -

tettlCld Of Testing

- - _ _._ ... - ....... _ ... _' .... -

...... _ - _ _ _ _ _

..,._~

...... - - - _ _ _ _ _ _ _ -

- - - - - - _ _ _ ... _ - - ... - - - - - , - - ..... -

... - . - - - - - - -

~.

-~

abow reaulta are naeting lIIit..!'l physical requirllll'lEl'lta of ASME SECTIQoIIX lIIithrespaet of test carried
'" --... - ... -._- - _... -- ........ - -----_.
-- , ............. _... -.- ------- ................ _. - _.......... _............ --- - .... - ... .... .... .,. --- -.- - ........ _.... _....

-_

- --

-- -

_ .... _ ......<00: - - - - - - - - - - - _ _

ASME SEC-IX.:: 2910

._..... ____ ... _._. ___ ...... _...... _________ -. ...... _______ ...... _______.___,_-___.______... __.___________________ ----- ________ ... - - - -- . .
I

-_ - _

--

... -----i.. . . . _-- ...;;;..----'

Cll.It~

_--- -------- -- --- --

....

'1JI1~.

Authorised Signatory . /

rvJ;S;;1

..,

C,~~T ENGINEERS PVT. LTD.

[r~HEPUFMt18J
857/2, G.LD.C,
INDUSTRIAL ESTATE, MAKARPURA,
VADODARA - 390 010,
TELEFAX: 0265-2632374, 2643655, 2648026
E-mail: info@methea!.com
Website .www.metheat.com

METALLURGICAL LABORATORY
ON APPROVED LIST OF VARIOUS GOVT. DEPARTMENTS
& PUBLIC SECTOR UNDERTAKINGS
(SINCE 1975)

WO:07/734 SrNo.l PI/

TEST REPORT
of The Customer

COMTECH METALS PVT LTD

PLOT NO:111.
NR.GUJARAT ENGG. CO.
VILLAGE-VADADALA

30-Cr

Test Report No.

Date

376-R /2012
20/07/2012

Date of Receipt

13/07/2012

lars of Sample Submitted:

Welded Test PIECE 16MM THK PLATE

al Specification

SA-S16 GRADE-60:2010 TO SA-S16 GRADE-70:2010

ication of Sample

Stamped As 'TUY' Of TUY-NORD.ID:CMPL/CMO-58/PQR/12/12-13

WPS.NO:CMPL/WPS/12/2012-13 PQR NO:CMPL/PQR/12/2012-13

f Test Required
mer's Reference No.

','

/0

V Notch Charpy Impact Test at -46 C. By ASTM E-23:2007A

[MINUS FORTY SIX Degree Centigrade ]
REF:CMPL/CMO-S8/MET-HEAT/21

ts

ocation

Size mm

Energy absorbed in Joules

I
II
III

Average
Value

Required
Value

-------------------------/----/----------?--------~----------~-------------

eld

10x10.00

20J

32J

20J

24.00J'

AZ (GR-60)
AZ (GR-70)

10x10.00 .I'
10x10 . 00./

22 :Y
38J ,/

30J . . .
42J ('"

34J/
30J .r

28.67J /'
36.67J ./

-----------------------------------------------------------------------~-----

-----x----
~

.J~

fey

Authorised Sianatorv