Larsen & Toubro Limited, Format No : LTCD/W&RE/WSBG/PQP/FMT/D04, Rev 0

Water & Effluent Treatment - SBG

FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)

Company Name L&T CONSTRUCTION - WET SBG - TDWSP Medak and Sangareddy Segments By :

Welding Procedure Specification No. L&T- WET/ TDWSP/ WPS-01 Revision No. 0 Date 9/2/2015

Supporting PQR No. (s) LT-TDWSP-PQR-001, Rev-0 IMPACT TEST : -

Welding Process (es) SMAW Type(s) MANUALCode Applied : ASME Sec IX Year : 2013 (Automatic, Manual<Machine, or Semi-Auto.)

JOINTS (QW-402) Details

Joint Design Single V

Backing NO t -thickness

Backing Material (Type) NA c - rootgap d - root face

(Refer to both backing and retainers.)

Metal Nonfusing Metal a

Nonmetal Other

Sketches, Production Drawings, weld Symbols or Written Descriptiontshould show the general arrangement of the parts to be welded. Where

applicable, the root spacing and the details of weld groove may bespecified. Root gap

(At the option of the Mfgr., sketches may be attached to illustrate jointdesign, weld layers and bead sequence, e.g. for notch toughness Inside root - seal run procedures, for multiple process procedures, etc.)

*Base Metals (QW-403)

P-No. 1 Group No. 1 to P-NO. 1 Group No. 1OR

Specification type and grade IS: 2062 Gr B or Equivalent

to Specification type and grade IS: 2062 Gr B or EquivalentOR

Chem. Analysis and Mech. Prop. N.A.

to Chem. Analysis and Mech. Prop. N.A.Thickness Range :

Base Metal : Groove 5mm to 38mm Fillet ALL

Pipe Dia. Range : Groove Any diameter ( procedure qualification wise) Fillet ALL

Other N.A.

*FILLER METALS (QW-404) 1st Pass Filling and caping Root

Spec. No. (SFA) 5.1 5.1 5.1

AWS No. (Class) E6013 E6013 E6013

Brand Name D&H (or) Equivalent D&H (or) Equivalent D&H (or) Equivalent

F-No. 2 2 2

A-No. 1 1 1

Size of Filler Metals 3.15 4 3.15Welds Metal

Thickness Range :

Groove Upto 3 mm Rest 1 pass

Fillet 1st pass Rest 1 pass

Electrode-Flux (Class) NA NA NA

Flux Trade Name NA NA NA

Consumable Insert NA NA NA

Other

L&T REVIEWED BY APPROVED BY

SIGNATURE

NAME

DATE

a - 30 ± 5 deg

a

Larsen & Toubro Limited, Format No : LTCD/W&RE/WSBG/PQP/FMT/D04, Rev 0

Water & Effluent Treatment - SBG

WPS No. L&T- WET/ TDWSP/ WPS-01 Rev. 0

POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407)

Temperature Range NA

Position(s) of Groove All position Time Range NA

Welding Progression : Up yes Down N.A

Position(s) of Fillet ALL

GAS (QW-408)

Precent Composition

PREHEAT (QW-406) Gas(es) (Mixture) Flow Rate

Preheat Temp. Min. Ambient temp. Shielding NA NA NA

Interpass Temp. Max. 250-350 deg Trailing NA NA NA

(Continuous or special heating where applicable should be recorded.) Backing NA NA NA

ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC DC Polarity DCEP

Amps (Range) 80-180 A Volts (Range) 24-32 V

(Amps and volts range should be recorded for each electrode size,

position, and thickness, etc. This information may be listed in a tabular

form similar to that shown below.)

Tungsten Electrode Size and Type N.A.

(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW N.A.

(Spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range N.A.

TECHNIQUE (QW-410)

String or Weave Bead String or Weave

Orifice or Gas Cup Size NA

Initial and Interpass Cleaning (Brushing, Grinding, etc.) Through wire brush, chipping and grinding

Method of Back Gouging By grinding or chipping

Oscillation NA

Contact Tube to Work Distance NA

Multiple or Single Pass (per side) Multi pass

Multiple or Single Electrodes Multiple

Travel Speed (Range) 55-60 mm/min

Peening NA

Other NA

Weld Layer(s) Process

Filler Metal Current Other

Class Type Polar.(e.g., Remarks, Comments, Hot Wire

Addition, Technique, Torch Angle etc.)

Root SMAW E6013 3.15 DCEP 80-140 A 24-32 V 1 mm/s

Filler pass II SMAW E6013 4 DCEP 105-180 A 24-32 V 1 mm/s ditto

Filler pass III SMAW E6013 4 DCEP 105-180 A 24-32 V 1 mm/s ditto

Back welding SMAW E6013 3.15 DCEP 80-140 A 24-32 V 1 mm/s ditto

As per QW 409.5 ±15 % will be permitted in amperage and voltage from the PQR tested values

Volt Range ( V )

Travel Speed Range

CM / MIN

Dia.

( mm )

Amp. Range ( A )

As per QW 409.5 15 % (Plus or minus) will be permitted in amperage and voltage from the

PQR tested values

Larsen & Toubro Limited, Format No : LTCD/W&RE/WSBG/PQP/FMT/D04, Rev 0

Water & Effluent Treatment - SBG

FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)

Company Name L&T CONSTRUCTION - WET SBG - TDWSP Medak and Sangareddy Segments

Procedure Qualification Record No. L&T- WET/ TDWSP/ PQR-01 Revision No. 0 Date 9/2/2015

WPS No. L&T- WET/ TDWSP/ PQR-01

Welding Process (es) SMAW Type(s) MANUALCode Applied : ASME Sec IX Year : 2013 (Automatic, Manual<Machine, or Semi-Auto.)

JOINTS (QW-402)α

t -thickness= 14 mmc - rootgap= 3 mm d - root face= 3 mm

t

3 mmInside root - seal run

*Base Metals (QW-403) POSTWELD HEAT TREATMENT (QW-407)Material Spec. IS 2062 Gr.B (Fe 410WA) Temperature NilType/Grade or UNS No. TimeP.No 1 Grade No. 1 to P.No. 1 Grade No. 1 OtherThickness of Test Coupon 14 mmMaximum Pass Thickness 5 mm GAS (QW-408)

Gas(es) Mixture Flow Rate*FILLER METALS (QW-404) Shielding NilSpec. No. (SFA) 5.1 5.1 TrailingAWS No. (Class) E6013 E6013 BackingF-No. 2 2 OtherA-No. 1 1Size of Filler Metals ELECTRICAL CHARACTERISTICS (QW-409)Weld Metal Thickness 3 mm 4 mm Current DCElectrode-Flux (Class) Polarity EPFlux Trade Name Amps 100-150 A Volts 24 VConsumable Insert Heat Input Max. 4200 J/mmOther Other

POSITION (QW-405) TECHNIQUE (QW-410)

Position of Groove Travel Speed 1 mm/s

Weld Progression (Uphill, Downhill) Nil String or Weave Bead String & Weave

Other OscillationPREHEAT (QW-406) Multiple or Single Pass MultiplePreheat Temperature Ambient Temp Single or Multiple Electrodes MultipleInterpass Temperature Other

Other

FORM QW-483 (Back) PQR No. 1

Tensile Test (QW-150)Specimen No. Width Thickness Area Ultimate Total Load Ultimate Tensile Stress (psi or Mpa) Type of Failure

1 19 mm 14 mm2 19 mm 14 mm

Guided Bend Tests (QW-160)Type and Figure No. Result

4 Side Bend Tests

or

2 Root and 2 Face bend Tests

Toughness Tests (QW-170) N.A

Fillet Weld Test (QW-180) N.A

Date:

a - 30 ± 5 deg

Φ3.15 mm Φ4 mm

1G (Qualification in 1G qualifies all) (Φposition not essential)

300-350˚C

266 mm²266 mm²

a

FORMAT FOR WELDING PERFORMANCE QUALIFICATION (WPQ)Welder's Name Identification No.

WPS followed 1 Test Coupon Production Weld YesSpecification and grade of Base Metal IS 2062 Gr.B Thickness 14 mm

Testing Variables and Qualification LimitsWelding Variables (QW-350) Actual Values Range Qualified

Welding Processes SMAW SMAWType(manual/automatic) Manual ManualBacking(with/without) without with(1), both(2)

No Plate Yes Pipe(Dia.) Pipe OD 1200mm 73 mm to MaximumBase Metal P-Number to P-Number 1 1-15F, 34, 41, 49Filler metal or Electrode Specification (SFA) (info) 5.1Filler metal or Electrode Classification (info) E6013Filler Metal F-No. 2 2(both), 1(backing)Process 1 SMAW 3 Layers Minimum Yes 15 mm Upto 30 mmPosition Qualified 5G F,V,OVertical Progression Uphill Both

ResultsVisual Examination of Completed Weld (QW-302.4) YesTransverse face and root bends (QW-462.3(a)) 2 each Side Bends(QW-462.2) 4

Type of Test Result2 Face Bend Tests2 Root Bend Tests

(or)4 Side Bend Tests

(or)Volumetric Examination Radiography Test Full Joint

(or)Volumetric Examination Ultrasonic Test Full Joint

QW-190 RT DefectsQW-163 Bend Test Acceptance CriteriaDate:

Material PropertiesIS 2062:1992, Fe 410WA Gr.B C.E=0.42C=0.23%, Mn=1.5% max, Si=.40% max, S=0.045%, P=0.045%Tensile Strength=410 Mpa, Yield Strength=250 Mpa, %El=23%

For PQR

Material PropertiesIS 2062:1992, Fe 410WA Gr.B

Tensile Strength=410 Mpa, Yield Strength=250 Mpa, %El=23%

For PQR

For PQR & WPQ

C=0.23%, Mn=1.5% max, Si=.40% max, S=0.045%, P=0.045%, CE=0.42

For PQR

For WPQ