Welding Book Revised 2012 07 14
Welding Book Revised 2012 07 14
Welding Book Revised 2012 07 14
Issued by: Safouh J. B 3. N.A. Date : 4. N.A. 14/07/2012 Type Supporting PQR No: Automatic Manual PQR 128 Semi-Automatic Machine
8015-0151-ENTR-01 1- SAW
Joints (QW-402) Joint Design: Backing Backing material (Type) Retainers Retainers Material Other Tolerance P-N : 1* Group Yes No NONE NONE IO 40 CQU Rev.2 1* Base Metals (QW-403) To P-N TO N.A Specification ,Type Grade 1* Group 2* See Joint Details in appendix No. 1.a Yes No Base Metal
Other Specification ,Type Grade Thickness Range Pipe Range Maximum (t) : for one pass
* according to API 650 ASTM A 283 GR. C / ASTM A 537 CL1 Groove Groove
Fillet : All Fillet : N.A <= 9.5 mm for thick<=32 mm /<=13 mm for thick>32 mm Filler Metals (QW-404) Deposited Weld Metal Thickness Range Deposited Weld Metal Groove Fillet All Welding process 1- SAW 2-N.A 1-N.A 4-N.A .3 Size(Gtaw) N.A. .4 F-N/O or Other 6 .5 A-N Or Other 1 .6 of filler Metal 3.2 mm .7 of filler Metal>1/4(SMAW) N.A. .9 Electrode Flux (class)(saw) N.A. .10 Alloying Flux (saw) N.A. .12 Specification (SFA) A5.17 .14 With or without filler metal(GTAW) N.A. .22 Consumable Insert (GTAW) N.A. .23 Solid or tabular Electrode Solid .24 Sup. Filler metal NONE .27 Alloying Elements (SAW,GMAW,FCAW) NONE .29 Flux Trade Name (SAW) Se trade name below .32 Limits S.CIR.ARC(GMAW,Fcw) NONE .33 AWS N(Class) F7A5-EM12K .34 Flux (Type)(SAW) F7A5 .35 Flux Wire Class (SAW) EM12K .36 Recurshed Slag (SAW) N.A .38 Diameter (1 st Layer )(SMAW W.O.) N.A .39 Nominal Flux comp.(SAW W.O;Esw W.O) N.A .50 Flux GTAW N.A Trade Name Of Wire : ESAB Autrod 12.22 + ESAB Flux 10.71 or equivalent like Lincoln L61+860 1. For tack weld see applicable WPS tack on WPS Summary. 2. for repair see applicable WPS repair on WPS Summary Other 3. Weld Joint Surfaces for a minimum 2 of inches (50.80 mm) on each side of the internal surfaces shall be cleaned and free of paint, Oil , Dirt , scale Notes oxides, and other foreign materials detrimental to the integrity of the weld . 4. for inter pass cleaning of austenitic stainless steel or nickel alloy steel ,rezoned ,silicon, carbide wheels, pencil ,grinders, and/or stainless steel brushes shall be used cleaning tools that where previously use in carbon or law alloy materials shall not be used.
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Position (s) of fillet PQR 1F 1F-R 2F 2F-R 3F 4F Welding progression Preheat (QW-406) Preheat Temp. Min. Inter pass Temperature Maximum Preheat Maintenance Other *For interrupted Welding only Electrical Data (QW-409) Tungsten Electrode Tungsten Type Mode of model transfer Pulsing : Inc.>10% 1st layer(SMAW, W.O): Inc.>10% heat input 1st Layer(SAW W.O,GMAW & FCAW W.O,ESW) See table below for current polarity ,Amp TECHNIQUE (QW-410) .1 String or Weave .3 0 mm Gas Cup size (GMAW & FCAW /W.O, GTAW) .5 Method of initial and inter pass Cleaning .6 Method of back gouging / back grinding (SMAWSAW;GMAW;FCAW;GTAW) .7 Oscillation (for machine or automatic) .8 Contact Tube to work distance ( SAW ) .9 Multiple or single pass (per side) (SMAW;SAW;GMAW;FCAW;GTAW) 10 Multiple or single electrode 11 closed to out chamber 15 electrodes spacing 26 peening 38 multiple to single layer 40 supplemental device (Saw w. o; ) 50 N of electrodes 64 Use of thermal process Surfaces are to be cleaned with both sides of weld preparation for N.A. NONE 1520 mm Multiple Single N.A. NONE None- removal of slag is not intended as peening Multiple Single NONE NONE see note at the end of page. String N.A. see note at the end of page. 10 C <= 250 C 10 C N.A. N.A. N.A. Short circuit NONE NO NO GAS (QW-408) Shielding Gas(es) Type N.A. Composition% N.A. Yes NO Flow Rate N.A. 5F F V Production H O T Limits: NA
Yes Composition% N.A. Yes Composition% N.A. Flow rate N.A. Flow rate N.A.
NO
NO
Welding may be interrupted provided minimum 9.0 mm of weld deposit or 25% of the weld groove is filled weldments are covered by insulating slow cooling during the time that welding is interrupted. Weld Layer 1n Process SAW Filler metals AWS class F7A5-EM12K Current Amps 530-550 Travel speed (mm/min) 500520 Heat input (J/ mm) 1980
mm 3.2
type DC
polarity Reverse
Volts 27-29
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ITEM:
Welding Procedure Specification No.:
Issued by: Eng. Safouh J. B Date: 14/07/2012 Supporting PQR No.: Automatic Manual PQR 95 Semi-Automatic Machine
Welding Process(es) Joint Design: Backing Backing material (Type) Retainers Retainers Material Other Tolerance
2-N.A.
3-N.A.
4-N.A.
Type
Base Metals (QW-403) P-N : 1* Group 1* To P-N 1* Group 2* Other * according to API 650 Specification ,Type ASTM A 283 GR.C / ASTM A 537 TO Specification ,Type Grade ASTM A 283 GR.C / ASTM A 537 CL1 Grade CL1 Thickness Range Groove Fillet : All Pipe Range Groove N.A Fillet : N.A Maximum (t) : for one pass <= 9.5 mm for thick <=32 mm /<=13 mm for thick > 32 mm ( QW-404 ) Filler Metals Deposited Weld Metal Thickness Range .1 Deposited Weld Metal Lap joint <= 200 mm Fillet All .2 Welding process 1.SMAW 2.N.A. 1.N.A 4.N.A .3 Size(GTAW) N.A. .4 F-N/O or Other 4 .5 A-N Or Other 1 .6 of filler Metal 3.25/4 mm .7 of filler Metal>1/4(SMAW) N.A. .9 Electrode Flux (class)(saw) NONE .10 Alloying Flux (saw) NONE .12 Specification (SFA) A5.1 .14 With or without filler metal(GTAW) N.A. .22 Consumable Insert (GTAW) N.A. .23 Solid or tabular Electrode N.A. .24 Sup. Filler metal NONE .27 Alloying Elements (SAW,GMAW,FCAW) NONE .29 Flux Trade Name (SAW) None .32 Limits S .Cir. Arc (GMAW,FCW) N.A. .33 AWS N (Class) E 7018 .34 Flux (Type ) (SAW) N.A. .35 Flux Wire Class (SAW) NONE .36 Re crushed Slag (SAW) NONE .38 Diameter (1st. layer ) (SMAW W.O.) N.A. .39 Nominal Flux comp.(SAW W.O;ESW W.O) N.A. .50 Flux GTAW N.A. Trade name of electrode : OK 48.00 or equivalent. 1. For tack weld see applicable WPS tack on WPS Summary Other 2. for repair see applicable WPS repair on WPS Summary Note 3. Weld Joint Surfaces for a minimum 2 of inches (50.80 mm) on each side of the internal surfaces shall be cleaned and free of paint, s Oil , Dirt , scale oxides and other foreign materials detrimental to the integrity of the weld . 4. for inter pass cleaning of austenitic stainless steel or nickel alloy steel, resionid ,silicon, carbide wheels ,pencil, grinders, and/or
that where previously use in carbon or law alloy materials shall not be used.
Page 2 OF 2
Position (s) (WQ-405) PQR 1F 1F-R 2F 2F-R 3F 4F Welding progression Preheat (QW-406) Preheat Temp. Min. Inter pass Temperature Maximum Preheat Maintenance Other *For interrupted Welding only Electrical Data (QW-409) Tungsten Electrode Tungsten Type N.A. Mode of model transfer Pulsing : Inc.>10% 1st layer(SMAW W.O): Inc.>10% heat input 1st Layer(SAW W.O,FCAW W.O,ESW)
5F
T Limits: (applicable with PWHT upper transformation temp.) GAS (QW-408) Shielding Gas(es) Type N.A. Gas Backing Yes Composition% N.A. Yes Composition% N.A. Yes Composition% N.A. Flow rate N.A. Flow rate N.A. NO NO Flow Rate N.A. NO
NA
See table below for current polarity ,Amp TECHNIQUE (QW-410) .1 String or Weave .3 0 mm Gas Cup size (GMAW & FCAW W.O, GTAW) .5 Method of initial and inter pass Cleaning .6 Method of back Gouging /back grinding (SMAW;SAW;GMAW;GTAW) .7 Oscillation (for machine or automatic) .8 Contact Tube to work distance (SMAW;SAW;GMAW;FCAW;GTAW) .9 Multiple or single pass (per side) (SMAW;SAW;GMAW;FCAW;GTAW) 10 Multiple or single electrode 11 closed to out chamber (GTAW) 15 electrodes spacing 26 peening 38 multiple to single layer 40 supplemental device (Saw w. o; ) 50 N of electrodes 64 Use of thermal process Surfaces are to be cleaned with both sides of weld preparation for String N.A. see note at the end of page. N.A. NONE NONE Multiple Single N.A. N.A. None- removal of slag is not intended as peening Multiple. N.A. N.A. N.A. seenote3-4 at the end of page.
Welding may be interrupted provided minimum 9.0 mm of weld deposit or 25% of the weld groove is filled, weldments, are covered by insulating, slow cooling during the time that welding is interrupted. Filler metals Weld Layer 1- n 2-3 Process AWS class SMAW SMAW E7018 E7018 mm 3.25 4 type DC DC polarity Reverse Reverse Current Amps 90-120 130-160 Volts 21-23 22-24 Travel speed (mm/min) 140-160 160-180 Heat input (J/ mm) 1281.4 1355.2
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ITEM: Tank TK 5109/5110/5111 Welding Procedure Specification No: Welding Process Joints (QW-402) Joint Design: Backing Backing material (Type) Retainers Retainers Material Other Tolerance Base Metals (QW-403) P-N : 1* Other Specification ,Type Grade Thickness Range Pipe Range Maximum (t) : for one pass Yes No NONE NONE IO 40 CQU Rev.2 Group 2* To TO See Joint Details in Appendix 1.c Yes No Base Metal 8015-0151-ENTR-03 1-SMAW Revision 2.N.A.
Issued by. Eng. Safouh J. B 3.N.A. Date: 4.N.A. 14/07/2012 Type Supporting PQR No: Automatic Manual PQR 95 Semi-Automatic Machine
1*
2*
556 mm Fillet : All All Fillet : All <= 9.5 mm for thick <= 32 mm /<=13 mm for thick > 32 mm Filler Metals (QW-404) Deposited Weld Metal Thickness Range 1. Deposited Weld Metal Groove <= 56 mm Fillet All 2. Welding process 1.SMAW 2.N.A 1.N.A 4.N.A 3. Size(GTAW) N.A. 4. F-N/O or Other 4 5. A-N Or Other 1 6. of filler Metal 3.2 / 4 mm 7. of filler Metal>1/4(SMAW) N.A. 8. Electrode Flux (class)(saw) N.A. 9. Alloying Flux (saw) N.A. 10. Specification (SFA) A5.1 11. With or without filler metal(GTAW) N.A. 12. Consumable Insert (GTAW) N.A. 13. Solid or tabular Electrode Solid 14. Sup.Filler metal NONE 15. Alloying Elements (SAW,GMAW,FCAW) NONE 16. Flux Trade Name (SAW) N.A 17. Limits S.CIR.ARC(GMAW,Fcw) NONE 18. AWS N(Class) E 7018 19. Flux (Type)(SAW) N.A 20. Flux Wire Class (SAW) N.A 21. Re crushed Slag (SAW) N.A 22. Diameter 1st. layer (SAW) N.A 23. Nominal Flux comp.(SAW W.O ; ESW W.O) N.A 24. Flux SMAW Basic Trade Name Of electrode : OK 48.00 or equivalent For tack weld see applicable WPS tack on WPS Summary for repair see applicable WPS repair on WPS Summary Other Weld Joint Surfaces for a minimum 2 of inches (50.80 mm) on each side of the internal surfaces shall be cleaned and free of paint, Oil, Dirt, scale oxides, and Notes other foreign materials detrimental to the integrity of the weld . for inter pass cleaning of austenitic stainless steel or nickel alloy steel, rezoned ,silicon, carbide wheels, pencil, grinders, and/or stainless steel brushes shall be used cleaning tools that where previously use in carbon or law alloy materials shall not be used.
pagem 2 OF 2
2F-R 3F 4F
5F
Welding progression Preheat Preheat Temp. Min. Inter pass Temperature Maximum Preheat Maintenance Other *For interrupted Welding only Electrical Data Tungsten Electrode Tungsten Type Mode of mode transfer Pulsing : Inc.>10% 1st layer(SMAW W.O): Inc.>10% heat input 1st Layer(SAW W.O,GMAW & FCAW W.O,ESW) See table below for current polarity ,Amp
T Limits: ( applicable with PWHT upper transformation temp.) GAS Shielding Gas (es) Type N.A.
NA
Yes N.A.
NO Flow Rate
Composition% N.A.
Yes Composition% N.A. Yes Composition% N.A. Flow rate N.A. Flow rate N.A.
NO
NO
TECHNIQUE .1 String or Weave 2 3 4 6 7 8 0 mm Gas Cup size (GMAW & FCAW /W.O, GTAW) Method of initial and inter pass Cleaning Method of back Gouging (SMAW;SAW;GMAW;FCAW;GTAW) Contact Tube to work distance (SMAW;SAW;GMAW;FCAW;GTAW) Multiple or single pass (per side) (SMAW;SAW;GMAW;FCAW;GTAW) Multiple or single electrode STRING & Weaving N.A. see note at the end of page. Grinding (if applicable) N.A. N.A. Multiple Single N.A. NONE None- removal of slag is not intended as peening NONE N.A. NONE NONE see note at the end of page.
9 closed to out chamber (G) 10 electrodes spacing 11 peening 12 multiple to single layer 13 supplemental device (Saw w. o; ) 14 N of electrodes 15 Use of thermal process 16 Surfaces are to be cleaned with both sides of weld preparation for
17 Welding may be interrupted provided minimum 9.0 mm of weld deposit or 25% of the weld groove is filled, weldments are covered by insulating, slow cooling during the time that welding is interrupted. Weld Layer Process Filler metals AWS class 1- n 2-3 3-4 SMAW SMAW SMAW E7018 E7018 E7018 mm 3.25 4 4 type DC DC DC polarity Reverse Reverse Reverse Current Amps 90-120 130-160 130-160 Volts 21-23 22-24 22-24 Travel speed (mm/min) 140-160 160-180 180-210 Heat input (J/ mm) 1281.4 1355.2 1355.2
Page 1 OF 2
2*
556 mm Fillet : All All Fillet : All <= 9.5 mm for thk. <=32 mm /<=13 mm for thk. >32 mm Filler Metals(QW-404) Deposited Weld Metal Thickness Range 1. Deposited Weld Metal Groove <= 56 mm Fillet All 2. Welding process 1.SAW 2.SAW 3.SAW 4.SAW 3. Size(GTAW) N.A. 4. F-N/O or Other 6 5. A-N Or Other 1 (See trade name below). 6. of filler Metal 3.2 mm 3.2 mm 3.2 mm 3.2 mm 7. of filler Metal>1/4(SMAW) N.A. 8. Electrode Flux (class)(SAW) N.A. 9. Alloying Flux (SAW) N.A. 10. Specification (SFA) A5.1 / A5.17 11. With or without filler metal(GTAW) N.A. 12. Consumable Insert (GTAW) N.A. 13. Solid or tabular Electrode Solid 14. Sup. Filler metal NONE 15. Alloying Elements (SAW,GMAW,FCAW) NONE 16. Flux Trade Name (SAW) See trade name below 17. Limits S.CIR.ARC(GMAW ,FCAW) NONE 18. AWS N(Class) F7A5-EM12K F7A5F7A5-EM12K F7A5EM12K EM12K 19. Flux (Type)(SAW) N.A 20. Flux Wire Class (SAW) N.A 21. Re crushed Slag (SAW) N.A 22. Diameter 1st. Layer (SMAW W.O.) N.A 23. Nominal Flux comp.(SAW W.O;ESW W.O) N.A 24. Flux GTAW N.A Trade Name Of Wire : ESAB OK Autrod 12.22 /OK Flux 10.71 or equivalent. For tack weld see applicable WPS tack on "WPS Summary" for repair see applicable WPS repair on WPS Summary Other Weld Joint Surfaces for a minimum 2 of inches (50.80 mm) on each side of the internal surfaces shall be cleaned and free of paint, Oil, Dirt, scale oxides, Notes and other foreign materials detrimental to the integrity of the weld . for inter pass cleaning of austenitic stainless steel or nickel alloy steel, resionid, silicon, carbide wheels, pencil, grinders, and/or stainless steel brushes shall be used cleaning tools that where previously use in carbon or law alloy materials shall not be used.
Page 2 OF 2
2F-R 3F 4F
5F
Welding progression Preheat (QW-406) Preheat Temp. Min. Inter pass Temperature Maximum Preheat Maintenance Other *For interrupted Welding only Electrical Data (QW-409) Tungsten Electrode Tungsten Type Mode of model transfer Pulsing : Inc.>10% 1st layer(SMAW W.O): Inc.>10% heat input 1st Layer(SAW W.O,GMAW & FCAW W.O,ESW) See table below for current polarity ,Amp
T Limits: (applicable with PWHT upper transformation temp.) GAS (QW-408) Shielding Gas (es) Type N.A.
NA
Yes N.A.
NO Flow Rate
Composition% N.A.
Yes Composition% N.A. Yes Composition% N.A. Flow rate N.A. Flow rate N.A.
NO
NO
TECHNIQUE (QW-410) .1 String or Weave 2 3 0 mm Gas Cup size (GMAW & FCAW /W.O, GTAW) Method of initial and inter pass Cleaning STRING N.A. see note at the end of page. Back Grinding None 15-20 mm Multiple Single N.A. NONE None- removal of slag is not intended as peening NONE N.A. NONE NONE see note at the end of page.
4 Method of Back Gouging / Back Grinding (SMAW;SAW;GMAW;FCAW;GTAW) 5 Oscillation (for machine or automatic) 6 7 8 Contact Tube to work distance (SMAW;SAW;GMAW;FCAW;GTAW) Multiple or single pass (per side) (SMAW;SAW;GMAW;FCAW;GTAW) Multiple or single electrode
9 closed to out chamber (GTAW) 10 electrodes spacing 11 peening 12 multiple to single layer 13 supplemental device (Saw w. o; ) 14 N of electrodes 15 Use of thermal process 16 Surfaces are to be cleaned with both sides of weld preparation for
17 Welding may be interrupted provided minimum 9.0 mm of weld deposit or 25% of the weld groove is filled, weldments are covered by insulating, slow cooling during the time that welding is interrupted. Weld Layer Process Filler metals AWS class 1-n SAW F7A5-EM12K mm 3.2 type DC polarity Reverse Current Amps 530-550 Volts 27-29 500-520 1980 Travel speed (mm/min) Heat input (J/ mm)
ffi
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3
ilrflt State Co. for Fertilizers/ Southern Region gn{t, Fi Engineering Inspection Department rfll rfri1lilc / e;rrilt
Tensile Test Laoratory
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ULTIMATE
UNIT STRESS
ks /mm2
52.66
WTDTII
TIIICKNESS
AREA
19.5*
18.4.-
14.8..
2gg.6*.2
15.200
(SAW) Qw-a62.1(a)
2-1-TS2
15.7.*
2gg.g..2
15.500
53.67
Base Metal
(sAW)
1
RESULT
Accept Accept Accept Accept
RESULT
Accept Accept Accept Accept
Remarks.
573 Grade 70 Tensile range (49.4 2- Dimension: ( 300 L x 300 wx22 th.)mm 3- Accordance with ASME code section lX 1-1-TSl Plate No.1 Tensile No.l 2-r-TS2 Plate No.l Tensile No.2 3-1-Sbl Plate No.l Side bend No.l 4-1-Sb2 Plate No.1 Side bend No.2 5-l-sb3 Plate No.l Side bend No.3 6-1-SM Plate No.l Side bend No.4
1-
Material
to 63.2)kglcr*
t. -1,q.
it,'
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Al Rafidian Oil Services Co. (ROSCO) a+lr-fJt oL.rill gsrsljl aS-2- . 6 !ilu!.q A{+ll
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SPECIMEN NO. Qw-462.1(a)
l-1-TS1
/;
6s14"&ll p!.,1
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6" I.r+S1
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38.1
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ULTIMATE TOTALLOAI)
ton
I]LTIMATE
IJ}TIT STRESS ks /mm2
(SAW)
l9*
18.7*
14.5'*
275.5;:
269.28*2
10.5
Qwa62.1(a)
2-t-TS2
14.4^
13.550
50.3
Base Metal
(sAlv) \-4Wa62.1(a)
l-2-TS1
(SMAW) Qw-462.1(a)
2-2-T32
[8.5*
18.7*
14.3*
14.9
264.55;?
14.750
55.7
Base Metal
(SMAW)
279.63*2
15.750
56.52
Base Metal
RESI}LT
Accept Accept Accept Accept
REST'LT
Accept Accept Accept Accept
Remarks.
573 Grade 70 Tensile range (49.4 2- Dimension: ( 300 L x 300 wx22 th.)mm 3- Accordance with ASME code section lX 1-1-TS1 Plate No.l Tensile No.l 2-1-TS2 Plate No.l Tensile No.2 1-2-TS1 Plate No.2 Tensile No.l 2-2-T32 Plate No.2 Tensile No.2 3-l-sbl Plate No.1 Side bend No.l 4-l-sb2 Plate No.l Side bend No.2 5-1-Sb3 Plate No.l Side bend No.3 6-1-Sb4 Plate No.l Side bend No.4 3-2-Sbr Plate No.l Side bend No. 1 4-2-Sbz Plate No.l Side bend No.2 s-2-sb3 Plate No.1 Side bend No.l Side bendNo.4
l- Material
to
63.2)kglcm2
'1"
I
I u[" J-s
;fo.Ll"*f:.rn
d-r{-)v
-"dV v / tr