WELDING PROCEDURE SPECIFICATION ( WPS )

Testing as per AWS D1.1-2010

Company Name : Simplex Engg. & Foundary. Works (P) Ltd.

Welding Process

: SMAW

Supporting PQR (s) No: SIMP-II /PQR/SMAW/041

Application: Welding of 16mo3 Plate

JOINT DESIGN USED
Type

Position of Groove : NA

FILLET WELD JOINT

Double Weld

Single ( )

(x )

Backing : Yes ( X )

Weld Progression

No( )

ELECT

Backing Material : NA
Root opening : NA

Root Face Dim. : NA

Groove angle : NA
Back Gouging : Yes (X )
No ()
Method
: Back grinding,Chipping

Radius (J-U): : NA

Current : AC ( X)

Power Source : CC (X)

Others_________:_______
(GTAW)
Type : NA

BASE METALS
Material Spec

16mo3 + AISI-316 L

Single or Weave Bead

Type or Grade

16mo3 + AISI-316 L

Multipass or single pas

Thickness

AS PER SKETCH

Number of Electrodes:

Diameter
(Pipe ) :

Electrode Spacing
FILLER METALS

AWS Specification

:Essab Terroweld DS-4

AWS Classification

:Essab Terroweld DS-4

SHIELDING

Contact Tube to Work D

Peening

Flux : NA

Interpass Cleaning: Chi

Composition : NA

Electrode Flux (Class) : NA

Gas Cup Size :NA

PRE HEAT
NA

POST

Flow Rate : NA
Temperature: NA
Time: NA

Pass or Weld
Process
Layer

Filler Metals

Current

Class

Dia(mm)

Type &
Polarity

Amps

Root

SMAW

TERROWELD DS-4

3.15

DCEP

70-100

1st

SMAW

TERROWELD DS-4

3.15

DCEP

70-100

Qualified by

2010
WPS No: SIMP-II /WPS/SMAW/041
Rev:
Date: 28/10/2015
By: QA. Dept.

Authorised by: QA.Department

Type: Manual ( )

Date:
Semi Automatic (X )

Machine (X )

Automatic (X )

POSITION

n of Groove : NA

Fillet : 3F

rogression

Up ( )

Down (X )

ELECTRICAL CHARACTERISTICS

: AC ( X)

DCEP( )

DCEN ( X)

Pulsed ( X)

Source : CC (X) CV (X)

_________:___________Nil____________ Tungsten Electrode
Size : NA
NA
TECHNIQUE

or Weave Bead

ss or single pass (per side)

Stringer /Weaving
: Multi-Pass

r of Electrodes:

Single

de Spacing

Longitudinal :

NA

Lateral

NA

Angle

NA

t Tube to Work Distance: NA

NIL

ss Cleaning: Chipping , Wire brushing , Grinding

ature: NA

NA

POSTWELD HEAT TREATMENT

Volts

Travel Speed
mm/min

15-22

NA

15-22

NA

Joint Details

3mm
316L

16Mo3

AISI

15mm

WELDING PROCEDURE SPECIFICATION ( WPS )

Qualified by
Testing as per AWS D1.1-2010

Company Name : Simplex Engg. & Foundary. Works (P) Ltd.

Welding Process

WPS No: SIMP-II /WPS/SMAW/039

Rev: 01 Date: 06/06/2015
By: QA. Dept.

: GTAW+ SMAW

Authorised by:

Supporting PQR (s) No: SIMP-II /PQR/SMAW/039

Date:

Type: Manual ( )

Semi Automatic (X )

Machine (X )
Application: Welding of A 106 Gr B
JOINT DESIGN USED
Type
BUTT WELD JOINT
Single ( )
(x )
Backing : Yes ( X )
No( )

Automatic (X )

POSITION
Position of Groove : 2 G

Double Weld

Fillet : N.A

Weld Progression

Up ( X )

Down (X )

ELECTRICAL CHARACTERISTICS

Backing Material : NA
Root opening : 1-2 mm

Root Face Dim. : 1-1.5mm

Groove angle : 60 +10/-5

Radius (J-U): : NA
Back Gouging : Yes (X )
No ()
Method
: Back grinding,Chipping
BASE METALS
Material
A 106 GrB+ A106Gr B
Spec
:
Type or Grade
: A 106 GrB+ A106Gr B
Thickness
AS PER SKETCH
:
Diameter (Pipe O.D.
) : 60.3XWALL THK8.7mm

Current
: AC (:X)
)
DCEN ( )
Pulsed ( X)
Power Source
CC DCEP(
(X) CVX(X)
Others_________:___________Nil____________ Tungsten Electrode (GTAW)
Size : NA
Type : NA
TECHNIQUE
Single or Weave Bead

Multipass or single pass (per side)

Stringer /Weaving
: Multi-Pass

Number of Electrodes:

Single

Electrode Spacing

Longitudinal :

NA

Lateral

NA

Angle

NA

FILLER METALS
AWS Specification

: A5.18

A5.1

AWS Classification : ER70S-2

E 7018

Contact Tube to Work Distance: NA

SHIELDING
Flux : NA

Peening

Gas: ARGON

Interpass Cleaning: Chipping , Wire brushing , Grinding

Composition : 99.9% Pure

Electrode Flux (Class) : NA

Gas Cup Size :NA

Filler Metals
Process

Root
*Sub
sequent
layer

Temperature: NA
Time: NA

NA

Pass or
Weld
Layer

POSTWELD HEAT TREATMENT

Flow Rate : 10-12 LPM

PRE HEAT

NIL

Current
Volts

Travel Speed
mm/min

Class

Dia(mm)

Type &
Polarity

TIG

ER 70 S-2

2.4

DCEN

60-90

15-22

NA

SMAW

E 7018

3.15

DCEP

90-120

22-24

NA

Amps

Joint Details
60

60.3X8.7
THK

1-2 mm

PROCEDURE QUALIFICATION RECORD (PQR)

Qualified by Testing as
per AWS D1.1-2010

Company Name : Simplex Engg. & Foundary. Works (P) Ltd.

WPS No: SIMP-II /WPS/SMAW/041

Rev: 01

Welding Process

: SMAW

Date: 28/10/2015

By: QA. Dept.

Authorised by:

Supporting PQR (s) No: SIMP-II /PQR/SMAW/041

Date:

Type: Manual ( )

Semi Automatic (X )

Machine
Application: Welding of 16Mo3
JOINT DESIGN USED
Type :

POSITION
Position of Groove : NA

FILLET JOINT

Single ( X )

Double "V" (x )

Backing : Yes ( X )

Automatic (X )

Fillet : 3G

Weld Progression

No( )

Up ( )

Down (X )

ELECTRICAL CHARACTERISTICS

Backing Material : NA
Root opening : NA

Root Face Dim. : NA

Groove angle : NA

Radius (J-U): : NA

Back Gouging : Yes (X )

Method
:

Current : AC ( X)

No (X)

DCEP( )

DCEN (X )

Pulsed ( X)

Power Source : CC (X) CV (X)

Others_________:___________Nil____________ Tungsten Electrode
Size : NA
Type : NA

BASE METALS

TECHNIQUE

Material Spec

16Mo3 TO AISI 316L

Single or Weave Bead

Type or Grade

16Mo3 TO AISI 316L

Multipass or single pass (per side)

Thickness

AS PER SKETCH

Number of Electrodes:

Single

Electrode Spacing

Longitudinal :

NA

Lateral

NA

Angle

NA

Diameter (Pipe )

NA

FILLER METALS
AWS Specification

: TERROWELD DS-4

AWS Classification : TERROWELD DS-4

Peening
Gas: NA

NIL

Interpass Cleaning: Chipping , Wire brushing , Grinding

Composition :
Flow Rate : NA

Electrode Flux (Class) : NA

: Multi-Pass

Contact Tube to Work Distance: NA

SHIELDING
Flux : NA

Stringer /Weaving

POSTWELD HEAT TREATMENT

Temperature: NA

Gas Cup Size :NA

PRE HEAT

Time: NA

NA

Filler Metals

Pass or
Weld
Layer

Process

1st
2nd

Current
Volts

Travel
Speed
mm/min

Class

Dia(mm)

Type &
Polarity

SMAW

TERROWELD DS-4

3.15MM

DCEP

100

20

NA

SMAW

TERROWELD DS-4

3.15MM

DCEP

100

20

NA

Amps

Joint Details

3mm

16Mo3

AISI 316L

15mm

PROCEDURE QUALIFICATION RECORDS ( PQR)

Qualified by Testing as pere AWS D1.1-2010

Identification:- SIMP-II / PQR/SMAW/041 Date - 28.10.2015

Specimen No.

Width
(mm)

Thickness
(mm)

Area (mm2)

Ultimate Tensile Load

(KN)

NA

NA

NA

NA

NA

GUIDED BEND TEST

Specimen No.

Type Of Bend

Result

NA

NA

NA

Visual Inspection

Satisfactory

Appearance

Satisfactory

Radiographic / Ultasonic Examination

Undercut

Nil

RT Report No.:

Piping Porosity

Nil

UT Report No.:

Convexity

Satisfactory

FILLET WELD TEST RESULTS

Test Date
Witnessed By

:
:

28.10.2015

Minimum size ; 3.15mm

Other Tests

: NIL

Macro etch Test :

After transverse cutting, the face of weld
subjected to etching and found no defect.

All - weld - Metal - Tension - Test

: NIL

Tensile Strength K.N.

Yield Point/ Stength K.N.

Elongation in 2inch %
Welder's Name
Test Conducted By

:
:Simplex Engg

Mr. SATISH
Bhilai

Laboratory Test :
As per AWS D1.1

We , the undersigned , certify that the statements in this record are correct and the test welds were

prepared, welded and tested in conformance with the requirements of section 4 Part B of ANSI/AWS D1.1
Welding Code - Steel.

ON RECORDS ( PQR)

ere AWS D1.1-2010

Ultimate Unit Stress

(N/mm2)

Chatacter of failure
and location

NA

NA

Result

Remarks

NA

NA

nic Examination
NIL

NIL

ULTS

Result:

Result:

NIL

Result:

Nil

: NIL
Maximum size : 3.15mm

utting, the face of weld

ng and found no defect.

nsion - Test

: NIL

: Nil
: Nil
: Nil

Stamp No. :
NIL

Date :

nd the test welds were

n 4 Part B of ANSI/AWS D1.1(2010) ,

Signature :
For, Simplex Engg. & foundry Works(p) Ltd

By
Title

SE-II/041

Date

PROCEDURE QUALIFICATION RECORDS ( PQR)

Qualified by Testing as pere AWS D1.1-2010

Identification:- SIMP-II / PQR/GTAW+SMAW/039 Date - 01.06.2015

Specimen No.

Width
(mm)

Thickness
(mm)

Area (mm2)

Ultimate Tensile Load

(KN)

SE-II/039/T1
SE-II/039/T2

18
17.5

8.5
8.6

153
150.5

74.2
69.2

GUIDED BEND TEST

Specimen No.
SE-II/039/SB1
SE-II/039/SB2

Visual Inspection
Appearance
Undercut
Piping Porosity
Convexity
Test Date
Witnessed By

Type Of Bend

Result
No Crack Observed - OK
No Crack Observed - OK

Side Band Test-I

Side Band Test-II

:
:
:
:
:
:
:

Satisfactory
Satisfactory
Nil
Nil
Satisfactory
05.06.2015

Radiographic / Ultasonic Examination

RT Report No.:
UT Report No.:
FILLET WELD TEST RESULTS

: NIL

Minimum size Multipass

Macro etch
1. Nil
2. Nil

Other Tests

All - weld - Metal - Tension - Test

Tensile Strength K.N.

: NIL

Yield Point/ Stength K.N.

Elongation in 2inch %
Welder's Name
Test Conducted By

:
Mr. DULAL DAY
:Simplex Casting Ltd.
Bhilai

Laboratory Test :
As per AWS D1.1

We , the undersigned , certify that the statements in this record are correct and the test welds were
prepared, welded and tested in conformance with the requirements of section 4 Part B of ANSI/AWS D1
Welding Code - Steel.

ATION RECORDS ( PQR)

as pere AWS D1.1-2010

Ultimate Unit Stress Chatacter of failure and

location
(N/mm2)
485
460

BROKEN OUT OF WELD

BROKEN OUT OF WELD

Result
Crack Observed - OK
Crack Observed - OK

Remarks
Satisfactory
Satisfactory

Ultasonic Examination
SE/SIM-II RT//NOV 12-04 DTD 20.11.2014

NIL

ST RESULTS

Result:

Result:Accepteable
Result: Nil

: NIL
Maximum size single pass

Macro etch
3. Nil

al - Tension - Test

1. Nil
2. Nil

3. Nil

Stamp No. :

SE-II/039

: NIL

: Nil
: Nil
: Nil

SE-II/5832/SCLAB/205

Date : 06.06.2015

.1

rrect and the test welds were

section 4 Part B of ANSI/AWS D1.1(2010) ,

Signature :
For, Simplex Engg. & foundry Works(p) Ltd

By
Title
Date

SIMPLEX ENGINEERING & FOUNDRY WORKS (P) LTD.

11,INDUSTRIAL ESTATE,BHILAI-490026 (C.G) INDIA

AWS D1.1/D1.1M:2010

ANNEX

WELDER QUALIFICATION TEST RECORD

Type of Welder _____________________WELDER
Name ___________MR. DULAL DAY
Welding Procedure Specification No. _____SIMP-II/WPS/SMAW/039

Variables
Process/Type [Table 4.11, Item (1)]
Electrode (single or multiple) [Table 4.11, Item (8)]
Current/Polarity
Position [Table 4.11, Item (4)]
Weld Progression [Table 4.11, Item (6)]
Backing (YES or NO) [Table 4.11, Item (7)]
Material/Spec. to
Base Metal
Thickness: (Plate)
Groove
Fillet
Thickness: (Pipe/tube)
Groove
Fillet
Diameter: (Pipe)
Groove
Fillet
Filler Metal [Table 4.11, Item (3)]
Spec. No.
Class
F-No. [Table 4.11, Item (2)]
Gas/Flux Type [Table 4.11, Item (3)]
Other

Type

SIDE BEND
NA
NA

Result

REV-01
Record Actual Values
Used in Qualification

GTAW+ SMAW
SINGLE
GTAW-DCEN
2G

Identification No.____SE-II/085
Date 12.06.2015

2G
SMAW-DCEP

Results
NSD

1G,2G,1F,2F

NO
A106 GrB+A 106 Gr B
A106 GrB

8.7 mm
GROOVE
NA
60.3
SINGLE

Unlimited

TIG-FILLER WIRE 2.4mm WELDING ELECTRODE 3.15mm

A5.1 ,E 7018
E 70S-2
E 7018

VISUAL INSPECTION (4.8.1)

Acceptable YES or NO _YES_
Guided Bend Test Results (4.30.5)
OK
Type

SIDE BEND
NA
NA
Fillet Test Results (4.30.2.3 and 4.30.4.1)
NA

Appearance _____
NA
Fracture Test Root Penetration __________
NA
(Describe the location, nature, and size of any crack or tearing of the specimen.)
Inspected by __________________________________ Test Number_____________________________NA
Organization __________________________________ Date _________________________________________

Film Identification
Number
SE-II/070

Qualification Range

RADIOGRAPHIC TEST RESULTS (4.30.3.2)

Film Identification
Remarks
Number
Results
OK SE-II/070
NSD

Interpreted by _____________________ NA
Organization ___SIMPLEX ENGINEERING & FOUNDRY WORKS (P) LTD

Result

OK

NA

Remarks
OK

Test nmber-SE/SIM-II RT/JUNE-15-04

Date-05.06.2015

We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in conformance with
the requirements of Section 4 of AWS D1.1/D1.1M, (__2010_____) Structural Welding CodeSteel.
(year)

Manufacturer or Contractor _______________________ Authorized By__________________________________

Form E-4
Date _________________________________________

AWS D1.1/D1.1M:2010

WELDER, WELDING OPERATOR, OR TACK WELDER QUALIFICATION TEST REC

Type of Welder _________________
Name _____________MR. DULAL DAY
Welding Procedure Specification SIMP-II/WPS/SMAW/039

Variables
Process/Type [Table 4.11, Item (1)]
Electrode (single or multiple) [Table 4.11, Item (8)]
Current/Polarity
Position [Table 4.11, Item (4)]
Weld Progression [Table 4.11, Item (6)]
Backing (YES or NO) [Table 4.11, Item (7)]
Material/Spec. to
Base Metal
Thickness: (Plate)
Groove
Fillet
Thickness: (Pipe/tube)
Groove
Fillet
Diameter: (Pipe)
Groove
Fillet
Filler Metal [Table 4.11, Item (3)]
Spec. No.
Class
F-No. [Table 4.11, Item (2)]
Gas/Flux Type [Table 4.11, Item (3)]
Other

Type

SIDE BEND
NA
NA

Result

REV-01
Record Actual Values
Used in Qualificat
GTAW+ SMAW
SINGLE
GTAW-DCEN
2G

SMAW-DCEP

NO
A106 GrB+A 106 Gr B
A106 GrB

8.7 mm
GROOVE
NA
60.3

TIG-FILLER WIRE 2.4mm WELDING ELECTRODE

A5.1 ,E 7018
E 70S-2
E 7018

VISUAL INSPECTION (4.8.1)

Acceptable YES or NO _YES_
Guided Bend Test Results (4.30.5)
OK
TypSIDE BEND
NA
NA
Fillet Test Results (4.30.2.3 and 4.30.4.1)
NA

Appearance _______
NA
Fracture Test Root Penetration _
NA
(Describe the location, nature, and size of any crack or tearing of the specimen.)
Inspected by __________________________________ Test Number_________________________NA
Organization __________________________________ Date _________________________________________

Film Identification
Number

Results
NSD

RADIOGRAPHIC TEST RESULTS (4.30.3.2)

Film Identification
Remarks
Number
OK

Interpreted by _________________
Organization _____SIMPLEX ENGINEERING & FOUNDRY WORKS (P) LTD

Results
NSD
SE-II/QC/RT/09

We, the undersigned, certify that the statements in this record are correct and that the test welds were prepared, w
conformance with the requirements of Section 4 of AWS D1.1/D1.1M, (__2010_____) Structural Welding CodeSteel
(year)

Manufacturer or Contractor _______________________ Authorized By__________________________________

Form E-4
Date ________________________________________

ANNEX E

EST RECORD

Date- Date 12.06.2015

Values
Qualification Range
2G
1G,2G,1F,2F

Unlimited

LECTRODE 3.15mm

Result

NA

OK

Remarks
OK

/RT/09

repared, welded, and tested in

odeSteel.

____
__________