WELDING PROCEDURE SPECIFICATION (ASME SECTION IX)

Form No. ASME WPS, Rev. 11/09

WPS No. GM-FC-1.1

Scope:

Page 1 of 2

Semiauto GMAW & FCAW (Flux Core) Welding of P1 (Mild Carbon) Steels 3/16 to 8 Inch Thick With or Without Postweld Heat Treatment (Open Root, Metal Backing) Project: General Distribution Notch Toughness Qualified: No Issue Date: 2/9/2010 Abstracts: Address NACE RP 0472 requirements for crack inducing environments in Note 2. Revision No: 5 Supporting PQRs: ... GT-GM-FC-P1-1.5 Joints (QW-402): 9 (Refer to drawings for weld sizes and additional joint details)

Joint Design: Single & Double-V, J or U Groove, Fillet & Socket Welds, Slot & Plug Welds, Seal Welds Metal Backing: Optional (Note 1) Alignment: +/- 1/16" or per Construction Drawings Nonmetalic / Nonfusing Backing or Retainers: Not Permitted Root Opening: w/o Backing: 3/32" - 5/32" w/Backing: 1/8" - 1/4" Code Application: ASME I, VIII-Div. 1, B31.1 & B31.3 Note 1: Metal backing may be used when permitted by project specifications. Backing materials shall consist of the same P number as the base material. When using split-type backing rings in pipe, tack welding across the split is not permitted. Backing rings in pipe and tube shall be securely tacked on the upstream side of the joint to prevent dislodgement in service.

Base Metals (QW-403): P-No: 1 - Group No: All ... to ... P-No: 1 - Group No: All Base Metal Thickness Range, Groove: 3/16 - 8 in. Deposited Weld Metal Limit, Groove: GMAW: 0.343 in. Max. / FCAW: 8 in. Max. Fillets: Not Limited Pipe Diameter Range, Groove Not Limited Filler Metals (QW-404): SFA Specification: GMAW: SFA-5.18 / FCAW: SFA-5.20 AWS Classification: GMAW: ER70S-6 / FCAW: E71T-1M F No: F-No. 6 (Both) Analysis: A-No. 1 Consumable Insert: Not Permitted Welding Positions (QW-405): Groove: All Positions Vertical Progression: Root: Downhill / Balance: Uphill Preheat (QW-406): Minimum Preheat Temperature Thickness Range, in. Up to 0.75 > 0.75 to 1.25 > 1.25 B31.3 Process Piping 50 F 175 F 175 F B31.1 Power Piping 50 F 200 F 200 F ASME I Pipes / Tubes 50 F 200 F 200 F ASME I Shells / Heads 50 F 50 F 200 F ASME VIII Pipes / Tubes 50 F 200 F 200 F ASME VIII Shells / Heads 50 F 50 F 200 F Maximum Interpass Temperature 650 F 650 F 650 F Fillets: All Positions Product Form GMAW: Solid Wire / FCAW: Flux Core Supplemental Filler / Alloying: Not Permitted Fillets: Not Limited Fillets: Not Limited Max. Single Pass Thickness: 1/2 in. (Note 2)

WELDING PROCEDURE SPECIFICATION (ASME SECTION IX)

Form No. ASME WPS, Rev. 11/09

WPS No. GM-FC-1.1

Preheat Maintenance: Insulate joint over 2" thick & allow to cool slowly. Postweld Heat Treatment (QW-407): PWHT Temperature, F Thickness, Pipe and Tube Drums, Shells inches (all applications) and Heads Up to 0.75 > 0.75 to 1 > 1 to 1.5 > 1.5 to 2 >2 Note 2: Optional (Note 2) 1,100 -1,200 1,100 -1,200 1,100 -1,200 1,100 -1,200 Optional (Note 2) Optional (Note 2) Optional (Note 2) 1,100 -1,200 1,100 -1,200 Minimum Holding Time @ Temp B31.3 Process Piping 1 Hour 1 Hour Note 3 Note 3 Note 5 B31.1, ASME I and ASME VIII Note 3 Note 3 Note 3 Note 3 Note 5

Page 2 of 2

Maximum Rate of Heating / Cooling B31.1 and B31.3 Above 600 F 600 F / Hr 600 F / Hr 600 F / Hr 600 F / Hr Note 6 ASME I and VIII Above 800 F 500 F / Hr 500 F / Hr Note 4 Note 4 Note 4

Note 3: Note 4: Note 5: Note 6:

PWHT is not required at this thickness range. However, if PWHT is performed the PWHT temperature range shall be as specified for greater thicknesses. Refer to the appropriate General Welding Standard for additional exemptions and the conditions for applying those exemptions (e.g., increased preheat, bead thickness restrictions, etc.). Also refer to PW-39 of ASME Section I for CE (carbon equivalence) limitations on materials over 3/4 in. thick. NOTE: PWHT IS MANDATORY FOR ALL JOINTS REGARDLESS OF THICKNESS for B31.3 applications in crack inducing environment as defined by the customer (ref. NACE RP 0472). 1 hour per inch of thickness, 15 minutes minimum. 500 degrees F per hour divided by the material thickness, inches. 2 hours plus 15 minutes for each additional inch of thickness over 2 inches. 600 degrees F per hour divided by half the material thicknes, inches.

Welding Gas (QW-408): Welding Process GMAW FCAW Note 7: Torch or Nozzle SFA-5.32 Class or Mixture SG-AC-25 SG-AC-25 Flow Rate (CFH) 35-55 35-55 Preflow (Seconds) N/A N/A Postflow (Seconds) N/A N/A Cup (Linde) or Nozzle Dia., in. 5/8 to 3/4 5/8 to 3/4 Trailing Gas SFA-5.32 Class or Mixture N/A N/A Flow Rate (CFH) N/A N/A Backing Gas SFA-5.32 Class or Mixture SG-A N/A Flow Rate (CFH) 5-50 N/A

Gas backing is optional. However, when used, the flow rate shall be adequate to provide positive pressure to the inside of the root deposit without distorting the profile of the root pass.
DCEN = Electrode Negative DCEP = Electrode Positive ipm = Inches per Minute Wire or Electrode Parameters Diam (in.) Wire Feed Tungsten Rate Range Class 180-300 ipm 185-300 ipm 200-450 ipm 150-400 ipm 150-350 ipm N/A N/A N/A N/A N/A Volts 15-19 15-19 22-29 23-31 23-33 Amps 90-160 120-160 150-275 155-360 180-410 Current Start Current, % of Main and Time N/A N/A N/A N/A N/A N/A Decay Current, % of Main and Time N/A N/A N/A N/A N/A N/A As Req'd As Req'd As Req'd Travel Speed As Req'd As Req'd Other Welding Process

Electrical Characteristics (QW-409):

Weld Layer Process, Current or Transfer Mode and Polarity GMAW Short-Arc Short-Arc Globular Globular Globular

Open Root

DCEP 0.035 DCEP 0.035 DCEP 0.045 DCEP 0.052 DCEP 0.062

Downhill Note 9

2nd Pass Optional GMAW Balance and Groove Welds with Backing FCAW FCAW FCAW

Technique (QW-410): Single or Multiple Electrode: Single Electrode Spacing: N/A Multiple or Single Pass per Side: As Required Peening: Not Permitted String or Weave Bead: Either Oscillation: N/A Contact Tube to Work Distance: 1 to 1-1/2 nozzle diameters Initial Cleaning: File, grind, chip or machine surfaces to be welded plus one-half inch on either side of the anticipated toe of the weld. Remove oil, grease and other contaminants using approved solvents. Method of Backgouging: For double-welded joints, back-gouge to sound weld metal using mechanical or thermal methods before welding second side. Interpass Cleaning: Chip, file, grind and/or brush each layer as needed. Inspect and remove defects prior to depositing next pass. Final Cleaning: Chip and wire brush. Note 9: Optional second pass of GMAW Short-Circuit Arc, if used, shall be uphill. When using GMAW for the build-up of thin wasted areas on boiler or heat exchanger tubes, vertical progression may be downhill to prevent burn-through (subject to limits of welder's qualification).
Digitally signed by Scot T. Forbes Date: 2013.01.08 09:27:13 -06'00'

Approved By:

Date:

Tuesday, February 09, 2010

Welding Procedure Qualification Record (PQR) ASME Section IX PQR No.

GENERAL
PQR Date: 4/18/2003 Welding Process(es): Type (Manual, Automatic, Semiauto): Welding Procedure Specification Used: Gas Tungsten-Arc (GTAW) & Gas Metal-Arc (GMAW & FCAW) GTAW: Manual, GMAW: Semi-Auto, FCAW: Semi-Auto GT-FC-1.1 & GM-FC-1.1

GT-GM-FC-P1-1.5

JOINT DESIGN (QW-402)

Groove Design of Test Coupon Amended Feb. 22, 2010 with API-582 hardness test results (last page added) for crack inducing environments Coupon Thickness (t, in.): Backing Type & Material: Land (Ld, in.): Bevel Angles (Bl, Degrees): Root Opening, (Ro, in.): 1.5 N/A 0 37.5 (10) 1/8

Actual deposit thickness of each process or filler metal used, in. GTAW: 3/16" FCAW GMAW: 5/16 1

BASE METALS (QW-403)

Base Metal Specification: Type or Grade: P-No. 1 Thickness of Test Coupon: Maximum Pass Thickness: Other: SA-516 to SA-516 Grade 60 to Grade 70 to P-No. 1 1.5" Less than 1/2" Shielding:

GAS (QW-407)
Gas / Gas Mixture Flow Rate GTAW: Welding Grade Argon 28 GMAW & FCAW: 75% Ar, 25% Co2 40 Trailing: None N/A Backing: N/A None Nozzle Diam: GTAW cup size: No. 8 / GMAW Cup Diam: 5/8" Contact Tube to Work Distance: 1 to 1-1/2 Nozzle Diameters Other:

FILLER METALS (QW-404)

SFA Specification: GT & GM: SFA-5.18 / FCAW: SFA-5.20 AWS Classification: GT: ER70S-2 / GM: ER70S-6 / FC: E71T-1M Filler Metal F-No. F-6 (All) Weld Metal Analysis: A-No. 1 (Page 2) Size of Filler Metal: GT: 1/8" / GM: 0.035" / FC: 0.045" GMAW / GTAW Product Form: (Other) Supplemental Filler / Alloying: None Other: GT: Solid Rod / GM: Solid Wire / FC: Cored Wire GTAW Tradename: ESAB Spoolarc 65 GMAW Tradename: ESAB Spoolarc 86 FCAW Tradename: ESAB Dual Shield 7000

TECHNIQUE (QW-410)
Travel Speed: GT: 1.5 - 3.8 ipm / GM: 3.5 - 5 ipm / FC: 4.7 - 11.2 ipm String or Weave Bead: Oscillation: Both N/A GMAW / FCAW Transfer Mode: GM: Short-Circuit / FC: Globular Multi or Single Pass: Single / Multi Electrode: Multipass Single GMAW, FCAW, SAW Wire Feed Rate: Not Recorded Heat Input Rate: GTAW: 36,474 - 57,200 joules per inch GMAW: 30,780 - 49,714 joules per inch Other: FCAW heat input: 23,142 - 58,212 joules per inch

POSITION (QW-405)
Position of Groove: Vertical Welding Progression Other: 1G - Flat N/A

ELECTRICAL CHARACTERISTICS (QW-409)

Current & Polarity: GTAW: DCEN / GM & FC: DCEP Amps: GT: 110 - 165 / GM: 135 - 145 / FC: 180 - 190 GT: 13 - 14 / GM: 19 - 20 / FC: 24 Volts: 1/8" EWTh-2 Tungsten Electrode Type & Size:

PREHEAT (QW-406)
Preheat Temp. 70 Deg. F. Preheat Maintenance: Other: Interpass Temp: None 640 Deg. F.

POSTWELD HEAT TREATMENT (QW-407)

As-Welded & PWHT PWHT: 1,150 Deg. F Temperature: As-Welded: N/A / PWHT Coupon: 2 Hrs. Time: Above 800 Deg. = 400 Deg. F per hr. Heating & Cooling Rate: Other:

Scheck Mechanical Corporation, Scheck Mechanical Wisconsin Corporation, Scheck Technical Services, Inc., Scheck Industrial Corporation

Welding Procedure Qualification Record (PQR) ASME Section IX PQR No.

Tensile Tests (QW-150) Specimen No.
1(AW) 2 (AW) 3 (HT) 4 (HT)

GT-GM-FC-P1-1.5
Ultimate Unit Stress, psi
77,434 78,061 74,460 74,710

Width, in. Thickness or ("0" if turned) Diameter, in.

1.4880 1.4670 1.4830 1.4820 0.7640 0.7730 0.7540 0.7660

Area, Square in.

1.1368 1.1340 1.1182 1.1352

Yield Load, lbs.

N/A N/A N/A N/A

Yield Point, psi

N/A N/A N/A N/A

Fail Load, lbs.

88,030 88,520 83,260 84,710

Type of Failure & Failure Location

Ductile, Base Metal Ductile, Base Metal Ductile, Base Metal Ductile, Base Metal

Guided Bend Tests (QW-160) Type

Transverse Side Bend Transverse Side Bend Transverse Side Bend Transverse Side Bend

Figure No.
QW-462.2 QW-462.2 QW-462.2 QW-462.2

Defects
1 & 2 As Welded - 1/64" poor in both 3 & 4 As Welded - No Defects 1 & 2 Heat treated - No Defects 3 & 4 Heat Treated - No Defects

Results
Acceptable Acceptable Acceptable Acceptable

Toughness Tests (QW-170) Specimen No. Notch Location Notch Type Test Temp. Impact Values Lateral Expansion % Shear Mils Drop Weight Break No Break

Result - Satisfactory: Macro - Results

Yes

N/A

No

N/A

Fillet Weld Tests (QW-180) Penetration into Parent Metal:

N/A

Yes

N/A

No

N/A

Other Tests Hardness Survey (BHN): Deposit Analysis: Other: Welder's Name Test Conducted By
N/A GTAW: Per SFA Specification ... GMAW: Per Mfg's C of C with 75% Argon, 25% Co2 welding gas (C 0.07, Mn 1.19, Si 0.62) .... FCAW: Per Mfg's C of C with 75% Argon, 25% Co2 welding gas (C 0.06, Mn 1.47, Si 0.75) Supplemental hardness tests per API-582 for crack inducing environment added 2-9-2010 (next page) Dave Marquardt

S.S. No.

398-74-5562

Symbol:
TA-581 / P00-0722

DM

Tech Aid / Anderson Laboratories, Inc.

Laboratory Test No.

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.
Digitally signed by Scot T. Forbes Date: 2013.01.08 09:26:58 -06'00'

Scheck Mechanical Corporation, By:

Date:

February 22, 2010

Scheck Mechanical Corporation, Scheck Mechanical Wisconsin Corporation, Scheck Technical Services, Inc., Scheck Industrial Corporation

Welding Procedure Qualification Record (PQR) Supplement Test Record PQR No.
SUPPLEMENTAL TEST COUPON
Test Coupon Details

GT-GM-FC-P1-1.5

Material Specification: Material Grade or Type: Coupon Thickness (t, in.): Backing Type & Material: Land (Ld, in.): Bevel Angles (Bl, Degrees): Root Opening, (Ro, in.):

SA-516 Grade 60 / 70 1.5 None 0 37-1/2 1/8"

Actual deposit thickness of each process or filler metal used, in. GMAW: 5/16" (Root) FCAW GTAW: 3/16" 1

Coupon welded 26-January-2010 using original PQR welding variables, including postweld heat treatment, for API-582 HV10 Tests Vickers Hardness Survey ... HV10 (API-582) for Crack Inducing Environments Face Location HV 10 Value Equivalent Hardness (HB) Root Location HV 10 Value Equivalent Hardness (HB) 1 155 155 11 155 155 2 230 230 12 167 167 3 237 237 13 186 186 4 237 237 14 206 206 5 232 232 15 193 193 6 237 237 16 193 193 7 247 236 17 193 193 8 237 237 18 185 185 9 219 219 19 188 188 10 155 155 20 156 156 Tested in accordance with ASTM E92 - 82(2003)e2. GTAW not tested ... refer to PQR No. GT-SM-P1(HtCv)-1.5 Brinell (HB) hardness values converted from Vickers hardness per ASTM E140-07, Table 2 Macrophotograph * Surface Hardness Survey - Weld Brinell Hardness, HB Location 187 Weld Face 1 183 Weld Face 2 Weld Face 3 197 Average 189 Root Face 1 179 Root Face 2 179 Root Face 3 179 Average 179 * Surface hardness surveys taken 2/16/2010 and amended to PQR on 2/22/2010 Welder's Name Test Conducted By S.S. No. Symbol:

Brandon Cobbs Stork Technimet, Inc.

Not Recorded

K2

Laboratory Test No.

TEC005353P-6 / *TEC005566P

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code and paragraph 12.6.1 of API-582, Second Edition, December 2009. Scheck Mechanical Corporation, By:
Digitally signed by Scot T. Forbes Date: 2013.01.08 09:26:46 -06'00'

Date:

February 22, 2010

Scheck Mechanical Corporation, Scheck Mechanical Wisconsin Corporation, Scheck Technical Services, Inc., Scheck Industrial Corporation