stainless steel reactor

STAINLESS STEEL REACTOR

8/23/2020 WPS & PQR FOR ALMUNIUM REACTOR TANK 1

1. Welding Process : Gas Tungsten Arc Welding [GTAW]

2. Base Material : Al-6061 alloy

3. Joint Detail : Single Butt Weld / Manual

4. Welding Position : ASME 6G


WELDING PROCEDURE SPECIFICATION AND PERFORMANCE QUALIFICATION RECORD [WPS & PQR ]

Each manufacturer and contractor shall prepare written Welding Procedure Specifications

Welding Procedure Specification (WPS). A WPS is a written qualified weldingprocedure prepared to provide direction for making production welds to Coderequirements. The WPS or other documents may be used to provide direction to thewelder or welding operator to assure compliance with the Code requirements

The WPS shall reference the supporting Procedure Qualification Record(s) (PQR) described in QW-200.2. The manufacturer or contractor may include any other information n the WPS that may be helpful in making a Code weldment.

Changes to the WPS. Changes may be made in the nonessential variables of a WPSto suit production requirement without requalification provided such changesdocumented with respect to the essential, nonessential, and, when required,supplementary essential variables for each process. This may be by amendment tothe WPS or by use of a new WPS.


• Changes in essential or supplementary essential (when required)variables require requalification of the WPS (new or additional PQRs tosupport the change in essential or supplementary essential variables).

• Procedure Qualification Record (PQR). A PQR ia record of the weldingdata used to weld a test coupon The PQR is a record of variables recordedduring the welding of the test coupons. It also contains the test results ofthe tested specimens. Recorded variables normally fall within a smallrange of the actual variables that will be used in production welding.

• Contents of the PQR. The completed PQR shall document all essentialand, when required, supplementary essential variables for eachweldingprocess used during the welding of the test coupon. Non essential orother variables used during the welding of the test coupon may berecorded at the manufacturer’s or contractor’s option.


• The PQR shall be certified accurate by the manufactureror contractor.The manufacturer or contractor may not subcontract the certificationfunction. This certification isintended to be the manufacturer’s orcontractor’s verification that the information in the PQR is a truerecord of thevariables that were used during the welding of the testcoupon and that the resulting tensile, bend, or macro (as required) testresults are incompliance with Section IX.

• All changes to a PQR require recertification (including date) by themanufacturer or contractor.


WELDING PROCEDURE SPECIFICATION


WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)Gas Tungsten-Arc Welding (GTAW)


A decrease in the distance between the approximate weld interface and the final surface of the production corrosion-resistant or hard-facing weld metal overlay below the minimum thickness qualified as shown in figures QW-462.5(a) through QW-462.5(e). There is no limit on the maximum thickness for corrosion - resistantor hard-facing weld metal overlay that may be used in production

A change from a base metal, listed under one P-Number in tableQW/QB-422, to a metal listed under another P-Number or to anyother base metal; from a base metal of one subgroup to any othergrouping in P-No. 10 or 11.


CHEMICAL ANALYSIS AND HARDNESS SPECIMEN CORROSION-RESISTANT AND HARD-FACINGWELD METAL OVERLAY


GROUPING OF BASE METAL


•The deletion or addition of filler metal.

• A change from one of the following filler metal product forms to another:

(a) bare (solid) or metal cored

(b) flux cored

(c) flux coated solid or metal cored

(d) Powder

• A change from any position to the vertical position uphill progression.Vertical-uphill progression(e.g., 3G, 5G, or 6G position) qualifies for allpositions. In uphill progression, a change from stringer bead to weave bead.


GROUPING OF FILLER METAL


TEST POSITION


• A change from upward to downward, or from downward to upward, inthe progression specified for any pass of a vertical weld, except that thecover or wash pass may be up or down.

• Qualification in the horizontal, vertical, or overhead position shall alsoqualify for the flat position. Qualification in the horizontal fixedposition,

• 5G position, shall qualify for the flat, vertical, and overhead positions.Qualification in the horizontal, vertical, and overhead positions shallqualify for all positions. Qualification in the inclined fixed position,

6G, shall qualify for all positions.


PERFORMANCE QUALIFICATION


• A decrease of more than 100°F (55°C) in the preheat temperature qualified or an increase in the maximum interpass temperature recorded on the PQR. The minimum temperature for welding shall be specified in the WPS.

• A change in post weld heat treatment condition an increase of 25%or more in total time at post weld heat treating temperature.

• A separate procedure qualification required for each of the following:


(a) For weld corrosion-resistant overlay of A-No. 8 on all basematerials, a change in post weld heat treatment condition in QW-407.1, or when the total time at post weld heat treatment encounteredin fabrication exceeds 20 hr, an increase of 25% or more in total time atpost weld heat treating temperature.

(b) For weld corrosion-resistant overlay of A-No. 9 on all basematerials, a change in post weld heat treatment condition in QW-407.1, or an increase of 25% or more in total time at post weld heattreating temperature.

(c) For all other weld corrosion-resistant overlays on all base materials, a change in post weld heat treatment condition in QW-407.1.


• A separate procedure qualification isrequired for each of thefollowing:

(a) a change from a single shielding gas to any other single

shielding gas

(b) a change from a single shielding gas to a mixture

of shielding gasses, and vice versa

(c) a change in the specified percentage composition of

a shielding gas mixture

(d) the addition or omission of shielding gas


• A change from AC to DC, or vice versa; and in DC welding, a change from electrode negative (straight polarity) to electrode positive (reverse polarity), or vice versa

• A change from multiple-layer to single layer cladding/hard surfacing, or vice versa.

• A change in the number of electrodes acting on the same welding puddle.


PERFORMANCE QUALIFICATION RECORD


TEST SPECIMEN FOR PQT


The radiographic examination in QW-142 for welders and in QW-143 forwelding operators shall meet the requirements of Article 2, Section V,

except as follows :

(a) a written radiographic examination procedure is not required.Demonstration of density and image quality requirements onproduction or technique radiographs shall be consideredsatisfactory evidence of compliance with article 2 of section V

(b) final acceptance of radiographs shall be based on the ability to see theprescribed image and the specified hole of a hole-type image qualityindicator (IQI) or thedesignated wire of a wire-type IQI. The acceptancestandards of QW-191.1.2 shall be met.


MANUAL AND SEMIAUTOMATIC GASTUNGSTEN-ARC WELDING (GTAW)Essential Variables


• The deletion of the backing in single welded groove welds. Double-welded groove welds are considered welding with backing.

• in QW-452, except as otherwise permitted in QW-303.1, QW-303.2, QW-381.1(c), or QW-382(c).

• A change from one P-Number to any other P-Number or to a base metal not listed in table QW/QB- 422, except as permitted in QW-423, and in QW-420


GROUPING OF BASE METAL


• The deletion or addition of filler metal.

• A change from one F-Number in table QW-432 to any other F-Number or to any other filler metal, except as permitted in QW-433.

• The omission or addition of consumable inserts. Qualification in asingle-welded butt joint, with or without consumable inserts, qualifies forfillet welds and single-welded butt joints with backing or double-weldedbutt joints. Consumable inserts that conform to SFA-5.30,except that thechemical analysis of the insert conforms to an analysis for any bare wiregiven in any SFA specification or AWS Classification, shall be consideredas having the same F-Number as that bare wire as given in table QW-432.


GROUPING OF ELECTRODE


• A change from one of the following filler metal product forms to another:

(a) bare (solid) or metal cored

(b) flux cored

(c) flux coated solid or metal cored

(d) Powder

• A change in deposited weld metal thickness beyond the range qualified inQW-451 for procedure qualification or QW-452 for performancequalification, except as otherwise permitted in QW-303.1 and QW-303.2.When a welder is qualified using radiography, the thickness ranges oftable QW-452.1(b) apply.


• The addition of other welding positions thanhose already qualified. See QW-120, QW-130, QW-203,and QW-303

• A change from upward to downward, or from downward to upward, inthe progression specified for any pass of a vertical weld, except that thecover or wash pass may be up or down. The root pass may also be runeither up or down when the root pass is removed to sound weld metal inthe preparation for welding the second side.


• The omission of inert gas backing except that requalification is not required when welding a single welded butt joint with a backing strip or a double-welded butt joint or a fillet weld. This exception does not apply

to P-No. 51 through P-No. 53, P-No. 61 through P-No. 62,and P-No. 10I metals.

• A change from AC to DC, or vice versa; and in DC welding, a change from electrode negative (straight polarity) to electrode positive (reverse polarity), or vice versa.


stainless steel reactor

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