WELDING PROCEDURE SPECIFICATION NO. 1-12-1

NATIONAL CERTIFIED PIPE WELDING BUREAU
WELDING PROCEDURE SPECIFICATION
NO. 1-12-1
FOR
SHIELDED METAL ARC WELDING (SMAW)
OF
CARBON STEEL PIPE, VALVES, FITTINGS AND FLANGES
USING E6010 ELECTRODE FOLLOWED BY E7018 ELECTRODE
This document is the property of
(NCPWB Member Company Name)
This Welding Procedure Specification (WPS) and Procedure Qualification Record(s) (PQR)
are issued by the NCPWB for adoption by its members. Reproduction or
use of this WPS and PQR(s) by anyone other than members of the NCPWB is
prohibited
© NCPWB
WELDING PROCEDURE SPECIFICATION (WPS)
Company Name:
WPS Number 1-12-1
Revision 5
Revision Date: 10/1/13
Supporting PQRs: 87103, 87110, 060626, 100815
Welding Process: SMAW
Date issued: 6-7-13
Type: Manual
Joints (QW -402)
Joint Design: Single-V or U, Double-V or U, Fillets, Repairs, Build-up. Details: See Typical Joint Designs
Backing: Optional for EXX10, required for E7018 Backing or Retainer type: Carbon Steel when used
Base Metals (QW-403)
Filler Metals and Electrodes (QW-404)
Root
P- Number 1 Group No. 1 and 2
P- Number 1 Group No. 1 and 2
Balance
Welding Process:
SMAW
Specification Number:
SFA 5.1 or 5.5
AWS Classification: E6010 or E7010-A1*
Base Metal Thickness Range*
F-number:
3
Groove Welds: 1/16” to 1-1/4”
A-Number:
1
or
2
Fillet welds: All
Maximum Weld Metal Thickness:
Grooves:
0.25”**
Minimum Outside Diameter
Fillets:
All
Groove Welds: All diameters.
Maximum Bead thickness:
3/16”
Fillet Welds: All diameters
Supplemental Filler Metal:
N/A
Consumable
Insert:
N/A
*This WPS may not be used on thicknesses where
Pulsed
Power
Supply:
N/A
the code or contracts requires PWHT
Penetration-enhancing flux:
N/A
Postweld Heat Treatment (QW-407)
1.0”
All
3/16”
N/A
N/A
N/A
N/A
*Use of E7010-P1 is also permitted. When welding Group 2 materials to themselves, use
E7010-XX. E7018-1, E7018M, E7018-R and E7018-H4 through H16 are also permitted.
** While the PQRs support a qualified weld metal thickness of 1.25”, only 0.25 in. may be
deposited with F-3 type electrodes.
Temperature: None
Max. Holding Time: N/A
Preheat (QW-406)
Positions (QW-405)
Minimum metal temp: 50 F
Interpass Temp. (Max): 350 F
Preheat Maintenance: Not required
SMAW
SFA 5.1
E7018
4
1
Positions permitted: All
Progression when in Vertical: Uphill
Gas (QW-408)
Shielding: N/A
Backing: N/A
Trailing Shield: N/A
Electrical Characteristics and Related Matters (QW-409)
Weld
Layer
Process
Electrode or Filler
Class
Diameter
SMAW
EXX10
3/32”
1/8
DCEP (+)
N/A
Fill
SMAW
and fillet
E7018
3/32”
1/8
5/32
DCEP (+)
N/A
Root
and fill
Current
Type/Polarity Volts Current or WFS
Travel Speed*
(ipm)
Other
40 to 80
75 to 125
3 to 5
4 to 6
70 to 100
105 to 155
130 to 200
3 to 6
3 to 7
4 to 9
No more than the root
pass may be deposited
using EXX10 type
electrodes
*recommended only
Technique (QW-410)
Tungsten Size and Type: Not applicable
Initial Cleaning: Remove grease or oil with solvent.
Shielding Gas Cup Size: Not applicable
Remove cutting oxide by grinding.
Single or Multiple Pass per Side: Either
Interpass Cleaning: Remove slag with slag hammer, grinder or
Single or Multiple electrodes: Single
wire brush.
Contact-tube-to-work distance (stickout): Not applicable
Backgouging: Grinding or carbon arc followed by grinding.
Repair Method: Grinding. Backwelding is permitted.
Peening: Not permitted
Stringer or Weave Bead: Either
Other:
The undersigned Contractor, a member of the National Certified Pipe Welding Bureau, hereby adopts this jointly developed procedure
as its Welding Procedure Specification and certifies that this procedure has been qualified as shown on the above referenced Procedure
Qualification Records.
Company Name:
By:
Date:
Title:
NCPWB Form QW-482
For use by NCPWB members only (©NCPWB)
WPS 1-12-1
Typical Joint Designs
Other joint designs shown on Engineering drawings supersede these joint details
Butt welds
30 to 45
3/32 to
1/8”
See note 1
30 to 45
3/32 to 1/8”
See Note 1
3/16 Nom.
3/32 to 1/8”
Note 1: 1/8 inch maximum except for B31.1 and B31.5 work, 1/16 inch maximum
Fillet, Nozzle and Branch Connection Welds
Throat
dimension
Size (leg)
Dimension
1/16”
max
1/8”
min
45 min
Socket and Slip-on Flange Welds
1/16” min
Y
1/16” min
X
Smaller of
T or 1/4”
Y
X
Approximately
1/16” before
welding
Z
T = The nominal thickness of the pipe
X = the lesser of 1.4T or the hub thickness unless another size is shown on the engineering drawings
Y = the lesser of 1.1T or the fitting thickness unless another size is shown on the engineering drawings
Z = for B31.9 work, minimum of the greater of the pipe nominal wall thickness or 1⁄4 in. (6 mm) and face
fillet is not required unless specified by the design.
September 20, 2012
For use by NCPWB Members Only (© NCPWB)
Procedure Qualification Record
Identification of WPS followed during welding of test coupon: SP-137KRev 1 dated 2-3-84
Welding Process(es) used: SMAW followed by SMAW, Manual
Date coupon was welded: 3-8-84
Base Metal Specification:
SA-106 Grade B
to Base Metal Specification: SA-106 Grade B
P-Number: 1
Group No: 1 to P-Number: 1 Group No: 1 Plate/Pipe Diameter: NPS 5
Base Metal Thickness(in.): 3/8” Joint Type: Single V-groove welded on backing
F-Number: 4
Filler metal specification:
SFA 5.1
AWS Classification: E7018
A-Number: 1
Weld Deposit Thickness(es)(in.): 0.375
Maximum Pass Thickness: 1/8”
Filler metal size:
1/8” and 3/32
Supplementary filler metal: N/A
Preheat temperature (ºF): 78
Interpass temp. (ºF) 500 Welding position/progression:1G
Current Type and polarity:
DCEP
Travel speed (ipm):
see below
Shielding gas composition, CFH: N/A
Backing gas composition, CFH: N/A
Tungsten size/type: N/A
GMAW transfer mode: N/A
Postweld Heat treatment (ºF): None
Postweld heat treatment time (hr.):
N/A
Stringer/Weave bead: Weave
Oscillation: N/A
Single/Multi-pass:
Multiple
Single/Multi-electrode: Single
Other:
Weld
Layer
Root
Fill
Fill
Process
SMAW
SMAW
SMAW
Electrode or
filler metal
E7018
E7018
E7018
Size (in)
3/32
3/32
1/8
Reduced Section Tensile Tests
Specimen
1
2
Width/dia (in.)
0.755
0.750
Bend Tests
Type
Side
Side
Specimen
Current
Volts
Area (in^2)
0.200
0.199
Transverse Face and Root
Ft-lbs
Load (lbs.)
14,400
14,100
X
Type
Side
Side
Full Section
Tensile Str. (psi)
72,000
71,000
Side
Location of failure
Base Metal
Base Metal
Longitudinal Face and Root
Result
Acceptable
Acceptable
Type
Result
Test Temperature
Lateral Expansion (mils)
Weld deposit analysis:
Other tests:
Welder’s name:
Stu Schwlim
Stamp: SS
Tests conducted by: E. Gallagher, Pittsburgh Testing Lab
Other
Turned
Charpy Specimen Size
Notch location
Travel Speed
(ipm)
6
6
6
Amps
100
100
100
X Rectangular
Thickness (in.)
0.265
0.266
Result
Acceptable
Acceptable
Toughness Tests
Type/Polarity
DCEP
DCEP
DCEP
Percent Shear
Drop Weight Break
No Break
Welding Witnessed by: Jim Sekely, Schneider, Inc
Laboratory test number: 846987
We hereby 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.
National Certified
Company:
By:
Date:
Chairman, Technical Committee
PQR Number 87103
NCPWB Form QW-483
For use by NCPWB members only (©NCPWB)
PROCEDURE QUALIFICATION RECORD (PQR)
WPS followed during welding of test coupon:
Welding Process(s) used:
SMAW
Base Metal Specification:
P Nunber:
1
Group No:
1
None
to Base Metal Specification:
to P Number:
1
Group No:
Joint Type:
Filler Metal Specification:
SFA5.1
below
1
87110
10-25-82
ASME SA106 Grade B
Plate/Pipe Diameter:
NPS 12 Std
Single V-groove without backing
Classification:
Deposited Weld Metal Thickness (in.): 0.375
Filler Metal Size (in.):
PQR Number:
Date Test Coupon was welded:
ASME SA106 Grade B
Base Metal Thickness(in.): 0.375
A-No.:
WPS 1.10, Rev 0 dated 8-1-74
E6010
F-No.:
Maximum Pass Thickness (in.):
Supplementary Filler Metal:
3
< 1/8
N/A
Preheat Temperature (◦F): 50 Interpass Temperature (◦F): Not Rec. Welding Position/Progression: 6G uphill
Current Type:
DC
Polarity:
Reverse
Shielding Gas Composition (CFH):
Tungsten Size/Type:
Travel Speed (lpm):
N/A
N/A
Stringer/Weaver Bead:
N/A
GMAW Transfer Mode:
Stringer and Weave
Single/Multi-Pass:
Below
Backing Gas (CFH):
Multiple
Oscillation:
N/A
Single/Multi-Electrode:
Postweld Heat Treatment (◦F):
None
N/A
Single
Heat Treatment Time(hr.):
N/A
Other:
Layer
Process
Filler Classification
Diameter
Amperage
Travel Speed
1
2
3,4
SMAW
SMAW
SMAW
E6010
E6010
E6010
1/8
5/32
3/16
100
140
160
Not Recorded
Not Recorded
Not Recorded
Reduced Section Tensile Tests
Rectangular Specimens
Turned Specimens
Specimen
Width/Dia.
(in)
Thickness
(in)
Area (sq
in)
Ult.imate Load
(lbs)
T-1
T-2
0.068
0.726
0.341
0.334
0.232
0.242
15,950
16,650
Bend Tests:
Trans. Root and Face (QW462.3a)
Trans. Side (QW-462.2)
Heat Input
Ultimate
Stress
(psi)
68,750
68,800
Failure
Location
Base Metal
Base Metal
Long.Root and Face (QW-462.3b)
Results
Type
Results
Root
Acceptable
Face
Acceptable
Root
Acceptable
Face
Acceptable
Charpy Specimen Size:
Notch
Location
None
Test Temperature
Charpy V-Notch Test
Foot-Lbs.
Ft-lb Av.
Percent Shear
N/A
Drop-Weight Test
Lateral Exp. (mils)
Fillet Weld Test Macro Examination
Other
Full-Section Specimen
Type
Toughness Test
Specimen
Number
Volts
Break
No Break
Fillet Weld Test Leg Sizes:
Weld Deposit Analysis:
Other Tests:
Welder’s Name:
Edward Deen
Test Conducted by:
Stamp No.
56
Welding Witnessed By:
Charles L. Moore, PE, PTL
Tompkins-Beckwith
Laboratory Test Number:
JAX3781
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.
NATIONAL CERTIFIED
Contractor:
PIPE WELDING BUREAU
By:
Date:
By:
Revised 3/94 to update A-number
Chairman, Technical Committee
NCPWB Form QW-483 6/91
For use by NCPWB members only (©NCPWB)
PQR Number 87110
Procedure Qualification Record
Identification of WPS followed during welding of test coupon: 1-12-1 Rev 3 dated 3-15-94
Welding Process(es) used: SMAW followed by SMAW, Manual
Date coupon was welded: 8-2-06
Base Metal Specification:
SA-106 Grade B
to Base Metal Specification: SA-106 Grade B
P-Number: 1
Group No: 1 to P-Number: 1 Group No: 1 Plate/Pipe Diameter: 2-3/4 in OD
Base Metal Thickness(in.): 5/8” Joint Type: Single V-groove welded one side
F-Number: 3 / 4
Filler metal specification:
SFA 5.1 / SFA 5.1
AWS Classification: E6010 / E7018
A-Number: 1 / 1
Weld Deposit Thickness(es)(in.): 0.125 / 0.50
Maximum Pass Thickness: 1/8”
Filler metal size:
1/8” and 5/32
Supplementary filler metal: N/A
Preheat temperature (ºF): 60 Interpass temp. (ºF) N/A
Welding position/progression:6G*
Current Type and polarity:
DCEP
Travel speed (ipm):
see below
Shielding gas composition, CFH: N/A
Backing gas composition, CFH: N/A
Tungsten size/type: N/A
GMAW transfer mode: N/A
Postweld Heat treatment (ºF): None
Postweld heat treatment time (hr.):
N/A
Stringer/Weave bead: Both
Oscillation: N/A
Single/Multi-pass:
Multiple
Single/Multi-electrode: Single
Other: *Root was run downhill, fill passes uphill. Two coupons were welded.
Weld
Layer
Root
Fill
Process
SMAW
SMAW
SMAW
Electrode or
filler metal
E6010
E7018
E7018
Size (in)
1/8
1/8
5/32
Reduced Section Tensile Tests
Specimen
1
2
Width/dia (in.)
0.757
0.892
Bend Tests
Type
Side
Side
Specimen
Current
Volts
Area (in^2)
0.424
0.407
Transverse Face and Root
Ft-lbs
Other
Turned
Load (lbs.)
34,200
33,900
X
Type
Side
Side
Full Section
Tensile Str. (psi)
80,700
83,300
Side
Location of failure
Weld Metal
Weld Metal
Longitudinal Face and Root
Result
Acceptable
Acceptable
Charpy Specimen Size
Notch location
Travel Speed
(ipm)
Amps
50 to 60
80 to 90
100 to 110
X Rectangular
Thickness (in.)
0.560
0.588
Result
Acceptable
Acceptable
Toughness Tests
Type/Polarity
DCEP
DCEP
DCEP
Type
Result
Test Temperature
Lateral Expansion (mils)
Weld deposit analysis:
Other tests:
Welder’s name:
S. Heine
Stamp: 9279
Tests conducted by: Inspection and Testing Services, Inc
Percent Shear
Drop Weight Break
No Break
Welding Witnessed by: Leonard Tune, Durr Mechanical
Laboratory test number: S112235
We hereby 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.
National Certified
Company:
By:
Date:
Chairman, Technical Committee
NCPWB Form QW-483
For use by NCPWB members only (©NCPWB)
PQR Number 06062
Procedure Qualification Record
Identification of WPS followed during welding of test coupon: 1-12-1 Rev 3 dated 3-15-94
Welding Process(es) used: SMAW, Manual
Date coupon was welded: 8-5-10
Base Metal Specification:
SA-36
to Base Metal Specification: SA-36
P-Number: 1
Group No: 1 to P-Number: 1 Group No: 1 Plate/Pipe Diameter: Plate
Base Metal Thickness(in.): 5/8” Joint Type: Single V-groove welded one side
F-Number: 3
Filler metal specification:
SFA 5.1
AWS Classification: E6010
A-Number: 1
Weld Deposit Thickness(es)(in.): 5/8”
Maximum Pass Thickness: 0.25”
Filler metal size:
1/8” and 3/32
Supplementary filler metal: N/A
Preheat temperature (ºF): 100
Interpass temp. (ºF) 500
Welding position/progression: 2G
Current Type and polarity:
DCEP
Travel speed (ipm):
see below
Shielding gas composition, CFH: N/A
Backing gas composition, CFH: N/A
Tungsten size/type: N/A
GMAW transfer mode: N/A
Postweld Heat treatment (ºF): None
Postweld heat treatment time (hr.):
N/A
Stringer/Weave bead: Both
Oscillation: N/A
Single/Multi-pass:
Multiple
Single/Multi-electrode: Single
Other:
Weld
Layer
Root
Fill
Process
SMAW
SMAW
Electrode or
filler metal
E6010
E6010
Size (in)
3/32
1/8
Reduced Section Tensile Tests
Specimen
1
2
Width/dia (in.)
0.730
0.765
Bend Tests
Type
Side
Side
Specimen
Current
Volts
Area (in^2)
0.427
0.447
Transverse Face and Root
Turned
Load (lbs.)
32,265
34,000
X
Type
Side
Side
Ft-lbs
Location of failure
Base Metal
Base Metal
Longitudinal Face and Root
Result
Acceptable
Acceptable
Type
Result
Test Temperature
Lateral Expansion (mils)
Weld deposit analysis:
Other tests:
Welder’s name:
Matthew Jones Stamp: 25L54
Tests conducted by: Bruce Tanner, CTL Engineering
Other
Full Section
Tensile Str. (psi)
75,560
75,100
Side
Charpy Specimen Size
Notch location
Travel Speed
(ipm)
2 to 6
2 to 6
Amps
70 to 80
100 to 125
X Rectangular
Thickness (in.)
0.585
0.584
Result
Acceptable
Acceptable
Toughness Tests
Type/Polarity
DCEP
DCEP
Percent Shear
Drop Weight Break
No Break
Welding Witnessed by: Dale Witte, Speer Mechanical
Laboratory test number: 100302294COL
We hereby 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.
National Certified
Company:
By:
Date:
Chairman, Technical Committee
PQR Number 100815
NCPWB Form QW-483
For use by NCPWB members only (©NCPWB)