Query for WPS & PQR of weld overlay

[Manindra Singh]

Dear friends,

I want to prepare WPS & PQR for weld overlay of Monel inside the NB 6" nozzle (material SA 106 Gr B, length 8-10").

i have a query whether i have to prepare two different WPS ( for 1.nozzle pipe to flange & 2. weld overlay inside the nozzle)

What type of procedure i should follow?

Nozzle pipe is having Sch 80 thickness & thickness of weld overlay of monel is 5 mm.

What type of NDT i should do to check the integrity of weld overlay.

what type of special techniques required in the above mentioned job.

Thanks & regards

M P Singh

Inspection Engineer

Dear materials-welding ! Get Yourself a cool, short @in.com Email ID now!

[James, GeraldJayakumar]

Singh,

 

If the inside of the Joint is accessible then you may go for an Overlay WPS/PQR.

 

If clad portion is included in the Design calculation then PQR shall be Qualified in accordance with QW217(a) as a Butt Weld PQR.

 

If clad protion is not included in the Design Calculation and inside of the weld is accessible then, carbon steel portion can be supported using suitable Butt weld PQR and the Weld Overlay using an Overlay PQR inaccordance with QW217(b) and tested as per requirements of QW453.

 

NDT depends on Applicable Code and Thickness. If it is ASME Sec.VIII Div.I, then UCL-35 & UCL-36 is applicable

 

Normally the NDT for clad is Root PT(Liquid penetrant testing) and Final layer PT.

 

Thanks & Regards

 

-----------------------------------------------------------------

J.Gerald Jayakumar

Senior Engineer-Technology

Equipment Engineering (Materials & Welding)

Foster Wheeler India Pvt Ltd

Chennai Execution Centre

Landline : 0091-(44)-66769047

Mobile    : 0091-9344954677

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[Muhammed Ibrahim PK]

i have a query whether i have to prepare two different WPS ( for 1.nozzle pipe to flange & 2. weld overlay inside the nozzle) --- You can use any existing butt welding procedure for butt welding and you have to make a seperate PQR for overlay.

What type of procedure i should follow?  Arrange a plate for overlay PQR with the same thickness or lower as in production. Deposit  required thickness of weld metal and carry out Penetrant test. Carry out 4 side bend and chemical analysis at minimum required depth from surface. Carry out hardness test  and macro examination if necessery.

Nozzle pipe is having Sch 80 thickness & thickness of weld overlay of monel is 5 mm.

What type of NDT i should do to check the integrity of weld overlay. --- PT

what type of special techniques required in the above mentioned job. --- Take care when depositing first layer. Reduce current as low as possible at first layer. Ensure an overlap of 40 - 50 % on each bead. Take care the inter pass temperature up to 150 deg.C and distortion of plate. Keep away from carbon steel work location, because chips and powder from carbon steel will give wrong chemical result. Do not use carbon steel wire brush and grinding wheel.

Thanks & Regards
Muhammed Ibrahim PK

On 4 March 2011 09:58, Manindra Singh <hell...@in.com> wrote:

Dear friends,

I want to prepare WPS & PQR for weld overlay of Monel inside the NB 6" nozzle (material SA 106 Gr B, length 8-10").

i have a query whether i have to prepare two different WPS ( for 1.nozzle pipe to flange & 2. weld overlay inside the nozzle) --- You can use any existing butt welding procedure for butt welding and you have to make a seperate PQR for overlay.

What type of procedure i should follow?  Arrange a plate for overlay PQR with the same thickness or lower as in production. Deposit  required thickness of weld metal and carry out Penetrant test. Carry out 4 side bend and chemical analysis at minimum required depth from surface. Carry out hardness test  and macro examination if necessery.

Nozzle pipe is having Sch 80 thickness & thickness of weld overlay of monel is 5 mm.

What type of NDT i should do to check the integrity of weld overlay. --- PT

what type of special techniques required in the above mentioned job. --- Take care when depositing first layer. Reduce current as low as possible at first layer. Ensure an overlap of 40 - 50 % on each bead. Take care the inter pass temperature up to 150 deg.C and distortion of plate. Keep away from carbon steel work location, because chips and powder from carbon steel will give wrong chemical result. Do not use carbon steel wire brush and grinding wheel.

Thanks & regards

M P Singh

Inspection Engineer

Dear materials-welding ! Get Yourself a cool, short @in.com Email ID now!

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[Yogesh kumar]

Additional to requirements as suggested by experts ,you may take care for  ;

• Each layer of alloy shall be tested for iron concentration in such a manner as to obtain the

profile characteristics of iron pick-up. This inspection shall be done progressively with the work. Locations shall be
chosen at random by the Inspector

• Iron concentration in the upper 1.6 mm of the nickel (or Monel,depending on filler ) first layer shall be less than
  25 percent with an average of less than 15 percent. Iron concentration in the upper 1.5 mm
  of the Monel layer shall be less than 5 percent at any point.
• If iron concentrations above these are recorded, a further layer of the overlay is required
• Each layer of overlay shall be dye penetrant inspected before proceeding with the following
  pass. All dye penetrant and developer must be removed before further welding.
• The weld overlay shall be free of laps, lack of penetration, fissures, undercutting, slag
  inclusions, cracks or other weld defects. Micro fissures not exceeding 0.8 mm in diameter
  shall be permitted provided they are not linearly disposed. The minimum distance between
  such permitted defects in line shall be 4.8 mm
• Shielding gas shall be welding grade argon with 99.999 purity
• A curved sweep gauge shall be used on each overlay pass. A 1.6 mm maximum gap is
  allowed on an arc length of 0.125 x inside diameter. If the gap is greater, additional beads
  of the pass in question shall be laid in the depressions
• Maximum hardness of all welds – 200 Brinell hardness number
  

Will be happy ,if you share the  results at your end.

regards

yogeshk.