Chevron

Nigeria

NNPC

Project Name : ESCRAVOS GAS TO LIQUIDS PROJECT

Project Location: ESCRAVOS – NIGERIA
Document Title : MANUFACTURER’S DATA BOOK

CONDENSATE CATION DEMINERALISER - A

172 –VC – 007 A

CONDENSATE POLISHING PACKAGE

172 – XP - 009

Rev Description Date Vendor Vendor Contractor COMPANY

Originator Approval Approval Approval
D1 FIRST ISSUE 23.08.2008 GLH VDK

THIS DOCUMENT IS THE

PROPERTY OF CHEVRON
COMPANY Purchase order no
NIGERIA LIMITED (CNL) EGTL1-MGN-PRC-PO-000082
OR CNL’S LICENSORS.
COPYRIGHT, PATENTS VENDOR Document Number Sht 1 Rev
AND ALL OTHER Of
INDUSTRIAL PROPERTY
RIGHTS RESERVED COMPANY Document number Sht Rev
174 D1
EGTL1-IEI -MEC-TC- 720125 - PART 1
 INDEX
EQUIPMENT TAG NO: 172-VC-007 A
CONDENSATE CATION DEMINERALISER A - MFG SR.NO. 62285 / 3

Sr.
Description PageNumbers
No.
Certificates
A: Certificate of Manufacturer A: 3
1
B: Certificate of conformity (by EGTL)
C: MGN Inspection Release Certificate (IRC) C: 5
2 Concessions, deviations and non-conformances NA
Drawings:
A: “As Built”.
3
B: General arrangement, assembly and detail B: 8
drawings.
4 Design Calculations 15
Material Map :( A sketch linking actual vessel parts
5 48
with material certificates of shell and dished end).
Certified mill test reports for all pressure parts as
6 well as load bearing parts. 50

7 Material certificates for all steel bolting materials. 87

8 Weld map relating each weld to the specified WPS 90

Welding:
9 A: WPS/PQR/WPQR 93
B: Welding consumable test certificates
10 RT Examination report with sketch 123

11 PT and MPT examination reports 141

12 Certified copies of NDE operator’s certificates 143

Heat treatment chart including map of thermocouple
13 151
location
Vessel Internal and External Dimensions report and
14 155
Pressure test certificates (Pneumatic and Hydro)
15 Protective coating & lining report. 165

16 Final signed-off copy of the Inspection and Test Plan 172

CHEVRON KBR
NIGERIA

SECTION 1A

CERTIFICATE OF MANUFACTURER
 Certificate of Compliance (BS EN 10204:2004)
Certificate No: IEI / EE220525 / COC / 001 Dated: 18.09.2008

Name of supplier/Manufacturer : ION EXCHANGE (INDIA) LTD.

Address : R-14, TTC INDUSTRIAL AREA, MIDC, THANE –

BELAPUR ROAD, RABALE, NAVI MUMBAI-400 701

Purchase Order Number : EGTL-6327-PMU003

Purchase Order Rev Number : Rev. 0

Plant Name : CONDENSATE POLISHING PACKAGE

Product Description : CONDENSATE CATION DEMINERALISER - A

TAG NO. : 172 – VC – 007 A

Qty. : 01 No.

Tag or equipment Number: AS ABOVE

This is to certify that the item(s)/equipment referenced above is/are in compliance with the
requirements of the above Purchase Order number.

Signature:
Name of Authorised Person: VINAYAK KADAM
Designation: PROJECTMANAGER
CHEVRON KBR
NIGERIA

SECTION 1A

MGN INSPECTION RELEASE

CERTIFICATE (IRC)
CHEVRON KBR
NIGERIA

SECTION - 3

GENERAL ARRANGEMENT, ASSEMBLY

AND DETAIL DRAWINGS
 EGTL1-IEI-MEC-GA-720007

Mach RKM
20-Feb-07
MGN-PRC-PO-000082

1 of 1
EGTL1-IEI-MEC-GA-720167

Mach RKM
20-Feb-07
MGN-PRC-PO-000082

1 of 1
EGTL1-IEI-MEC-GA-720168

Mach RKM
20-Feb-07
MGN-PRC-PO-000082

1 of 1
EGTL1-IEI-MEC-DD-720201

Mach RN
27-Nov-06
MGN-PRC-PO-000082

1 of 1
EGTL1-IEI-MEC-DD-720202

Mach RN
27-Nov-06
MGN-PRC-PO-000082

1 of 1
EGTL1-IEI-MEC-DD-720203

Mach RN
27-Nov-06
MGN-PRC-PO-000082

1 of 1
CHEVRON KBR
NIGERIA

SECTION - 4

DESIGN CALCULATIONS
EGTL1-IEI-MEC-CA-720077

Mach RN
14-Nov-06
MGN-PRC-PO-000082

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 CATION DEMINERALISER
Local Stress Analysis (Edge of Attachment) : A1
Effective stress calculation & comparision

Stress due to σx σφ
0 90 180 270 0 90 180 270
Membrane Nφ 5.2797 5.2797 5.2797 5.2797
Nx 5.6749 5.6749 5.6749 5.6749
Radial load,
Bending Mφ 35.7420 35.7420 35.7420 35.7420
Mx 21.5380 21.5380 21.5380 21.5380
Membrane Nφ 20.1870 -20.1870
Nx 6.1446 -6.1446
Logitudinal moment,ML
Bending Mφ 62.0460 -62.0460
Mx 115.0150 -115.0150
Membrane Nφ 7.6775 -7.6775
Nx 9.7447 -9.7447
Circumferential Moment,Mc
Bending Mφ 128.0150 -128.0150
Mx 72.5370 -72.5370
Pi x Rm/t σφ 129.6200 129.6200 129.6200 129.6200
Internal pressure,Pr
pi x Rm/2t σx 64.8100 64.8100 64.8100 64.8100
Shear Load, Q Q / 3.142 C t τs 1.3665 1.3665 1.3665 1.3665 1.3665 1.3665 1.3665 1.3665
Torsional Moment, T T / (2 x 3.142 C^2 t) Ms 5.5340 5.5340 5.5340 5.5340 5.5340 5.5340 5.5340 5.5340
Membrane Σ Nx, Nφ 76.6295 80.2296 64.3403 60.7402 155.0867 142.5772 114.7127 127.2222
Total Σ All 213.1825 174.3046 -29.1367 9.7412 252.8747 306.3342 88.4087 34.9492
Effective Membrane (1) 155.11 142.61 114.75 127.25 Should be less than 1.5 Sv
Total Stresses
(2) 76.61 80.20 64.30 60.71
Total Effective (3) 254.04 306.69 88.81 36.71 Should be less than 3 Sv
(4) 212.02 173.94 -29.54 7.98

(1),(2) 0.5 x ( Σ Nx + Σ Nφ + ( Σ Nx - Σ Nφ )^2 + 4τs^2) ^ .5

(3),(4) 0.5 x ( Σ All σx + Σ Αll σφ + ( Σ All σx - Σ Αll σφ )^2 + 4(τs+Ms)^2) ^ .5

PROJECT: ESCRAVOS, NIGERIA 11/14/2006, REV. 1

 CATION DEMINERALISER
Local Stress Analysis (Edge of pad) : A1
Effective stress calculation & comparision

Stress due to σx σφ
0 90 180 270 0 90 180 270
Membrane Nφ 5.29 5.29 5.29 5.29
Nx 8.80 8.80 8.80 8.80
Radial load,
Bending Mφ 27.94 27.94 27.94 27.94
Mx 17.50 17.50 17.50 17.50
Membrane Nφ 21.47 21.47
Nx 8.40 -8.40
Logitudinal moment,ML
Bending Mφ 31.65 -31.65
Mx 51.92 -51.92
Membrane Nφ 10.24 -10.24
Nx 17.58 -17.58
Circumferential Moment,Mc
Bending Mφ 94.73 -94.73
Mx 46.41 -46.41
Pi x Rm/t σφ 129.26 129.26 129.26 129.26
Internal pressure,Pr
pi x Rm/2t σx 64.63 64.63 64.63 64.63
Shear Load, Q Q / 3.142 C t τs 0.96 0.96 0.96 0.96 0.96 0.96 0.96 0.96
Torsional Moment, T T / (2 x 3.142 C^2 t) Ms 1.94 1.94 1.94 1.94 1.94 1.94 1.94 1.94
Membrane Σ Nx, Nφ 81.83 91.01 65.03 55.84 156.01 144.78 156.01 124.31
Total Σ All 151.24 154.92 30.60 26.92 215.60 267.46 152.31 57.52
Effective Membrane (1) 156.03 144.80 156.02 124.32 Should be less than 1.5 Sv
Total Stresses
(2) 81.81 90.99 65.02 55.83
Total Effective (3) 215.73 267.53 152.38 57.79 Should be less than 3 Sv
(4) 151.11 154.85 30.54 26.65

(1),(2) 0.5 x ( Σ Nx + Σ Nφ + ( Σ Nx - Σ Nφ )^2 + 4τs^2) ^ .5

(3),(4) 0.5 x ( Σ All σx + Σ Αll σφ + ( Σ All σx - Σ Αll σφ )^2 + 4(τs+Ms)^2) ^ .5

PROJECT: ESCRAVOS, NIGERIA 11/14/2006, REV. 1

 CATION DEMINERALISER
Local Stress Analysis (Edge of Attachment) : B1
Effective stress calculation & comparision

Stress due to σx σφ
0 90 180 270 0 90 180 270
Membrane Nφ -1.11 -1.11 -1.11 -1.11
Nx -3.71 -3.71 -3.71 -3.71
Radial load,
Bending Mφ 4.46 4.46 4.46 4.46
Mx 12.15 12.15 12.15 12.15
Membrane Nφ -5.73 5.73
Nx -14.52 14.52
Moment, M
Bending Mφ 51.01 -51.01
Mx 0.00 0.00
Shear Load, Q Q / 3.142 C t τs
Torsional Moment, T T / (2 x 3.142 C^2 t) Ms 4.90 4.90 4.90 4.90 4.90 4.90 4.90 4.90
Membrane Σ Nx, Nφ -18.23 -3.71 10.81 -3.71 -6.84 -1.11 4.62 -1.11
Total Σ All -6.08 8.44 22.96 8.44 48.63 3.35 -41.94 3.35
Effective Membrane (1) -6.84 -1.11 10.81 -1.11 Should be less than 1.5 Sv
Total Stresses
(2) -18.23 -3.71 4.62 -3.71
Total Effective (3) 49.07 11.41 23.33 11.41 Should be less than 3 Sv
(4) -6.51 0.38 -42.30 0.38

(1),(2) 0.5 x ( Σ Nx + Σ Nφ + ( Σ Nx - Σ Nφ )^2 + 4τs^2) ^ .5

(3),(4) 0.5 x ( Σ All σx + Σ Αll σφ + ( Σ All σx - Σ Αll σφ )^2 + 4(τs+Ms)^2) ^ .5

PROJECT: ESCRAVOS, NIGERIA 11/14/2006, REV. 1

 PROJECT: ESCRAVOS, NIGERIA

CATION DEMINERALISER
Local Stress Analysis (Edge of pad) : B1
Effective stress calculation & comparision

Stress due to σx σφ
0 90 180 270 0 90 180 270
Membrane Nφ -0.63 -0.63 -0.63 -0.63
Nx -4.25 -4.25 -4.25 -4.25
Radial load,
Bending Mφ 7.22 7.22 7.22 7.22
Mx -0.28 -0.28 -0.28 -0.28
Membrane Nφ -24.28 24.28
Nx -20.40 20.40
Moment, M
Bending Mφ 97.20 -97.20
Mx 0.00 0.00
Shear Load, Q Q / 3.142 C t τs 0.91 0.91 0.91 0.91 0.91 0.91 0.91 0.91
Torsional Moment, T T / (2 x 3.142 C^2 t) Ms 1.84 1.84 1.84 1.84 1.84 1.84 1.84 1.84
Membrane Σ Nx, Nφ -24.65 -4.25 16.14 -4.25 -24.92 -0.63 23.65 -0.63
Total Σ All -24.92 -4.53 15.87 -4.53 79.51 6.59 -66.32 6.59
Effective Membrane (1) -23.86 -0.42 23.76 -0.42 Should be less than 1.5 Sv
Total Stresses
(2) -25.70 -4.47 16.03 -4.47
Total Effective (3) 79.58 7.23 15.96 7.23 Should be less than 3 Sv
(4) -25.00 -5.17 -66.41 -5.17

(1),(2) 0.5 x ( Σ Nx + Σ Nφ + ( Σ Nx - Σ Nφ )^2 + 4τs^2) ^ .5

(3),(4) 0.5 x ( Σ All σx + Σ Αll σφ + ( Σ All σx - Σ Αll σφ )^2 + 4(τs+Ms)^2) ^ .5

11/14/2006, REV. 1
 CATION DEMINERALISER
Local Stress Analysis (Edge of Attachment) : V1,W1
Effective stress calculation & comparision

Stress due to σx σφ
0 90 180 270 0 90 180 270
Membrane Nφ -0.96 -0.96 -0.96 -0.96
Nx -2.47 -2.47 -2.47 -2.47
Radial load,
Bending Mφ 4.09 4.09 4.09 4.09
Mx 11.21 11.21 11.21 11.21
Membrane Nφ -2.50 2.50
Nx -3.56 3.56
Moment, M
Bending Mφ 32.24 -32.24
Mx 0.00 0.00
Shear Load, Q Q / 3.142 C t τs
Torsional Moment, T T / (2 x 3.142 C^2 t) Ms 4.57 4.57 4.57 4.57 4.57 4.57 4.57 4.57
Membrane Σ Nx, Nφ -6.04 -2.47 1.09 -2.47 -3.46 -0.96 1.55 -0.96
Total Σ All 5.17 8.73 12.30 8.73 32.86 3.13 -26.60 3.13
Effective Membrane (1) -3.46 -0.96 1.55 -0.96 Should be less than 1.5 Sv
Total Stresses
(2) -6.04 -2.47 1.09 -2.47
Total Effective (3) 33.60 11.29 12.83 11.29 Should be less than 3 Sv
(4) 4.43 0.57 -27.13 0.57

(1),(2) 0.5 x ( Σ Nx + Σ Nφ + ( Σ Nx - Σ Nφ )^2 + 4τs^2) ^ .5

(3),(4) 0.5 x ( Σ All σx + Σ Αll σφ + ( Σ All σx - Σ Αll σφ )^2 + 4(τs+Ms)^2) ^ .5

PROJECT: ESCRAVOS, NIGERIA 11/14/2006, REV. 1

 CATION DEMINERALISER
Local Stress Analysis (Edge of PAD) : V1,W1
Effective stress calculation & comparision

Stress due to σx σφ
0 90 180 270 0 90 180 270
Membrane Nφ -1.95 -1.95 -1.95 -1.95
Nx -3.90 -3.90 -3.90 -3.90
Radial load,
Bending Mφ 5.83 5.83 5.83 5.83
Mx 4.78 4.78 4.78 4.78
Membrane Nφ -14.81 14.81
Nx -7.68 7.68
Moment, M
Bending Mφ 43.99 -43.99
Mx 0.00 0.00
Shear Load, Q Q / 3.142 C t τs
Torsional Moment, T T / (2 x 3.142 C^2 t) Ms 1.71 1.71 1.71 1.71 1.71 1.71 1.71 1.71
Membrane Σ Nx, Nφ -11.58 -3.90 3.78 -3.90 -16.76 -1.95 12.86 -1.95
Total Σ All -6.80 0.88 8.56 0.88 33.06 3.88 -25.30 3.88
Effective Membrane (1) -11.58 -1.95 12.86 -1.95 Should be less than 1.5 Sv
Total Stresses
(2) -16.76 -3.90 3.78 -3.90
Total Effective (3) 33.14 4.65 8.64 4.65 Should be less than 3 Sv
(4) -6.87 0.11 -25.39 0.11

(1),(2) 0.5 x ( Σ Nx + Σ Nφ + ( Σ Nx - Σ Nφ )^2 + 4τs^2) ^ .5

(3),(4) 0.5 x ( Σ All σx + Σ Αll σφ + ( Σ All σx - Σ Αll σφ )^2 + 4(τs+Ms)^2) ^ .5

PROJECT: ESCRAVOS, NIGERIA 11/14/2006, REV. 1

CHEVRON KBR
NIGERIA

SECTION - 5

MATERIAL MAP
(A SKETCH LINKING ACTUAL VESSEL PARTS WITH MATERIAL
CERTIFICATES OF SHELL AND DISHEND)
 CHEVRON KBR
NIGERIA

SECTION - 6

CERTIFIED MILL TEST REPORTS

(FOR ALL PRESSURE PARTS AS WELL AS LOAD BEARING PARTS)
CHEVRON KBR
NIGERIA

SECTION - 7

MATERIAL CERTIFICATES
(FOR ALL STEEL BOLTING MATERIALS)
CHEVRON KBR
NIGERIA

SECTION - 8

WELD MAP
(RELATING EACH WELD TO THE SPECIFIED WPS)
 CHEVRON KBR
NIGERIA

SECTION - 9

WELDING
(A:WPS/PQR/WPQR &
B: WELDING CONSUMABLE TEST CERTIFICATES)
 Chevron
Nigeria

NNPC

Project Name: ESCRAVOS GAS TO LIQUIDS PROJECT

Project Location: ESCRAVOS, NIGERIA
Document Title: WELD PROCEDURE SPECIFICATION (WPS)
& QUALIFICATION RECORD (PQR)
Project Name: Ion Exchange (India) Limited
Package Name: Condensate Polishing Package (172-XP-009)

Rev Description Date Vendor Vendor Contractor COMPANY

Originator Approval Approval Approval
D0 FIRST ISSUE 20.07.06 VDK RSA

D1 FIRST ISSUE 20.07.06 VDK RSA

D2 AS PER COMMENTS 30/8/2006 VDK RSA

D3 SECOND ISSUE 13/11/06 SPR VDK

D4 THIRD ISSUE 27/02/07 GLH VDK

D5 FOURTH ISSUE 15/05/07 GLH VDK

D6 FIFTH ISSUE 05.03.2008 GLH VDK

D7 SIXTH ISSUE 05.08.2008 GLH VDK

THIS DOCUMENT IS
THE PROPERTY OF
CHEVRON NIGERIA
LIMITED (CNL) OR
CNL’S LICENSORS. Purchase Order Number Sht Rev
COPYRIGHT, Of
PATENTS AND ALL
EGTL1-MGN-PRC-PO-000082
OTHER INDUSTRIAL Project Document number Sht Rev
PROPERTY RIGHTS 1 Of 60 D7
RESERVED EGTL1-IEI-MEC-PR-720104
 ESCRAVOS
GAS TO LIQUIDS EGTL1-IEI-MEC-PR-
WELD PROCEDURE PROJECT 7200104
SECIFICATION & PAGE 2 OF 60
QUALIFICATION RECORD REV D7

Contents
WPS & PQR

Pg. No
1. RHINE ENGINEERING PRIVATE LTD.
• WPS & PQR No 7 ( P No 1 to 1. ) …………………………………… 3
• WPS & PQR No 9 ( P No 1 to 1. ) …………………………………… 7
• WPS & PQR No 15 ( P No 1 to 1. ) …………………………………… 11
• WPS No 38 & PQR No 35 (P No 1 to 1 ) ……………………………… 16
• WPS No 39 & PQR No 36 (P No 1 to 1 ) ……………………………… 20

2. UNIDRO SPA ( WELDING PROCEDURE ) …………………………………… 22

3. PUMA ENGINEERING (WPS FOR S.S PIPE SCH 40 ) …………………………. 44

4. THERMOFAB (WPS FOR C.S TANK (Less than 13 mm thickness ) ………….. 52.

EGTL1-IEI-MEC-PR-720104
 RHINE ENGINEERING Private Limited
Plot No.454, GIDC, N.H.No.8, Por-Ramangamdi, Baroda, India.
QW - 482 WELDING PROCEDURE SPECIFICATIONS (WPS)
Company Name : M/s. RHINE ENGINEERING Private Limited.
Welding Procedure Specification No.: : 38 Rev.: 3 Date: 20.04.2007

Supporting PQR No.(s) : R-35 Rev.: 0 Date: 24.11.2004

Process #1 Process #2
Welding Process(es) GTAW FCAW
Type(s) Manual Semiautomatic
JOINTS (QW-402)
Joint Design : Refer Below
Backing : Yes and/or No
Backing Material : Weld Metal, Base Metal, Non-Fusing Metal, Non-metallic, Other
Retainer : Not Allowed
For FCAW process " Not permitted for the root pass or single or double welded butt joints without backing pass is completely
weld"
Joint design shall be as per approved production drawing and /or weld map

BASE METALS(QW-403)

P No. : 1 Group No.: All to P No. : 1 Group No.: All

OR

Specification Type and Grade to :----

Specification Type and Grade :----
OR

Chem. Analysis and Mech Prop to : ----

Chem. Analysis and Mech. Prop. : ----
Thickness Range :
Base Metal Groove : 1.5 mm to 16 mm Fillet : All
Pipe Dia Range Groove : All Fillet : All
Thickness per Pass : NA for GTAW; < 7 mm for FCAW
Others 1. QW- 403.7 and QW-403.13 - NA for GTAW and FCAW
2.QW-403.10: NA for GTAW; Short Circuiting Arc not allowed for FCAW

FILLER METALS (QW-404)

Process #1 Process # 2
Spec. No. (SFA.). 5.18 5.20
AWS No.(Class)). ER 70S-2 E71T-1
Filler Metal F No. 6 6
Weld Metal A No. 1 1
Size of Filler Metals 2.0, 2.5 mm φ 0.8, 1.2 mm φ
Weld Metal :- Thickness Range Groove : 5 mm (max.) Fillet : All Groove : 11 mm (max.) Fillet : All
Addition or Deletion of Filler Metal Deletion Not Allowed NA
Filler Metal Product Form Solid only Flux cored only
Consumable Insert Not Allowed NA
Flux Not Allowed NA
Supplemental Filler metal NA Not Allowed
Alloy Elements NA NA
Mode of metal Transfer NA Spray Arc
Sht 1 of 2
 WPS No. : 38 Rev. : 3
POSITION (QW-405) PREHEAT (QW-406)

Less than or Equal to 13mm = 10 C, >

13mm but less than or equal to 25mm = 750C, ,
Process #1 Process #2 Preheat Temp ( Min. ) > 25mm but less than or equal to 50mm = 1000C
o
Position(s) of Groove All Interpass Temp ( Max ) 205 C
Welding progression Uphill for vertical weld o
Pre Heat Maintenance ( C) None
Positions of Fillet All

POST WELD HEAT TREATMENT (QW-407) GAS (QW - 408) % Composition

Type of Heat Treatment. : No PWHT Gas(es) Mixture Flow Rate in lpm

o
Soaking Temp. Range ( C) : NA GTAW FCAW GTAW FCAW GTAW FCAW

Soaking Time Range (Hrs.) : NA Shielding Argon CO2 Welding Grade 8-12 10-20

Heating Rate ( oC / Hr. ) : NA Trailing Nil Nil NA NA NA

o
Cooling Rate ( C / Hr.) : NA Backing Nil Nil NA NA NA
Others
: QW 408.9 and QW 408.10 : NA
ELECTRICAL CHARACTERISTICS (QW-409)
Current (AC or DC ) : DC Polarity : EN for GTAW and EP for FCAW
Amps : See 'Table' Volts : See 'Table'
Tungsten Electrode size and Type : 2.4 mm φ, EWTh-2 (2% Thoriated) for GTAW
Mode of Metal Transfer for FCAW : NA for GTAW; Spray Arc for FCAW
Pulsing Current : Not Allowed for GTAW; NA for FCAW

TECHNIQUE (QW-410)
String or Weave Bead : String and/or Weave
Orifice / Cup Size : 6 to 12 mm dia for GTAW and 10 to 20 mm for FCAW
Contact Tube to Work Distance : NA for GTAW; 10-30 mm for FCAW
Oscillation : NA
Single to Multi Electrodes : Single
Multi to Single pass per side : Single and/or Multi Pass
Electrode spacing : NA
Initial and interpass Cleaning. : Wire Brushing and Grinding
Method of Back Gouging : Grinding for double welded joints
Peening : Not allowed
Closed to out Chamber : NA

Weld Filler Metal Current Voltage Travel Speed

Layer(s) Process Class Dia Polarity Amp. Range Range Range-mm/min. Remarks
Any GTAW ER70S-2 2.0 mm DCEN 90-150 10-18 50 min.
2.5mm DCEN 100-180 10-18 55 min.

Any FCAW E71T-1 0.8 mm DCEP 90-170 20-24 90 min

1.2 mm DCEP 100-180 22-26 100 min.

As many layers to fill the groove maintaining the same weld characteristics.

Note : NA = Not Applicable

Prepared By. : ______________________

Approved By. : ______________________

Date: 20.04.2007 TPIA

Sht 2 of 2
 RHINE ENGINEERING Private Limited
Plot No.454, GIDC, N.H.No.8, Por-Ramangamdi, Baroda, India.
QW - 482 WELDING PROCEDURE SPECIFICATIONS (WPS)
Company Name : M/s. RHINE ENGINEERING Private Limited.
Welding Procedure Specification No.: : 39 Rev.: 3 Date: 20.04.2007

Supporting PQR No.(s) : R-36 Rev.: 0 Date: 24.11.2004

Process #1 Process #2
Welding Process(es) GTAW SMAW
Type(s) Manual Manual
JOINTS (QW-402)
Joint Design : Refer Below
Backing : Yes and/or No
Backing Material : Weld Metal, Base Metal, Non-Fusing Metal, Non-metallic, Other
Retainer : Not Allowed

Joint design shall be as per approved production drawing and /or weld map

BASE METALS(QW-403)

P.No. : 1 Group No.: All to P.No. : 1 Group No.: All

OR

Specification Type and Grade to :----

Specification Type and Grade :----
OR

Chem. Analysis and Mech Prop to : ----

Chem. Analysis and Mech. Prop. : ----
Thickness Range :
Base Metal Groove : (1.5 mm to 16 mm) Fillet : All
Pipe Dia Range Groove : All Fillet : All
Thickness per pass : NA for GTAW and <(7 mm) for SMAW
Others : QW- 403.7 and QW-403.13 - NA

FILLER METALS (QW-404)

Process #1 Process # 2
Spec. No. (SFA.). 5.18 5.1
AWS No.(Class)). ER 70S-2 E7018
Filler Metal F No. 6 4
Weld Metal A No. 1 1
Size of Filler Metals (2.0, 2.5 mm φ) (2.5, 3.15 and 4.0 mm φ )
Weld Metal :- Thickness Range Groove : (4.8 mm) max. Fillet : All Groove : (11.2 mm) max. Fillet : All
Addition or Deletion of Filler Metal Deletion Not Allowed NA
Filler Metal Product Form Solid only NA
Consumable Insert Not Allowed NA
Flux Not Allowed NA

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POSITION (QW-405) PREHEAT (QW-406)
Less than or Equal to 13mm = 10 C,
> 13mm but less than or equal to 25mm = 750C, ,
Process #1 Process #2 Preheat Temp ( Min. ) > 25mm but less than or equal to 50mm = 1000C

Position(s) of Groove All Interpass Temp ( Max ) (205º C)

Welding progression Uphill for vertical weld o
Pre Heat Maintenance ( C) None
Positions of Fillet All

POST WELD HEAT TREATMENT (QW-407) GAS (QW - 408) % Composition

Type of Heat Treatment. : No PWHT Gas(es) Mixture Flow Rate

o
Soaking Temp. Range ( C) : NA Shielding Argon Welding Grade 8 - 12 lpm
Soaking Time Range (Hrs.) : NA Trailing Nil NA NA
o
Heating Rate ( C / Hr. ) : NA Backing Nil NA NA
o
Cooling Rate ( C / Hr.) : NA Others : QW 408.9 and QW 408.10 : NA

ELECTRICAL CHARACTERISTICS (QW-409)

Current (AC or DC ) : DC Polarity : EN for GTAW and EP for SMAW
Amps : See 'Table' Volts : See 'Table'
Tungsten Electrode size and Type : 2.4 mm φ, EWTh-2 (2% Thoriated)
Pulsing Current : GTAW-Not Allowed; SMAW : NA

TECHNIQUE (QW-410)
String or Weave Bead : String and/or Weave (Weaving shall not be more than 3 times of Electrode diameter for SMAW)
Orifice / Cup Size : 6 to 12 mm dia for GTAW; NA for SMAW
Oscillation : NA
Single to Multi Electrodes : Single for GTAW; NA for SMAW
Multi to Single pass per side : Multi pass and/or single
Electrode spacing : NA
Initial and interpass Cleaning. : Wire Brushing and Grinding
Method of Back Gouging : Grinding for double welded joints
Peening : Not allowed
Closed to out Chamber : NA

Weld Filler Metal Current Voltage Travel Speed Remarks

Layer(s) Process Class Dia Polarity Amp. Range Range Range-in/min (mm/min.)

Any GTAW ER70S-2 (2.0 mm) DCEN 90-150 10-18 1.968 (50) min.
(2.5mm) DCEN 100-180 10-18 2.165 (55) min.
Any
SMAW E7018 (2.5mm) DCEP 70-100 20-24 2.362 (60) min.
(3.15 mm) DCEP 90-130 22-26 2.559 (65) min.
(4.0 mm) DCEP 120-180 24-28 2.756 (70) min.
As many layers to fill the groove maintaining the same weld characteristics.

Note : NA = Not Applicable

'T' - Base Metal Thickness

Prepared By. : ______________________

Approved By. : ______________________

TPIA
Date: 20.04.2007

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SECTION - 10

RT EXAMINATION REPORT
WITH SKETCH
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SECTION - 11

PT & MT EXAMINATION REPORTS

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SECTION - 12

CERTIFIED COPIES OF NDE OPERATOR’S

CERTIFICATES
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SECTION - 13

HEAT TREATMENT CHART

INCLUDING MAP OF THERMOCOUPLE
LOCATION
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SECTION - 14

VESSEL INTERNAL & EXTERNAL

DIMENSION REPORTS & PRESSURE TEST
CERTIFICATES
(PNEUMATIC AND HYDRO)
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SECTION - 15

PROTECTIVE COATING & LINING

REPORTS
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SECTION - 16

FINAL SIGNED-OFF COPY OF THE

INSPECTION AND TEST PLAN