Form No.

101 - 401

BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPPALLI-620014
P91 P22 WELDING TECHNOLOGY CENTRE

WELDING PROCEDURE SPECIFICATION Page 1 of 2

WPS. No. : 1038 Date : 31/07/2003 Supporting 904 &

Rev. No : 03 Date : 22/09/2007 PQR. No 1099

Welding Process : GTAW + SMAW Type : Manual

(Auto/Semi-Auto/Manual/Machine)
Application : Groove welding of 2 ¼[Link] (P22/T22/F22/Gr22) to 9Cr.1Mo. ¼V
steel ( P91 / T91 / F91 / Gr.91 ) for site fabrication with preheat & with
PWHT. ( For t < 20mm only )

JOINTS ( QW – 402 )
Joint Design : Groove as per drawing
Backing ( Yes / No ) : GTAW : No ; SMAW : Yes.
Backing Material Type : GTAW : Nil ; SMAW : Metal.
(Metal/Non fusing metal/Non metallic/Others)

BASE METAL ( QW – 403 )

P. No. : 5A Group No. : 1 to P. No : 5B Group No. : 2
Spec. Type & Grade : N.A.
Chem. Analysis & Mech. Prop. : N.A.
Thickness Range : Groove : 1.5 to 20.0mm Fillet : N.A
Pipe Diameter Range : Groove : Unlimited Fillet : N.A.
Others : Nil

FILLER METALS ( QW – 404 )

GTAW SMAW
AWS No. ( class ) : ER90S – B3 E9018 –B3 Size of Filler metal : Refer Table
Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A.
F. No. : 6 4 Electrode-flux (Class ) : N.A..
A. No. : 2 4 Consumable insert : N.A.
Deposited weld metal thickness range (t)
Groove : 20.0mm Max. GTAW : [Link].( Max. 2 mm / pass )
SMAW : Balance (Max.5 mm / pass)
Fillet : N.A.
Others : Nil

POSITION ( QW – 405 ) PRE HEAT ( QW – 406 )

Position(s) of Groove : All Preheat Temp.(min) : 220 0C
Position(s) of Fillet : N.A. Interpass Temp. (Max) : 350 0C
Weld Progression.(Up/Down): Vertical up Preheat Maintenance : Nil
Others : Nil Others : After welding cool the joint to
80 – 100 0C & hold it for 1 hour
minimum, before PWHT.
 BHEL Page 2 of 2
Trichirappalli – 14 WPS. No. : 1038 Revision : 03

PWHT ( QW – 407 ) GAS ( QW – 408 )

Temp. Range : 745 ± 15 0C Gases Mix/Purity % [Link].(lpm )
Time Range : 2.5minutes/mm Shielding : Argon 99.99 8 - 14
(Min.60minutes) Trailing : N.A --- ---
Others : Induction heating Backing : Argon . 99.99 8 - 14
ROH ( Above 350 0C ) : 120 0C / hr max. ( For Root welding )
ROC ( Upto 350 0C ) : 120 0C / hr max.

ELECTRICAL CHARACTERISTICS (QW – 409 )

Current (AC / DC ) : Refer Table Polarity : Refer Table
Amps ( Range ) : Refer Table Volts : Refer Table
Tungsten Electrode type & size : EW Th-2 / EW Ce-2 Ø 2.4mm
Mode of Metal transfer for GMAW : N.A.
Electrode wire feed speed range : N.A.
Pulsing current ( GTAW ) : N.A.

TECHNIQUES ( QW – 409 )
String or weave bead : Root : String; Others : String /weave bead ( Max. 3 Dia. )
Orifice or Gas cup size :6/9
Initial and Interpass cleaning : Chipping / Brushing / Grinding
Method of Back Gouging : Nil
Oscillation : Nil
Contact tube to work distance : N.A.
Multiple or Single pass per side : Single or Multiple
Multiple or Single Electrode : Single
Electrode Spacing : N.A.
Peening : N.A.
Others : Nil

Weld Process Filler metal Current Voltage Travel Others(Hot wire,

Layer range speed Torch angle,
Class Dia Type Amps Range ROL )

Root GTAW ER90S-B3 2.4 DCEN 70 - 100 N.A. N.A Nil

Further SMAW E9018-B3 2.5 DCEP 70 - 100 N.A. N.A Nil
--do-- SMAW E9018-B3 3.15 DCEP 90 -120 N.A N.A Nil
--do-- SMAW E9018-B3 4.0 DCEP 140 -180 N.A N.A Nil

Approved by Prepared by
([Link]) ([Link])
DGM / WTC Manager / WTC
 Form No. 101 - 401

BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPPALLI-620014
WELDING TECHNOLOGY CENTRE

WELDING PROCEDURE SPECIFICATION Page 1 of 2

WPS. No. : 1034 Date : 30/03/2000 Supporting 1173

Rev. No : 02 Date : 22/09/2007 PQR. No

Welding Process : GTAW + SMAW Type : Manual

(Auto/Semi-Auto/Manual/Machine)
Application : Groove welding of 9 Cr.1Mo.¼V ( P91 / F91 / Gr.91 etc. ) steel components
for site fabrication with preheat & with PWHT.

JOINTS ( QW – 402 )
Joint Design : Groove as per drawing
Backing ( Yes / No ) : GTAW : No ; SMAW : Yes.
Backing Material Type : GTAW : Nil ; SMAW : Metal.
(Metal/Non fusing metal/Non metallic/Others)

BASE METAL ( QW – 403 )

P. No. : 5B Group No. : 2 to P. No : 5B Group No. : 2
Spec. Type & Grade : 9 Cr.1Mo.¼V or equivalent
Chem. Analysis & Mech. Prop. : N.A.
Thickness Range : Groove : 20.0 to 200.0mm Fillet : N.A
Pipe Diameter Range : Groove : Unlimited Fillet : N.A.
Others : Nil

FILLER METALS ( QW – 404 )

GTAW SMAW
AWS No. ( class ) : ER90S – B3 E9015 –B9 Size of Filler metal : Refer Table
Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A.
F. No. : 6 4 Electrode-flux (Class ) : N.A..
A. No. : 2 5 Consumable insert : N.A.
Deposited weld metal thickness range (t)
Groove : 200.0mm Max. GTAW : [Link].( One pass only )
SMAW : Balance (Max.4mm / pass)
Fillet : N.A.
Others : Nil

POSITION ( QW – 405 ) PRE HEAT ( QW – 406 )

Position(s) of Groove : All Preheat Temp.(min) : 220 0C
Position(s) of Fillet : N.A. Interpass Temp. (Max) : 350 0C
Weld Progression.(Up/Down): Vertical up Preheat Maintenance : Nil
Others : Nil Others : After welding cool the joint to
80 – 100 0C & hold it for 1 hour
minimum,before PWHT.
 BHEL Page 2 of 2
Trichirappalli – 14 WPS. No. : 1034 Revision : 02

PWHT ( QW – 407 ) GAS ( QW – 408 )

Temp. Range : 745 ± 15 0C Gases Mix/Purity % [Link].(lpm )
Time Range : 2.5minutes/mm Shielding : Argon 99.99 6 - 14
(Min.60minutes) Trailing : N.A --- ---
Others : Induction heating Backing : Argon 99.99 10 - 25
ROH / ROC :Above 350 0C as below ( For Root welding )
t upto 50mm : 110 0C / hr max.
t 50 – 75mm : 75 0C / hr max.
t above 75mm : 55 0C / hr max.

ELECTRICAL CHARACTERISTICS (QW – 409 )

Current (AC / DC ) : Refer Table Polarity : Refer Table
Amps ( Range ) : Refer Table Volts : Refer Table
Tungsten Electrode type & size : EW Th-2 / EW Ce-2 Ø 2.4mm
Mode of Metal transfer for GMAW : N.A.
Electrode wire feed speed range : N.A.
Pulsing current ( GTAW ) : N.A.

TECHNIQUES ( QW – 409 )
String or weave bead : Root : String; Others : String /weave bead ( Max. 3 Dia. )
Orifice or Gas cup size :6/9
Initial and Interpass cleaning : Chipping / Brushing / Grinding
Method of Back Gouging : Nil
Oscillation : Nil
Contact tube to work distance : N.A.
Multiple or Single pass per side : Single or Multiple
Multiple or Single Electrode : Single
Electrode Spacing : N.A.
Peening : N.A.
Others : Nil

Weld Process Filler metal Current Voltage Travel Others(Hot wire,

Layer range speed Torch angle,
Class Dia Type Amps Range ROL )

Root GTAW ER90S-B3 2.4 DCEN 70 - 100 N.A. N.A Nil

Further SMAW E9018-B9 2.5 DCEP 70 - 100 N.A. N.A Nil
--do-- SMAW E9018-B9 3.2 DCEP 90 -130 N.A N.A Nil
--do-- SMAW E9018-B9 4.0 DCEP 140 -160 N.A N.A Nil

Approved by Prepared by
([Link]) ([Link])
DGM / WTC Manager / WTC
 BHARAT HEAVY ELECTRICALS LIMITED
WELDING TECHNOLOGY CENTRE
Tiruchirappalli-620014

T22 WELDING PROCEDURE SPECIFICATION

Form No. 101-401 Page 1 of 2
WPS No.: 1023 Date: 01.08.97 Supporting PQR No.: 509.118.
Rev. No.: 00 Date: ----
Welding Process: SMAW Type: Manual
(Auto,Semi-Auto,Manual,Machine)
Application: Fillet & Socket welding of P5A tubes/ pipes with PWHT.

JOINTS (QW-402)
Joint Design : Fillet as per drawing
Backing (Yes/No) : Yes.
Backing Material (type) : Metal
Metal/Non fusing metal/
Non metallic/Others

BASE METAL (QW-403)

P. No.:5A Group No.: 1 TO P. No.: 5A Group No.: 1
Spec. Type & Grade : N.A
Chem. Analysis & Mech. Prop : N.A
Thickness Range
Groove: N.A Fillet: Unlimited
Pipe Dia range:
Groove: N.A Fillet: Unlimited
Others: Nil
FILLER METALS (QW-404)
AWS No. (Class): E 9018B3
Specn. No. (SFA): 5.5 Size of filler metal: See table
F. No.: 4 Flux Trade Names: N.A
A. No.: 4 --- Consumable insert: N.A
Electrode |Flux (Class): N.A.
Deposited weld metal thickness range: -
Groove: N.A
Fillet: Unlimited (Max.6 mm per pass)

POSITION (QW-405) PREHEAT (QW-406)

Position of Groove: N.A. Preheat temp. : t < 13: Nil (Min10OC min)
o
Position of fillet: All. t > 13: 150 C
Weld Progression: Vertical up Inter pass temp. (Max.): 300oC
Pre heat maintenance: 200Oc for 2 hrs. for
pipes
Others: Nil
 BHARAT HEAVY ELECTRICALS LIMITED
WELDING TECHNOLOGY CENTRE
Tiruchirappalli-620014

WELDING PROCEDURE SPECIFICATION

Form No. 101-401 WPS No.: 1023 Page 2 of 2

PWHT (QW-407) GAS (QW-408)
Temp. Range: 680-750 ºC Gases Mix% Flow Rt.
Time Range 1Hr/25mm Shielding N.A -- ----
(min.1 Hr. for pipe & ½ hr for tube)
Trailing N.A --- ---
Others: Nil
Backing N.A. --- ---

ELECTRICAL CHARACTERISTICS (QW-409)

Current (AC/DC): See table Polarity: See table
Amps. (Range): -Do- Volts: -do-
Tungsten Electrode type and size: EWTh2 ; Ø 2.4mm
Mode of metal transfer for (GMAW): N.A.
Electrode wire feed speed range: N.A.
Pulsing current (GTAW): Nil

TECHNIQUES (QW-410)
String or Weave Bead: Root & H: String; Others: String/Weave (3 Dia. max.)
Orifice or Gas cup size: N.A.
Initial and inter pass cleaning: Brushing/Chipping/Grinding
Method of back gouging: N.A
Oscillation: N.A
Contact tube to work distance: N.A
Multiple or single pass (per side): Single or Multiple
Multiple or single electrode: Single
Electrode spacing: N.A.
Peening: Nil
Others: Nil
Filler Current Travel Others (hot
Weld Volt
Process Dia. speed wire, torch
Layer Class Type Amps. Range
mm range angle etc.)

All SMAW E9018B3 2.5 DCEP 70-100 N.A. N.A. Nil

-Do- -Do- -Do- 3.15 DCEP 100-140 N.A. N.A. Nil
-Do- -Do- -Do- 4.0 DCEP 140-190 N.A N.A Nil

Approved by: ([Link]) Prepared by: (PSivasubrmainan)

[Link]/WTC WELDING ENGINEER/WTC
 Form No. 101 - 401

T22 BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPPALLI-620014
WELDING TECHNOLOGY CENTRE

WELDING PROCEDURE SPECIFICATION Page 1 of 2

WPS. No. : 1014 Date : 06/11/93 Supporting 118 &

Rev. No : 02 Date : 22/09/07 PQR. No 509

Welding Process : GTAW + SMAW Type : Manual

(Auto/Semi-Auto/Manual/Machine)
Application : Groove welding of P5A tubes / pipes with preheat & with PWHT.

JOINTS ( QW – 402 )
Joint Design : Groove as per drawing
Backing ( Yes / No ) : With or without
Backing Material Type : Metal
(Metal/Non fusing metal/Non metallic/Others)

BASE METAL ( QW – 403 )

P. No. : 5A Group No. : 1 to P. No : 5A Group No. : 1
Spec. Type & Grade : N.A.
Chem. Analysis & Mech. Prop. : N.A.
Thickness Range : Groove : 5.0 to 200.0mm Fillet : N.A
Pipe Diameter Range : Groove : Unlimited Fillet : N.A.
Others : Nil

FILLER METALS ( QW – 404 )

GTAW SMAW
AWS No. ( class ) : ER90S – B3 E9018 –B3 Size of Filler metal : Refer Table
Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A.
F. No. : 6 4 Electrode-flux (Class ) : N.A..
A. No. : 2 4 Consumable insert : N.A.
Deposited weld metal thickness range (t)
Groove : 200.0mm Max. GTAW :[Link].;SMAW:Balance (Max.5mm / pass)
Fillet : N.A.
Others : Nil

POSITION ( QW – 405 ) PRE HEAT ( QW – 406 )

Position(s) of Groove : All Preheat Temp.(min) :t < 13mm : Nil (min 100C )
t > 13mm :1500C)
Position(s) of Fillet : N.A. Interpass Temp. (Max) : 300 0C
Weld Progression.(Up/Down): Vertical up Preheat Maintenance : 150 0C for 2 hrs. for pipes

Others : Nil Others : Nil

 BHEL Page 2 of 2
Trichirappalli – 14 WPS. No. : 1014 Revision : 02

PWHT ( QW – 407 ) GAS ( QW – 408 )

Gases Mix/Purity % [Link].(lpm )
Temp. Range : 680 – 750 0C Shielding : Argon 99.99 6 - 14
Time Range : 2.5 minutes/mm Trailing : N.A --- ---
( Min.30 minutes for tubes & Backing : N.A. --- ---
Min. 60 minutes for pipes )
Others : Nil

ELECTRICAL CHARACTERISTICS (QW – 409 )

Current (AC / DC ) : Refer Table Polarity : Refer Table
Amps ( Range ) : Refer Table Volts : Refer Table
Tungsten Electrode type & size : EW Th-2 / EW Ce-2 Ø 2.4mm
Mode of Metal transfer for GMAW : N.A.
Electrode wire feed speed range : N.A.
Pulsing current ( GTAW ) : N.A.

TECHNIQUES ( QW – 409 )
String or weave bead : Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. )
Orifice or Gas cup size : 6 / 9.
Initial and Interpass cleaning : Chipping / Brushing / Grinding
Method of Back Gouging : Nil
Oscillation : Nil
Contact tube to work distance : N.A.
Multiple or Single pass per side : Single or Multiple
Multiple or Single Electrode : Single
Electrode Spacing : N.A.
Peening : N.A.
Others : Nil

Weld Process Filler metal Current Voltage Travel Others(Hot wire,

Layer range speed Torch angle,
Class Dia Type Amps Range ROL )

Root GTAW ER90S-B3 2.4 DCEN 60 - 110 N.A. N.A Nil

Further SMAW E9018-B3 2.5 DCEP 70 - 110 N.A. N.A Nil
--do-- SMAW E9018-B3 3.15 DCEP 100 -140 N.A N.A Nil
--do-- SMAW E9018-B3 4.0 DCEP 140 -190 N.A N.A Nil

Approved by Prepared by
([Link]) ([Link])
DGM / WTC Manager / WTC
 -Form No. 101 - 401

T11 BHARAT HEAVY ELECTRICALS LIMITED

TIRUCHIRAPPALLI-620014
WELDING TECHNOLOGY CENTRE

WELDING PROCEDURE SPECIFICATION Page 1 of 2

WPS. No. : 1010 Date : 06/11/93 Supporting 555

Rev. No : 05 Date : 22/09/07 PQR. No

Welding Process : GTAW + SMAW Type : Manual

(Auto/Semi-Auto/Manual/Machine)
Application : Butt welding of 1 Cr. ½Mo. / 1¼Cr. ½Mo tubes / pipes
with preheat & with PWHT.

JOINTS ( QW – 402 )
Joint Design : As per Production drawing
Backing ( Yes / No ) : With or without
Backing Material Type : Metal
(Metal/Non fusing metal/Non metallic/Others) :

BASE METAL ( QW – 403 )

P. No. : 4 Group No. : 1 to P. No : 4 Group No. : 1
Spec. Type & Grade : N.A.
Chem. Analysis & Mech. Prop. : N.A.
Thickness Range : Groove : 5.0 to 200.0mm Fillet : N.A
Pipe Diameter Range : Groove : OD > 127mm Fillet : N.A.
Others : Nil

FILLER METALS ( QW – 404 )

GTAW SMAW
AWS No. ( class ) : ER80S – B2 E8018 –B2 Size of Filler metal : Refer Table
Spec. No. ( SFA ) : 5.28 5.5 Flux trade name : N.A.
F. No. : 6 4 Electrode-flux (Class ) : N.A..
A. No. : 2 3 Consumable insert : N.A.
Deposited weld metal thickness range (t)
Groove : 200.0mm Max. GTAW :[Link].;SMAW:Balance (Max.5mm / pass)
Fillet : N.A.
Others : Nil

POSITION ( QW – 405 ) PRE HEAT ( QW – 406 )

Position(s) of Groove : All Preheat Temp.(min) : 1500C)
Position(s) of Fillet : N.A. Interpass Temp. (Max) : 300 0C
Weld Progression.(Up/Down): Vertical up Preheat Maintenance : Nil

Others : Nil Others : Nil

 BHEL Page 2 of 2
Trichirappalli – 14 WPS. No. : 1010 Revision : 05

PWHT ( QW – 407 ) GAS ( QW – 408 )

Gases Mix/Purity % [Link].(lpm )
Temp. Range : 655 ± 150C Shielding : Argon 99.99 6 - 12
Trailing : N.A --- ---
Time Range : 2.5 minutes/mm Backing : N.A. --- ---
( Min.30 minutes)
Others : Nil

ELECTRICAL CHARACTERISTICS (QW – 409 )

Current (AC / DC ) : Refer Table Polarity : Refer Table
Amps ( Range ) : Refer Table Volts : Refer Table
Tungsten Electrode type & size : EW Th-2 / EW Ce-2 Ø 2.4mm
Mode of Metal transfer for GMAW : N.A.
Electrode wire feed speed range : N.A.
Pulsing current ( GTAW ) : N.A.

TECHNIQUES ( QW – 409 )
String or weave bead : Root & 2G : String; Others : String /weave bead ( Max. 3 Dia. )
Orifice or Gas cup size : 6 / 13.
Initial and Interpass cleaning : Chipping / Brushing / Grinding
Method of Back Gouging : Nil
Oscillation : Nil
Contact tube to work distance : N.A.
Multiple or Single pass per side : Multiple
Multiple or Single Electrode : Single
Electrode Spacing : N.A.
Peening : N.A.
Others : Nil

Weld Process Filler metal Current Voltage Travel Others(Hot wire,

Layer range speed Torch angle,
Class Dia Type Amps Range ROL )

Root GTAW ER80S-B2 2.4 DCEN 60 - 110 N.A. N.A Nil

Further SMAW E8018-B2 2.5 DCEP 70 - 110 N.A. N.A Nil
--do-- SMAW E8018-B2 3.15 DCEP 100 -140 N.A N.A Nil
--do-- SMAW E8018-B2 4.0 DCEP 140 -190 N.A N.A Nil

Approved by Prepared by
(Dr. K. P .Dhandapani) (S. Singaravelu)
DGM / WTC Manager / WTC