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)