WELDING PROCEDURE SPECIFICATION

PROCCESS

APPLICABLE

WELDING

CASING PUMP

WPS NO : 011-WP-WE-07-11
ISSUED BY : DETH

APPROVED BY

DATE BY

: 05 JULY 2011

Procedure Qualification No.01-PQR-A436-07-11

Revision new
Welding Process(es) GTAW
1

SCOPE
This Repair Procedure specification is proposed for repair including building up, of
A436 Casing using GTAW Welding process with matching filler material, and postweld heat treatment.

2
Applicable document
2 1 The following standard, specification,code and related document form part of this welding

procedure to extend specified here in

2 1 1. American society of mechanical engineers
2 1 2. Section IX Welding and Brazing Qualification
3
Base Material
3 1 The Base metal/s to be repair welded under this welding procedure specification, shall be

that specified below.

Ni- Resist(A-436 )

4
Prepare before Welding process
4 1 Cleaning

4.

All area to be welded should be cleaning by using chemical and/ or mechanical

Chemical should be use alkaline Solution then Follow by mechanical by using aluminumoxide grit 80-120
2 Removing any stress concentraction
Remove any sharp edges, cracks,dent and heavy scracth on areas to welded by using
Grinding process, under penetrant tested
Welding
All welding peformed under this procedure using GTAW method

6
Welding Equipment
6 1 All Welding power sources use in the performance of production welding to this specification

shall be of DC constant current type and shall be capable of maintaining a uniform output
throughout their entire operation range
6 2 All welding power sources used shall be equipped with control capable of infinitely the weld6.

ing Current
3 Cable, Lug, electrode holder,ground Clamp,power source,controls,and related item shall be
suitable for the work being performed and shall be maintained in good kondition.

WELDING PROCEDURE SPECIFICATION

PROCCESS

APPLICABLE

WELDING TIG

CASING PUMP

WPS NO : 007-WP-WE-08-09
ISSUED BY : DETH

APPROVED BY

DATE BY

: 22 AUGUST 2009

Filler Metal
Welding electrode/filler use in performing production welding specified below:
Ni Cr

Base metal preparation

8 1 Casting shall be prepared for repair welding in general accord the procedure specified
below
8

8 1 1. Thermal method

Where arc-Air gouging is employed the casting shall be uniformly preheat to a minimum
400 deg F. Before applying the arc air process
Where thermal method are used this shall be followed by mechanical removal
8 1 2. Mecanical method

Discrepant areas shall be prepared for welding using one or more of the mechanical method
as specified belom
Grinding
Chiping
Machining
Preparation of the casting shall be performed carefully to ensure removal of all discrepant
material. Following removal of all discrepant metal the wall of the resltant excavation shall
be tapered as required to minimize the posibility of lack of fusion type weld depect
8 1 3. where preheating is required the temperature shall be monitored by use of one or more

method specified bellow

- Temperature indicating crayons
- Contact pyrometer
- Thermocouple
- Laser detector
9
BACKING MATERIAL
9 1 Where depect extend through the wall, backing materials shall be used to facilitate filling

the excavation. The type of backing material shall be as specified below:

9 1 1. Back up material shall be pabricated for P No 1 steel and shall be formed
and fitted to undeside of the casting the minimum overlap should be 1/4 inch on all side
9 1 1. Where backing material is to remain in place then the back-up plate should be joined to

undeside of the casting with a contnuous fillet weld.

9 1 1. Where backing material is to removed after excavation has been filled. Then the backing

need only be tack welded in place on the underside casting

WELDING PROCEDURE SPECIFICATION

PROCCESS

APPLICABLE

WELDING TIG

CASING PUMP

WPS NO : 007-WP-WE-08-09
ISSUED BY : DETH

APPROVED BY
DATE BY

: 22 AUGUST 2009

10
CLEANING
10 1 Prior to Welding

Following verification that all discrepants material has been removed, the repair areas shall
be cleaned as required to remove all oil, grease, paints, water, shop oil, and other foriegn
material detrimental to welding. This should be followed by wipping with clean paper wiper
moistened with isopropyl alcohol. This should be continue with fresh wiper until no more
soil can be removed.
10 2 Interpass Cleaning

All slags and other foregn material shall be removed from each weld bead prior to desposition of additional weld passes. This shall be accomplished using wire brush with aclean
satain less steel brush. Follow by blowing with clean dry air.
Following this each weld bead shall be inspected visually in adequate light and any
discrepant material removed by grinding
10 3 Post Weld Cleaning

following completion of the weld of the final weld surface should be cleaned of all slag and
other foreign material as detail in paragraph 10.1 and the surface visually examined for
defects open to the surfaces. Any dicrepant material noted shall be removed and repaired
11
PREHEATING
11 1 Uniformly preheat the casting to minimum temperature of 200 deg F. Preheating shall be

accomplished using one more of the method specified below

- Furnance
- Induction
- Resistance
- Gas burner
where gas burner are used care shall be taken to avoid direct flame impingement to the
cating
11 2 where preheating temperature shall be monitored by use of one or more

method specified bellow

- Temperature indicating crayons
- Contact pyrometer
- Thermocouple
- Laser detector
11 3 Where local surface heating source are employed the heat source should be removed and

a minimum of 60 seconds shall be alapse before temperature leading are taken.

12

INTERPASS TEMPERATURE
The maximum interpass temperature shall be 800 deg F. Interpass temperature shall be

WELDING PROCEDURE SPECIFICATION

PROCCESS

APPLICABLE

WELDING TIG

CASING PUMP

WPS NO : 007-WP-WE-08-09
APPROVED BY

D BY : DETH

DATE BY

: 22 AUGUST 2009

maintained and shall be monitored continuously throughout the repair welding cycle,
The minimum interpass temperature shall be 700 deg F.
13

POSTWELD HEATREATMENT

13 1 All welding repaired castings shall be postweld stress relieved as specified below:
13 1 1. Following completion of the repair allow the casting temperature to fall to 600 deg F

to ensure completion of the transformation to martensite. Cooling must be accomplished

in still air.
13 1 2. When casting has reached a temperature of 300 deg F the casting should be placed in

furnace.
furnace. Temperature at this time should be 600 deg F
casting temperature should not be permitted to fall below 300 deg F at any time.
3. Increase furnace temperature at rate not exceeding 1150 deg F.
4. Hold temperature for a minimum of one hour per inch.
5. Furnace cool at rate permitted temperature
6. Remove Casting from furnace when it has cool to 600 deg F and allow it to cool to room

temperature
14
WELDING TECHNIQUE
1 The maximum weld bead thickness shall be 5/32 inch
2 Weld bead shall be limited to four (4) time the wire diameter
3 Welding parameter should be in accordance with welding parameter chart

BASECASING

WELD PARAMETER CHART

WELD
LAYER/PASS

1-2 / 1-6
3-6 / 1-6
7-8 / 1-7

FILLER METAL
TYPE
NiFe-CI
NiFe-CI
NiFe-CI

SIZE
1/8"
5/32"
3/16"

ARC VOLTAGE

AMPERAGE

24
25
25

40
70
90

26
28
28

70
110
140