Indian Engineer · WPS Helper 2026
Welding Procedure Validation & Inspection Audit Report
Cross-code engine: ASME IX · AWS D1.1 · API 1104 · BS EN ISO 15614 · IBR
IEW-AUD-0008-20261022
Issued: 22 Oct 2026
QA/QC Controlled Document
| WPS Number / Rev | WPS-IEW-2026-108 · Rev. 0 | Governing Code | ASME IX |
| Title | DMW nozzle attachment P-1 shell to P-8 nozzle neck (filler under review) | ||
| Fabricator | Godrej & Boyce Mfg. Co. Ltd., Mumbai | Domain | Pressure Vessel |
| Prepared By | Er. Vikram J. Patil | Registry Status | NON_COMPLIANT |
1 · Procedure Variables (QW-400 mapping)
| Variable | Declared Value | Variable Class |
|---|---|---|
| Welding process | GTAW | Essential |
| Joint type / design | J-Groove — Set-in nozzle, J-groove + external fillet, buttered edge prep | Non-Essential |
| Base metal | SA-516 Gr.70 + SA-240 Type 316L | Essential |
| P-Number / Group | P-No. 1 Gr.2 ↔ P-No. 8 | Essential |
| Qualified thickness range | 8 – 16 mm | Essential |
| PQR coupon thickness | 16 mm | Essential |
| Diameter range | Nozzle NPS 2–8 | Essential |
| Filler spec / class | SFA-5.18 / ER70S-6 | Essential |
| F-Number / A-Number | F-No. 6 / A-No. 1 | Essential |
| Preheat minimum | 95 °C | Essential |
| Interpass maximum | 150 °C | Essential |
| PWHT | Not required | Essential |
| Current / polarity | DCEN | Essential |
| Amperage | 100 – 170 A | Non-Essential |
| Voltage | 11 – 15 V | Non-Essential |
| Travel speed | 80 – 130 mm/min | Non-Essential |
| Heat input ceiling | 2 kJ/mm | Non-Essential |
| Shielding gas / flow | Argon 99.99% (I1) / 14 L/min | Essential |
| Backing gas | Argon 99.99% | Suppl. Essential |
| Position | 6G | Non-Essential |
| Notch toughness regime | Not invoked | Supplementary |
| Supporting PQR | PQR-DMW-2026-108 | Essential |
2 · Automated Compliance Verdict
FAIL
Non-Compliant
Engine run of 24 Feb 2026, 09:30 pm by v.patil@godrej.com evaluated 30 cross-code rules against ASME IX with clause-level evidence for every finding.
Passed: 29 · Warnings: 0 · Failures: 1 · Compliance score: 97 / 100
The procedure shall NOT be released for production welding until all essential and supplementary-essential deviations are dispositioned and the WPS is re-validated.
3 · Clause-Level Findings
| # | Variable / Rule | Class | Clause Ref. | Result | Remarks |
|---|---|---|---|---|---|
| 1 | Dissimilar-metal weld compatibility | Essential | QW-403.2 / QW-403.3 | FAIL | P-No. 1 ↔ P-No. 8: carbon/low-alloy filler (A-No. 1) not permitted on DMW to austenitic base metal; use ER309L/ENiCrFe class (A-No. 8/10). |
| 2 | Supporting PQR referenced | Essential | QW-200.1 / QW-200.2 | PASS | Qualified by PQR PQR-DMW-2026-108. Traceability established. |
| 3 | Base metal P-Number assigned | Essential | QW-403.1 / QW-422 | PASS | Base metal group P-No. 1 Gr.2 — SA-516 Gr.70 + SA-240 Type 316L. |
| 4 | Thickness qualification range (coupon) | Essential | QW-451.1 / QW-451.2 | PASS | Range 8–16 mm within qualified 1.5–32 mm for 16 mm test coupon. |
| 5 | Thickness range sanity | Non-Essential | QW-451 | PASS | Commercial range 8–16 mm is within conventional procedure limits. |
| 6 | Small-bore thin-wall root control | Non-Essential | QW-404.30 / QW-405 | PASS | Small-bore root check applicable to piping only. |
| 7 | Minimum preheat temperature | Essential | QW-406.1 | PASS | Preheat ≥ 95°C satisfies the 10°C minimum for P-No. 1 base metal. |
| 8 | Interpass temperature ceiling | Essential | QW-406.3 | PASS | Interpass 150°C within 315°C ceiling. |
| 9 | Thermal window logic | Non-Essential | QW-406 | PASS | Thermal window 95–150°C is internally coherent. |
| 10 | Mandatory PWHT by thickness/code | Essential | QW-407.1 / UCS-56 | PASS | 16 mm within 32 mm exemption threshold — PWHT correctly waived with documented basis. |
| 11 | PWHT cycle parameters | Essential | QW-407.4 / QW-407.5 | PASS | PWHT not required — cycle parameters not applicable. |
| 12 | PWHT soak window & hold adequacy | Suppl. Essential | QW-407.5 / UCS-56 Table | PASS | PWHT not required — soak band check not applicable. |
| 13 | F-Number consistent with process | Essential | QW-404.3 / QW-432 | PASS | F-No. 6 (ER70S-6) is consistent with GTAW. |
| 14 | Weld-metal A-Number compatibility | Essential | QW-404.5 / QW-442 | PASS | A-No. 1 weld deposit is chemically matched to P-No. 1. |
| 15 | Shielding gas / medium per process | Essential | QW-408.1 | PASS | Shielding medium “Argon 99.99% (I1)” acceptable for GTAW. |
| 16 | Root backing gas protection | Suppl. Essential | QW-408.5 / QW-408.8 | PASS | Root protection declared: Argon 99.99%. |
| 17 | Shielding gas flow rate | Non-Essential | QW-408.1 | PASS | Flow 14 L/min within the 8–20 L/min band for GTAW. |
| 18 | Current type & polarity | Essential | QW-409.1 / QW-409.4 | PASS | DCEN polarity consistent with GTAW and ER70S-6. |
| 19 | Amperage operating window | Non-Essential | QW-409.2 / QW-409.3 | PASS | Amperage 100–170 A inside the GTAW operating envelope. |
| 20 | Arc voltage operating window | Non-Essential | QW-409.4 | PASS | Voltage 11–15 V inside the GTAW operating envelope. |
| 21 | Travel speed control | Non-Essential | QW-409.9 | PASS | Travel speed 80–130 mm/min is plausible for GTAW. |
| 22 | Heat input ceiling (toughness) | Suppl. Essential | QW-409.1 (suppl. essential) | PASS | Computed worst-case heat input ≈ 1.91 kJ/mm (declared ceiling 2 kJ/mm) — no toughness restriction invoked. |
| 23 | Welding position qualification | Non-Essential | QW-405 / QW-461.9 | PASS | 6G inclined-fixed qualification covers all pipe groove positions (QW-461.9 matrix). |
| 24 | GMAW metal-transfer mode | Essential | QW-409.32 | PASS | Transfer-mode variable applies to GMAW only (GTAW exempt). |
| 25 | Process admissibility under code | Essential | QW-250 series | PASS | GTAW is an admissible process under ASME IX. |
| 26 | ISO 15614 impact-test mandate | Suppl. Essential | QW-403.5 | PASS | Impact regime not invoked for the declared thickness/application. |
| 27 | Storage-tank qualification route | Essential | QW-200 (via API 650 §9.2) | PASS | Tank-specific routing not applicable. |
| 28 | IBR statutory governance | Essential | QW-201 | PASS | IBR statutory route not applicable to this scope. |
| 29 | Administrative data completeness | Non-Essential | QW-201.1 | PASS | Administrative header fields adequately populated for issue. |
| 30 | Group Number under toughness | Suppl. Essential | QW-403.5 | PASS | Group-No. split applies only when notch toughness is specified. |
4 · Traceability Excerpt
| Timestamp | Actor | Action | Details | Source IP |
|---|---|---|---|---|
| No audit events recorded for this entity. | ||||
Prepared By
Welding Engineer (IWE)
Er. Vikram J. Patil
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Reviewed By
QA/QC Manager
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Approved By
Client / TPI Inspector
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