Wps - Rev 4 First Page Print

CONSULTANTS STICKERCONTRACTORS STICKER

1FOR APPROVALA.P. ORVELL BT.KARATEKE25 NOV 2014

0FOR APPROVALH.KOKSALS.I. ZAIDIT.KARATEKE05 JUL 2013

REV ISSUED FOR PERPARED BY CHECKED BYAPPROVED BYDATE

KINGDOM OF SAUDI ARABIA

CLIENT MINISTRY OF WATER AND ELECTRICTY

PROJECT NAME

EXTENSION OF PHASE-1 WATER SUPPLY TO VILLAGES AT HAIL PROJECT

CONSULTANT

OTAISHAN CONSULTING ENGINEERS

CONTRACTOR

BIN SAMMAR FOR CONTRACTING

DOCUMENT NAMEWELDING PROCEDUR QUALIFICATION RECORD (PQR)

SCALE DOCUMENT NUMBERSHEETS REV

NAWTS-PH1-CPL-MEC-QAC-002A01

ProjectEXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL

ClientMINISTRY OF WATER AND ELECTRICITY (MOWE)

ConsultantOTAISHAN CONSULTING ENGINEERS

ContractorBIN SAMMAR CO.

Document NameWELDING PROCEDURE SPECIFICATION (WPS)

Rev. No0123Document NoPage

Rev. date07 Nov 201308 Dec 201312 May 201415 June 2014WTS-PH1-CPL-MEC-QAC-002Page 17 of 16

CONTENTS

ITEMDESCRIPTIONPAGE

1QUALIFICATION OF WELDING PROCEDURE SPECIFICATION (WPS).3

1.1General3

1.2Proposed Welding Procedure Specification (PWPS)3

1.3Grouping of Materials..3

1.4Welding Procedure Qualification Record (PQR).3

1.5Testing of Qualification Welds3

1.6Qualification of Repair Welding Procedures.3

1.7Re-Tests..4

1.8Procedure Qualification Records (PQR's) and final approval of WPS's..4

2PROCEDURE TO ESTABLISH WPS FOR PROJECT PIPELINE WELD JOINTS..5

2.1WPS Grade X-56, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm, 15.88mm Pipes weld joint.5

2.2WPS Grade X-65, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm, 15.88mm Pipes weld joint.5

2.3Types of tests & certificates for PQR..5

2.4Certificates for Filler Metals & Base Materials6

Appendix-1WPS for API 5L, 36, Grade X56, Pipe Joint Weld with Internal Clamp.7

Appendix-2WPS for API 5L, 36, Grade X56, Pipe Joint Weld with External Clamp8

Appendix-3WPS for API 5L, 36, Grade X56, Pipe Joint Weld Full Penetration Repair9

Appendix-4WPS for API 5L, 36, Grade X56, Pipe Joint Weld Partial Repair10

Appendix-5WPS for API 5L, 36, Grade X56, Pipe Tie-in Weld11

Appendix-6WPS for API 5L, 36, Grade X65, Pipe Joint Weld with Internal Clamp12

Appendix-7WPS for API 5L, 36, Grade X65, Pipe Joint Weld with External Clamp13

Appendix-8WPS for API 5L, 36, Grade X65, Pipe Joint Weld Full Penetration Repair14

Appendix-9WPS for API 5L, 36, Grade X65, Pipe Joint Weld Partial Repair15

Appendix-10WPS for API 5L, 36, Grade X65, Pipe Tie-in Weld..16

Appendix-11 Coupon Test Report..16a

1. QUALIFICATION OF WELDING PROCEDURE SPECIFICATION (WPS)1.1 General

Accredited and experienced test laboratory has to be nominated to perform all necessary destructive testing (DT) and non-destructive testing (NDT) as per requirements of specification of Standard API 1104, Sept 2013 Welding pipeline and related facilities or ASME Sec.IX Qualification for welding and brazing. Further, WPS shall be and follow according to the contract specifications. 1.2 Proposed Welding Procedure Specification (PWPS)Proposed (PWPS) submit for review and approval prior to the beginning of welding procedure qualification. The proposed (WPS) shall be in accordance with the requirements of the applicable standard API 1104, Sept 2013 or ASME section- IX. 1.3 Grouping of Materials

The applicable welding standards API 1104, Sept 2013 and ASME Section IX allow a wide range of materials to be grouped for the qualification of welding procedures. This can be considered sufficient for most applications in pipeline construction.1.4 Welding Procedure Qualification Record (PQR) The qualification test welds will be performed simulating production like clamping, lifting and lowering. All welding parameters and conditions influencing the essential variables will be recorded using calibrated equipment. All welding for procedure qualification and for production will do by using calibrated welding machines.

The quality of the qualification welds will be determined by non-destructive testing (NDT) and destructive testing (DT) as per applicable standards.

1.5 Testing of Qualification Welds

Preparation of test samples and testing will be performed at an approved test laboratory. All qualifications welds will be subjected to (NDT) after completion of welding, if post - weld heat treatment is necessary (NDT) will be performed after treatment. Non-destructive testing consists of the following. Visual Exam

Radiographic/ Ultrasonic Test.

As applicable to the design and specification requirement by using approved equipment and procedures that will be employed for production.

The (NDT) acceptance criteria are defined in the applicable standards and any welds failing to meet the acceptance criteria not be subjected to destructive testing. For destructive testing as a minimum all qualification welds subjected to hardness test. Supplemented by further tests and required in applicable standards.

1.6 Qualification of Repair Welding Procedures: All repairs welding shall be performed in accordance with an approved repair welding WPS and shall be executed by qualified welders. The repair welding WPS is separate from the original welding procedure with the addition of the following:

Method of defect removal

NDT requirements to determine complete removal of detectTo qualify a repair welding procedure, a production weld shall be produced in accordance with the approved WPS and shall be non-destructive tested after completion. If acceptable, a section within the allowable limits has to be removed and re-welded in accordance with the proposed repair procedure. Finally this repair weld has to pass all required test described in the relevant sections of the applicable standards and this specification. 1.7 Re-Tests

General

If the mechanical test fails for whatever reason, it should investigate the cause of the failure, and re-test or re-evaluation of PQR parameters.

If after re-testing the qualification weld finally fails to meet the minimum requirements, a new WPS proposal shall be established and qualification welding and testing repeated. Tensile and Bend Tests

If one tensile test or bend specimens does not meet the acceptance criteria, two additional specimens shall be tested and both have to meet the acceptance criteria.

Hardness Tests

If only one hardness result exceeds the specified maximum then three further impressions shall be made in close proximity to that which failed such that they do not mutually interfere. If all of the further tests are below the specified maximum then the test shall be accepted. 1.8 Procedure Qualification Records (PQR's) and final approval of WPS'sDuring procedure qualification all the parameters used shall be recorded. After complication of the welding procedure qualification a procedure qualification record shall be complied, containing the following information: Revised WPS based on "as-run" parameters

Printout or datasheet of the "as-run" parameters and welding details

Summary of the welding parameters

Certificates of base materials

Certificates of filler metals and other welding consumables

Calibration certificates of equipment

Pre-heated treatment records

PWHT (Post Weld Heat Treatment) records

Visual inspection report of NDT Radiographic and Ultrasonic Reports. Result of destructive testing Coupon Test Reports

Certificate of Welders

Certificate of NDT InspectorsThe final WPS, accompanied by the PQR, shall be submitted for review and approval. Based on satisfactory results the WPS will be stamped and signed as "APPROVED FOR CONSTRUCTION".

2. Procedure to establish WPS for Project Pipeline weld joints2.1 WPS Grade X-56, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm, 15.88mm Pipes weld jointsPrepare WPS for following weld joints for API 5 L, X-56 grade and wall thickness from 4.8mm to 19.1 mm; Pipe outside diameter > 12.750 inch as per API 1104, Sept 20132.1.1 For: Transmission & distribution line. Standard: API 1104, Welding process: SMAW + FCAW; Type of clamp: External, Direction of welding: Uphill/ Downhill, Position:5 G fixed, min 2 welders2.1.2 For: Transmission & distribution line. Standard: API 1104, Welding process: SMAW + FCAW; Type of clamp: Internal Clamp. Position: 5G Fixed. Direction of welding: Downhill

2.1.3 For: Full Penetration Repair, Standard: API 1104, Welding process: SMAW; Direction of welding: Uphill/ Downhill, Position: 5G Fixed

2.1.4 For Partial Repair, Welding process: SMAW, Direction of welding: Downhill.

2.1.5 For: Tie-In Weld. Welding Process: SMAW, External clamp. Uphill/ Downhill. No. of Welders: min 2 welders.

Note: WPS & PQR for weldolet & Fillet-welding for branch-connection with main pipeline based on ASME Boiler & Pressure Vessel Code- IX will be submitted later for base material API 5L, X-56 grade.2.2 WPS Grade X-65, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm, 15.88mm Pipes weld joint

Prepare WPS for following weld joints for API 5 L, X-65 grade and wall thickness from 4.8mm to 19.1 mm; Pipe outside diameter > 12.750 in as per API Standard 1104 21st Edition, Sept 2013.2.2.1 For: Transmission & distribution line. Standard: API 1104, Welding process: SMAW + FCAW; Type of clamp: External, Direction of welding: Uphill/ Downhill, Position:5 G fixed, min 2 welders2.2.2 For: Transmission & distribution line. Standard: API 1104, Welding process: SMAW + FCAW; Type of clamp: Internal Clamp. Position: 5G Fixed. Direction of welding: Downhill2.2.3 For: Full Penetration Repair, Standard: API 1104, Welding process: SMAW; Direction of welding: Uphill/ Downhill, Position: 5G Fixed2.2.4 For Partial Repair, Welding process: SMAW, Direction of welding: Downhill. 2.2.5 For: Tie-In Weld. Welding Process: SMAW, External clamp. Uphill/ Downhill. No. of Welders: min 2 welders.

Note: Base Material (API 1104 Sept.2013; 5.4.2.2) group b: Specified Minimum Yield Strength greater than 42,000 psi but less than 65,000 psi. Group c: For material with a SMYS great or equal to 65,000 psi, each grade shall receive a separate qualification test.

Note: WPS & PQR for weldolet & Fillet-welding for branch-connection with main pipeline based on ASME Boiler & Pressure Vessel Code- IX will be submitted later for base material API 5L, X-65 grade.

2.3 Types of tests & certificates for PQR

Following Types of tests & certificates are required for establishing Procedure Qualification Record (PQR) as per API Standard 1104 21st Edition, Sept 2013 from approved laboratory.

2.3.1 Destructive Test of weld joint of API 5L PSL2, X-56 grade and wall thickness of pipe less than or equal to 12.7 mm for pipe outside diameter > 12.75 inches. Tensile strength . 4 no.

Nick-Break.. 4 no.

Root Bend 4 no.

Face Bend... 4 no. Total 16 no. (Table 2)Radiographic Test (RT) and 16 destructive tests are require for following weld joints of pipe sample of same material grade API 5L, PSL2, X-56 of Transmission & Distribution pipeline.

Weld joint of pipeline produced from Internal or External clamp pipe aligning device. (16 tests) Table 2. For Table 2 & Table 5 refer API standard 1104, 21st Edition, Sept 2013. Weld joint of Tie-in.(16 tests). Refer Table 2. Root Repair of weld joint/ full penetration repair. (5 tests). Refer Table 5. Partial Repair of weld joint.(4 tests) Refer Table 5.2.3.2 Destructive Test of weld joint of API 5L PSL2, X-56 grade and wall thickness of pipe > 12.7 mm for pipe outside diameter > 12.75 inches.

Tensile strength 4 no.

Nick-Break.. 4 no.

Side Bend. 8 no. Total 16 no. (Refer Table 2) Radiographic Test (RT) and 16 destructive tests are require for following weld joints of pipe sample of same material grade API 5L, PSL2, X-56 of Transmission & Distribution pipeline.

Weld joint of pipeline produced from Internal or External clamp pipe aligning device. (16 tests). Refer Table 2. Weld joint of Tie-in.(16 tests). Refer Table 2 Root Repair of weld joint/ full penetration repair. (5 tests) Refer Table 5. Partial Repair of weld joint.(4 tests)Refer Table 5.2.3.3 Destructive Test of weld joint of API 5L PSL2, X-65 grade and wall thickness of pipe > 12.7 mm for pipe outside diameter > 12.75 inches.

Tensile strength . 4 no.

Nick-Break.. 4 no.

Side Bend. 8 no. Total 16 no. (Refer Table 2) Radiographic Test (RT) and 16 destructive tests are require for following weld joints of pipe sample of same material grade API 5L, PSL2, X-56 of Transmission & Distribution pipeline.

Weld joint of pipeline produced from Internal or External clamp pipe aligning device. (16 tests). Refer Table 2. Weld joint of Tie-in.(16 tests) Refer Table 2. Root Repair of weld joint/ full penetration repair. (5 tests) Refer Table 5. Partial Repair of weld joint.(4 tests). Refer Table 5.2.4 Certificates for Filler Metals & Base MaterialsFollowing certificates are required for Filler metal group (Electrode & FCAW wire) & base material:

Inspection certificate of Filler metal group (All electrodes and FCAW wire) issued by manufacturer covering chemical analysis & classification (EN#, AWS & ISO #).

2.4.1 Certificate of compliance of base material (pipe) supplied for Testing.

2.4.1.1 Mill Inspection & Test certificate:

Nondestructive Testing

Destructive Testing

Hydrostatic Testing. D) Dimensional Inspection.

2.4.1.2 Pipe Manufacturers QA Report: Chemical Composition, Tensile, Charpy Impact Test, Guided Bend Test, Viker Hardness Test.

2.4.1.3 Packing list of Pipe Manufacturer.APPENDIX-1: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD WITH INTERNAL CLAMP

WELDING PRECEDURE SPECIFICATIONProject / Contract No

WTS-PH1-CPL-MEC-WPS-001REV 3

WTS-PH1-CPL-MEC-PQR-001PAGE 1

Standard: API 1104, Sept 2013

For : Transmission and Distribution Line

Welding process: SMAW+FCAW

Material: API-5L , Grade X-56

Diameter & Wall thickness: OD>12.75" & from 4.8 to 19.1 mm thickness

Joint design: V Groove

Filler metal : AWS, A-5.1 E6010 /A-5.29 E71T8

Position: 5G Fixed

Direction of welding: Downhill

Number of welders: Min.2 welders

Time lapse between welding: Between root & hot pass 15 min;

weld interruption after finishing 70% of welding only

Type and removal of lineup clamp: Internal Clamp, removal of clamp after finishing root pass

Cleaning & or grinding: Mechanical Brushing & Grinding

Preheat temperature: 50 C

Temperature between passes: 300 C max

Shielding gas & flow rate: NA

Shielding flux: NA

Plasma gas composition: NA

Plasma gas orifice size: NA

Plasma gas flow rate: NA

Joint Design Sketch

Electrical Characteristics and Travel Speed

LAYERPROCESSFILLER MATERIALVOLTAGE

(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED

AWS No (mm)APOLARITYcm/min

ROOTSMAWE60103.2 4 25 30100 110DC ( - )DOWNHILL12 15

HOTFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 - 26

FILLFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26

CAPFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26

CONTRACTORTHIRD PARTY NDT/WELDING INSPECTORCONSULTANT

APPENDIX-2: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD WITH EXTERNAL CLAMP

EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL











Position: 5G Fixed

Direction of welding: Uphill / Downhill




Type and removal of lineup clamp: External Clamp, removal of clamp after finishing 50% of root pass





Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED


ROOTSMAWE60103.2- 4 25 30100 110DC ( - )UPHILL12 15




CONTRACTORCLIENT

APPENDIX-3: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD FULL PENETRATION REPAIR






For : Full Penetration Repair

Welding process: SMAW




Filler metal : AWS, A-5.1 E6010 /A-5.5 E7010

Position: 5G Fixed


Number of welders: 1 welders

Time lapse between welding: NA

Type and removal of lineup clamp: NA





Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED

AWS No (mm)APOLARITYCm/min

ROOTSMAWE60103.2 4.024 2890 100DC ( - )UPHILL7 - 13

HOTSMAWE70104.0 5.024 28100 - 110DC ( + )DOWNHILL10 - 15

FILLSMAWE70104.0 5.024 28135 145DC ( + )DOWNHILL13 - 15

CAPSMAWE70104.0 5.0 24 28130 - 140DC ( + )DOWNHILL13 - 15

CONTRACTORCLIENT

APPENDIX-4: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD PARTIAL REPAIR






For : Partial Repair





Filler metal : AWS, A-5.5 E7010

Position: 5G Fixed









Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED


FILLSMAWE70104.0 5.026 28120 - 130DC ( + )DOWNHILL10 15

CAPSMAWE70104.0 5.026 - 28115 - 125DC ( + )DOWNHILL7 13

CONTRACTORCLIENT

APPENDIX-5: WPS FOR API 5L, 36, Grade X56, PIPE TIE-IN WELD






For : Tie-in Weld





Filler metal: AWS, A-5.1 E6010 /A-5.5 E7010

Position: 5G Fixed










Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED





CAPSMAWE70104.0 5.025 30130 - 140DC ( + )DOWNHILL15 - 26

CONTRACTORCLIENT

APPENDIX-6: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD WITH INTERNAL CLAMP












Position: 5G Fixed





Type and removal of lineup clamp: Internal Clamp, removal of clamp after finishing root pass





Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED


ROOTSMAWE60103.2 4.025 30100 110DC ( - )DOWNHILL12 15




CONTRACTORCLIENT

APPENDIX-7: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD WITH EXTERNAL CLAMP












Position: 5G Fixed










Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED


ROOTSMAWE60103.2 4.025 30100 110DC ( - )UPHILL12 15




CONTRACTORCLIENT

APPENDIX-8: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD FULL PENETRATION REPAIR






For : Full Penetration Repair






Position: 5G Fixed









Shielding flux: NA

Plasma gas composition



Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED


ROOTSMAWE60103.2 - 4.024 2890 100DC ( - )UPHILL7 - 13

HOTSMAWE80104.0 - 5.024 28100 - 110DC ( + )DOWNHILL10 - 15



CONTRACTORCLIENT

APPENDIX-9: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD PARTIAL REPAIR






For : Partial Repair Procedure





Filler metal : AWS, A-5.5 E8010

Position: 5G Fixed









Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED


FILLSMAWE80104.0 5.026 28120 - 130DC ( + )DOWNHILL10 15

CAPSMAWE80104.0 5.026 - 28115 - 125DC ( + )DOWNHILL7 13

CONTRACTORCLIENT

APPENDIX-10: WPS FOR API 5L, 36, Grade X65, PIPE TIE-IN WELD






For : Tie-in Weld






Position: 5G Fixed










Shielding flux: NA




Joint Design Sketch



(V)CURRENTDIRECTION

OF

WELDTRAVEL SPEED






COUPON TEST REPORT

Date_______________________________________________Test No_____________________________________

Location_____________________________________________________________________________________________

State_______________________________________________Weld Position: Roll Fixed

Welder_____________________________________________Mark_______________________________________

Welding Time________________________________________Time of day__________________________________

Mean Temperature___________________________________Wind break used______________________________

Weather conditions____________________________________________________________________________________

Voltage_____________________________________________Amperage___________________________________

Welding machine type_________________________________Welding machine size__________________________

Filler metal___________________________________________________________________________________________

Reinforcement________________________________________________________________________________________

Pipe type and grade____________________________________________________________________________________

Wall thickness_______________________________________Outside diameter_____________________________

Coupon stenciled1234567

Original specimen dimension

Original specimen area

Maximum load

Tensile strength

Fracture location

Procedure Qualified test Qualified

Welder Line test Disqualified

Maximum tensile___________________Minimum tensileAverage tensile

Remarks on tensile-strength test__________________________________________________________________________

1. __________________________________________________________________________________________________

2. __________________________________________________________________________________________________

3. __________________________________________________________________________________________________

4. __________________________________________________________________________________________________

Remarks on bend test___________________________________________________________________________________

1. __________________________________________________________________________________________________

2. __________________________________________________________________________________________________

3. __________________________________________________________________________________________________

4. __________________________________________________________________________________________________

Remarks on nick-break test______________________________________________________________________________

1. __________________________________________________________________________________________________

2. __________________________________________________________________________________________________

3. __________________________________________________________________________________________________

4. __________________________________________________________________________________________________

Test made at __________________________________________Date _________________________________________

Tested by ____________________________________________Supervised by __________________________________

2 (0.5)

30-35

2 (0.5)

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CAP

FILL

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RP

2 (0.5)

30-35

2 (0.5)

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2 (0.5)

CAP

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Weld Preparation;

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RP

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30-35

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30-35

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Weld Preparation;

40

DL

40

50

50

Repair Area

DL : Defect Length

CAP

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RP

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2 (0.5)

30-35

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Documents

Wps - Rev 4 First Page Print