Wps - Rev 4 First Page Print

Project
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
Client
MINISTRY OF WATER AND ELECTRICITY (MOWE)
Consultant
OTAISHAN CONSULTING ENGINEERS
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date
WELDING PROCEDURE SPECIFICATION (WPS)

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Document No
WTS-PH1-CPL-MEC-QAC002
Page
Page 2 of 16
Project
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BIN SAMMAR CO.

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2014
Document No
Page
Page 3 of 16
CONTENTS
ITEM
DESCRIPTION
PAG
E
QUALIFICATION OF WELDING PROCEDURE
SPECIFICATION (WPS).
1.1
General
1.2
Proposed Welding Procedure Specification (PWPS)
1.3
Grouping of
Materials
1.4
..
Welding Procedure Qualification Record (PQR)
1.5
.
Testing of Qualification
Welds
1.6
Qualification of Repair Welding
1.7
Procedures.
Re-
Tests
1.8
..
Procedure Qualification Records (PQR's) and final approval of
WPS's..
PROCEDURE TO ESTABLISH WPS FOR PROJECT PIPELINE
WELD JOINTS..
2.1
WPS Grade X-56, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm,
2.2
15.88mm Pipes weld joint.

WPS Grade X-65, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm,
2.3
15.88mm Pipes weld joint.

Types of tests & certificates for
2.4
PQR..
Certificates for Filler Metals & Base
Materials
WPS for API 5L, 36, Grade X56, Pipe Joint Weld with Internal
Clamp.
WPS for API 5L, 36, Grade X56, Pipe Joint Weld with External
Clamp
WPS for API 5L, 36, Grade X56, Pipe Joint Weld Full Penetration
Appendix1
Appendix2
Appendix3
Repair
Project
Client
Consultant
Contractor
Document
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Rev. No
BIN SAMMAR CO.
Rev. date
Appendix4
Appendix5
Appendix6
Appendix7
Appendix8
Appendix9
Appendix10
Appendix11

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WPS for API 5L, 36, Grade X56, Pipe Joint Weld Partial
10
Repair
WPS for API 5L, 36, Grade X56, Pipe Tie-in
11
Weld
WPS for API 5L, 36, Grade X65, Pipe Joint Weld with Internal
12
Clamp
WPS for API 5L, 36, Grade X65, Pipe Joint Weld with External
13
Clamp
WPS for API 5L, 36, Grade X65, Pipe Joint Weld Full Penetration
14
Repair
WPS for API 5L, 36, Grade X65, Pipe Joint Weld Partial
15
Repair
WPS for API 5L, 36, Grade X65, Pipe Tie-in
16
Weld..
Coupon Test Report.
16a
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BIN SAMMAR CO.
Rev. date
1.
i.

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QUALIFICATION OF WELDING PROCEDURE SPECIFICATION

(WPS)
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.
ii.
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.
iii.
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.
iv.
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.
v.
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.
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vi. 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 detect
To 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.
vii.
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.
viii.
Procedure Qualification Records (PQR's) and final approval of WPS's

During 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
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Radiographic and Ultrasonic Reports.

Result of destructive testing
Coupon Test Reports
Certificate of Welders
Certificate of NDT Inspectors
The 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".
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PROCEDURE TO ESTABLISH WPS FOR PROJECT PIPELINE

WELD JOINTS
1. WPS Grade X-56, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm,
15.88mm Pipes weld
joints
Prepare 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 2013
2.1.1
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 welders
2.1.2
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. 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

process: SMAW + FCAW; Type
of clamp: External, Direction of welding:
Uphill/ Downhill, Position:5 G fixed, min 2 welders
2.2.2
process: SMAW + FCAW; Type
of clamp: Internal Clamp. Position: 5G Fixed.
Direction of welding: Downhill
2.2.3
For: Full Penetration Repair, Standard: API 1104, Welding process:
SMAW; Direction of welding: Uphill/ Downhill, Position: 5G Fixed
2.2.4
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
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Page 9 of 16
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.
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)
weld joints of pipe
sample of same material grade API 5L, PSL2, X-56 of
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)
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weld joints of pipe sample of same material grade API 5L, PSL2, X-56 of
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.
4. Certificates for Filler Metals & Base Materials
Following 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.
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APPENDIX-1: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD WITH INTERNAL CLAMP
Project / Contract No
WTS-PH1-CPL-MECREV 3
WPS-001
WTS-PH1-CPL-MECPAGE 1
PQR-001
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Diameter & Wall thickness
Joint design
Filler metal
Position
Direction of welding
Number of welders
Time lapse between
welding
Type and removal of lineup
clamp
Cleaning & or grinding
Preheat temperature
Temperature between
passes
Shielding gas & flow rate
Shielding flux
Plasma gas composition
Plasma gas orifice size
Plasma gas flow rate
:
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

Transmission and Distribution Line
SMAW+FCAW
API-5L , Grade X-56
OD>12.75" & from 4.8 to 19.1 mm thickness
V Groove
AWS, A-5.1 E6010 /A-5.29 E71T8
5G Fixed
Downhill
Min.2 welders
Between root & hot pass 15 min;
weld interruption after finishing 70% of welding only
: Internal Clamp, removal of clamp after finishing root pass

: Mechanical Brushing & Grinding
: 50 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
CAP
FILL
HP
3035
R
P
2
(0.5)
2 (0.5)
Electrical
Characteristics and Travel Speed
LAYER
ROOT
HOT
PROCESS
2
SMAW
(0.5)
FCAW
FILLER MATERIAL
AWS No
(mm)
2
(0.5)
VOLTAGE
(V)
CURRENT
A
POLARITY
E6010
3.2 4
25 30
100 110
DC ( - )
E71T8
2.0
17 - 21
160 - 260
DC ( + )
DIRECTIO
N
OF
WELD
DOWNHIL
L
DOWNHIL
TRAVEL
SPEED
cm/min
12 15
15 - 26
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Document No
FILL
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
CAP
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
CONTRACTOR
THIRD PARTY NDT/WELDING

INSPECTOR
Page
Page 12 of
16
L
DOWNHIL
L
DOWNHIL
L
CONSULTANT
15 26
15 26
APPENDIX-2: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD WITH EXTERNAL CLAMP
WPS-002
PQR-002
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
:
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

SMAW+FCAW
API-5L , Grade X-56
V Groove
AWS, A-5.1 E6010 /A-5.29 E71T8
5G Fixed
Uphill / Downhill
Min.2 welders
: External Clamp, removal of clamp after finishing 50% of
root pass
: 50 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
Project
Client
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Rev. No
BIN SAMMAR CO.
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Page
Page 13 of
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CAP
FILL
HP
3035
R
P
2
(0.5)
2 (0.5)
Electrical
LAYER
PROCES
S
FILLER MATERIAL
CURRENT
VOLTAGE
(V)
E6010
3.2- 4
25 30
100 110
POLARIT
Y
DC ( - )
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
FILL
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
CAP
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
ROOT
HOT
2
SMAW
(0.5)
2 (mm)
(0.5)
AWS No
CONTRACTOR
DIRECTI
ON
OF
WELD
UPHILL
DOWNHIL
L
DOWNHIL
L
DOWNHIL
L
TRAVEL
SPEED
cm/min
12 15
15 - 26
15 26
15 26
CLIENT
APPENDIX-3: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD FULL PENETRATION REPAIR
WPS-003
PQR-003
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

Full Penetration Repair
SMAW
API-5L , Grade X-56
V Groove
AWS, A-5.1 E6010 /A-5.5 E7010
5G Fixed
Uphill / Downhill
1 welders
: NA
: NA
: 100 C
Project
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Temperature between
passes
Shielding flux
2
12 May
2014
3
15 June
2014
Document No
Page
Page 14 of
16
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
Weld Preparation;
40
DL CAP
40
FILL
HP
R
P
50
50
Repair Area
DL : Defect
Length
LAYER
Electrical Characteristics and Travel Speed
PROCES
S
FILLER MATERIAL
AWS No
(mm)
ROOT
SMAW
E6010
3.2 4.0
HOT
SMAW
E7010
4.0 5.0
FILL
SMAW
E7010
4.0 5.0
CAP
SMAW
E7010
4.0 5.0
CONTRACTOR
VOLTAGE
(V)
24 28
24 28
24 28
24 28
CURRENT
90 100
POLARIT
Y
DC ( - )
100 - 110
DC ( + )
135 145
DC ( + )
130 - 140
DC ( + )
CLIENT
DIRECTI
ON
OF
WELD
UPHILL
DOWNHIL
L
DOWNHIL
L
DOWNHIL
L
TRAVEL
SPEED
Cm/min
7 - 13
10 - 15
13 - 15
13 - 15
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Document No
APPENDIX-4: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD PARTIAL REPAIR
WTS-PH1-CPL-MECWPS-004
WTS-PH1-CPL-MECPQR-004
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
:
:
:
:
:
:
:
:
:
:
Page
Page 15 of
16
REV 3
PAGE 1
API 1104, Sept 2013

Partial Repair
SMAW
API-5L , Grade X-56
V Groove
AWS, A-5.5 E7010
5G Fixed
Downhill
1 welders
: NA
: NA
: 100 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
CAP
FILL
HP
Electrical Characteristics
and Travel Speed
LAYER
FILL
PROCESS
SMAW
FILLER MATERIAL
AWS No
(mm)
E7010
4.0 5.0
P
VOLTAGE
(V)
26 28
CURRENT
A
POLARITY
120 - 130
DC ( + )
DIRECTIO
N
OF
WELD
DOWNHIL
L
TRAVEL
SPEED
cm/min
10 15
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date
CAP

0
07 Nov
2013
SMAW
1
08 Dec
2013
E7010
CONTRACTOR
2
12 May
2014
4.0 5.0
3
15 June
2014
26 - 28
Document No
115 - 125
DC ( + )
CLIENT
DOWNHIL
L
Page
Page 16 of
16
7 13
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Rev. No
BIN SAMMAR CO.
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2014
Document No
APPENDIX-5: WPS FOR API 5L, 36, Grade X56, PIPE TIE-IN WELD
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
Page
Page 17 of
16
REV 3
PAGE 1
:
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

Tie-in Weld
SMAW
API-5L , Grade X-56
V Groove
AWS, A-5.1 E6010 /A-5.5 E7010
5G Fixed
Uphill / Downhill
1 welders
root pass
: 50 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
CAP
FILL
HP
3035
R
P
2
(0.5)
2 (0.5)
Electrical
LAYER
ROOT
HOT
PROCESS
2SMAW
(0.5)
SMAW
FILLER MATERIAL
AWS No
E6010
E7010
(mm)
2
(0.5)
3.2 4.0
4.0 5.0
VOLTAGE
(V)
27 35
25 32
CURRENT
A
POLARITY
80 95
130 - 150
DC ( - )
DC ( + )
DIRECTIO
N
OF
WELD
UPHILL
DOWNHIL
TRAVEL
SPEED
cm/min
12 - 15
15 - 26
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date
FILL
CAP

0
07 Nov
2013
1
08 Dec
2013
SMAW
E7010
SMAW
E7010
2
12 May
2014
4.0 5.0
4.0 5.0
3
15 June
2014
25 30
25 30
Document No
120 140
DC ( + )
130 - 140
DC ( + )
CONTRACTOR
L
DOWNHIL
L
DOWNHIL
L
Page
Page 18 of
16
15 - 26
15 - 26
CLIENT
APPENDIX-6: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD WITH INTERNAL CLAMP
WPS-006
PQR-006
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
:
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

SMAW+FCAW
API-5L , Grade X-65
V Groove
AWS, A-5.1 E6010 /A-5.29 E71T8
5G Fixed
Downhill
Min.2 welders
: Internal Clamp, removal of clamp after finishing root pass

: 50 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date

0
07 Nov
2013
1
08 Dec
2013
2
12 May
2014
3
15 June
2014
Document No
Page
Page 19 of
16
CAP
FILL
HP
3035
R
P
2
(0.5)
2 (0.5)
Electrical
LAYER
ROOT
PROCES
S
2
SMAW
(0.5)
FILLER MATERIAL
CURRENT
VOLTAGE
(V)
2 (mm)
(0.5)
AWS No
POLARIT
Y
E6010
3.2 4.0
25 30
100 110
DC ( - )
HOT
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
FILL
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
CAP
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
CONTRACTOR
DIRECTI
ON
OF
WELD
DOWNHIL
L
DOWNHIL
L
DOWNHIL
L
DOWNHIL
L
TRAVEL
SPEED
cm/min
12 15
15 - 26
15 26
15 26
CLIENT
APPENDIX-7: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD WITH EXTERNAL CLAMP
WPS-007
PQR-007
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
:
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

SMAW+FCAW
API-5L , Grade X-65
V Groove
AWS, A-5.1 E6010 /A-5.29 E71T8
5G Fixed
Uphill / Downhill
Min.2 welders
root pass
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date

0
07 Nov
2013
1
08 Dec
2013
Preheat temperature
Temperature between
passes
Shielding flux
2
12 May
2014
3
15 June
2014
Document No
Page
Page 20 of
16
: 50 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
CAP
FILL
HP
3035
R
P
2
(0.5)
2 (0.5)
Electrical
LAYER
PROCES
S
FILLER MATERIAL
CURRENT
VOLTAGE
(V)
E6010
3.2 4.0
25 30
100 110
POLARIT
Y
DC ( - )
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
FILL
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
CAP
FCAW
E71T8
2.0
17 - 21
160 - 260
DC ( + )
ROOT
HOT
2
SMAW
(0.5)
2 (mm)
(0.5)
AWS No
CONTRACTOR
DIRECTI
ON
OF
WELD
UPHILL
DOWNHIL
L
DOWNHIL
L
DOWNHIL
L
TRAVEL
SPEED
cm/min
12 15
15 - 26
15 26
15 26
CLIENT
APPENDIX-8: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD FULL PENETRATION REPAIR
WPS-003
PQR-003
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
:
:
:
:
:
:
:
API 1104, Sept 2013

Full Penetration Repair
SMAW
API-5L , Grade X-65
V Groove
AWS, A-5.1 E6010 /A-5.5 E8010
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.

0
07 Nov
2013
Rev. date
1
08 Dec
2013
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
2
12 May
2014
3
15 June
2014
Document No
Page
Page 21 of
16
: 5G Fixed
: Uphill / Downhill
: 1 welders
: NA
: NA
: 100 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
Weld Preparation;
40
DL CAP
40
FILL
HP
R
P
50
50
Repair Area
DL : Defect
Length
LAYER
Electrical Characteristics and Travel Speed
PROCES
S
FILLER MATERIAL
AWS No
(mm)
ROOT
SMAW
E6010
3.2 - 4.0
HOT
SMAW
E8010
4.0 - 5.0
FILL
SMAW
E8010
4.0 5.0
CAP
SMAW
E8010
4.0 5.0
CONTRACTOR
VOLTAGE
(V)
24 28
24 28
24 28
24 28
CURRENT
90 100
POLARIT
Y
DC ( - )
100 - 110
DC ( + )
135 145
DC ( + )
130 - 140
DC ( + )
CLIENT
DIRECTI
ON
OF
WELD
UPHILL
DOWNHIL
L
DOWNHIL
L
DOWNHIL
L
TRAVEL
SPEED
cm/min
7 - 13
10 - 15
13 - 15
13 - 15
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date

0
07 Nov
2013
1
08 Dec
2013
2
12 May
2014
3
15 June
2014
Document No
APPENDIX-9: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD PARTIAL REPAIR
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
:
:
:
:
:
:
:
:
:
:
Page
Page 22 of
16
REV 3
PAGE 1
API 1104, Sept 2013

Partial Repair Procedure
SMAW
API-5L , Grade X-65
V Groove
AWS, A-5.5 E8010
5G Fixed
Downhill
1 welders
: NA
: NA
: 100 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
CAP
FILL
HP
Electrical Characteristics
and Travel Speed
LAYER
FILL
PROCES
S
SMAW
FILLER MATERIAL
AWS No
(mm)
E8010
4.0 5.0
R
P
VOLTAGE
(V)
26 28
CURRENT
A
POLARIT
Y
120 - 130
DC ( + )
DIRECTI
ON
OF
WELD
DOWNHIL
L
TRAVEL
SPEED
cm/min
10 15
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date
CAP

0
07 Nov
2013
SMAW
1
08 Dec
2013
E8010
CONTRACTOR
2
12 May
2014
4.0 5.0
3
15 June
2014
26 - 28
Document No
115 - 125
DC ( + )
CLIENT
DOWNHIL
L
Page
Page 23 of
16
7 13
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date

0
07 Nov
2013
1
08 Dec
2013
2
12 May
2014
3
15 June
2014
Document No
APPENDIX-10: WPS FOR API 5L, 36, Grade X65, PIPE TIE-IN WELD
WELDING PRECEDURE
SPECIFICATION
Standard
For
Welding process
Material
Joint design
Filler metal
Position
Number of welders
Time lapse between
welding
clamp
Preheat temperature
Temperature between
passes
Shielding flux
Page
Page 24 of
16
REV 3
PAGE 1
:
:
:
:
:
:
:
:
:
:
:
API 1104, Sept 2013

Tie-in Weld
SMAW
API-5L , Grade X-65
V Groove
AWS, A-5.1 E6010 /A-5.5 E8010
5G Fixed
Uphill / Downhill
1 welders
root pass
: 50 C
: 300 C max
:
:
:
:
:
NA
NA
NA
NA
NA
Joint Design Sketch
CAP
FILL
HP
3035
R
P
2
(0.5)
2 (0.5)
Electrical
LAYER
ROOT
HOT
PROCES
S
2
SMAW
(0.5)
SMAW
FILLER MATERIAL
AWS No
E6010
E8010
VOLTAGE
(V)
2 (mm)
(0.5)
3.2 4.0
4.0 5.0
27 35
25 32
CURRENT
A
80 95
130 - 150
POLARIT
Y
DC ( - )
DC ( + )
DIRECTI
ON
OF
WELD
UPHILL
DOWNHIL
TRAVEL
SPEED
cm/min
12 - 15
15 - 26
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.

0
07 Nov
2013
Rev. date
FILL
CAP
1
08 Dec
2013
SMAW
E8010
SMAW
E8010
2
12 May
2014
4.0 5.0
4.0 5.0
3
15 June
2014
25 30
25 30
Document No
120 140
DC ( + )
130 - 140
DC ( + )
L
DOWNHIL
L
DOWNHIL
L
Page
Page 25 of
16
15 - 26
15 - 26
COUPON TEST REPORT

Date______________________________________________
Test No_____________________________________
_
Location____________________________________________________________________________________________
_
State______________________________________________
Weld Position:
Roll
_
Fixed
Welder____________________________________________
Mark_______________________________________
_
Welding
Time of
Time________________________________________
day__________________________________
Mean
Wind break
Temperature___________________________________
used______________________________
Weather
conditions____________________________________________________________________________________
Voltage___________________________________________
Amperage__________________________________
__
_
Welding machine
Welding machine
type_________________________________
size__________________________
Filler
metal___________________________________________________________________________________________
Reinforcement______________________________________________________________________________________
__
Pipe type and
grade____________________________________________________________________________________
Wall
Outside
thickness_______________________________________
diameter_____________________________
Coupon stenciled
Original specimen
dimension
Original specimen
area
Maximum load
Tensile strength
Fracture location
Procedure
Welder
Qualified test
Line test
Qualified
Disqualified
Maximum
tensile___________________
Minimum tensile
Average tensile
Project
Client
Consultant
Contractor
Document
Name
Rev. No
BIN SAMMAR CO.
Rev. date

0
07 Nov
2013
1
08 Dec
2013
2
12 May
2014
3
15 June
2014
Document No
Page
Page 26 of
16
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
__________________________________________
Tested by
____________________________________________
Date
_________________________________________
Supervised by
__________________________________

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Project

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

QUALIFICATION OF WELDING PROCEDURE

Proposed Welding Procedure Specification (PWPS)

Qualification of Repair Welding

PROCEDURE TO ESTABLISH WPS FOR PROJECT PIPELINE

WPS Grade X-56, Diameter 36 and WT 7.93mm, WT 9.53, 12.7mm,

15.88mm Pipes weld joint.

15.88mm Pipes weld joint.

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

QUALIFICATION OF WELDING PROCEDURE SPECIFICATION

Proposed Welding Procedure Specification (PWPS)

Welding Procedure Qualification Record (PQR)

Testing of Qualification Welds

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

vi. Qualification of Repair Welding Procedures: All repairs welding shall be

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

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

Radiographic and Ultrasonic Reports.

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

PROCEDURE TO ESTABLISH WPS FOR PROJECT PIPELINE

For: Transmission & distribution line. Standard: API 1104, Welding

For: Transmission & distribution line. Standard: API 1104, Welding

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)

OTAISHAN CONSULTING ENGINEERS

BIN SAMMAR CO.

WELDING PROCEDURE SPECIFICATION (WPS)

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

MINISTRY OF WATER AND ELECTRICITY (MOWE)