wps - rev 4 first page print
DESCRIPTION
WPS FOR WELDINGTRANSCRIPT
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
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-002REV 3
WTS-PH1-CPL-MEC-PQR-002PAGE 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: Uphill / 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: External Clamp, removal of clamp after finishing 50% of 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 ( - )UPHILL12 15
HOTFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 - 26
FILLFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26
CAPFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26
CONTRACTORCLIENT
APPENDIX-3: WPS FOR API 5L, 36, Grade X56, PIPE JOINT WELD FULL PENETRATION REPAIR
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-003REV 3
WTS-PH1-CPL-MEC-PQR-003PAGE 1
Standard: API 1104, Sept 2013
For : Full Penetration Repair
Welding process: SMAW
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-5.5 E7010
Position: 5G Fixed
Direction of welding: Uphill / Downhill
Number of welders: 1 welders
Time lapse between welding: NA
Type and removal of lineup clamp: NA
Cleaning & or grinding: Mechanical Brushing & Grinding
Preheat temperature: 100 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 4.024 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
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-004REV 3
WTS-PH1-CPL-MEC-PQR-004PAGE 1
Standard: API 1104, Sept 2013
For : Partial Repair
Welding process: SMAW
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-5.5 E7010
Position: 5G Fixed
Direction of welding: Downhill
Number of welders: 1 welders
Time lapse between welding: NA
Type and removal of lineup clamp: NA
Cleaning & or grinding: Mechanical Brushing & Grinding
Preheat temperature: 100 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
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
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-005REV 3
WTS-PH1-CPL-MEC-PQR-005PAGE 1
Standard: API 1104, Sept 2013
For : Tie-in Weld
Welding process: SMAW
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-5.5 E7010
Position: 5G Fixed
Direction of welding: Uphill / Downhill
Number of welders: 1 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: External Clamp, removal of clamp after finishing 50% of 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 4.027 3580 95DC ( - )UPHILL12 - 15
HOTSMAWE70104.0 5.025 32130 - 150DC ( + )DOWNHILL15 - 26
FILLSMAWE70104.0 5.025 30120 140DC ( + )DOWNHILL15 - 26
CAPSMAWE70104.0 5.025 30130 - 140DC ( + )DOWNHILL15 - 26
CONTRACTORCLIENT
APPENDIX-6: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD WITH INTERNAL CLAMP
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-006REV 3
WTS-PH1-CPL-MEC-PQR-006PAGE 1
Standard: API 1104, Sept 2013
For : Transmission and Distribution Line
Welding process: SMAW+FCAW
Material: API-5L , Grade X-65
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 4.025 30100 110DC ( - )DOWNHILL12 15
HOTFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 - 26
FILLFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26
CAPFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26
CONTRACTORCLIENT
APPENDIX-7: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD WITH EXTERNAL CLAMP
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-007REV 3
WTS-PH1-CPL-MEC-PQR-007PAGE 1
Standard: API 1104, Sept 2013
For : Transmission and Distribution Line
Welding process: SMAW+FCAW
Material: API-5L , Grade X-65
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: Uphill / 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: External Clamp, removal of clamp after finishing 50% of 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 4.025 30100 110DC ( - )UPHILL12 15
HOTFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 - 26
FILLFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26
CAPFCAWE71T82.017 - 21160 - 260DC ( + )DOWNHILL15 26
CONTRACTORCLIENT
APPENDIX-8: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD FULL PENETRATION REPAIR
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-003REV 3
WTS-PH1-CPL-MEC-PQR-003PAGE 1
Standard: API 1104, Sept 2013
For : Full Penetration Repair
Welding process: SMAW
Material: API-5L , Grade X-65
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-5.5 E8010
Position: 5G Fixed
Direction of welding: Uphill / Downhill
Number of welders: 1 welders
Time lapse between welding: NA
Type and removal of lineup clamp: NA
Cleaning & or grinding: Mechanical Brushing & Grinding
Preheat temperature: 100 C
Temperature between passes: 300 C max
Shielding gas & flow rate: NA
Shielding flux: NA
Plasma gas composition
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 - 4.024 2890 100DC ( - )UPHILL7 - 13
HOTSMAWE80104.0 - 5.024 28100 - 110DC ( + )DOWNHILL10 - 15
FILLSMAWE80104.0 5.024 28135 145DC ( + )DOWNHILL13 - 15
CAPSMAWE80104.0 5.024 28130 - 140DC ( + )DOWNHILL13 - 15
CONTRACTORCLIENT
APPENDIX-9: WPS FOR API 5L, 36, Grade X65, PIPE JOINT WELD PARTIAL REPAIR
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-004REV 3
WTS-PH1-CPL-MEC-PQR-004PAGE 1
Standard: API 1104, Sept 2013
For : Partial Repair Procedure
Welding process: SMAW
Material: API-5L , Grade X-65
Diameter & Wall thickness: OD>12.75" & from 4.8 to 19.1 mm thickness
Joint design: V Groove
Filler metal : AWS, A-5.5 E8010
Position: 5G Fixed
Direction of welding: Downhill
Number of welders: 1 welders
Time lapse between welding: NA
Type and removal of lineup clamp: NA
Cleaning & or grinding: Mechanical Brushing & Grinding
Preheat temperature: 100 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
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
EXTENSION OF PHASE-1 WATER SUPPLY PROJECT TO VILLAGES AT HAIL
WELDING PRECEDURE SPECIFICATIONProject / Contract No
WTS-PH1-CPL-MEC-WPS-005REV 3
WTS-PH1-CPL-MEC-PQR-005PAGE 1
Standard: API 1104, Sept 2013
For : Tie-in Weld
Welding process: SMAW
Material: API-5L , Grade X-65
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-5.5 E8010
Position: 5G Fixed
Direction of welding: Uphill / Downhill
Number of welders: 1 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: External Clamp, removal of clamp after finishing 50% of 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 4.027 3580 95DC ( - )UPHILL12 - 15
HOTSMAWE80104.0 5.025 32130 - 150DC ( + )DOWNHILL15 - 26
FILLSMAWE80104.0 5.025 30120 140DC ( + )DOWNHILL15 - 26
CAPSMAWE80104.0 5.025 30130 - 140DC ( + )DOWNHILL15 - 26
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)
2 (0.5)
2 (0.5)
CAP
FILL
HP
RP
2 (0.5)
30-35
2 (0.5)
2 (0.5)
2 (0.5)
CAP
FILL
HP
RP
Weld Preparation;
40
DL
40
50
50
Repair Area
DL : Defect Length
CAP
FILL
HP
RP
CAP
FILL
HP
RP
2 (0.5)
30-35
2 (0.5)
2 (0.5)
2 (0.5)
CAP
FILL
HP
RP
2 (0.5)
30-35
2 (0.5)
2 (0.5)
2 (0.5)
CAP
FILL
HP
RP
2 (0.5)
30-35
2 (0.5)
2 (0.5)
2 (0.5)
CAP
FILL
HP
RP
Weld Preparation;
40
DL
40
50
50
Repair Area
DL : Defect Length
CAP
FILL
HP
RP
CAP
FILL
HP
RP
2 (0.5)
30-35
2 (0.5)
2 (0.5)
2 (0.5)
CAP
FILL
HP
RP