PT.

DUTA GRAHA INDAH Tbk

Project Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Method Statement
ITEM: 00 16-Jul-09

MS 16
Revision Date

WELDING PROCEDURE (PREPARATION)

Prepared by Approve to issue TS SKW

Location Pages

Soroako Sulawesi Selatan 2 of 5

1.0 PURPOSE The purpose of this procedure is to provide guidelines for qualifying WPS required in the pipeline welding work. 2.0 SCOPE This procedure shall be applied for welding procedure qualification test on all WPS established in the pipeline welding work and related works. 3.0 REFERENCE ASME B31.4-2002 : Pipeline Transportation System for Liquid Hydrocarbon and Other Liquid API 1104-2005 : Welding of Pipeline and related Facilities. 4.0 DEFINITION /ABBREVIATION WPS - Welding Procedure Specification. WPQT - Welding Procedure Qualification Test. PQR - Procedure Qualification Record. WQT - Welder Qualification Test. 5.0 PROCEDURES 5.1 WPS preparation 5.1.1 DGI Welding Engineer and Sucofindo Crew would identify and submit to KHP the list of relevant WPS to be used for the project from the pre-accepted WPS. If additional WPS is required, WPS shall be developed and submitted for KHP approval before WPQT. 5.1.2 The Welding Engineer and Sucofindo Crew would formulate the welding procedures to the joint configuration and application. The WPS would reference to ASME B31.4-2002, Pipeline ASME B31.4 paragraph 434.8.3 for WPS for Cross Country Pipeline would be performed in accordance with API 1104. 5.1.3 The proposed WPS would contain all Specification Information (API 1104-2005 paragraph 5.3.2) including the essential welding parameters (API 1104-2005 paragraph 5.4) 5.1.4 Upon approval of the WPS, a WPQT would be carried out in the presence of KHP. KHP shall be informed as soon as possible in advance prior to the testing. 5.2 Step in Conducting WPQT 5.2.1 Prior to commencement of WPQT, the following shall be verified by KHP, DGI welding engineer, Sucofindo Crew. a) Test materials used, including the pipe number, heat number. b) Dimensions of the test materials e.g. length, diameter, thickness etc. c) Edge preparation of the test materials. d) Adequacy of lighting for cleaning and visual inspection.

PT. DUTA GRAHA INDAH Tbk

Project Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Method Statement
ITEM: 00 16-Jul-09

MS 16
Revision Date

WELDING PROCEDURE (PREPARATION)

Prepared by Approve to issue TS SKW

Location Pages

Soroako Sulawesi Selatan 3 of 5

5.2.2

5.2.3 5.2.4 5.2.5

5.2.6 5.2.7

5.2.8 5.2.9

e) Current i.e. amperage and voltage by mean of AC/DC Digital Clamp Meter. f) Setting of current type, polarity including amperage and voltage. g) Correctness of welding consumables to be used as per proposed WPS. Upon fit-up, weld preparation and alignment shall be checked for compliance to the proposed WPS. After fit-up inspection, mark the PQR number, test position and indicate the top of joint position. The test piece shall be secured firmly per the required test position. A trial test may be carried out on a separate specimen prior to welding on the test piece to ensure the welding parameters set out in the WPS are maintained. Monitor and record the following welding parameters in the PQR form on each pass until completion of test weld to ensure compliance within the ranges specified in the proposed WPS. a) Travel speed, wire feed speed current i.e. Amperage and voltage by mean of AC/DC Digital Clamp meter. b) Type of Shielding Gas, Purging Gas & flow rate. c) Direction of travel for vertical welding d) Use of specified welding consumables diameter, electrode stick out length. e) Welding technique i.e. string, weave, split layer. f) Interpass temperature by use of Thermosticks or digital thermometer. g) Approximate width of weld pass. h) Approximate thickness of welds layer. i) Interpass cleaning method. j) Sequence and number of weld passes per layer. Welding would be check with visual inspection and NDT RT (Refer to ASME 13.4-2002 paragraph 434.8.5(a)(1)) DGI Welding Engineer would procees the locations of test specimens on the welded test piece for each type of destructive test before cutting at site or direct dispatch to aft approved independent testing laboratory for both cutting and machining work. The location for removal of the required specimen shall be in accordance with API 1104-2005 paragraph 5.6. The entire required test carried out in the laboratory would be witnessed by the Sucofindo, DGI Representative and Clients Representative. Accordance to API 1104 table 2, type and number of test speciments for PQT are a) For tensile strength are 2 spicements b) For nick-break test are 2 spicements c) For root bend test are 2 spicements d) Fof face bend test are 2 speciments

PT. DUTA GRAHA INDAH Tbk

Project Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Method Statement
ITEM: 00 16-Jul-09

MS 16
Revision Date

WELDING PROCEDURE (PREPARATION)

Prepared by Approve to issue TS SKW

Location Pages

Soroako Sulawesi Selatan 4 of 5

5.2.10 The following would be checked during the course of mechanical testing: a) Identification markings on the specimen (refer to API 1104 Fig-3) to its related PQR number, type of test and number of specimens required. b) Dimensions of Tensile-Strength Test, Nick-Breake Test, Root-and Face-Bend Test, specimens (Refers to API 1104 Fig-4, Fig-5, Fig-6, Fig-7) c) Calibration certificates of Tensile Test and Nick-Break Test equipment are valid. d) Dimensions of guided bend test equipment must be adequate to produce bending radius specified by test code for root (Refer to API 1104 Fig-9). e) Imperfections dimension after Nick-Break Test in exposed weld surface shown in API 1104 Fig-8. 5.2.11 During each test all results would be recorded on the draft copies of test report by the laboratory tester. 5.2.12 Upon completion, test results shall be signed off and a copy extended to the DGI, Sucofindo and KHP representative for signature and evaluation against the test code and specification. 5.2.13 Upon acceptance of the mechanical test results, the WPS/PQR would be prepared by the DGI welding engineer using the format shown in appendix I. The WPS/PQR would be submitted to CLIENT for review and approval. 5.3 Retest 5.3.1 When Retest is not allowed unacceptable defects evaluated by visual, NDT and Mechanical testing shall be cause for rejection. A new test weld shall be required. 5.3.2 When retest is allowed when one of the following mechanical test specimens fails to meet the required acceptance criteria, two additional specimens shall be prepared for retesting. The location of the two additional specimens shall reflect the location of the failed specimen. If one or both of the retest specimens fail, then this shall be cause for rejection. A new weld would be required Prior to retest, a study and evaluation shall be made on the failed test to established probable cause of failure. 6.0 SPECIAL REQUIREMENTS 6. 1 DGI welding engineer and Sucofindo shall be prepared the WPS to simulate, the actual welding conditions and materials to be used for production welding. Limitations imposed by the essential variables of the procedure qualification shall be adhered to in production welding. 6. 2 Only skilled and experienced welder(s) shall be assigned for WPQT to minimize rework.

PT. DUTA GRAHA INDAH Tbk

Project Karebbe HEP- Package K-8A Road and Oil Pipeline Realignment

Method Statement
ITEM: 00 16-Jul-09

MS 16
Revision Date

WELDING PROCEDURE (PREPARATION)

Prepared by Approve to issue TS SKW

Location Pages

Soroako Sulawesi Selatan 5 of 5

7.0 RECORDS All records pertaining to welding qualification test shall be kept by the DGI Welding Engineer. All copies of the approved WPS shall be readily available for reference by the Welders, Welding Engineers and KHP.