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UPPER ZAKUM 750

ISLANDS SURFACE FACILITIES PROJECT - EPC2


PROJECT No. P7512
Petrofac Job No. : PE-103

SUBCONTRACTOR COMMENTS RESOLUTION SHEET


Discipline : QC

Original Document Title : WPS for CRA Date : 25-01-2016


SUBCONTRACTOR’s Original Transmittal No. : DCN-PED-TRA-0278

Original Document No. : P7512-04-001-WM-WPS-0003 Rev : E CONTRACTOR’s Review Comments Transmittal No. :P7512-04-001-TRA-OUT-744 Date : 08-02-2016

CONTRACTOR’s
Serial No. Page No. CONTRACTOR’s COMMENT SUBCONTRACTOR RESPONSE Response
(Open or Closed)
1 - General Comments Closed
Incoporated (Rev.B)
2 General Comments Comments Incorporated

3 Sketched to change Updated

4 PMI Report to Include attached

5 Comments incorporated In corporated in Rev E

SIGNED BY CONTRACTOR SIGNED BY SUBCONTRACTOR

Prepared / Approved By (Name): Prepared / Approved by (Name):


Date :
Signature: Signature: Date :

PE-103-GD-FRM-0023-001-A
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT NO. P7512

WPS FOR CS & LTCS WITH PWHT (GTAW + SMAW)

Doc. No. P7512-04-001-WM-WPS-0003 REV. F PAGE: 1 OF 39

UPPER ZAKUM 750


ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT NO. P7512

CONTRACT NO. : CT750 UZ110110


PETROFAC JOB NO.: PE-103

DES-WPS-A/B-1-003
WELDING PROCEDURE SPECIFICATION
FOR CS &LTCS - NORMALIZED (NACE / NON NACE)
GTAW + SMAW (WITH PWHT)

SUBCON. Document
PQR-A/B-1-003 F
Document. No. Rev.
SUBCON. NO. SUBCON. NAME SUBCONTRACT TITLE

STR, Mechanical & Piping


04-001 DESCON Engineering
Works for all Islands

REVIEW CODE 1 2 3 4 5

Legend:
1. Approved; 2. Approved With Comments; 3. Reviewed With Comments, Correct & Re-Submit;
4. Information Only, Review Not Required; 5. Rejected

Name: Signature: Date:


By Muhammad.Farooq at 6:46 am, Jun 29, 2016

This Document is already reviewed / approved at site by PED/COMPANY


after incorporating all COMMENTS on previous revisions. Refer approval
F 18-JUN-2016 on WPS.
signatures ISSUED FOR APPROVAL NA AH SH

E 22-JAN-2016 ISSUED FOR APPROVAL NA AH SH

D 09-NOV-2015 ADDITIONAL IMPACT TEST ADDED NA AH SH

C 06-SEP-2015 ISSUED FOR REVIEW NA AH SK

B 05-JUL-2015 ISSUED FOR REVIEW NA AH SK

A 08-JUN-2015 ISSUED FOR REVIEW NA AHS SK

PROJ.
REV. DATE DESCRIPTION PRPD CHKD APPD
APPD
UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT NO. P7512

WPS FOR CS & LTCS WITH PWHT (GTAW + SMAW)

Doc. No. P7512-04-001-WM-WPS-0003 REV. F PAGE: 2 OF 39

TABULATION OF REVISED SECTIONS / PAGES


Revision Page / Section Description

TABULATION OF HOLDS

Page / Section Description


UPPER ZAKUM 750
ISLANDS SURFACE FACILITIES PROJECT – EPC2
PROJECT NO. P7512

WPS FOR CS & LTCS WITH PWHT (GTAW + SMAW)

Doc. No. P7512-04-001-WM-WPS-0003 REV. F PAGE: 3 OF 39

CONTENTS

Sr. Description Page

1. WELDING PROCEDURE SPECIFICATION 4-6

2. PQR 7-8

3. PQR RUN SHEET 9-10

4. PQR TESTING REPORTS 11-14

5. WELDING MATERIAL CONSUMABLES CERTIFICATES 15-19

6. BASE MATERIAL CERTIFICATES 20-28

7. NDT TEST REPORTS if (MT/ PT/ RT/ PMI/ UT) 29-30

8. PWHT REPORT 31-32


Doc. No.: AUH/QA&QC/FRM-66
DESCON ENGINEERING ABU DHABI Rev. No.: 00
PROCEDURE QUALIFICATION RECORD (PQR)
Date: 1/Jul/06
Sheet: 2 of 2
PQR-A/B-1-003 Tensile Test (QW-150)
Ultimate
Dimensions Area Ultimate Tensile
Specimen No. Type Total Load Type of Fracture / Location
(mm) (mm)2 Strength (N/mm2)
KN
MT:001 Cross weld 35.40 19.20 679.68 357.70 526 Ductile / Parent Metal (Pipe Side)
MT:002 Cross weld 35.20 19.10 672.32 350.30 521 Ductile / Parent Metal (Pipe Side)
Guided Bend Tests (QW-160)
Specimen No. Specimen Type Bend Angel Result
MT:003 Side Bend 180° Accepted
MT:004 Side Bend 180° Accepted
MT:005 Side Bend 180° Accepted
MT:006 Side Bend 180° Accepted
Charpy Test (QW-170)
Test Impact Values Avg.
Specimen No. Position Dimensions Temp (Jouls) Value Comments
°C 1 2 3 Jouls
007: Weld Center line 90 Deg / Cap 10x10x2V -46.0 48 58 58 55
008: Weld Center line 90 Deg / Root 10x10x2V -46.0 18 28 30 25
009: Heat affected zone 90 Deg / Cap 10x10x2V -46.0 378 380 382 380 A333
010: Heat affected zone 90 Deg / Cap 10x10x2V -46.0 178 252 260 230 LF+2
011: Heat affected zone 90 Deg / Root 10x10x2V -46.0 186 224 72 161 A333
012: Heat affected zone 90 Deg / Root 10x10x2V -46.0 50 68 100 73 LF+2
013: Parent Metal Pipe / Cap 10x10x2V -46.0 378 370 370 373
014: Parent Metal Flange / Cap 10x10x2V -46.0 110 142 146 133
Additional Impact Test (FL, FL+2) as per closure weld philosophy to cover golden joints
* 001: Weld Center Line 90 Deg / Mid-T 10x10x2V -46.0 108 46 42 65 A333
* 002: Fusion Line 90 Deg / Cap 10x10x2V -46.0 230 224 200 218 LF+2
* 003: Fusion Line 90 Deg / Cap 10x10x2V -46.0 96 58 82 77 A333
* 004: Fusion Line 90 Deg / Root 10x10x2V -46.0 196 184 108 163 LF+2
* 005: Fusion Line 90 Deg / Root 10x10x2V -46.0 120 118 70 103 A333
* 006: Fusion Line 90 Deg / Mid-T 10x10x2V -46.0 50 62 224 112 LF+2
* 007: Fusion Line 90 Deg / Mid-T 10x10x2V -46.0 56 60 52 56 A333
* 008: Fusion Line + 2 90 Deg / Cap 10x10x2V -46.0 342 328 318 329 LF+2
8 009: Fusion Line + 2 90 Deg / Cap 10x10x2V -46.0 254 202 180 212 A333
* 010: Fusion Line + 2 90 Deg / Root 10x10x2V -46.0 240 152 310 234 LF+2
* 011: Fusion Line + 2 90 Deg / Root 10x10x2V -46.0 120 134 122 125 A333
* 012: Fusion Line + 2 90 Deg / Mid-T 10x10x2V -46.0 362 320 320 334 LF+2
* 013: Fusion Line + 2 90 Deg / Mid-T 10x10x2V -46.0 180 206 152 179 A333
Macro Examination WQ-183
Specimen No. Position Comments
015:Weld Section 108 Deg No Significant defacts observed . ( See attached Photograph )
Hardness Test Examination (ASTM E384)
Load Depth Number of
Specimen No. Position Methed Max Details
( kgf ) ( mm ) Traverses
016:Weld Section 108 Deg Vickers 10.00 2.00 3 246 See attached table

Results Satisfactory : Yes No Penetration into Parent Metal Yes No

Other Tests
Radiography Test (Report# RT-PQR- 012) Date 19-08-2015 Results : Acceptable
Deposit Analysis : MPI Test (Report# DES-PQR-MPI- 004) Date 14-08-2015 Results : Acceptable
Deposit Analysis : N/A
Welder's Name : M Yasir / M Sulman Stamp No. 20013 / 18494
Tests conducted by : EXOVA Laboratory Test No. A507975, A506385
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with ASME
Sec IX & B31.3
TPIA
DESCON PED ZADCO
COMPLETED BY (If Applicable)
Prepared By Approved By Approved By Approved By

Position

Signature

Name

Date
Descon Engineering
Doc. No.: AUH/QA&QC/FRM-64
DESCON ENGINEERING ABU DHABI
Rev. No.: 00
ACTUAL PARAMETERS FOR PROCEDURE
Date: 1-Jul-06
QUALIFICATION RECORD Sheet: 1 of 2

TEST LOCATION : Descon Engineering AMW Ruwais DATE : 13/08/2015

WPS No. : DES-WPS-A/B-1-003 Actual Joint Design:

PQR No. : PQR-A\B-1-003

BASE METAL : A 333 Gr.6 to A 350 LF2 `

WELDING PROCESS : GTAW

POSITION / PROGRESSION : 6G

DIA. (INCHES) x THICKNESS (mm) : 12" x 35.71 mm


PREHEAT TEMPERATURE °C : 105°C ROOT/HOT DEPOSITION THK. (mm): 5.5 mm

PWHT : YES INTERPASS TEMPERATURE °C: 180 °C (Mix)

HEAT No. / UNIQUE ID: P- 181117 F- 71778

A. CONSUMABLES:

BRAND NAME / TYPE CLASS Ø (mm) HEAT No / LOT No.

1 EASAB E7018-1 3.2 SFP09134


ELECTRODE
2 EASAB E7018-1 4 SF241156

FILLER WIRE ESAB E 80S Ni 2.4 AE20612001

SHIELDING GAS ARGON 99.999% PURE

B. WELDING PROCESS:

FILLER METAL VOLTAGE AMP TRAVEL Shielding Gas


WELD Heat Input
PROCESS POLARITY SPEED Flow Rate
PASS KJ/mm
CLASS Ø (mm) Min Max Min Max (mm / min) (Lt / min)

1(ROOT) GTAW ER 80S Ni1 2.4 11 12 109 120 DCEN 92.8 7 ~18 0.93

2(HOOT) GTAW ER 80S Ni1 2.4 12 12 129 149 DCEN 119.2 7 ~18 0.89

3(FILL) SMAW E 7018-1 H4R 3.2 22 22 110 118 DCEP 84.6 NA 1.84

4(FILL) SMAW E 7018-1 H4R 3.2 23 23 118 140 DCEP 86.7 NA 2.22

5(FILL) SMAW E 7018-1 H4R 3.2 23 24 125 143 DCEP 91.6 NA 2.24

6(FILL) SMAW E 7018-1 H4R 3.2 24 24 130 135 DCEP 71.2 NA 2.73

7(FILL) SMAW E 7018-1 H4R 3.2 23 23 125 128 DCEP 84.7 NA 2.08

8(FILL) SMAW E 7018-1 H4R 3.2 24 25 130 150 DCEP 84.8 NA 2.65

9(FILL) SMAW E 7018-1 H4R 3.2 24 24 134 147 DCEP 76.1 NA 2.78

10(FILL) SMAW E 7018-1 H4R 3.2 24 24 129 138 DCEP 70.8 NA 2.80

11(FILL) SMAW E 7018-1 H4R 4 25 26 144 154 DCEP 86.7 NA 2.77

12(FILL) SMAW E 7018-1 H4R 4 24 30 140 150 DCEP 94.0 NA 2.87

13(FILL) SMAW E 7018-1 H4R 4 23 23 151 155 DCEP 73.4 NA 2.91

Maximum Heat Input 2.96

1 WELDER NAME: Muhammad Yasir STAMP NO.: 20013

2 WELDER NAME: Muhammad sulman STAMP NO.: 18494

Third Party Inspection


COMPLETED DESCON PED Company
(If Applicable)
BY
Prepared By Approved By

Position

Signature

Name

Date
Doc. No.: AUH/QA&QC/FRM-64
DESCON ENGINEERING ABU DHABI
Rev. No.: 00
ACTUAL PARAMETERS OF WELDING
Date: 1-Jul-06
PROCEDURE QUALIFICATION Sheet: 2 of 2

B. WELDING PROCESS:

FILLER METAL VOLTAGE AMP TRAVEL Shielding Gas


WELD Heat Input
PROCESS POLARITY SPEED Flow Rate
PASS CLASS Ø (mm) Min Max Min Max KJ/mm
(mm / min) (Lt / min)
14(FILL) SMAW E 7018-1 H4R 4 22 24 148 155 DCEP 76.8 NA 2.90
15(FILL) SMAW E 7018-1 H4R 4 26 26 151 157 DCEP 85.6 NA 2.86
16(FILL) SMAW E 7018-1 H4R 3.2 23 29 125 133 DCEP 78.2 NA 2.96
17(FILL) SMAW E 7018-1 H4R 3.2 25 28 127 142 DCEP 82.7 NA 2.88
18(FILL) SMAW E 7018-1 H4R 4 24 28 150 155 DCEP 91.8 NA 2.83
19(FILL) SMAW E 7018-1 H4R 4 25 27 151 155 DCEP 84.7 NA 2.96
20(FILL) SMAW E 7018-1 H4R 4 24 28 150 155 DCEP 92.3 NA 2.82
21(FILL) SMAW E 7018-1 H4R 3.2 24 26 122 133 DCEP 76.7 NA 2.70
22(CAP) SMAW E 7018-1 H4R 3.2 22 31 118 125 DCEP 126.5 NA 1.83
23(CAP) SMAW E 7018-1 H4R 3.2 21 32 118 125 DCEP 128.9 NA 1.86
24(CAP) SMAW E 7018-1 H4R 3.2 20 30 121 125 DCEP 129.9 NA 1.73
25(CAP) SMAW E 7018-1 H4R 3.2 21 31 118 125 DCEP 132.1 NA 1.76
26(CAP) SMAW E 7018-1 H4R 3.2 22 32 122 127 DCEP 154.9 NA 1.57
27(CAP) SMAW E 7018-1 H4R 3.2 20 31 118 126 DCEP 150.8 NA 1.55
28(CAP) SMAW E 7018-1 H4R 3.2 20 33 115 129 DCEP 159.1 NA 1.60

Maximum time between Commencement & Completion of weld 2.96


Third Party Inspection
DESCON PED Company
COMPLETED BY (If Applicable)
Prepared By Approved By

Position

Signature

Name

Date
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