WELDING
PROCEDURE SPECIFICATION
&
PROCEDURE QUALIFICATION
RECORD
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10-Mar-14
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For Review & Comments
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Chris
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SBY SWH
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YDL
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REV.
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DATE
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DESCRIPTION
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PREPARED
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CHECKED
REVIEWED
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APPROVED
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OWNER:
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PROJECT:
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CONTRACTOR:
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PROJET
/ AREA:
SINGAPORE MAINLAND AND JURONG ISLAND
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TITLE :
&
PROCEDURE
QUALIFICATION RECORD
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SCALE
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DOCUMENT NUMBER
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Rev
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SHEET
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NTS
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SUT1-Z05-Q
00-4-006
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A
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1 of 1
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REVISION LOG
REV.
NO.
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REV.
DATE
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REVISED
PAGE
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REVISION
DESCRIPTION
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A
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10-Mar-14
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First Issue
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Table of Contents
1.
Scope……………………………………….… 4
2. Definition………………………………..… 4
3. Reference………………………………..… 4
4. Responsibility……………………………. 5
5. General……………………………………… 5
6. Procedure…………………………………… 6
7. DOCUMENTATION……..……………………… 11
8. Attachment………………………………….. 12
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This procedure is
to delineate the method of WPS & PQR (Welding Procedure Specification
& Procedure
Qualification Record) qualification to the requirements of ASME sec. IX, and
AWS D 1.1 which shall
be prepared and executed for fabrication and construction at the site
of EfW Project @
Sakra at Jurong Island Singapore.
(Hyundai-HEC
Joint Venture - hereinafter, referred to as “HEC”)
2. DEFINITION
2.1 Welding
Procedure Specification (WPS) : A WPS is a written qualified welding
procedure
prepared to provide direction for making
production welds to code requirements.
2.2 Procedure
Qualification Record (PQR) : A PQR is a record of the welding data used to
weld
a test coupon.
2.3 Test
Coupon : A weld or Braze assembly for procedure or performance qualification
testing.
The coupon may be any product from plate, Pipe,
tube, etc., and may be a fillet weld, overlay,
deposited weld metal, etc.
2.4 Test
specimen : A sample of a test coupon for specific test. The specimen may be a
bend test,
impact test, chemical analysis, macro test, etc. A
specimen may be a complete test coupon, for
example, in radiographic testing or small diameter
pipe tension testing.
3. REFERENCE
3.1
ASME SEC.IX Welding and Brazing Qualification
3.2
ASME SEC.II Part C: Specification for Welding Rods, Electrodes and
Filler Materials.
3.3
ASME B31.1, Power Piping
3.4 ASME
B31.3, Process Piping
3.5
API 1104, Welding of Pipelines and Related Facilities
3.6 AWS
D1.1, Structural Steel Welding Code
3.7 API
650, Welded Oil Storage Tanks(If Necessary)
3.8 SUT1-Z05-Q00-4-021
General Welding Procedure
4. RESPONSIBILITY
4.1 The
Construction Manager is responsible for the implement of qualification test
for WPS
and PQR.
4.2
Construction(Welding) Engineer is responsible for preparation and
execution of the
qualification test of WPS and PQR. He is also
responsible for providing of WPS and PQR.
4.3 The
QA/QC Engineer is responsible for witness, control and monitor welding
parameters
during welding procedure qualification test. He is
also responsible for review the WPS
and PQR.
4.4 The
QA/QC Manager or his designee is responsible for certification of WPS and PQR
5. GENERAL
5.1 Qualification
test for WPS and PQR shall be carried out according to applicable code and
specifications described in this procedure,
para.3.0.
5.2 Qualified
WPS shall be used for site welding of permanent piping, pipe line,
equipments, tanks
and steel structure including tack weld.
5.3 Numbering
system for WPS/PQR shall be follow as below;
      WPS: HEC - WPS - -  PQR: HEC - PQR -    
Serial Number; 3
digit
Application Code;
ASME(4 Char.), AWS(3 Char.), etc
The Applying Code and Standard for qualification
of WPS/PQR is following;
- AWS D1.1: Structure welding, Pile welding
- ASME Sec.IX: Above Ground Piping system
Piping system associated to an underground
storage
Field fabricated Tank (API 650) –If necessary
Pressure Vessel(ASME Sec. VIII)
5.4 If any
PQR which was developed in previous project of HEC and satisfied for it’s requirements
of applicable code/standard, it can be utilized for EfW project under SCC
approval. The existing PQR No. should be used without change.
5.5 All
production welding work of this project shall be executed as specified on
qualified
welding procedure specification (WPS) and carried
out by qualified welder or welding
operator for a specific work.
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6. PROCEDURE
6.1 Preparation
of Test coupon and welding consumables
6.1.1 ‘Request for inspection’ of the
Qualification Test shall be submitted to SCC with draft WPS.
6.1.2 Test
coupon should be prepared in accordance with the draft WPS. And it should
have
material classification including grade and
heat number, and unrecognized material shall
not be used for test coupon.
6.1.3 The
Procedure Qualification Test number and welder number or name should be
stamped
on the surface of tack welded test coupon.
6.1.4 After
preparation, test coupon shall be confirmed and verified with mill
certificate by
QA/QC Engineer.
6.1.5 Welding
consumable such as electrodes should be stored and used according to
manufacturer instruction and Welding consumable
control procedure. Before qualification
test, QA/QC Engineer shall verify welding consumables
with mill certificate as per draft
WPS.
6.1.6 When
all inspection and verification is completed for test coupon, install coupon
on the
welding die, and QA/QC Engineer verify coupon
position (5G, 2G, etc) and mark ‘top
position’ on the coupon.
6.2 Welding
and monitoring
6.2.1 Welding should be carried out according to
instruction of draft WPS.
6.2.2 The
M&TEs which measure the welding data shall be prepared.
6.2.3 Follow
welding parameters as minimum shall be monitored and recorded by QA/QC
Engineer during welding of test coupon;
• Pre-heating
• Ampere and voltage for each pass
• Welding time to check travel speed
• Inter-pass temperature
• Welding sequence
• Deposit thickness for each process if multi
process is used
• Consumable size
• Other essential
variable if required
6.2.4 The
welding parameters records should be verified by QA/QC Engineer or SCC, if
required.
6.3 Visual
inspection should be done for welded coupon.
6.4 Post
Weld Heat Treatment should be done if required.
6.5 The
test coupon for AWS D1.1 radiographic test shall be done by accredited NDT
Company.
However the test coupon for ASME Sec.IX the
radiographic test may be examined for
information.
6.6 MT or
PT examination may be done if required.
6.7 The
test coupon which is accepted by visual inspection and NDT shall be sent to
accredited
laboratory for the required mechanical test
according to the requirements of specification,
code and standard.
6.8 If it
is necessary to cut the welded coupon to several pieces because of transportation
to
laboratory, it is required that PQ number,
material classification for each materials and
original location of piece shall be verified by
QA/QC Engineer.
7 DOCUMENTATION
7.1 Construction(Welding) Engineer shall prepare
WPS and PQR with all reference report and
certificate such as NDT report(if required), PWHT
report, laboratory test reports for
mechanical test and mill certification of base
material.
7.2 QA/QC Engineer shall checked and verify the
WPS and PQR with all reference documents.
7.3 QA/QC Manager shall Certify the WPS and PQR.
7.4 The Certified WPS and PQR shall be submitted
to SCC for approval.
7.5 The approved WPS shall be distributed to
related construction department and subcontractor.
The WPS shall be displayed at the welding work
area.
7.6 The approved WPS and PQR shall be controlled
and stored as a Quality Record.
7.7 The tested specimens for qualification of
WPS/PQR shall be identified and stored at site.
8. ATTACHMENT
8.1 Welding
Procedure Specification form (WPS-ASME)
8.2 Welding
Procedure Specification form (WPS-AWS)
8.3 Procedure
Qualification Record form.(PQR-ASME)
8.4 Procedure
Qualification Record form (PQR-AWS)
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Attachment 8.1 : Welding Procedure Specification form(WPS-ASME
Sec. IX)
Attachment 8.2 : Welding Procedure Specification
form(WPS-AWS D1.1)
Attachment 8.3 : Procedure Qualification Record form(PQR-ASME
Sec. IX)
Attachment 8.3 : Procedure Qualification Record form(PQR-AWS
D1.1) Front
Attachment 8.4 : Procedure Qualification Record form(PQR-AWS
D1.1) Back
