WELDING PROCEDURE SPECIFICATION & PROCEDURE QUALIFICATION RECORD

REVISION LOG

REV. NO.	REV. DATE	REVISED PAGE	REVISION DESCRIPTION
A	10-Mar-14		First Issue

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

1. SCOPE

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.

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)

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

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Wednesday, 12 March 2014

WELDING PROCEDURE SPECIFICATION & PROCEDURE QUALIFICATION RECORD

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