qcp-04 - welding procedure qualification - qc procedure

8/9/2019 QCP-04 - Welding Procedure Qualification - QC Procedure

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q Doc Ref: QCP-04QUALITY CONTROL Date : 1" January 2009Kencana Infrastructure PROCEDURE Revision No : 0

I " Cover Page

ICONTROLLED COpy NO. IWELDING PROCEDURE QUALIFICATION

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KENCANA INFRASTRUCTURE SDN BHDREV NO. DATE PREPARED BY REVIEWED BY APPROVED BY

NAME SIGN DATE NAME SIGN DATE NAME IGN r DATE0 26.12.08 TLS 7"-l - 15.12.08 Suryono .t (>.Ib, 22.12.08 co /vCV;' 26 .1208

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Date : 1st January 2009

Revision No : 0

WELDING PROCEDUREQUALIFICATION

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TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 REFERENCES 2

4.0 DEFINITIONS / ABBREVIATION 2

5.0 PROCEDURES 2

5.1 WPS PREPARATION. 2

5.2 STEP IN CONDUCTING WPQT. 3-5

5.3 RE-TEST. 6

6.0 SPECIAL REQUIREMENT 6

7.0 RECORDS 6

APPENDICES

APPENDIX I - WELDING PROCEDURE SPECIFICATION

APPENDIX II - PROCEDURE QUALIFICATION RECORD.


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1.0 PURPOSE

The purpose of this procedure is to provide guidelines for qualifying WPS required in thesteel fabrication works.

2.0 SCOPE

This procedure shall be applied for welding procedure qualification test on all WPSsestablished in the fabrication of structure, process pipe-works, pressure vessels andrelated works.

3.0 REFERENCE

AWS D1.1, 2006 : Structural Welding CodeASME IX 2007 : Steel Welding and Brazing QualificationAPI 1104, 2005 : Welding of Pipeline and related Facilities.BS EN 288-3 :1992(Part 3) Welding Procedure test for Arc Welding of Steel.

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 KIs Welding Engineer shall identify and submit to CLIENT the list ofrelevant WPS to be used for the project from the pre-accepted WPS. Ifadditional WPS is required. WPS shall be developed and submitted forClients approval before WPQT.

5.1.2 The Welding Engineer shall formulate the welding procedures to the jointconfiguration and application. The WPS shall be prepared as per AWSD1.1 for structural and ASME IX for piping or other code requirements.(See appendix I for the WPS format).

5.1.3 The proposed WPS shall contain all the essential welding parameterswhichever are applicable as per appendix I.

5.1.4 Upon approval of the WPS, a WPQT shall be carried out in the presence ofCLIENT Representative. CLIENT Representative shall be informed 48 hrsin advance prior to the testing.


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5.2 Step in Conducting WPQT

5.2.1 Prior to commencement of WPQT, the following shall be verified byCLIENTs representative and KIs welding engineer.

a) Test material (s) used, including the heat number.

b) Dimensions of the test material (s) e.g. length, diameter, thickness etc.

c) Edge preparation of the test material (s).

d) Adequacy of lighting for cleaning and visual inspection.

e) Current i.e. amperage and voltage by mean of AC/DC Digital ClampMeter (tong tester).

f) Setting of current type, polarity including amperage and voltage.

g) Correctness of welding consumables to be used as per proposed WPS.

5.2.2 Upon fit-up, weld preparation and alignment shall be checked forcompliance to the proposed WPS. After fit-up inspection, mark the PQR

number, test position and indicate the top of joint position (if pipe is used forthe test).

5.2.3 The test piece shall be secured firmly per the required test position.Preheat the test piece properly by gas burners or other approved method tothe required temperature specified in the proposed WPS. Check thepreheat temperature with thermo sticks or equivalent before allowing thewelder to commence welding. The required preheat shall be achieveduniformly across the thickness of the test piece.

5.2.4 A trial test may be carried out on a separate specimen prior to welding onthe test piece to ensure the welding parameters set out in the WPS aremaintained.


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5.2.5 Monitor and record the following welding parameters in the PQR form (seeappendix II) on each pass until completion of test weld to ensurecompliance within the ranges specified in the proposed WPS.

a) Travel speed, wire feed speed current i.e. Amperage and voltage bymean of AC/DC Digital Clamp meter (tong tester).

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 outlength.

e) Welding technique i.e. string, weave, split layer.

f) Interpass temperature by use of or Thermosticks digital thermometer.

g) Approximate width of weld pass.

h) Approximate thickness of weld layer.

i) Interpass cleaning method.

j) Sequence and number of weld passes per layer.

k) Treatment to back side (back gouged, ground, back welded, inspectionetc.).

5.2.6 Upon completion of welding, visual inspection shall be carried out inaccordance with applicable CODE & Spec.

5.2.7 Upon verification and acceptance of the recorded welding parameters inthe PQR form followed by visual acceptance of test weld, the KIs weldingengineer shall arrange for the required NDT in accordance with codes andclients specification.

5.2.8 NDT result shall be verified by Clients Representative prior to any furthertesting. For acceptable test weld, it shall be subjected to destructive testing.


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5.2.9 KIs Welding Engineer shall proceed to illustrate the locations of testspecimens on the welded test piece for each type of destructive test beforecutting at site or direct dispatch to aft approved independent testinglaboratory for both cutting and machining work. The location for removal ofthe required specimen shall be in accordance with Code/ Client Spec.

5.2.10 The entire required test carried out in the laboratory shall be witnessed bythe KIs Representative and Clients Representative.

5.2.11 The following shall be checked during the course of mechanical testing:

a) Identification markings on the specimen to its related PQR number, typeof test and number of specimens required.

b) Dimensions of tensile, bend, impact test specimens.

c) Calibration certificates of tensile test and impact test equipment arevalid, dimensions of guided bend test equipment must be adequate toproduce bending radius specified by test code for root, face and sidebend testing.

d) Impact testing is carried out at the specified temperature.

e) Specified numbers of hardness spots are taken on the regions of themacro etched test specimen i.e. weld heat affected zone, weld area andbase metal.

5.2.12 During each test all results shall be recorded on the draft copies of testreport by the laboratory tester.

5.2.13 Upon completion, test results shall be signed off and a copy extended tothe KIs representative and clients representative for signature andevaluation against the test code and specification.

5.2.14 Upon acceptance of the mechanical test results, the WPS/PQR shall beprepared by the KIs welding engineer using the format shown in appendix Iand II. The WPS/PQR shall be submitted to CLIENT for review andapproval.


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5.3 Retest

5.3.1 When Retest is not allowed

Unacceptable defects evaluated by visual; NDT and macro etch testingshall 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 therequired acceptance criteria, two additional specimens shall be preparedfor 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 he cause for rejection. A new weld shall be required

Tensile test.Bend test.Impact test (when applicable).Hardness test.

Prior to retest, a study and evaluation shall be made on the failed test toestablished probable cause of failure.

6.0 SPECIAL REQUIREMENTS

6. 1 KIs welding engineer shall prepare the WPSs to simulate, the actual weldingconditions and materials to be used for production welding. Limitationsimposed by the essential variables of the procedure qualification shall beadhered to in production welding.

6. 2 Only skilled and experienced welders shall be assigned for WPQT to minimizerework.

7.0 Records

All records pertaining to welding qualification test shall be kept by the KIsWelding Engineer. All copies of the approved WPS shall be readily availablefor reference by the Welders, Welding Engineers and Clients Representative.


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APPENDICES


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QCP-04 Rev-0

Appendix I

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QCP-04 Rev-0

Appendix II

qcp-04 - welding procedure qualification - qc procedure

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