@ REFERENCE NO. : HMM/SP/1S01/WELD:001 DATE. 27 JANUARY 2015 HMM CONSTRUCTION (M) SDN BHD. PROECT PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM ISUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, [PERAK DARUL RIDZUAN, 0 CONTENTS METHOD STATEMENT FOR WELDING PROCEDURE, WELDING PROCEDURE SPECIFICATION (WPS) FLUX CORED WIRE SEPECIFICATION, FCAW MACHINE, AND PRODUCT USAGE. ACCEPTANCE CRITERIA OF WELDS& REFERENCE NO, -HIMWSP/ISOINWELDICN RG Date 27 JANUARY 2015 q HMM CONSTRUCTION (M) SDN BHD. PROIECY PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM SSUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, [PERAK DARUIL RIDZUAN. 2.0 3.0 4.0 PURPOSE The purpose of this procedure is to provide guidelines when welding of steels during fabrication / installation to assure that BS 4515-1 : 2009 standard is met. SCOPE This procedure is applicable to steels that assembly by welding and shall be used conjunetion with BS 4515-1 : 2009 Code & Standard. RESPONSIBILITIES 3.1 The Site Manager or his representative is responsible for the proper implementation of this procedure. 3.2. The Quality Control Inspector or his designer is responsible for the monitoring, surveillance and inspection of welded steel to ensure that all welding activities are performed in accordance with this procedure. PROCEDURE 4.1 Base Metal Materials to be welded in accordance with this procedure are carbon steel and alloy steels basically used in the fabrication / installation of steel pipe / structures as listed in BS 4515-1 : 2009 - Fusion welding of steel 42 Base Metal Preparation Plate, beams and angle bats may be cut to shape and size by mechanical means such as machining, paring, grinding or by oxygen or are cutting, After oxygen or are cutting all slag and displaced material ‘which have been molten shall be removed by mechanical or grinding smooth prior to further fabrication or use. Surface and edges to be welded shall be smooth, uniform and free from fins, tears, eracks and other discontinuities, which could adversely affect the quality or strength of the weld. Surface 10 be welded and surface adjacent to weld shall also be free from scale, slag, rust moisture, grease and other foreign material that would prevent proper welding, The limits of acceptability and repair or visually observed edge discontinuities shall be in accordance with code or standard,@ HMM/SP/1SOV/WELDIAOL 27 JANUARY 2015 HMM CONSTRUCTION (M) SDN BHD PRODECT PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM. ISUNGA! SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN. 43 Joint Preparation The patt to be joined by fillet welds shall be brought into as close contact as practicable. The root opening shall not exceed 4.8 mm in case involving either shape or plate 75 mm or greater in thickness if, after straightening and in assembly, the root opening cannot be closed sufficiently to meet this tolerance. In such case a maximum root opening of 8 mm is acceptable provided a backing weld or suitable backing use. If the sepatation is 1.6 mm or greater the leg of the fillet weld shall be increased by the amount of the root opening, ‘The parts to be joined by partial joint penetration groove welds parallel to the length of the member shall bbe brought into as close opening between parts shall not exceeds 4.8 mm except in involving rolled shapes or plate 75 mim or greater in thickness, If after straightening or assembly the root opening cannot be close sufliciently to meet this tolerance, a maximum root opening of 8 mm is acceptable provided a backing is used and final weld meets the requirements for effective throat. Parts to be jointed by groove welded butt joint shall be carefully aligned. Where the parts are effectively restrained against bending due to eccentricity, 10% of the thickness of the thinner part joined, but not more than 3.2 mm shall be permitted as a departure from the theorectical alignment. In correcting misalignment in such cases the part shall not be drawn into a greater slope than 12 mm, Measurement of offset shall be based upon the center line of parts unless otherwise shown on the drawing, Root opening wider than these permitted in Code but not greater than twice the thickness of the thinner part or 20 mm, whichever is less may be corrected by welding to acceptable dimension prior to joining the part by ‘welding, Root opening larger than the above may be corrected by welding only with the approval of the Engineer. Grooves produced by gouging shal be in accordance with groove profile dimensions specification Members to be welded shall be brought into correct alignment and held in position by bolt, clamp, wedges, guy lines, struts and other suitable devices or by tack welds until welding has been completed. The use of jigs and fixtures is recommended when practicable, Suitable allowances shall be made for war page and shrinkage.& REFERENCENO. —: HMMSP/.SOLAWELDIOL BRS Date 27 JANUARY 2015, HMM CONSTRUCTION (M) SDN BHD @ PROLE : PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM, ISUNGAI SELAMA INTAKE TO SUNGAI BAYOR |WATER TREATMENT PLANT, DAERAH SELAMA, [PERAK DARUL RIDZUAN, 5.0 PREHEAT AND INTERPASS TEMPERATURE. ‘The minimum preheat and interpass ternperature shall be in accordance with the code for the welding process. 6.0 WELDING PROCEDURE SPECIFICATION (See Attached WPS) 6.1 Welding Procedure Specification (WPS) shail be prepared and qualified to provide directions to the welders when making production welds, The WPS shall describe all of the essential and non-essential variables for each welding processes used in WPS. The WPS shall reference the supporting Procedure Qualification Record, a) Essential Variables Essential variable are those in which a change, as described (base metal, filler metals, and welding process) is considered to affect mechanical properties of the weldment and shall require requalification WPS. b) —_Non-essential Variable Non-essential variables are those in which a change as described in the specific variable (weld joints, welding positions and welding technique) may not required re-qualification. 6.2 Change to the WPS may be made in non-essential variable of a WPS to suit production requirement without re-qualification. Change essential variable requires re-qualification of the WPS. 6.3 The WPS, used for production welding shall be avzilable for reference and when requested by the Inspector of Client Representative. 6.4 Procedure Qualification Record (PQR) shall be prepared to record the variables during welding of {est coupons, It shall also contain the result of the specification tested.& eerERENCENO. —-iMusensoirvELDeOI BRS bate 27 JANUARY 2015 @ HMM CONSTRUCTION (M) SDN BHD. PROIE PROPOSED UPGRADING WORKS FOR RAW WA'TER SUPPLY SYSTEM FROM |SUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN, 7.0 9.0 WELDERS PERFORMANCE QAULIFICATION 7.1 Welder and welding operator shall be qualified for each welding process to be used in production welding in accordance with BS 4515-1 : 2009. 7.2 Each qualified welder and welding operator shall have assigned identification number, letter or symbol which shall be used to identify the work of particular welder or welding operator. 7.3 The record of welder / Welding Operator Performance Qualification (WPQ) test shall be prepared and maintained. This record shall be available when requested for verification by Inspector or Client Representative, EXPIRATION AND RENEWAL OF WELDERS QUALIFICATION ‘The performance qualification of a welder or welding operator shall be affected when one of the following condition occurs 8,1 When he has not welded with a process during a continuous period of 6 months or more, this qualification for that provess expire. 8.2 When there is a specific reason to question his ability to make welds that meet the specification, the qualification which supports the welding he is doing shall be revoked. Alll other qualification not questioned remains in effect. WELDING PROCESS 9.1 Gas Metal Are Welding 9.1.1 Electrode and Shielding for Gas Metal Electrodes and shielding for Gas Metal Are Welding shall conform to the requirements of the latest edition of BS 4515-1 : 2008. Shielding Gas Mixture shall be with a welding grade having a dew point of (-40 C) or lower,RS pe ZSNZ@ um construction (mp sb BHD REFERENCE NO. = HMMISP/1S01/WELDOOL 27 JANUARY 2015, PRosECT PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM. ISUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN. 10.0 11.0 9.1.2 Technique - Gas Metal Are Welding ‘The thickness of weld layers in groove welds except root and surface layers shall not exceed 6mm, A multiple pass split layer technique shall be used to complete the weld to required size, The split layer technique shall also be use in making all multipass welds when the ‘widths of the layer exceed 15 mm. Complete joint penetration groove welds made without the use of backing plate shall have the root ofthe initial weld gouged, chipped or otherwise removed, but traces of the root of the initial weld before welding is started from the second side, ‘The welding current arc voltage, gas flow mode of metal transfer and speed of travel shall be such that each pass will have complete fusion with adjacent base metal and weld metal and there will be no overlap or excessive porosity or undercutting. The progression for all passes of vertical position welding shall be upwards except that undercut may be repaired vertically downwards. Gas metal are welding with external gas shielding shall not be done in a draft or wind unless the weld is protected by a shelter. Such shelter shall be of material and shape appropriate to reduce wind velocity. To prevent melt thru roots of groove or fillet welds may be backed by copper, flux, glass tape, iron powder or similar materials or sealed by means of root passes deposited by shielded metal are welding with low hydrogen electrodes or other are welding processes. ARC STRIKES Are strikes outside the area of permanent welds must be avoided on any base metal, Cracks or blemishes caused by are strikes shall be grooved to a smooth contour and checked to ensure soundness. WELD CLEANING In process cleaning before welding over previously deposited metal, all slag shall be removed in the weld and adjacent base metal shall be cleaned. Stag shall be removed on completed welds and the adjacent base metal shall be cleaned by brushing or other suitable means.x 12.0 13.0 IREFERENCE NO. : HMM/SP/ISO\/WELDIOOT DATE 27 JANUARY 2015, HMM CONSTRUCTION (M) SDN BHD. lpRosecy PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM ISUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN, NON-DESTRUCTIVE TESTING (NDT) ‘When required by the Client and or by the code non-destructive testing shall be conducted on complete welds. ‘The NDT methods shall be radiographic inspection or Ultrasonic Test, Magnestic Particle Testing or Dye Penetrant as approved by the Engineer. REPAIR WELDMENTS 132 133 134 13s Welds found with defects not meeting the specified requirement shall be repaired. The removal of ‘weld metal or portion of the base metal may be done by grinding, or electrode gouging. It shall be in such a manner that the remaining welds metal or base metal is not nicked or undercut, eptable portion of the weld shall be removed without unnecessary removal of the base metal Additional weld metal to compensate for any deficiency in size shall be deposited using the same qualified welding procedure. The surface shall be cleaned thoroughly before welding, ‘The repaired or replaced weld shall be re-tested by the same approved method and with the same quality acceptance criteria shall be applied.% HMM CONSTRUCTION (M) SDN BHD IREFERENCE NO, : HMMSP/1S01/WELD/001 DATE. 27 JANUARY 2015 lpRosecr PROPOSED UPGRADING WORKS POR RAW WATER SUPPLY SYSTEM FROM. ISUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN. WPS Nos Tested to : BS 4515, WELDING PROCEDURE SPECIFICATION 2009 Date of test Extend Of Approval Welding Process (es) IGAS METAL ARC WELDING (FLUX CORE) Joint Type. Fillet welds on Plates and Branch Connections Parent Metal (s) [All Group 1 Materials Metal Thickness (es) mm [6.3 mm |Outside Diameter (min) NIA Filler Metal Type AWS A5.20 E7IT- IC, Speedoore - 71T or EQUIVALENT Shielding Gas / Flux Co2 [Type of Welding Curent : De Welding Position () lar Preheat AMBIENT Post Weld Heat Treatment : NFA [Other Information = Examiner / Inspector : Name Date: Signature [Centficate that test weld prepared, welded and tested satisfactorily in accordance with the requirements of the code / testing standard indicated above. est House& REFERENCENO. —-HMMSPASDIAWELDOOL BS Dare 27 YANUARY 2018 ING HMM CONSTRUCTION (M) SDN BHD. WORKS FOR RAW WATER SUPPLY SYSTEM FROM |SUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN. Location Selama, Perak ‘Test Body : Nusatek - Nusantara Technologies Sdn Bhd WPS No GMAW / 0711/01 Method of Preparation and Cleaning : Oxy Cut and WPAR No WPAR/01 Grinding Parent Metal Specification: $275 Materials ‘Thickness (mm); 6.3 mm Welding Position 4aF Welding Process (es) Gas Metal Are Welding (FCAW) Joint Type + Fillet Joint Weld Preparation Details (Sketch) Welding Details: Run! | cece Size of Filer” [Current] Voltage] 5.74.) Woe Feed | Travel Ty Pass Metal A y_[FOME' speed mimin | Speed Pee 1 GMAW 12 120- | 25-38] pcer | 3-15m/min | '-% 250 om au Maw 12 120+ | 95.38] pcer | 3-15m/min | 1° 3 250 em rant Short Circuiting Fil ce Spray Are iller Metal Classification and Trade Name Any Special Baking or Dryin: N/A Gas / Flux. + C02; 8-20|/ min Backing : CO2; 8-20) / min ‘Tungsten Electrode (Type /Size) N/A Details of Back Gouging / Banking: N/A. Preheat Temperature : Ambient Interpass Temperature max 200 C PWHT. Rate of Rise NIA RateofCool =: N/A Dwell Time NIA MOX SPEEDCORE - 71T OR Equivalent. Other Information; Orifice 12 - 15 mm Dia, Weaving / Stringer :15 mm Maximum Osillatior: N/A Maximum Pulse Welding Details, Stand Of Distance : 6 - 15 mm Plasma Welding Details: N/A Torch Angle NIA Examiner / Test House : Inspector Name Date SignatureUF @ HMM CONSTRUCTION (M) SDN BHD. REFERENCE NO. : HMM/SP/1S01/¥ELD/001 DATE 27 JANUARY 2015 lpRomecr PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM FROM. ISUNGAI SELAMA INTAKE TO SUNGAI BAYOR WATER TREATMENT PLANE, DAFRAH SELAMA, PERAK DARUL RIDZUAN. WELDING PROCEDURE SPECIFICATION WPS Nos : Tested to : BS 4515 Date of test: 2009 Extend Of Approval Welding Process (es) IGAS METAL ARC WELDING (FLUX CORE) [Joint Type Fillet welds on Plates and Branch Connections | Parent Metal (5) |All Group | Materials Metal ‘Thickness (es) mm : {6.3 mm [Outside Diameter (mm) : NTA. Filler Metal Type AWS AS.20 E7IT- 1C, Speedeore - 71T or EQUIVALENT ‘Shielding Gas / Flux : ico2 [type of Welding Current : DC Welding Position (s) 3F Preheat AMBIENT Post Weld Heat Treatment NUA [Other Information [Centficate that test weld prepared, welded and tested satisfactorily in accordance with the requirements of the code / testing standard indicates above. Examiner / Test House Inspector : Name Date : SignatureREFERENCE NO. = HMMSP/ISOKAWELDO1 RS pare TT JANUARY 2015 IN HMM CONSTRUCTION (M) SDN BHD PRovECT PROPOSED UPGRADING WORKS FOR RAW WATER SUPPLY SYSTEM PROM, ISUNGAI SELAMA INTAKE TO SUNGAI BA YOR WATER TREATMENT PLANT, DAERAH SELAMA, PERAK DARUL RIDZUAN, Location + Selama, Perak Test Body : Nusatek - Nusantara Technologies Sdn Bhd WPS No GMAW /0711/01 Method of Preparation and Cleaning : Oxy Cut and WPAR No WPAR/01 Grinding Parent Metal Specification: $ 275 Materials Thickness (mm) 6.3 mm Welding Position 3k Welding Process (es) = Gas Metal Are Welding (FCAW) Joint Type : Fillet Joint Veld Preparation Details (Sketch) Welding Details: Run / Size of Filer | Current Wire Feed | Travel Process Polarity! ; Heat Input Pass Metal A Speed m/min | Speed 20 10-30 1 GMAW 12 120° 59-40] DcEP | 3-1Sm/min 250 om 2K : 7 a omaw 12 120 V 59-40] cep} 3-ism/min | 1°20 3 250 em i Sh Root 7 Cirouiting Fil Spray Are Cap m | Filler Metal Classiti tion and Trade Name: MOX SPEEDCORE - 71'T OR Equivalent. Any Special Baking or Dryin: N/A Gas / Flux (C02; 8-20} / min Other Information : Orifice 12 - 15 mm Dia. Backing : CO2; 8-20) / min Weaving / Stringer : 15 mm Maximum. Tungsten Electrode (Type /Size) N/A Osillatior : N/A Maximum Details of Back Gouging / Banking: N/A. Pulse Welding Details, Preheat Temperature Ambient Stand Off Distance : 6 - 15 mm Interpass Temperature max 200 C Plasma Welding Details. =: N/A PWHT Rate of Rise NIA Yorch Angle NIA Rate of Cool NIA Examiner / Test House Dwell Time NIA Inspector Name Date