General Welding Procedure

DOCUMENT NUMBER
General Welding MD-451-0000-QD-QA-PRO-00002

MA’ADEN Rolling Mill PROJECT Procedure Revision 0
(For Subcontractor)
Issue Date Nov. 08, 2011 Page 1 of 27
General Welding Procedure

(For Subcontractor)
0 Nov. 08, 2011 Issued for Approval I.Y.Kim

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REV DATE DESCRIPTION PREPARED REVIEWED APPROVED J.V
Document No:
MD-451-0000-QD-QA-PRO-00002
DOCUMENT NUMBER
(For Subcontractor)
TABLE OF CONTENTS
1.0 PURPOSE
2.0 DEFINITIONS
3.0 REFERENCE DOCUMENTS
4.0 WELDING CONSUMABLES
5.0 JOINT PREPARATION CLEANING AND IDENTIFICATION
6.0 PREHEAT AND INTERPASS TEMPERATURE
7.0 CONVENTIONAL WELDING PROCESSES
8.0 WELDING PROCEDURES AND TECHNIQUES
9.0 POST WELD HEAT TREATMENT
10.0 REPAIR OF WELD DEFECTS
11.0 CLEANING
12.0 WELD EXAMINATION AND INSPECTION
13.0 WELDING PROCEDURE SPECIFICATION
14.0 WELDING PROCEDURE QUALIFICATION
15.0 PREPARATION OF QUALIFICATION

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(For Subcontractor)
1.0 PURPOSE
This procedure gives the minimum requirements for welding activities, preparation of
welding procedure specification and qualification test for welder and welding operator for
the piping construction work to be performed by the Subcontractor for Ma’aden Rolling
Mill Project.
Any conflict between the requirements of this procedure and the provisions of any
applicable codes, standards and Employer’s requirements shall be referred to the
Contractor for resolution prior to the work.
2.0 DEFINITIONS
For the purpose of understanding this procedure, the following definitions apply:
Employer MAADEN/ALCOA Joint Venture
Contractor Samsung Engineering Co., Ltd. or his authorized representative
Subcontractor The company or organization engaged by the Contractor to perform the
works Contractor
Supplier Manufacturer and/or Supplier of material/equipment, and/or representative
to assist Contractor/Employer with manufacturer or supplier scope of
works
WPS Welding Procedure Specification

PQR Procedure Qualification Report
WQT Welder Qualification Test
SMAW Shield Metal Arc Welding
SAW Submerged Arc Welding
FCAW Flux Cored Arc Welding
GTAW Gas Tungsten Arc Welding
GMAW Gas Metal Arc Welding
UTS Ultimate Tensile Strength
LTCS Low Temperature Carbon Steel
3.0 REFERENCE DOCUMENTS
All codes and standards referred to herein shall be to the latest edition.
MD-451-0000-QD-QA-PQP-00002, Site Quality Control Plan

MD-451-0000-QD-QA-PRO-00006, Procedure for Welder Control
MD-451-0000-QD-QA-PRO-00014, Inspection and Test Plan for Piping Works
MD-451-0000-QD-QA-PRO-00007, Procedure for Radiographic examination (R.T)
MD-451-0000-QD-QA-PRO-00008, Procedure for Liquid Penetrant examination (P.T)
MD-451-0000-QD-QA-PRO-00009, Procedure for Magnetic Particle examination (M.T)
MD-451-0000-QD-QA-PRO-00010, Procedure for Ultrasonic examination (U.T) 0
MD-451-0000-QD-QA-PRO-00011, Procedure for Alloy Verification (A.V)
ASME Section IX, Qualification Standard for Welding and Brazing Procedures, Welder,
Brazers and Welding and Brazing Operators
ASME B16.25, Butt Welding Ends
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ASME B31.1, Power Piping

ASME B31.3, Process Piping
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(For Subcontractor)
4.0 WELDING CONSUMABLES
4.1 General
4.1.1 The same brand name and manufacturer source consumables used for procedure
qualification shall be used for production welding. Any change or variation shall require
requalification.
4.1.2 All batches or consumables shall be proven suitable and certified to be in accordance
with the specification before their use on production welding. Batch testing can be
performed by the consumable supplier.
4.1.3 All consumables shall be stored, handled and used in accordance with the manufacturer’s
instruction. The preference shall be for consumables such as coated electrodes to be
supplied dry in sealed vacuum packed containers. These commonly available
consumables can be supplied in individual small packs sufficient for one welder to use in
one shift.
4.1.4 Filler wires shall be stored with manufacturer wrapping intact. Partly used filler packs and
coils shall be identified and protected against contamination. Filler wire shall be checked
for cleanliness by use or clean wipes before use, no evidence or dirt or grease shall be
seen after wiping. Any wires that are contaminated in any way shall not be acceptable
and shall require cleaning before use.
4.1.5 Submerged arc flux shall be kept and stored in low humidity (60% max.) warm (min.
50¶C) controlled storage area. Unused flux may be recovered and recycled once
provided this machine has a controlled specified capability, otherwise flux shall be
discarded after use.
4.1.6 Consumable for dissimilar metals joins, both in sour and non sour services, shall be
referred to Contractor for approval prior to the qualification process. Detailed WPS’s shall
be provided with joint designed and location details involved.
4.2 Consumable for Carbon Steel
4.2.1 Welding consumables shall be selected to match the mechanical properties of pipe.
Alloying of carbon steel with nickel is permitted up to 1.0% maximum in deposited weld
metal. Overmatch of weld metal UTS on actual base material tensile strength is to be
limited to the minimum base metal UTS + 20%
4.2.2 For low temperature carbon steel materials toughness is an essential requirement. All
consumables for low temperature applications shall be specified Charpy V notch
toughness at -46¶C or below for carbon steel, in both the as welded and the PWHT
condition.
4.2.3 Consumables by any known major manufacturer may be permitted following acceptance
qualification testing of the welding process and consumables. The Contractor shall
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review for acceptance evidence of previous qualification tests and production welds made
with any proposed consumables and process.
4.2.4 Carbon 0.5% Mo consumables shall not be used.
4.2.5 SMAW electrodes of non-low hydrogen classifications are not permitted for pressure-
retaining welds. Exception: E6010 or E7010 electrodes may be used for the root pass
only in singled-sided full penetration open root groove weld joint in P-No. 1 material.
4.3 Consumable for Stainless Steel
4.3.1 Consumables for austenitic stainless steels shall be “L” grade unless other wise noted on
the data sheets, e.g. for 304L SS use 308L type and for 316L SS use 316L type.
4.3.2 When using type 308, 316, 317, 321 or 347 filler metals for high temperature applications
above 530¶C, the as deposited carbon content shall be greater than 0.04%.
4.3.3 FCAW filler metal used to weld austenitic stainless steel base metal with operating
temperatures greater than 455¶C or to make welds to be PWHT shall be limited to
0.002wt % Bi (bismuth) maximum. Actual (not typical) CMTRs (Certified Mill Test
Reports) shall be available for Contractor QC inspector to review and be traceable to all
production filler metal to be used. METRODE brand filler prior to its use in production
shall be used for welding base metal with operating temperatures above 455¶C.
4.4 Consumable for Dissimilar Metal Joints
4.4.1 Dissimilar metal joints between P-No. 1 through P-No. 7 base metals on one side, to P-
No. 8 or high nickel alloys on the other side, in services containing less than 1 % sulfur,
shall be welded with ERNiCr-3 or ENiCrFe-2.
4.4.2 Alternately type 309 or 309L filler metal may be used with prior written approval from
Contractor.
4.4.3 Selection of filler metal for other dissimilar metal joints requires review by Contractor prior
to starting production welding.
4.4.4 Dissimilar metal joints between P-No. 1 through P-No. 7 base metals shall use low
hydrogen type filler metal similar in composition to either base metal or to an intermediate
composition.
4.5 Shielding Gases
4.5.1 The supplier of shielding gases needs to be verified and proven to Contractor satisfaction.
Test welds may be required to prove gas quality prior to their production use, at the
discretion of the Contractor.
4.5.2 High purity (99.995% min) argon with a dew point of -40¶C or lower shall be used for all
GTAW welding and for internal purging (backing gas) where required or specified.
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4.5.3 Back purge shall be required for all materials except P-No. 1, 3 and 4 materials root
welded by GTAW. Purge shall continue until the root and 1st fill pass are complete.
4.5.4 Purge gas quality shall be proven suitable by oxygen meter before welding can proceed.
Purge gas must contain less than 1% Oxygen.
5.0 JOINT PREPARATION CLEANING AND IDENTIFICATION
5.1 The joint bevels shall be prepared in accordance with ASME and WPS. Internal and
external surfaces to be welded shall be clean and free from paint, oil rust and scale.
5.2 Inside surface of piping components at ends to be joined in girth or miter groove weld
shall be aligned within the dimensional limits in the WPS and the engineering design.
Refer to ASME B31.3, Fig. 328.4.2 and 328.4.3
5.3 Single side welded joints shall normally be used wherever possible. The angle of weld
preparation shall be as per ASME B16.25 and compound preparations shall be used on
high wall thickness (over 19 mm thick) pipe. For joints between dissimilar thickness
materials such as at a pipe to fitting butt weld, the maximum difference in thickness shall
be machined to within 10mm; outside the butt weld area 1 in 4 tapered transitions shall be
required to full thickness.
5.4 Permanent weld backing bars other than consumable inserts are not permitted.
Temporary backup rings may be used provided they are of the same nominal composition
as the bases materials.
5.5 Tack welding may be used for alignment and to be made in accordance with an approved
WPS using the same electrodes as the first pass of the final weld and shall be deposited
in such a manner as to facilitate incorporation in the weld.
Cracked or broken tack welds shall be chipped out, and all others thoroughly cleaned
prior to being fused in with the final weld.
5.6 Materials that require preheat for welding may receive a proper preheat for thermal
cutting or gouging, when required.
5.7 Grinding and cleaning of stainless steel and nonferrous material shall be done only with
tools that will not leave detrimental deposits on the base metal, aluminum oxide or silicon
carbide grinding wheels or austenitic stainless steel wire brushes shall be used. These
tools shall never be previously used other than the material to be cleaned.
5.8 All materials such as paint, grease, oil, pencil markings and other materials which may
contain lead, sulfur and other low melting point elements shall not be used on austenitic
stainless steels and non ferrous alloy surfaces.
The permanent marking material used on austenitic stainless steel shall not contain any
harmful metal, metal salts or elements. These harmful chemicals contain Zinc, Lead,
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Chlorides, Sulfur, and other low melting point metals. Submit type of paint or ink including,
analysis of the above elements for purchaser’s approval.
5.9 Marking the welder’s identification symbol adjacent to all pressure welds. On austenitic
stainless steel and other high alloy steels and the welders symbol shall be applied with
the waterproof paint.
6.0 PREHEAT AND INTERPASS TEMPERATURE
6.1 Preheat and Interpass temperatures shall be in accordance with ASME B31.1, Paragraph
131.4 or ASME B31.3, Paragraph 330 and WPS also provides a guideline for the
minimum preheat temperature. In case of a conflict between the code and this standard,
use the higher preheat. Maintain the minimum preheat temperature throughout the
welding operation. The minimum preheat requirement is also applicable to tack welding,
fillet welds, attachment welds, thermal gouging and cutting
6.2 The maximum Interpass temperature shall be 230¶C when welding austenitic stainless
steel (P-No. 8).
7.0 CONVENTIONAL WELDING PROCESSES
7.1 Conventional welding processes shall be performed as follow;
7.1.1 Welding from one side (OD) only pipes up to and including 100mm nominal diameter
- Root, fill and cap; GTAW with filler rod, all passes
7.1.2 Welding from one side (OD) only pipes larger than 100mm nominal diameter.
- Root pass; GTAW with filler rod or SMAW using basic coated AWS type EXX15/16/18
or cellulosic coated AWS type EXX10/EXX11 electrodes FCAW using gas shielding,
or GMAW
- Fill out and Cap; SMAW using basic coated electrodes, or FCAW using gas
shielding, or GMAW, or GTAW with filler rod for all passes.
7.1.2 Rotatable and double joints, welded from outside only.
- Root pass; Any manual or automatic gas shielded welding process

- Fill out and Cap; SMAW using basic coated electrodes, or FCAW using gas
shielding, or GMAW, or SAW using wire and basic agglomerated flux.
7.2 Other welding process, such as PAW, SW shall be permitted for specific applications
following Contractor’s acceptance in writing.
7.3 Processes and consumables not permitted bare GMAW with CO2, only shield gas,
gasless FCAW and SMAW using rutile AWS E6012/3 and E7024/8 type electrodes.
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8.0 WELDING PROCEDURES AND TECHNIQUES
8.1 All welding including tacking and welding supports to piping shall be made by welding
procedures, welders and welding operators qualified in accordance with ASME section IX.
Use the filler metal and or flux equivalent to AWS Classification in production welding as
qualified in welding procedure qualification test.
8.2 Contractor shall prepare and submit for acceptance written Welding Procedure
Specifications (WPS) and applicable Procedure Qualification Records (PQR).
8.3 Procedures and Procedure qualification Test records shall be submitted on ASME section
IX, forms QW-482 and QW-483 or equivalent. All items on this form must be completed.
8.4 The WPS make reference to include joint preparation sketch showing dimensions for
bevel angle, land size, offset and root gap.
8.5 No welding shall be performed prior to Contractor written approval of the welding
procedures.
8.6 Subcontractor is responsible for the welding performed by his welders and shall conduct
the required qualification tests by independent agency or laboratory. Qualifications of
welders and welding operators by others are not acceptable. Copies of the welders and
welding operator qualification test records shall be available for review by Contractor.
8.7 For attachments and supports not directly welded to pipes, welding may be in accordance
with AWS D1.1.
8.8 Use Employer Project Specification, such as number of passes and electrical
characteristics.
8.9 All single-side butt joints in nickel alloy, stainless steel, and ferritic steel containing more
than 2% chromium shall be welded using a gas tungsten-arc or a gas metal-arc root pass
with an inert gas back purge.
8.10 The welding of butt welds in carbon or alloy steel pipe with wall thickness 3/4 inch or
greater may only be interrupted provided that a minimum of 3/8-inch of weld metal is
deposited or 25% of the welding groove is filled, whichever is greater. If the welding is
interrupted prior to that, then the weld shall be covered with adequate insulating material
to insure slow cooling. The partially completed weld may be examined by Magnetic
Particle or Liquid Penetrant methods before resuming welding.
8.11 Peening is not permitted. The use of a needle gun for scale removal is not considered to
be peening.
8.12 Welding shall not be done when the ambient temperature is below 0¶C or during sand 0
storms, rain and heavy winds unless proper protection is provided. Each weld shall be
uniform in width and size throughout its full length. In addition the cover pass (final weld
layer) shall be free of coarse ripples, grooves, overlaps, abrupt ridges and valleys.
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The surface smoothness of the finished weld shall be suitable for proper interpretation of
Non Destructive Examination of the weld.
Each pass shall be cleaned free of slag before the next pass is deposited. Each weld
layer shall be visually free of slag, inclusions, cracks, porosity and lack of fusion.
9.0 POST WELD HEAT TREATMENT
9.1 All ferrous pressure piping shall require PWHT in accordance with ASME B 31.1,
Paragraph 132 or ASME B31.3, Paragraph 331 and WPS.
9.2 PWHT shall follow all welding and repairs but shall be performed prior to any hydrotest or
other load test.
9.3 PWHT of austenitic stainless steel and non-ferrous alloy requires review by Contractor
and Employer. Piping and Equipment fabricated in austenitic stainless steel materials
shall not normally require PWHT.
9.4 Code exceptions for PWHT of ferritic materials based on the use of austenitic or nickel-
based consumables are permitted only if approved by Contractor and Employer. Code
exemptions for PWHT of P-No. 4 and 5 materials are permitted for applications involving
either sour service or materials exceed 2.5% nominal chromium content only if permitted
by Contractor and Employer.
9.5 PWHT of P-No. 4 and 5 material shall be below the tempering temperature shown on the
production mill certificates or as permitted by Contractor.
9.6 PWHT for piping welds, when required, shall normally be performed either in a fully
enclosed furnace with full control and zone monitoring, or by use of resistance or
induction heating coils wrapped around the weld.
9.7 Thermocouples shall be located on the pipe at the weld.
9.8 For pipes up to 6inch (150mm) diameter one thermocouple at 6 o’clock is required.
9.9 For pipes over 6inch (150mm) diameter to 16inch (450mm) diameter at least two
thermocouples at 6 and 12 o’clock shall be used.
9.10 For pipes over 16inch (450mm) there shall be one thermocouple per 24inches (600mm)
of weld length, to include the 6 and 12 o’clock positions.
9.11 When groups or multiple welds are simultaneously heat treated there shall be at least one
thermocouple on each weld.
9.12 The process of heating for PWHT in furnace shall be at Manufacturer’s option.
9.13 For local heating, electrical resistance or induction heating shall be used.
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9.14 Direct frame heating and exothermic method for PWHT shall not be allowed.
9.15 A detailed procedure for PWHT shall be required for Contractor and Employer review and
approval; this shall include locations and types of thermocouples, method of
thermocouple attachment, insulation details, and heating control system details. All heat
treatments shall be detail recorded on a time temperature chart. Details of any methods
used to prevent scaling on machined surface shall be included.
9.16 All overlay and cladding restoration shall be completed before application of PWHT.
9.17 Heating and cooling rates shall be as permitted by relevant Code but shall not in any case
exceed 100¶C per hour above 300¶C.
9.18 Following PWHT, items shall be allowed to cool in still air under insulation; forced cooling
shall not be permitted.
9.19 Welding procedures for carbon steels shall be qualified with PWHT at 600¶C to 620¶C
(unless otherwise specified in Manufacturer instruction, for 1 hour per 25mm of thickness,
with 1 hour minimum. This temperature however should always be below the tempering
temperature for any items such as valves, fittings or flanges that have been tempered
during their normal production.
9.20 For process qualification test welds only, the PWHT total time at temperature shall be
adequate to cover the thickest material used on the Project that shall be PWHT but not
less 1 hour, i.e. if the maximum thickness of material is 38 mm, then the time required for
qualification is 1.5 hours.
9.21 PQRs for welding P-No. 8 to P-No. 1 through P-No. 6 materials, shall use the highest
PWHT temperature specified on the WPS when the WPS specifies a PWHT temperature
range that exceeds 704¶C, e.g. if the WPS PWHT temperature range is 677¶C to 732¶C,
then 732¶C must be used for the PQR PWHT.
9.22 Attachment of clips, brackets, or other devices requiring welding directly to the inside or
outside surface of pressure containing components after PWHT is not allowed.
9.23 PWHT detailed requirements shall be referred to the Data Sheet attached as Appendix 1
of Employer Project Specification.
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10.0 REPAIR OF WELD DEFECTS
10.1 Repair of weld defects shall be made using WPS qualified in accordance with ASME B
31.1, Paragraph 127.4.11 or ASME B31.3, Paragraph 328.2.1.
10.2 Repair of welds by chipping, grinding or gouging shall be done in such a manner as not to
reduce the adjacent base material thickness. Repair welding shall be done only by
qualified welders using an approved welding procedure.
10.3 Major weld defects such as cracks (surface and internal), which indicate a fundamental
materials problem shall be repaired utilizing a written procedure that has been approved
by the Contractor. The written procedure shall include extent and location of the defect,
how defects removed and removal verified, how repaired, subsequent heat treatment and
Non Destructive Examination.
10.4 For the field weld joints subjected to spot radiography(୘100%, RT), the subcontractor
shall carry out two(2) additional radiography for every defective weld that was
radiographed. If defect was revealed again, and then following action will be taken as
bellows;
a) two further samples of the same kind shall be examined for each defective item
found by that sampling
b) if any of the items examined as required by a) above reveals a defect, all items
represented by the progressive sampling shall be either
b-1) repaired or replaced and reexamined as required or,
b-2) fully examined and repaired or replaced as necessary, and reexamined as
necessary to meet the requirements of the applicable code
Contractor will select the weld joints to be radiographed.
11.0 CLEANING
After fabrication and any necessary heat treatment, clean the pipes by removing all loose
foreign materials such as sand, scale weld spatter, and cut chips from inside and outside
of the pipe spools using any suitable means. The supplier shall make a visual inspection
to make sure that proper cleaning has been accomplished for each spool.
12.0 WELD EXAMINATION AND INSPECTION
12.1 Examination/inspection requirements and acceptance criteria shall be in accordance with

ASME B 31.1 and the requirements of this procedure.
12.2 Alloy Verification

All ferritic chrome alloy pipe welds shall be tested for chromium in content in accordance
with Alloy Verification Procedure, MD-451-0000-QD-QA-PRO-00011 or Subcontractor’s
Procedure.
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12.3 Examination
12.3.1 Visually examine all welds for completeness, excess crown reinforcement, and evidence
of undercutting. Where possible, examine all welds internally for burn-through, excess
crown, lack of penetration or fusion, and weld spatter, flux or icicles. Repair all defects
found. Make sure each spool is properly cleaned.
12.3.2 Sufficient preparation of weld is required to permit meaningful interpretation of

radiographic, liquid penetrant, magnetic particle, and ultrasonic examinations
12.3.3 Indicate the method of extent Nondestructive Examinations on the fabrication drawing.
12.3.4 The minimum requirements for radiography for the various piping materials classes are
given on Employer’s Project Specification. Where the ASME Codes impose more
stringent requirements, those requirements shall be met.
Acceptance requirements are to be in accordance with ASME B31.3, Paragraph 341.3.
12.3.5 All Nondestructive Examinations shall be performed by personnel qualified in accordance

with ASNT recommended practice SNT-TC-1A. Certification of personnel shall be made
available to Contractor and/or Employer representative upon request.
12.3.6 All Nondestructive Examinations shall be performed in accordance with written

Nondestructive Examinations Procedures that confirm the ASME Section V. No
examination shall be performed prior to the written approval of the procedures.
12.3.7 Results of Nondestructive Examinations shall be reported on forms authorized by the

Contractor upon request. Contractor reserves the rights to approve all final Radiographs
and results of other examinations and tests. Include all Nondestructive Examinations
results in the final reports.
12.3.8 Locations of Nondestructive Examinations shall be in accordance with the applicable

code and standards or selected by Contractor QC personnel.
12.3.9 Nondestructive Examination shall be performed in accordance with ASME B31.1,

Paragraph 136.4 or ASME B31.3, Paragraph 341.4.
12.4 Compliance with Inspection and Test Plan 0
All Inspections and Examination shall be conducted as per approved Inspection and Test
Plan for Piping Works, MD-451-0000-QD-PRO-00014.
Contractor / Sub-Contractor quality inspectors and construction supervisor shall aware of

inspection point as per ITP and train to welders and welding crews for their awareness.
Inspection and Examination will be confirmed during hydro test preparations and related
document will be attached on test package for review and approval.
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12.5 Welding Reports for Filing

0
Welding reports for hand over document will be confirmed during hydro test preparation.
All Inspection reports and examination reports will be filed at Contractor document room.
JV representative has right to review inspection and examination reports all the time.
13.0 WELDING PROCEDURE SPECIFICATIONS
13.1 Subcontractor shall provide the Detailed Welding Procedure Specification (WPS) for each
type of joint and material, piping line class and pipe sixe to be jointed. These shall clearly
identify all of the essential variables, materials and specifications, consumables by name
and specification as well as the normal standard “Code” requirements. WPS shall show
the minimum and maximum number of passes permitted per size and heat inputs for each
nominal welded thickness for information only.
13.2 The size of consumable and heat inputs shall be considered a supplementary essential
variable. This heat input specified on the WPS shall not exceed the highest qualified
value on the relevant Procedure Qualification Record (PQR).
13.3 Stringer bead welding technique is preferred; however weave beads will be allowed for
positional welding providing the maximum width of weave does not exceed 3 times the
electrode core wire diameter for SMAW or 10mm for other processes.
13.4 For fillet welds used for attachment of supports, etc. the number and passes sequence
shall be detailed as applicable for particular fillet weld throat size.
13.5 Fillet welds shall be qualified on butt welds with full mechanical testing when different
consumables or welding processes are used.
13.6 Single pass fillet welds shall not be permitted. Socket welds are considered the same as
fillet welds and shall be made in at least two passes.
13.7 Interpass temperatures shall be considered an essential variable for all materials and
shall not exceed 250¶C for carbon steels, 150¶C for stainless steels and high nickel alloy,
or that temperature qualified by PQR if lower.
13.8 The application for each WPS shall be shown on a separate weld map or welding and
testing plan. This shall clearly indicate the WPS for each main type of joint piping line
class and for the various attachments. A cross reference matrix showing line class, pipe
sizes and applicable WPS is required.
13.9 Subcontracted items shall also be provided with weld identification plan and cross
reference.
13.10 Each WPS shall clearly identify the qualifying PQR's that are applicable.
13.11 WPS’s and weld maps shall be provided for review, comment and/or approval by
Contractor and Employer prior to the commencement of welding of any new PQR’s or
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production welds. WPS’s will be accepted only for qualification testing until the relevant
PQR’s are also approved by Contractor and Employer.
13.12 Previously qualified WPS’s shall be considered for use without the need for
requalification; full details and reference information shall be provided to Contractor and
Employer for review and approval prior to the WPS being used in production.
14.0 WELDING PROCEDURE QUALIFICATION
14.1 New Procedure Qualifications

Welding procedures shall be qualified in accordance with the requirements of ASME
Section IX with the addition of the following:
14.1.1 Charpy “V” Notch impact tests are required for all qualifications on low temperature
materials and shall be arranged to specifically sample weld metal center, fusion line and
fusion line plus 2mm. Tests shall be made at -46¶C for LTCS and at the line class
minimum design temperature or lower for stainless steels and nickel alloys. Minimum
energy values shall not be less than those required for the original base materials.
14.1.2 Full cross section macro shall be provided for examination. A cross weld micro hardness
survey shall be performed along lines within 0.5mm of both inner and outer surface.
Cross weld outer surface values shall also be obtained. Maximum values permitted are
shown in the Table below.
Material P-No. Brinell Hardness

P-1 200
P-3, 4 225
P-5(A), P-6, P-7 235
P-10A, B, C & F 225
P-11 225
Note: A) The Contractor and Employer shall designate hardness requirements for P-91
and F-91 (9Cr1Mo) materials
B) Hardness testing shall be performed after any required PWHT.
14.1.3 The qualification tests shall include all the size of consumable that may be required in
production welding; each required size of consumable shall be used in performance of the
qualification tests.
14.1.4 The qualified range of materials and thickness shall be limited to steels of same type and
strength grade and within a particular ASME P Group Number.
14.1.5 The qualified thickness shall be limited to test weld thickness ·0.5t only, where “t” is the
test weld plate thickness.
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14.1.6 Cross qualification for other similar materials will be permitted only as per ASME P Group
rules.
14.1.7 Multiple welds may be required to provide sufficient material for the required tests when
small diameter piping materials are involved.
14.1.8 Charpy Impact specimen locations shall be removed and sampled as per ASME B31.1
requirements. Specimens shall be removed as near as possible to the pipe OD such that
the centerline of the specimen is within 7mm of the outer surface. Another set located
within 7mm of the inner surface is required when large thickness materials (over 20mm
thickness) are welded.
14.1.9 Where a different welding process or consumable is used for root or filling, both the root
and fill weld metals shall be impact test sampled. It may be necessary to fully weld out a
butt using only the root welding process and consumable to obtain a suitable size of weld
to provide a sample for testing.
14.1.10 When different welding processes or consumables are used for each side of a double
welded joint then each process and consumable shall be tested.
14.1.11 PQR’s with details of all tests and the results shall be reported on a form containing
all the details required by this Procedure and ASME Section IX. The completed PQR’s
shall be required for review and acceptance by Contractor and Employer before
production welding
14.1.12 Contractor and Employer reserves right to witness PQR preparation, welding and testing.
14.2 Existing Procedure Qualification
Previously qualified PQR’s shall be considered for use, full details and reference
information shall be provided to Contractor and Employer for review and approval prior to
the start of production welding.
14.3 Socket Weld Qualification
14.3.1 Socket welds shall require a special qualification test on actual socket flange to pipe weld.
This weld shall be sectioned for two macros. Detailed hardness surveys shall be made,
the maximum hardness shall not exceed the values stated above in 14.1.2.
14.3.2 All carbon steel and low alloy socket welds shall require 100¶C min. preheat and
minimum interpass temperature.
14.3.3 The gap from end of pipe to socket shall be 1 to 2 mm.
14.3.4 All carbon steel production socket welds subject to PWHT shall be hardness tested using
suitable hardness testing equipment such as Microdur MIC 10 at equal spaced locations
around the weld; max. Hardness shall not exceed values stated above.
14.4 Stud Welding Procedure Qualification

DOCUMENT NUMBER
(For Subcontractor)
14.4.1 Arc and resistance stud welding for attaching non-load-carrying stud (such as extended
heat transfer surfaces and insulation attachment pins) shall be qualified in accordance
with ASME Section IX on base materials at least as thick and having the same nominal
chemistry as the production materials. The PQR shall include a record of all welding
variables and equipment settings used during qualification
14.4.2 A production test sample of at least 5 consecutively welded studs shall be tested at the
beginning of each shift and after performing maintenance operations on automatic
equipment.
14.4.3 Production welds shall be inspected by hammer testing (1 kg hammer and 50 to 75

strokes) or 15 degree bend tests as agreed between Subcontractor and
Contractor/Employer.
DOCUMENT NUMBER
(For Subcontractor)
15.0 PREPARATION OF QUALIFICATION TEST
15.1 Qualification Required for Application

Welders shall be qualified in accordance with ASME IX and this Procedure
All applicants for the qualification test shall be welders either, having an authorized
license, appropriate welding experience or can demonstrate a suitable level of training.
Subcontractor shall be responsible for timely application for welders to perform the
qualification test, including making available all prerequisite documentation,
The Subcontractor has no authority in the performing or assessment of the welder

qualification test.
Each welder or welding operator shall be qualified specifically for this project. The use of
prequalified welders or operators shall depend on documented evidence of satisfactory
performance in the previous 3 months commencing work for this project subject to
meeting the essential variable requirements of ASME IX and this Procedure.
15.2 Essential Variables for Welder Qualification

In addition to ASME IX Paragraph QW 350, QW 360, a welder or welding operator shall
be re-qualified if any of the following apply
a) A change from one of the following consumable product forms to another for GMAW
or FCAW
- Flux cored electrode,
- Metal cored composite electrode,
- Bare solid wire
b) A change in the number of wires or addition or deletion of iron powder for SAW from
that used to weld the test piece.
15.3 Welder Qualification Test

The supervision of the welder qualification test shall be the responsibility of the
Subcontractor Supervisor together with Contractor QC Personnel. Each welder and
welding operator shall be assigned an identifying number, letter or symbol which shall be
used to identify the work of that welder or welding operator.
Inspection and acceptance of the welder test shall be the responsibility of the Contractor
QC Manager and the level II personnel for non-destructive examination in accordance
with ASME Section IX.
15.4 Documents
15.4.1 Applicants for the qualification test shall be required to submit the following documents
filled in with the necessary data prior to the test, the type of qualifications, required test
and qualified range of welder shall be in accordance with Table 1.
a) Welder Test Application
b) Welder Qualification Test Record
DOCUMENT NUMBER
(For Subcontractor)
c) Welder Certificate (ID Card)
15.4.2 Welder Certificate as per Form No. 600S-33Z-0019AA4-03 will be issued to the welders
who passed the qualification test. The period of validity of the Welder ID Card shall be
one year from the date of issuance in a specific job. Validity may be extended until the
completion of the work, when the welder continues to work beyond the one year limit.
15.4.3 Record of tests for welder shall be filled in Form No.: 600S-33Z-0019AA4-02 and retained
onsite until the completion of the project.
15.4.4 The qualification certificate shall be returned to the Contractor Site QC Manager when,
either the welder leaves the project, or, on completion of the project.
15.4.5 Subcontractor shall for the examination, submit to Contractor an “Welder Test
Application” completed with all necessary information, at least 24 hours prior to the
examination.
15.5 Preparation of Test Coupon
15.5.1 Pipe test coupons shall be used for the qualification test of pipe welder. However, plate
test coupons may be substituted for the welder qualification test of pipe welder.
15.5.2 The edge profile preparation of the test material shall be achieved by machining or
grinding.
15.5.3 Dimensions and shape of edge preparation of test coupons shall be Fig. 1(a) and 1(b).
Dimension of Pipe Dimension of Plate

APP. 125 APP. 125
APP. 125 APP. 125
APP. 300
APP. 250
APP. 250
Fig. 1(a): Dimension of Test Coupon

DOCUMENT NUMBER
(For Subcontractor)
37.5 ± 2.5°
1.6 ± 0.8
Fig. 1(b): Edge Preparation (Dimensions in mm)
15.5.4 Fixing of test coupon and welding position shall be as follows:
a) In the case of pipe test coupon, 6G position or 2G + 5G position shall be adopted.
b) In the case of plate test coupon, 2G, 3G and 4G shall be adopted. A qualification test
by plate coupon shall cover the pipe welder for over NPS 24 inch.
15.5 Welding
15.5.1 General
a) The procedure adopted for welding shall be in accordance with qualified WPS.
b) Welding shall be performed in one direction only; back welding shall not be performed.
c) Heat treatment of the test coupon before and after welding is not required.
15.5.2 Welding Manner for Pipe Welder

Welding of the pipe test coupon shall be performed in accordance with the following
sequence, in the case of the 2G + 5 G position.
a) Fix the test coupon horizontally (5G)
b) Weld the test coupon from “A” to “B” and from “A” to “D” portions as shown in Fig. 2.
The point “A” shall be at the bottom at this time. The welding shall be performed up to
the final layer.
c) Change fixing position of the test coupon from horizontal to vertical position (2G)
d) Weld the test coupon between “B”, “C” and “D” completely. Welding may be started
either “B” or “D”.
e) Boundary parts between weld seams at point “B” and “D” in Fig. 2 may be treated with
grinder so as to remove crater.
DOCUMENT NUMBER
(For Subcontractor)
vertical fixing (2G)

horizontal position
starting point
C
B 120°
D
test coupon
overhead position
overhead position A
starting point
horizontal fixing (5G)
Fig. 2 Test Position of Pipe
15.5.3 Welding at 6G position shall be performed without a change of position.
15.5.4 Welding of the plate test coupon shall be performed in accordance with the following
manner;
a) Provided that the plate test coupon are made of material from the same P-No. as the
applied pipe test coupon.
b) Weld the test coupons in vertical (3G), horizontal (2G) and overhead (4G) positions
respectively as applied position of applicant.
15.6 Inspection and Acceptance
15.6.1 Inspection Item

a) Visual inspection shall be carried out in accordance with Table 2.
b) Radiographic examination shall be carried out in accordance with Article 2 of ASME

Section V after a visual inspection has been successfully completed.
15.6.2 Acceptance Criteria

a) Welder shall be qualified by radiographic examination result in accordance with QW-
191 of ASME Section IX.
b) A welder, who has failed the qualification test, may re-apply to take the qualification
test again but only after sufficient training.
DOCUMENT NUMBER
(For Subcontractor)
15.7 Qualification of Tack Welder, Support Welder
15.7.1 Tack Welder, Shoe Welder

Welders who carry out tack welding shall have the same qualification as plate welder
stipulated in Paragraph 15.1 through 15.6.
15.7.2 Support and Steel Structure Welder
a) Welders who carry out support and steel structure welding of carbon steel material (P-
No. 1) shall be qualified in accordance with this Procedure with one (1) plate coupon,
so that one-half of the welded seam of the plate coupon shall be 2G position and the
remaining half welded seam shall be 3G position.
b) The assessment shall be done by the visual inspection in accordance with Paragraph
15.6.1.(a), no radiographic examination may be applied.
Table 1. Type of Welder’s Qualifications
(1) Pipe Welder
Welding Process Test Coupon(Pipe) P-No. F-No. Base Material Qualified Range
A333 Gr. 6, Carbon Steel
GTAW 1 6
A106 Gr. B or eq. (P-No. 1, F-No. 6)
GTAW+SMAW 1 6+4
A106 Gr. B or eq. (P-No. 1, F-No. 6+4)
SMAW(U)+SMAW 1 4
A106 Gr. B or eq. (P-No. 1, F-No. 4)
SMLS Alloy Steel
GTAW A335 Gr. P11 4 6
(P-No. 4, F-No. 6)
SMLS Alloy Steel
GTAW+SMAW A335 Gr. P11 4 6+4
(P-No. 4, F-No. 6+4)
SMLS Alloy Steel
SMAW(U)+SMAW A335 Gr. P11 4 4+4
(P-No. 4, F-No. 4)
A312 Gr. TP304/304L, Stainless Steel
GTAW 8 6
A312 Gr. TP316/316L (P-No. 8, F-No. 6)
A312 Gr. TP304/304L, Stainless Steel
GTAW+SMAW 8 6+5
A312 Gr. TP316/316L (P-No. 8, F-No. 6+5)
(2) Support and Structural Steel Welder
Base Material Qualified

Welding Process Test Coupon(Pipe) P-No. F-No.
Range
Carbon Steel
SMAW A36 1 4 (P-No. 1, F-No. 4)
Note: SMAW(U) : Root Pass Welding by SMAW

DOCUMENT NUMBER
(For Subcontractor)
(3) Qualified Range of Welder
Size and OD of Pipe used for Qualification

Qualified Range
Test
Nominal Pipe Size Actual Nominal Pipe Size Thickness
OD Range (mm)
(NPS in) OD (mm) (NPS in) (mm)
D < 25.4mm 1/8 10.3 1/8 ~ no limitation
1/4 13.7 1/4 ~ no limitation
1/2 21.3 1/2 ~ no limitation
25.4mm ˺ D < 73mm 3/4 26.7 3/4 ~ no limitation
1 33.4 3/4 ~ no limitation
1-1/2 48.3 3/4 ~ no limitation
2 60.3 3/4 ~ no limitation
73.0 and
73mm ˺ D 2-1/2 and over 2-1/2 ~ no limitation
larger
Note: 1) When the welder or welding operator is qualified by radiographic examination,

the minimum weld length of coupon(s) shall be 6 in. Therefore, qualification test
with small diameter pipe (1-1/2 NPS in. and smaller) will require multiple numbers
of coupons
i.e., OD. (mm) x Ɋ x (numbers of coupons) ≥152mm
2) Alternatively, a 6 inch length of the first production weld(s) made by a welder

may be qualified by radiography.
3) “T” means nominal thickness of test coupon. When test coupon having T≥1/2
in. (12.7mm), no limitation is applied to qualified thickness.
Table 2. List of Items for Visual Inspection
Item Degree of defect Sketch

Uneven bead no marked defect 1
Uneven bead width 2
0.3 or less
Undercut 25 or less for length of one undercut, 8 % 3
DOCUMENT NUMBER
(For Subcontractor)
or less of peripheral length for total length

Overlap 4
Excessive penetration 5
Inner surface misalignment no marked defect 6
Bead center shift 7
Height of reinforcement of weld no excess reinforcement of weld 8
Incomplete weld pene-tration not allowed 9
Angle (strain angel after plate welding) 8 (18 mm) 10
Sketch
1 2 3 4
5
6 7 8 9 10
5q (11)
8q (18)
125
16.0 ATTACHMENTS
Attachment 1: Welder Test Application
Attachment 2: Welder Qualification Test Record
Attachment 3: Welder Certificate (ID Card)
DOCUMENT NUMBER
(For Subcontractor)
Attachment 1: Welder Test Application (Form No.: 600S-33Z-0019AA4-01)
WELDER TEST APPLICATION
Project Name MA’ADEN Rolling Mill PROJECT

Photo Project No.
(50mmX50mm) Test Date
Name of Applicant
Date of Birth
Address/Employer Name
Attached WPS
Process
Position/Size
Material (P-No)
Radiography Test Yes No
Bend Test Yes No
Tensile Strength Test Yes No

Note: 1) The welding procedure to be approved by Contractor shall be confirmed to this
welder test application.
2) Two photographs are required;
One is attached on this welder test application and
another (Size : 50mm x 50mm) will be used to make a I.D Card.
We submit this welder test application to perform the welder performance qualification
test in accordance with MD-451-0000-QD-QA-PRO-00002, General Welding Procedure
for Subcontractor.
Requested by Name: _____________________ Sign : _________________ Date : __________
Subcontractor Name: _________________________________ Tel : _____________________

DOCUMENT NUMBER
(For Subcontractor)
Attachment 2: Welder Qualification Test Record (Form No.: 600S-33Z-0019AA4-02)
Project Name MA’ADEN Rolling Mill PROJECT

Project No.
Ref. Spec.
A. General Record
Welder Name ID No.
B. Test Record
Process Test No
Position WPS No.
Material (P-No.) Type
Thickness Range Progression
Elec. Current Filler Metal
Polarity
C. Supporting Report
Radiographic Test Results for Alternative Qualification Groove Welds by Radiography
RT Report No. Conducted by
Length and Percent of Defect
PQ Report No. Conducted by
E. Fillet Test Result

Conducted by
Length and Percent of
Defect
We certify that the statements in this record are correct and that the test welds were prepared
welded and tested in accordance with ASME Section IX.
Name Signature Date
Subcontractor
Contractor
Employer
DOCUMENT NUMBER
(For Subcontractor)
Attachment 3: Welder Certificate (ID Card, Form No.: 600S-33Z-0019AA4-03)
WELDER'S CERTIFICATE
NAME :
PHOTO
WELDER ID No. :
Front
ISSUED DATE :
QA/QC MANAGER QA/QC MANAGER

SubContractor Name SAMSUNG ENG.
Basic: White
Letter: Black
QUALIFICATION
WELDING POSITION
WPS No. THICK/DIA.
PROCESS QUALIFIED
THK DIA
Rear

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DOCUMENT NUMBER

General Welding MD-451-0000-QD-QA-PRO-00002

0 Nov. 08, 2011 Issued for Approval I.Y.Kim

REV DATE DESCRIPTION PREPARED REVIEWED APPROVED J.V

3.0 REFERENCE DOCUMENTS

4.0 WELDING CONSUMABLES

5.0 JOINT PREPARATION CLEANING AND IDENTIFICATION

6.0 PREHEAT AND INTERPASS TEMPERATURE

7.0 CONVENTIONAL WELDING PROCESSES

8.0 WELDING PROCEDURES AND TECHNIQUES

9.0 POST WELD HEAT TREATMENT

10.0 REPAIR OF WELD DEFECTS

12.0 WELD EXAMINATION AND INSPECTION

13.0 WELDING PROCEDURE SPECIFICATION

14.0 WELDING PROCEDURE QUALIFICATION

15.0 PREPARATION OF QUALIFICATION

WPS Welding Procedure Specification

3.0 REFERENCE DOCUMENTS

MD-451-0000-QD-QA-PQP-00002, Site Quality Control Plan

ASME B31.1, Power Piping

4.0 WELDING CONSUMABLES

4.2 Consumable for Carbon Steel

4.2.4 Carbon 0.5% Mo consumables shall not be used.

4.3 Consumable for Stainless Steel

4.4 Consumable for Dissimilar Metal Joints

4.5 Shielding Gases

5.0 JOINT PREPARATION CLEANING AND IDENTIFICATION

6.0 PREHEAT AND INTERPASS TEMPERATURE

7.0 CONVENTIONAL WELDING PROCESSES

7.1 Conventional welding processes shall be performed as follow;

7.1.2 Rotatable and double joints, welded from outside only.

- Root pass; Any manual or automatic gas shielded welding process

8.0 WELDING PROCEDURES AND TECHNIQUES

9.0 POST WELD HEAT TREATMENT

9.7 Thermocouples shall be located on the pipe at the weld.

10.0 REPAIR OF WELD DEFECTS

Contractor will select the weld joints to be radiographed.

12.0 WELD EXAMINATION AND INSPECTION

12.1 Examination/inspection requirements and acceptance criteria shall be in accordance with

12.2 Alloy Verification

12.3.2 Sufficient preparation of weld is required to permit meaningful interpretation of

Acceptance requirements are to be in accordance with ASME B31.3, Paragraph 341.3.

12.3.5 All Nondestructive Examinations shall be performed by personnel qualified in accordance

12.3.6 All Nondestructive Examinations shall be performed in accordance with written

12.3.7 Results of Nondestructive Examinations shall be reported on forms authorized by the

12.3.8 Locations of Nondestructive Examinations shall be in accordance with the applicable

12.3.9 Nondestructive Examination shall be performed in accordance with ASME B31.1,

12.4 Compliance with Inspection and Test Plan 0

Contractor / Sub-Contractor quality inspectors and construction supervisor shall aware of

12.5 Welding Reports for Filing

13.0 WELDING PROCEDURE SPECIFICATIONS

14.0 WELDING PROCEDURE QUALIFICATION

14.1 New Procedure Qualifications

Material P-No. Brinell Hardness

14.2 Existing Procedure Qualification

14.3 Socket Weld Qualification

14.4 Stud Welding Procedure Qualification

14.4.3 Production welds shall be inspected by hammer testing (1 kg hammer and 50 to 75

15.0 PREPARATION OF QUALIFICATION TEST

15.1 Qualification Required for Application

The Subcontractor has no authority in the performing or assessment of the welder

Requested by Name: _____________ Sign : _ Date : __

Subcontractor Name: _____________ Tel : _