Attach-16 Work Procedure For Welding Work Management

WUHUAN Job. No.
17125
WUHUAN
Talcher Fertilizers Project
ENGINEERING 17125-PC10-WD-001
CO.,LTD
WORK PROCEDURE 1 of 14 Rev. 0
WELDING WORK MANAGEMENT PROCEDURE
0 For Bidding
REV. DESCRIPTION DEGND CHEKD APPRD DATE
MUST NOT BE COPIED, TRANSMITTED TO OTHERS OR USED WITHOUT PERMISSION OF WUHUAN
ENGINEERING CO. LTD
WUHUAN Talcher Fertilizers Project WUHUAN Job. No.17125
ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

PROCEDURE
CO.,LTD 2 of 14 Rev. 0
CONTENTS
1. Purpose .................................................................................................................................. 3
2. References ............................................................................................................................. 3
3. Scope ..................................................................................................................................... 3
4. Definition ...............................................................................................................................3
5. Responsibilities ......................................................................................................................3
6. Management .......................................................................................................................... 5
7. Appendix ............................................................................................................................. 13
MUST NOT BE COPIED, TRANSMITTED TO OTHERS OR USED WITHOUT PERMISSION OF WUHUAN ENGINEERING CO. LTD

PROCEDURE
1. Purpose
The purpose of this procedure is to ensure welding management and welding quality on site
of this PROJECT.
2. References
 EPC CONTRACT
 QHSE Management Manual of WUHUAN
 ASME Standard
 Non-Destructive Examination Procedure
 Welder Training and Qualification Procedure
3. Scope
The procedure is applicable for management of welding construction, heat treatment and
NDT for pipe and equipment prefabrication and installation of xxxxx PROJECT.
The application scope of this procedure includes steel structure construction, field equipment
construction and pipe construction.
4. Definition
1) WPQ： Welder Performance Qualification
2) PQR： Procedure Qualification Record
3) WPS： Welding Procedure Specification

4) PWHT：Post weld heat treatment
5) NDT：Non-destructive test
 RT- Radiographic test
 UT-Ultrasonic test
 MT-Magnetic-particle inspection
 PT-Penetration test
 VT-Visual inspection
5. Responsibilities
Owner QA/QC has the right of supervision on quality and welding Procedure at all stage.
5.1 Welding Engineer
1) Prepare welding construction plan and organize welding technician to clearly understand
this plan.

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2) Prepare WPQ and resource planning of welding for this project, and also prepare the WPS
and organize exam for welders, be responsible for the welder qualification management.
3) Be responsible for the supervision and inspection of welding and heat treatment，instructing
welding technician in visual inspection of weld joints.
4) Supervision and inspection for the daily management of the welding consumables
warehouse.
5.2 Weld quality inspector
1) Assist technician with preparation of welding quality inspection document and

implementation plan and be responsible for the quality control of welding during overall
process and execution of relevant quality control measures.
2) Participate in review and approval of welding construction plan, and supervise the
execution of welding procedure.
3) Confirm the weld joints to be checked, check and record the quality, and prepare relevant
document of welding, such as welding data record, statistics of weld qualification rate.
5.3 Welding team leader
1) The team leader is an organizer for work implementation, and also a director to convert the
design and technical requirement into actual work. The team leader shall be responsible for
the construction quality of weld and organize welders to inspect by themselves.
2) Strictly execute quality control regulations and technical operation specifications, and
strictly carry out construction following construction procedure to ensure the quality of
construction.
3) Accept supervision and inspection by technical personnel and quality inspectors for
construction of this team, and assist them and provide them with technical data.
5.4 Welder
1) Welding shall be carried out in accordance with technical requirement and WPS. When the
working conditions do not meet requirement, welding shall not be carried out..
2) The welders shall check the weld joints shall by themselves. If weld size is excessive, weld
form is bad, weld surface has defects and so on, which must be promptly processed and
eliminated.
3) Welder who has work permit shall clearly understand his work scope of welding.
4) Welders shall know the steel grade of welding pieces, use welding consumables accurately
and understand welding process clearly according to technical requirement.

PROCEDURE
5.5 Welding consumables keeper in warehouse
The welding consumables shall be stored and welding rod shall be baked according to
requirement of Welding Consumables Control Procedure, meanwhile, the welding
consumables distribution and the baking information shall be recorded.
5.6 Heat treatment workers
Heat treatment worker shall have appropriate qualification and experience, perform his
duties according to relevant regulations, and reject to carry out heat treatment when weld
appearance is unqualified.
5.7 NDT Engineer
1) Review NDT work entrusting sheet and weld layout drawing.
2) Check NDT test results, evaluate the quality of welding, and review the test report.
5.8 NDT personnel
1) Obtain appropriate qualifications for NDT. It requires that the operators shall obtain
grade-1 qualification certificate and the person for film evaluation and report preparation
shall obtain grade-2 qualification certificate at least.
2) The test shall be carried out strictly according to the weld information provided by
technician, and NDT personnel shall be responsible for the facticity and accuracy of test.
6. Management
Production welding shall start only when qualified welding procedures and welders have been
approved by CONTRACTOR/OWNER.
Production welding shall be done in accordance with Approved WPS by qualified

welders/welding operators.
6.1 Qualification Management
6.1.1 Welder qualification
1) Qualification management shall follow" 10048-PC10-WD-002 Welder Training and

Qualification Procedure".
2) All welders shall be trained in theory and in operation, and obtain the welding qualification
certificate by examination of national departments. All welders shall pass the exam on site
according to the related regulations of WUHUAN and Owner before starting welding work.
And the qualified welders shall perform the welding work complying with qualification
certificate..

PROCEDURE
6.1.2 PQR and WPS

For the welding material which used for the first time , subcontractor and/or WUHUAN's
construction team shall actively prepare base material and welding consumables, the
qualified PQR shall be obtain before welding work. The verification of PQR including:
（1） PQR
（2） WPS
（3） Post weld heat treatment report (if any)
（4） NDT report

（5）Mechanical property report
（6）Qualification of base material, welding consumables and so on.
6.1.3 Qualification of NDT person
NDT person shall obtain relevant qualification certificate.

6.2 Machines and tools management
6.2.1 Welding equipment
1) Welding machine, oven, thermal container and other equipment shall be provided with
production certificate, and checked and maintained regularly to ensure that the equipment
shall be safe, steady and easily operated, satisfying the requirement of welding
specification.
2) Welding machines shall be placed at dry place with ventilation, if environment is not good
enough, the facilities for windbreak, waterproof, fireproof, sunshade shall be prepared.
6.2.2 Heat-treatment equipment

Thermocouple, compensatory wire, insulation felt, temperature control cabinet,
temperature cure recorder and other equipment shall be prepared; all of these must be
qualified after check and calibration.
6.2.3 Auxiliary tools
Necessary auxiliary tools for each welder, includes attemperator, saw blade, hand hammer,
flat shovel, pointed shovel and small flashlight (used for check root bead).
6.3 Materials management
6.3.1 Base material list

PROCEDURE
Material
NO. Material class Content
1 P-NO.1 SA106 Gr.B、A333 Gr6、API5LGrB、A283 Gr.C 、A516Gr.60
2 P-NO.4 A335 P11
3 P-NO.5A A335 P22
4 P-NO.8 347H、304、304L、316L
Prepare relevant WPS and PQR according to material and thickness of pipes.
6.3.2 Welding consumables control

1) Subcontractor and/or WUHUAN's construction team shall build special warehouse for
consumables, specially assign a person to take charge of management and distribution of
welding consumables in accordance with Welding Consumables Control & Management
Procedure.
2) Welders shall be careful to prevent welding rod tip, welding wire tip or welding rod
dropping from a height. Each welder shall clean up welding rod, welding wire and the tips,
and put them into welding rod drum and recovery bucket separately, which shall be sent
back to welding consumables warehouse.
6.3.3 Drying Equipment :
1) Subcontractor shall provide the necessary drying and holding ovens, and shall also provide
the portable dryer for each welder.
2) The baking and holding ovens shall be clearly marked to show the type of electrodes
contained and the re-drying or stock locations.
3) The temperature accuracy of measuring system for main ovens shall be checked using a
calibrated thermometer as required.
Also consider condition use of Drying Equipment(Baking/Main Drying Oven-Holding
Oven-Welder Portable Oven) and Baking/Holding Process
6.3.4 Other material
Pole of argon tungsten-arc welding shall be cerium-tungsten pole, and the purity of argon
shall not be less than 99.99%, the production certificate shall be presented. The purity of
oxygen and acetylene shall not be less than 98.5% and quality certificate shall be provided.
6.4 Operation requirements
6.4.1 Groove preparation
The groove type, size and gap shall satisfy the requirement of WPS, it shall be prepared by
mechanical processing. If the groove is prepared by flame cutting, the oxides, slag and

PROCEDURE
spatter on the cutting surface shall be cleaned up, and the groove shall be flattened. Before
fit-up, the oil, coatings, dirt, rust and etc. on the groove surface and outside/inside surface
of base material close to groove so that the metallic luster can be shown. The clean-up
range:
1) Butt welding joint : outside surface:10～15mm; Inside surface: 10mm.
2) Fillet welding joint: fillet K value + 10 mm.
Surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides and other
materials detrimental to welding. Cleaning shall be done in a manner that will not lead to
contamination of the weld or base metal. Only stainless steel brushes and tools shall be
used on stainless steels, nickel and non-ferrous materials. Grinding discs containing sulfur
(iron sulfite) or other harmful components shall not be used on stainless steels, nickel or
non- ferrous materials.
6.4.2 Preheat before welding
The preheat temperatures for different materials are shown in the following table:
PIPE
MATERIAL
Thk(mm ) Preheat temp(℃)
P-No. 1
≥25 ≥80
Carbon steel and casting in which C<0.35
P-No. 3
≥13 ≥80
Alloy steels Cr ≤ 0.5%
P-No. 4
ALL ≥120
A335P11
P-No. 5A
ALL ≥175
A335P22
Preheat temperature for dissimilar material: the preheat temperature of higher alloy steel
shall be selected.
Preheat temperature is set according to the standard Table 330.1.1 in ASME B31.3 .
6.4.3 Fit-up and welding
1) The spot welding shall be the same with normal welding after fit-up, the defects (if any)
shall be repaired immediately, and spot welding shall be redone, fit-up by force shall be
strictly prohibited.
2) Welding of austenitic stainless steel shall be carried out by filling with argon gas backside,
and the temperature between layers shall be controlled below 175 ℃.

PROCEDURE
3) When material of P-No.4，5A［A335P11、A335P22（content of Cr≤3%）］ be compelled

stopped, thickness of deposited metal shall be ＞ 9.53mm or groove of pipeline shall be
filled 25%. Or else, when move and bear the load, the pipe shall be supported sufficiently
to prevent damage by excessive stress.
4) For the welding of important parts and special materials, subcontractor shall prepare
welding construction plan and submit to WUHUAN and OWNER for review and approval,
this plan shall be advanced and feasible, and the welding engineer shall hand over to
welders and relevant technicians.
5) Welding shall not be done when the quality of the weld would be impaired by the
prevailing weather conditions such as below:
a) When surfaces are wet or exposed to rain

b) High wind velocities unless the weld is protected by a shelter
c) Welding personnel are exposed to inclement conditions
d) When weather conditions become too severe
6) All butt welds in pipe shall be made using at least two passes.
7) Welding shall be performed by completion of each layer before starting next layers.
8) Weld passes shall not start or stop at the same point.

9) The temporary welds shall be subsequently removed and ground flush with the base
materials.
10) The method of removing attachments shall not injure base metal. They shall not be
removed by hammering off.
11) Peening of welds is not permitted.
12) The metal surfaces at the area of temporary weld shall be inspected by MT or PT after
attachments' removal, if material is susceptible to crack.
13) Welding is not permitted on the pressure retaining shell after hydrotest.
14) Arc strikes shall be avoided outside the weld bevel. Should this occur, the deposit shall be
carefully removed by smooth grinding. In serious cases, the removal areas shall be subject
to MT or PT .
15) The welding work for pipe diameter exceeds than 14 inch should be performed by
assigning two welders simultaneously.
6.4.4 Weld marking and record

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1) After welding, the weld joint identification, welder No. and date shall be marked on the
specified place and the weld record shall be prepared according to the related requirement.
2) Subcontractor and/or WUHUAN's construction team shall be responsible for weld marking
and record according to the requirement on timeliness, trueness, accuracy, clearness and
completeness, and submit weld record to WUHUAN periodically.
6.4.5 Weld defect precaution
The common defect of weld includes: cracks, incomplete penetration, incomplete fusion,
porosity, inclusions, concave, undercut, crater, over-burning. Any defect has a certain
degree of harm, which will result in brittle fracture and pipe burst, reduce the weld joint
strength, cause stress concentration and shorten the service life of component. Detail
prevention measures are as follows:
1) Crack prevention measures: select proper welding consumables, improve the
microstructure and plasticity of weld joint, and decrease the weld stress.
2) Incomplete penetration and incomplete fusion prevention measures: control the groove size
of connections, select relative higher welding current within the range of current, adopt
relative slower weld speed, adjust the angle of welding rode, and adopt preheating
measures.
3) Inclusions prevent measure: reduce the deposited weld layer thickness, so that the slag can
float on the surface of molten pool. Adjust the welding current, swing the welding rod and
stir molten pool regularly, so that the slag can be fully separated from metal of molten
pool.
4) Porosity prevention measures: do not use the welding rod with coating cracking, spalling,
deterioration, eccentricity and corrosion of the core. Welding rod shall be dried before use,
the dirt like oil, rust and etc. shall be removed from groove and welding wire. Proper
current, welding speed and arc length shall be selected, and the preheating measures shall
be adopted when the temperature of welding construction environment is too low.
5) Concave prevention measures: welding rod or wire shall stretch to groove root as far as
possible, and moved quickly to accelerate cooling of molten pool. When welding for
finishing layer, the smaller current shall be used to reduce the energy input.
6) Over-burning prevention measures: when argon arc welding, if the metal was over burnt,
the pipe inside shall be filled with argon to reinforce gas protection for welding.
6.4.6 PWHT
The temperature chosen for heat treatment:

PROCEDURE
PWHT
MATERIAL
THICKNESS TEMPERATURE
(MM) ℃
SA210A1,SA210C,SA106 GRB、
＞20 593–649
SA299（ASME P-NO.1）
P-NO. 3
＞20 593–718
ALLOY STEELS CR ≤0.5%
P-NO. 4 A335 P11 ＞13 704–746
P-NO. 5A A335 P22 ＞13 704–746
The heat treatment temperature of dissimilar metal shall be confirmed according to the
base metal and welding rod (wire), generally no more than the Ac1 of the base metal with
lower critical point. Refer to the following table for common steel Ac1 point:
MATERIAL AC1 (℃ )
CS（P-NO.1） 725
C-MO STEEL (P-NO.3） 730
P-NO.4,GR. NO.1 745
P-NO.4,GR. NO.2 775
P-NO.5A 805
During the process of heat treatment, the rate of temperature rise/drop and the time of
constant temperature is stipulated as follows:
1）When the temperature rises to above 400 ℃, the heating rate shall not exceed 205 × 25
/wall thickness ℃ / h , and not more than 330 ℃ / h.
2）Holding time of temperature is according to one hour per 25 mm wall thickness ，and not
less than 15 minutes, during the process, tolerance between high and low temperature shall
be smaller than 65 ℃.
3）Heat width is required as follows, counting from the weld’ center, each side’ width shall be
not smaller than 3 times of the pipe wall thickness , and not less than 60mm.
4 ） Heat insulation width is required as follows, counting from the weld’ center, each side’
width shall be not smaller than 5 times of the pipe wall thickness , to reduce the
temperature gradient.

PROCEDURE
5 ） The temperature of heat treatment must be accurate and reliable. The instrument,
thermocouple and its annex, shall be calibrated or verified as corresponding requirements.
6 ） If post welding heat treatment of some alloy pipe cannot be conducted in time. We shall
immediately heat to regulated temperature, and then make the treatment of hydrogen
elimination. For material of SA335-P11, SA335-P22, , treatment’ specification of
hydrogen elimination is recommended: heated to 300 ~ 350 ℃, holding for 2h.
6.4.7 NDT
General requirement on weld quality inspection: a) if the visual inspection for weld joint is
not accepted, other inspections shall not be carried out; b) if weld joint need heat treatment,
the NDT shall be carried out after heat treatment. NDT shall meets the requirement of
design document with reference to relevant codes, if welding consumables and
performance after weld need to be confirmed, the PMI and hardness test shall be carried
out.
VT requirements: weld joint is good in appearance, and the surface is clean, does not allow
welding tumor, spatter, crack, surface porosity, undercut, and other defects, and also meet
the acceptance standard for visual inspection as required by design documents at the same
time.
In this project, the inspection for appearance of weld joint includes PT and MT, while the
inspection for volume includes UT and RT, the specific ratio of NDT shall meet design
requirement and relevant standard, NDT Company shall be responsible for the facticity of
test result.
NDT shall be carried out with reference to NDT Procedure.

6.4.8 Repair of weld joint
1）When welding is completed, welding slag and spatter shall be treated, the appearance of the
weld joint shall be checked, if there is appearance defect like undercut, nonfill and etc., it
needs to be repaired in time.
2）If the weld joint need to be repaired with grinding as confirmed by NDT, it shall be carried
out according to NDT result notification and repair process card. The defect weld joint
shall be clean, and the groove in the repair welding area shall have proper width without
slot, sharp corner or steps but be smooth. The repair with grinding at the same place shall
not more than 3 times, and not more than 2 times for middle or high alloy steel.
3）Welding consumables and process of repair welding shall be the same with normal welding.
If the weld needs to be repaired without post-weld heat treatment, the hammering process
shall be applied to eliminate welding stress. If repair weld requires heat treatment, the heat

PROCEDURE
treatment after repair welding shall follow the same specifications of former heat
treatment.
6.5 Welding document
The following documents shall be prepared for welding construction: PQR, WPS, work
permit card of welders, welding consumables document for approval, welding map, visual
inspection report of welding consumables (based on ITP), preheat and PWHT record (if
any), weld joint hardness test report (if any), welding record, NDT report, welding
construction plan (if any).
And those document will be submitted to OWNER for approval according to ITP
requirement.
6.6 Safety protection
6.6.1 Safety education

Because there are hazards like explosion, fire, electric shock, arc radiation, high frequency
electromagnetic wave, dust, noise, radiation and etc. during welding and cutting operation,
so the effective precautions shall be adopted to ensure the safety and health of operators.
The subcontractor /or WUHUAN's construction team shall be responsible for general
introduction of the plant and safety education for new comers for welding work in
accordance with national requirements on safety of special operation personnel, the
hazards during welding and cutting operations and the precautions shall be introduced in
detail, so that each welding operator shall clearly understand.
6.6.2 Safety measures

Effective safety precautions shall be adopted actively to prevent occurrence of any accident
as explosion, fire and electric shock. The dust hazards shall be considered when welding
method and material being confirmed. If welders working in harsh environments, measures
as ventilation, rest breaks, personal care and etc. shall be adopted. Paying attention to the
balance between work and leisure of welders, to ensure the safety and health of welders.
6.6.3 Safety feedback

Timely feedback the information for the incident and learn the lessons. Everyone is a
safety barrier.
7. Appendix
 Appendix 1 PQR

PROCEDURE
 Appendix 2 WPS
 Appendix 3 WPQ
 Appendix 4 Qualified Welder Card
 Appendix 5 Qualified Welder Label

 Appendix 6 Qualification Rate Statistics of Welders
 Appendix 7 Welding Report And Daily Visual Inspection
 Appendix 8 PWHT List Format
 Appendix 9 HDT List Format
Job No.
17125-PQR-001
PQR Page: 1 of 7
PROCEDURE QUALIFICATION RECORD (PQR)
SUB-CONTRACTOR WUHUAN OWNER
Name
Signature
Date
FORM NO. WD-001
PROCEDURE QUALIFICATION RECORD (PQR)
=============================================================================================
Organization Name
Procedure Qualification Record No. Date
Welding Process(es)
Types (Manual, Automatic, Semi-Automatic)
JOINTS (QW-402)
Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal and process used.)
BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407)
Material Spec. Temperature
Type/Grade, or UNS Number Time
P-No. Group No. to P-No. Group No. Other
Thickness of Test Coupon
Diameter of Test Coupon
Maximum Pass Thickness GAS (QW-408)
Other Percent Composition
Gas(es) (Mixture) Flow Rate
FILLER METALS (QW-404) 1 2 Shielding
SFA Specification Trailing
AWS Classification Backing
Filler Metal F-No. Other
Weld Metal Analysis A-No.
ELECTRICAL CHARACTERISTICS (QW-409)
Size of Filler Metal
Current
Filler Metal Product Form
Polarity
Supplemental Filler Metal
Amps Volts
Electrode Flux Classification
Tungsten Electrode Size
Flux Type
Mode of Metal Transfer for GMAW (FCAW)
Flux Trade Name
Heat Input
Weld Metal Thickness
Other See Welding Record
Other
POSITION (QW-405) TECHNIQUE (QW-410)

Position of Groove Travel Speed
Weld Progression (Uphill, Downhill) String or Weave Bead
Other Oscillation
Multipass or single Pass (Per Side)
Single or Multiple Electrodes
PREHEAT (QW-406)
Other See Welding Record
Preheat Temperature
Interpass Temperature
Other
PQR (Back)
PQR No.
WELDING RECORD
Weld Process Filler Metal Current Amps Energy or Volts Travel Speed Other
Pass(es) Type (Range) Power (Range) (Range)
Classification Diameter and (Range)
Polarity
1 GTAW ER70S-6 φ2.4 DCEN 70~90 10~15 90~100
2 SMAW E7015 φ3.2 DCEP 90~110 21~23 100~120
3 SMAW E7015 φ3.2 DCEP 90~120 22~24 100~120
4 SMAW E7015 φ3.2&4.0 DCEP 110~130 22~26 100~120
Tensile Test (QW-150)

Specimen Ultimate Ultimate Type of Failure and
No. Width Thickness Area Total Load Unit Stress,(MPa) Location
1
2
Guided-Bend Tests (QW-160)

Type and Figure No. Result
Face Bend 1
Face Bend 2
Root Bend 1
Root Bend 2
Toughness Tests (QW-170)

Specimen Notch Specimen Test Impact Valves Drop Weight
No. Location Size Temperature J % Shear mm Break (Y/N)
1
2
3
Comments
Fillet-Weld Test (QW-180)

Result—Satisfactory: Yes No Penetration into Parent Metal: Yes No
Macro—Result
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………
Welder’s Name Clock No. Stamp No.
Tests Conducted by Laboratory Test No.
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with
the requirements of Section IX of the ASME Boiler and Pressure Vessel Code.
Organization
Date Certified by
(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code.)
Job No.
17125-WPS-001
WPS Page: 1 of 3
WELDING PROCEDURE SPECIFICATION (WPS)
SUB-CONTRACTOR WUHUAN OWNER
Name
Signature
Date
FORM NO. WD-002
WELDING PROCEDURE SPECIFICATION (WPS)
=============================================================================================
Organization Name By
Welding Procedure Specification No. Date Supporting PQR No.(s)
Welding Process(es) Type(s)(Automatic Manual, Machine, or Semi-Automatic)

JOINTS (QW-402) Details
Joint Design
Root Spacing
Backing: Yes No
Backing Material (Type)
(Refer to both backing and retainers)
□ Metal □ Nonfusing Metal
□ Nonmetallic □ Other
Sketches, Production Drawings, Weld Symbols, or Written Description
should show the general arrangement of the parts to be welded. Where
applicable, the details of weld groove may be specified.
Sketches may be attached to illustrate joint design, weld layers, and bead
sequence (e.g., for notch toughness procedures, for multiple process
procedures, etc.)]
*BASE METALS (QW-403)

P-No. Group No. to P-No. Group No.
OR
Specification and type/ grade or UNS Number to Specification and type/ grade or UNS Number
OR
Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove Fillet
Maximum Pass Thickness ≤13 mm (Yes) (No)
Other
* FILLER METALS (QW-404) 1 2

Spec. No. (SFA)
AWS No. (Class)
F-No.
A-No.
Size of Filler Metals
Filler Metal Product Form
Supplemental Filler Metal
Weld Metal Deposited Thickness:
Groove
Fillet
Electrode-Flux (Class)
Flux Type
Flux Trade Name
Consumable Insert
Other
* Each base metal-filler metal combination should be recorded individually.

WPS (Back)
WPS No.
POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407)
Position(s) of Groove Temperature Range
Welding Progression: Up Down Time Range
Position(s) of Fillet Other
Other
GAS (QW-408)
PREHEAT (QW-406) Percent Composition
Preheat Temperature, Minimum Gas(es) (Mixture) Flow Rate
Interpass Temperature, Maximum Shielding
Preheat Maintenance Trailing
Other Backing
(Continuous or special heating, where applicable, should be recorded) Other
ELECTRICAL CHARACTERISTICS (QW-409)
Weld Process Filler Metal Current Amps Wire Energy or Volts Travel Other
Pass(es) Type (Range) Feed Power (Range) Speed
Classifica Diameter and Speed (Range) (Range)
tion Polarity (Range)
1 GTAW ER70S-6 φ2.4 DCEN 70~90 NA 10~15 90~100

2 SMAW E7015 φ3.2 DCEP 90~110 NA 21~23 100~120
3 SMAW E7015 φ3.2 DCEP 90~120 NA 22~24 100~120
4 SMAW E7015 φ3.2&4.0 DCEP 110~130 NA 22~26 100~120
Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc.
Pulsing Current Heat Input (max.)

Tungsten Electrode Size and Type (Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW (FCAW) (Spray Arc, Short Circuiting Arc, etc.)
Other
TECHNIQUE (QW-410)
String or Weave Bead
Orifice, Nozzle, or Gas Cup Size
Initial and Interpass Cleaning (Brushing, Grinding, etc.)
Method of Back Gouging

Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (Per Side)
Multiple or Single Electrode
Electrode Spacing
Peening
Other
Organization
Date Certified by
Job No. 17125
Talcher Fertilizers Limited
17125-00000-WPQ-001
Welder Performance Qualification (WPQ) Page: 1 of N
Certified Welders Registration Table
Item Welder's Name Welder's Code Certificate No. Certified Project No. Nation Remarks
1 XXX W-CT1-001 1001 HGKS-01

2 2001
3
4
5
SUB-CONTRACTOR WUHUAN OWNER/PMC
Name
Signature
Date
WELDER PERFORMANCE QUALIFICATION (WPQ)
=============================================================================================
Welder’s name Identification No.
Test Description
Identification of WPS followed □ Test coupon □ Production weld
Specification and type/grade or UNS Number of base metal(s) Thickness
Testing Variables and Qualification Limits
Welding Variables (QW-350) Actual Values Range Qualified
Welding process(es)
Type (i.e.; manual, semi-automatic) used
Backing (with/without)
□Plate □Pipe(enter diameter if pipe or tube)
Base metal P-Number to P-Number
Filler metal or electrode specification(s) (SFA) (info. only)
Filler metal or electrode classification(s) (info. only)
Filler metal F-Number(s)
Consumable insert (GTAW or PAW)
Filler Metal Product Form (solid/metal or flux cored/powder)
(GTAW or PAW)
Deposit thickness for each process
Process 1 3 layers minimum □Yes □No
Process 2 3 layers minimum □Yes □No
Position qualified (2G, 6G, 3F, etc.)
Vertical progression (uphill or downhill)
Type of fuel gas (OFW)
Inert gas backing (GTAW, PAW, GMAW)
Transfer mode (spray/globular or pulse to short circuit-GMAW)
GTAW current type/polarity (AC, DCEP, DCEN)
----------------------------------------------------------------------------------------------------------------------------------------------------------------
RESULTS
Visual examination of completed weld (QW-302.4)
□ Transverse face and root bends [QW-462.3(a)] □ Longitudinal bends [QW-462.3(b) □ Side bends (QW-462.2)
□ Pipe bend specimen, corrosion-resistant weld metal overlay [QW-462.5(c)]
□ Plate bend specimen, corrosion-resistant weld metal overlay [QW-462.5(d)]
□ Pipe specimen, macro test for fusion [QW-462.5(b)] □ Plate specimen, macro test for fusion [QW-462.5(e)]
Type Result Type Result Type Result
Alternative Volumetric Examination Results (QW-191): RT □ or UT □ (check one)

Fillet weld — fracture test (QW-181.2) Length and percent of defects
□ Fillet welds in plate [QW-462.4(b)] □ Fillet welds in pipe [QW-462.4(c)]
Macro examination (QW-184) Fillet size (in.) x Concavity/convexity (in.)
Other tests
Film or specimens evaluated by Company
Mechanical tests conducted by Laboratory test no.
Welding supervised by
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance
with the requirements of Section IX of the ASME BOILER AND PRESSURE VESSEL CODE.
Organization
Date Certified by
Certificate No. 1001

Photo
Qualified Welder Card
Welder No. : Welder Name :

Base Metals: Filler Metals:
Specification:
Welding Process : Welding Position:
Wuhuan: Owner/PMC:
Test Date: Issue Date:
Certificate No. 2001

Photo
Qualified Welder Card
Welder No. : Welder Name :

Base Metals: Filler Metals:
Specification:
Welding Process : Welding Position:
Wuhuan: Owner/PMC:
Test Date: Issue Date:
WUHUAN ENGINEERING CO.,LTD
Talcher Fertilizers Project Project No:17125

Qualification rate statistics of welders
2016.04.25--2015.05.01
UT RT UT-Reject RT-Reject UT Rate RT Rate
No. Welder No. Welder Name. Mark
Week(m) Total(m) Week(films) Total(films) Week(m) Total(m) Week(films) Total(films) Total Total
1 W-CT1-XXX
2 W-CT2-XXX
10
11
12
13
14
15
16
17
18
19
Welding Report And Daily Visual Inspection
Report No.: Unit: Date:
Joint Welding Process Welder No. Preheat Visual
Item Line No. Dwg No Remarks
No. φ/mm DIN thick Prime Fill/Cover Welder 1 Welder 2 Check Check
PIPE11/DN200-A-11210-AJBA1-
1 07011-03000-PP21-0014 1 200 8 5 GTAW GTAW W-00hj-001 W-00hj-001 NA Acc WPS-001
A
2 2 350 14 25 GTAW SMAW W-00hj-001 W-00hj-001 Acc Acc WPS-001
3 3 200 8 8 GTAW SMAW W-00hj-001 W-00hj-001 NA Acc WPS-002
4 4
5 5
6 6A
7 7
8
9
10
11
12
13
14
15
16
17
18
19
Total(φ/DIN) 750 30
Subcontractor WUHUAN OWNER
Date Date Date Date

FORM No. WD-004
PWHT Report List
17125-Unit Code-PWHT-Serial Number
Qualified Reject
No. Report No. Line No. or Item No. Joint No. Remarks
Qty.(DIN) Qty.(DIN)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Total
FORM No. WD-005

HDT Report List
17125-Unit Code-HDT-Serial Number
Qualified Reject
Qty.(point) Qty.(point)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Total
FORM No. WD-006

RT Report List
17125-Unit Code-PP-RT-001
Qualified Reject
Qty.(pcs) Qty.(pcs)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Total
FORM No. NDT-001

PT Report List
17125-Unit Code-PP-PT-001
Qualified Reject
Qty.(mm) Qty.(mm)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Total
FORM No. NDT-002

UT Report List
17125-Unit Code-EQ-UT-001
Qualified Reject
Qty.(mm) Qty.(mm)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Total
FORM No. NDT-003

MT Report List
17125-Unit Code-PP-MT-001
Qualified Reject
Qty.(mm) Qty.(mm)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Total
FORM No. NDT-004

Project:
Quality Control Form Client:

Proj No.: Unit No:
NDT REQUEST Base Standard:
Construction Team(or Subcontractor): Request No.:
Item: NDT type:RT/UT/PT/MT
Material
Welding Welding Circumference
NO. Pipeline No. OR Item Drawing No. Welder No. Remarks
Joint No. Processing rate
Grade Spec
1 Q235B D219×10
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Note:
Subcontractor WUHUAN Supervisor NDT Company
Name:________________
Date:
FORM No. NDT-005

Attach-16 Work Procedure For Welding Work Management

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WUHUAN Job. No.

WELDING WORK MANAGEMENT PROCEDURE

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

2) PQR： Procedure Qualification Record

3) WPS： Welding Procedure Specification

 RT- Radiographic test

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

1) Assist technician with preparation of welding quality inspection document and

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

1) Review NDT work entrusting sheet and weld layout drawing.

Production welding shall be done in accordance with Approved WPS by qualified

6.1.1 Welder qualification

1) Qualification management shall follow" 10048-PC10-WD-002 Welder Training and

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

6.1.2 PQR and WPS

（4） NDT report

（6）Qualification of base material, welding consumables and so on.

6.1.3 Qualification of NDT person

NDT person shall obtain relevant qualification certificate.

6.2.1 Welding equipment

6.2.2 Heat-treatment equipment

6.3.1 Base material list

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

6.3.2 Welding consumables control

6.4.1 Groove preparation

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

2) Fillet welding joint: fillet K value + 10 mm.

6.4.2 Preheat before welding

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

3) When material of P-No.4，5A［A335P11、A335P22（content of Cr≤3%）］ be compelled

a) When surfaces are wet or exposed to rain

d) When weather conditions become too severe

8) Weld passes shall not start or stop at the same point.

11) Peening of welds is not permitted.

6.4.4 Weld marking and record

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

The temperature chosen for heat treatment:

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

P-NO. 5A A335 P22 ＞13 704–746

C-MO STEEL (P-NO.3） 730

P-NO.4,GR. NO.1 745

P-NO.4,GR. NO.2 775

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

NDT shall be carried out with reference to NDT Procedure.

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

6.6.1 Safety education

6.6.2 Safety measures

6.6.3 Safety feedback

ENGINEERING WELDING WORK MANAGEMENT 17125-PC10-WD-001

 Appendix 5 Qualified Welder Label

 Appendix 9 HDT List Format

PROCEDURE QUALIFICATION RECORD (PQR)

SUB-CONTRACTOR WUHUAN OWNER

Groove Design of Test Coupon

POSITION (QW-405) TECHNIQUE (QW-410)

Tensile Test (QW-150)

Guided-Bend Tests (QW-160)

Toughness Tests (QW-170)

Fillet-Weld Test (QW-180)

WELDING PROCEDURE SPECIFICATION (WPS)

SUB-CONTRACTOR WUHUAN OWNER