Preparation of Welding

Procedure Specification
(WPS)
 WHAT IS WPS?
• Documented procedure (recipe) of how welding to be
made to achieve intended quality
• Pre WPS (Preliminary/Proposal of WPS) to be made
before starting to weld, checked and tested by qualified
personnel
• PQR – document based on pre WPS to be prepared to
record actual material, welding parameters used, and
results of tests
• Approved WPS – qualified WPS, supported by qualified
PQR, Welder Certificate, and Authentic Signatories
 WHY WPS REQUIRED?
• For Quality Assurance, Quality Control
purposes
• Standard and Codes Requirement
• Customer Requirement
• Inspecting Authority (e.g. DOSH, DCA)
Requirement
• Insurance Company Requirement (e.g.
Lloyd’s Register of Shipping)
 Sample of Contents in WPS
• Parent Metal
• Welding Process
• Consumables – specification, care, etc
• Preparation – cleaning, edge preparation, assembly, etc
• Position of Welding
• Number and Arrangement of Runs
• Electrical Conditions
• Gas Shielding
• Heat input
• Preheat and Interpass temperature
• PWHT
• Etc, etc
 Preparation of Test Coupon and
Test Samples (Test Specimen)
• Test Coupon and Test Specimen (Test
Samples) prepared
• Test according to agreed Standard Codes
(e.g. AWS,ASME,API or BS)
• Examination by Visual, NDT, DT
 WELDING PROCEDURE SPECIFICATION (WPS)
(APPLICATION CODE: API STANDARD 1104, 2.2)
Company Name : SKA (M) SDN. BHD.
Address : PLAZA DAMANSARA, MEDAN SETIA, DAMANSARA
HEIGHTS, 50490 KUALA LUMPUR
Tel: 013-3993360
Fax: 03-55435160

PROCEDURE SPECIFICATION NO. : P-001

Scope of Work Butt Welding of Pipe and Fittings

Process of Welding GTAW/SMAW (manual)
Material API 5L – X42 Steel Pipe
API 5L – GrB Steel
Pipe

Yield Strength Range Less than or equal to 42,000 psi (289.58 mPa
Diameter Range Outside diameter from 2 3/8” (60.3 mm) to 12 ¾” (324 mm)
Thickness Range From 4.78 mm to 19.05 mm
Joint Design/Type Single ‘V’ Groove

Filler Metal GTAW – AWS A 5.18 ER70S.G

SMAW – AWS A 5.1 E7016
No. of Beads 3
Electrical Characteristic
GTAW
Current Direct Current (DC)
Polarity Straight Polarity
Amperage Range 60 – 90 Amps
Voltage Range 11 – 16 Volts

SMAW
Current Direct Current (DC)
Polarity Reverse Polarity
Amperage Range 60 – 110 Amps
Voltage Range 20 - 26 Volts

Flame Characteristic GTAW

Position 6G
Welding Progression Uphill
Time Lapse Between Passes 5 Min
Type of Line-Up Clamp External
Removal of Line-up (Minimum Percetange of Root – pass) 50%
Cleaning/Grinding Power Tool

Heat Treatment
Preheat Temperature N/A
Interpass Temperature 150C

Stress Relief N/A

Shielding Gas and Flow Rate 100% ARGON, 10 – 18 Litre/Min.
Shielding Flux N/A

Range of Travel Speed

GTAW 4 – 12 cm/min
SMAW 4 – 12 cm/min

Joint Design Sequence of Beads

30 - 35

3
2
1
1.0 0.5
3.2 0.5
 ELECTRODE SIZE AND NUMBER OF BEADS
Current
Electrode
Bead No. Process Type AWS No. Dia. Polarity Amp Volt Speed Direction
(mm) cm/min
1 GTAW TGS- A5.18 2.4 DCSP 60 - 90 11 - 16 4 - 12 Uphill
50 ER 70S-G
2 SMAW LB 52 7016 2.6 DCRP 60 - 110 20 - 26 4 – 12 Uphill
3 SMAW LB 52 7016 3.2 DCRP 80 - 110 20 - 26 4 – 12 Uphill

Test location Date

Witness by
Manufacturer Welder
Name Tested by
Date Name
Client Date
WELDING PROCEDURE QUALIFICATION RECORD

REFERENCE PART A B
REPORT NO. SRM/420/93/8/4 BASE METAL API 51 Gr B API 51 Gr B
CLIENT GMalaysia Sdn. Bhd. THICKNESS (mm) 7.1 7.1
PROJECT DIAMETER (in) 6 (162/170 mm) 6 (162/170 mm)
REF. STANDARD API 1104 Ceq.
WPS NO. P 001
NAME OF WELDER Ong Min Teck
I/C
A5533909
DATE 18.8.1993
Ө 60 – 70o

G 3.2 + 0.5 (mm)

F 1.0 +0.5 (mm)

Pass 3
F
G Position 6G
 TECHNIC CONSUMABLE SHIELDING WELDING COND.
Pass Proces Progressio Dia Filler / Trade Polarit Gas / Flow Current Voltage Speed
s n (mm) Electrod y Flux Rate (A) (V) (cm/min)
e Name (I/min)

Root GTAW Uphill 2.4 ER70SG Kobe DCSP Argon 12 85 12-14 5.46
TGS50
Hot SMAW Uphill 2.6 E7016 Kobe LB52 DCRP - - 70-80 20-24 5.32

Cap SMAW Uphill 3.2 E7016 Kobe LB52 DCRP - - 90-100 20-24 7.37

TIG cup size 4

HEAT TREATMENT INSPECTOR

Date
PREHEATING TEMP. 20.8.1993
INTERPASS TEMP. 150C
PWHT HEATING RATE
SOAKING TEMP.

SOAKING TIME
COOLING RATE

PROCESS
Visual examination results QW-302.4) Acceptable

Radiographic test results (QW-304 and QW-305)

(For alternative qualification of groove welds by radiography)

Fillet Weld – Fracture test Length and percent of defects in

Macro test : fusion Fillet leg size in in. Concavity/convexity

in Welding test conducted by

Mechanical tests conducted by Laboratory test no.

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 Code.

Organization
By
Date
 TAYLOR-WHARTON ASIA (M) SDN. BHD. (204301-h)
A Traditional of Excellence Since 1742
Lot Nos: PT 5076 & 5077, Jalan Jangur 28/43, Hicom Industrial
Estate, P.O.Box 7193, Pejabat Pos Besar 40706 Shah Alam,
Selangor Darul; Ehsan, Malaysia.
Tel.: 03-5113003 (3 Lines) Fax: (603) 5111472
RADIOGRAPHIC INSPECTION REPORT

Vessel Serial No.: W.Q-T Report No.: TNA/RT/4291

Material: SA-553 TYPE 1 Date: 2 August 97
Welding Process: GTAW/SMAW Radiographic SWSI
Technique
Inspection Code ASME DT Source Activity 27 ci
Film Type Agfa D7 Radiation Source IR-192
Film Diagnostic length 8” Source Size 3 x 2 mm
Panetrameter ASTM 1B Source Film Distance 18-
Sensitivity 2% Density 2-3

Weld Positio Materi Tungs Exces Burn Slag Porosi Conca Under Incom Lack Crack Surfac No Rej GRADE Analysis
n al ten s Throu Inclusi ty vity cut plete of e Signifi ecta Minor 1 (Location
Refer Thickn Pen. gh on Pen. Fusion cant ble Moderate 2 of
ence ess Disc Large 3 Defects)
Excessive 4

.
 WELDING PROCEDURE QUALIFICATION RECORD (Cont’d)

Tensile Tests
Specimen No. Width Thickness mm Area Ulti Ultimate Character of Failure & Location
mm mate Unit
mm2 Stress
Total N kg/mm2

Load
kg

1 19.02 8.15 155.01 6975 441.29 DUCTILE/BMGR60

2 18.93 7.91 149.74 6675 437.17 DUCTILE/BMGR60

Guided Bend Tests

Type & Specimen No. Result
FACE BEND 1 SATISFACTORY
FACE BEND 2 SATISFACTORY
ROOT BEND 1 SATISFACTORY
ROOT BEND 2 SATISFACTORY
 Toughness Tests (SPECIMEN SIZE : 10 x 7.5 x 55)
Specimen No. Notch Notch Test Impact Lateral Exp. Drop Weight
Location Type Temp
. Values % Shear Mils Break No. Break

1 WELD V -20C 45 J NA NA NA NA
METAL
2 WELD V -20C 58 J
METAL

3 WELD V -20C 64 J

METAL
4 HAZ GR 70 V -20C 154 J

5 HAZ GR 70 V -20C 144 J

6 HAZ GR 70 V -20C 144 J

7 HAZ GR 60 V -20C 158 J

8 HAZ GR 60 V -20C 157 J

9 HAZ GR 60 V -20C 164 J

 Nick Break Tests

Specimen No. Result

NA NA
 WELDING PROCEDURE QUALIFICATION RECORD (Cont’d)

Hardness Test Result

Base Haz Depo Haz Base

min max min max min max min max Min max

1.

2.

Individual Values:

Line 1 NA

Line 2 NA
 Fillet Weld Tests

Result-Satisfactory : □ Yes □ No Penetration into Parent Metal : □ Yes □ No

Type and Character of Failure NA Macro-Results NA

Other Test

Type of Test NONE

Deposit Analysis NONE

Welder Name KUN WENG Stamp No. T207

Tests Conducted By NUSATEK Laboratory Test No. MAT/0597-02/92

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 ASME SECT. IX / ASME SECT. VIII DIV. 1 (Applicable Code).

Signature : Signature :

(SKA Sdn. Bhd) (Client)

Date : Date :

Signature : Signature :

(Third Party) (Factories & Machine Dept.)

Date : Date :
 SKA Sdn. Bhd.
(incorporated in Malaysia)
WELDER QUALIFICATION TEST (WQT) RECORD

Welder Name KUN WENG I/C No. 7876312

WPS No. MLNG – 4 Welder No. W – 9
Welding Process SAW Type MACHINE WELD

Backing □ Yes □ No Backing Material WELD/BASE METAL

Material Specification SA516-60 to SA516-70
P. Number 1 Group 1 to 1 Group 2
Thickness 9 mm Dia. NA
Qualified Thickness Range 18 mm Qualified Dia. Range 73 mm and Over
Filler Metal Spec. No. & Class 5.17 EH14 / -
F. No. 6 / -
Maker and Brand KOBELCO US-36/MF38
Other NA
Position 1G Welding Progression NA
Gas Type NA Composition NA %
Electrical Characteristics Current DC / - Amp. 340 – 380 / -
Polarity REVERSE / - Volt 28.5 / -

Guided Bend Test Results Fillet Weld Test Results

Face Bend F1/F2 SATISFACTORY Visual Test NA
Root Bend R1/R2 SATISFACTORY Fracture Test NA
Side Bend NA Macro Test NA
Radiographic Test Result: NA
(For alternative qualification of groove weld by radiography in accordance with: NA )
Test conducted by NA Laboratory Test No. NA

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 ASME 1X & ASME V111 DIV. 1
(Applicable Code)

Signature: Signature:

Tepat Sdn Bhd. (Client)

Date: Date:

Signature: Signature:

(Third Party) (Factory & Machinery Dept.)

Date: Date: