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TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCE

3.0 RESPONSIBILITY

4.0 DEFINITION

5.0 PROCEDURE

6.0 ATTACHMENTS

Attachment 1A Welding Procedure Specification

Attachment 1B Welding Procedure Specification (Continuation)

Attachment 2A Procedure Qualification Record

Attachment 2B Procedure Qualification Record (Continuation)

Attachment 3 Welding Procedure Qualification Test Plan

Attachment 4 Index of WPS

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1. SCOPE

This procedure applies to the instruction for qualification and control method of the Welding

Procedures Specification (WPS) and Procedure Qualification Record (PQR) in order that the

welding work conforms to the requirements of the applicable codes and standards

2.0 REFERENCE

2.1 Site Quality Plan (6423DA060-00-00200 00)

2.2 Document Control Procedure (6423MJ050-00-00010 00)

2.3 Welding and Brazing Qualification (ASME Section IX)

2.4 Structural Welding Code-Steel (AWS D1.1)

2.5 Power Piping (ASME B31.1)

2.6 Process Piping (ASME B31.3)

3.0 RESPONSIBILITY

3.0 The Construction Manager is responsible for ;

(1) Requesting the Quality Manager to provide the required WPS.

(2) Supporting PQ Test performed by the Quality Team.

3.1 The Quality Manager is responsible for ;

(1) Ensuring that all procedure qualifications are carried out in accordance with this

procedure.

(2) Approval of WPS and certification of PQR

3.2 The Welding Engineer is responsible for ;

(1) Preparation of Welding Procedure Qualification Test Plan

(2) Preparation and maintenance of WPS and PQR

(3) Manufacturing of test specimen and request of test

(4) Preparation of test report

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(5) Review of Subcontractor’s WPS & PQR.

4.0 DEFINITION

4.1 WPS : Welding Procedure Specification.

4.2 PQR : Welding Procedure Qualification Record

4.3 PQT : Welding Procedure Qualification Test

4.4 Welder : Welder or Welding Machine Operator

5.0 PROCEDURE

5.1 Establishment of Welding Procedure Qualification Test Plan

5.1.1 The Welding Engineer shall prepare the Welding Procedure Qualification Test Plan

(Attachment 3) through review of technical specifications and drawings in order to prepare

the WPS to be applied for construction work.

5.1.2 Attention shall be paid to the following during review of the technical specifications and

drawings:

(1) Limitation for the welding process

(2) Base metal

(3) Limitation for the welding material

(4) Preheat and post weld heat treatment

(5) Welding position

(6) Gas

(7) Electrical characteristic

(8) Joint design

(9) Reference to applicable approval code, i.e. ASME IX, AWS D1.1

5.1.3 The Welding Engineer shall prepare the draft WPS with all the information in accordance

with applicable Code and Standards. The WPS (Attachment 1A & 1B) shall be approved

when the procedure qualification testing is completed and a PQR (Attachment 2A & 2B) is

certified by Quality Manager and accepted by OWNER.

5.2 The Numbering System is as follows.

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5.2.1 Welding Procedure Specification (WPS)

DZ01- 1 2 3 - 4 5 - 6 7

Where

DZ01 : Project Identification

1 : P-No of Base Metal (refer to ASME Sec. IX)

2 : Classification of PWHT (A: No heat treatment, P: Heat treatment)

3 : P-No of Base Metal (refer to ASME Sec. IX)

4 5 : Classification of welding process (refer to following abbreviation)

SM : Shielded Metal Arc Welding (SMAW)

GT : Gas Tungsten Arc Welding (GTAW)

GS : GTAW + SMAW

FC : Flux Cored Arc Welding (FCAW)

TG : TGX + GTAW

TS : TGX + SMAW

ST : Stud Welding

6 7 : Serial number (Issue order of WPS, ex. : 01, 02,........)

5.2.2 Welding Procedure Qualification Record (PQR)

DZ01 - PQR -

Where

DZ01 : Project Identification

PQR : Welding Procedure Qualification Report

1 2 : Serial number (ex.: 01, 02,........)

1 2

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5.2.3 Tension Test, Bend Test, Notch-toughness Test and Hardness Test shall be performed in

accordance with ASME Sec. IX QW-150, QW-160 and QW-171.

5.3. Test Preparation

5.3.1 The Welding Engineer shall review contractual documentation and applicable Code

requirements to identify those design and material requirements necessitating the

preparation of new welding procedure qualification.

5.3.2 The Quality Team shall give a minimum formal notice of two (2) days to OWNER prior to

commencing welding of the test coupon.

5.3.3 The PQ Test shall be performed by the skilled Welder or Welding Machine Operator.

5.3.4 The Construction Team shall prepare the test coupon for Welding Procedure Qualification Test.

5.4 Performance of Test

5.4.1 The welder performing welding work for the PQ Test shall be under the supervision

of the Welding Engineer, and the welding work performed by other personnel shall not

be permitted in the test area.

5.4.2 The Procedure qualification test may be witnessed by OWNER.

5.4.3 The completed procedure qualification test welds shall first be subjected to visual

inspection by Welding Engineer and OWNER.

5.4.4 The test specimens to be tested for PQ Test shall be prepared by the same method as the

applicable codes and standards by the Quality Team. The type and quantity of test

specimens shall be prepared in accordance with the requirements of applicable code,

standard and technical specification.

5.4.5 The test method and acceptance criteria shall comply with the requirements of applicable

code, standard and technical specification. If any test specimen required by applicable codes

and standards does not conform to applicable acceptance criteria, the test coupon shall be

regarded as rejected and a new test coupon shall be prepared.

5.4.6 Welded test coupons shall show complete joint penetration with complete fusion of weld

metal and base metal in accordance with the applicable code requirements.

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5.4.7 Welder who is involved in the welding of a procedure qualification which is subsequently

proved to be acceptable will automatically be qualified to carry out that procedure weld

requirements/criteria/range.

5.5 Welding Procedure Qualification Record (PQR)

5.5.1 The PQR shall be prepared by the Welding Engineer who supervised the PQ Test

and the test results. The original reports of the WPS and PQR which ha recorded test results

shall be submitted to OWNER for approval.

5.5.2 The actual variables used during the welding of the test coupons are recorded on a

PQR. The completed PQR shall be documented with all essential and supplementary

essential variables (when required) for each welding process. A separate data run

sheet shall be attached to PQR as applicable.

5.5.3 The nonessential or other variables used during welding of test coupon may be recorded

on the PQR.

5.5.4 Variables shall be followed as required by the code and technical specification.

5.5.5 The PQR shall be certified by the Quality Manager.

5.5.6 Any other Daewoo E&C’s PQR’s that meet the contract criteria and applicable code

requirements shall be considered acceptable for this project..

5.6 Welding Procedure Specification (WPS)

5.6.1 The Welding Engineer shall prepare the WPS to be used for the permanent welding

based on the PQR certified. The WPS shall be submitted to OWNER for approval.

5.6.2 The WPS shall describe all essential, supplementary essential (if required) and

non-essential variables for each welding process specified in applicable code and standard

and all requirements of the technical specification. The WPS shall include supporting

PQR number(s).

5.6.3 The Welding Engineer shall prepare and maintain an Index of Welding Procedure

Specification (Attachment 4) which identifies qualified Welding Procedure Specification

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5.6.4 All WPS and Index of Welding Procedure Specification shall be distributed in accordance

with the Document Control Procedure.

5.6.5 When there is a specific reason to question the Welding Procedure Specification, the

Quality Manager or the OWNER representative may require re-qualification.

5.7 Records

5.7.1 All WPS and PQR and related data of qualification shall be maintained on file by the

Welding Engineer.

5.7.2 All WPS and PQR and related data of qualification shall be controlled as QA Records in

accordance with the Quality Records Control Procedure.

6.0 ATTACHMENTS

Attachment 1A Welding Procedure Specification (WPS)

Attachment 1B Welding Procedure Specification (WPS) - Continuation

Attachment 2A Welding Procedure Qualification Record (PQR)

Attachment 2B Welding Procedure Qualification Record (PQR) - Continuation

Attachment 3 Welding Procedure Qualification Test Plan

Attachment 4 Index of Welding Procedure Specification

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Attachment 1A

6423DA060-005-01A(0)

WELDING PROCEDURE SPECIFICATION(WPS))))

Project name AOFP

Project NO. DZ01

Prepared by

Checked by

Approved by

WPS No.: Rev: Date

Supporting PQR No(s)

Welding Process(es) Type(s)

Applicable Code

Joints (QW–402)

JOINT DETAIL (TYPICAL

Joint Design:

Backing:□ Yes □ No Backing Material

Other

Base Metal (QW-403)

P. No.: Group No: to P. No Group No:

Specification Type & Grade to

Chem. Analysis & Mech. Prop. to

Thickness Range: Fillet

Pipe Dia. Range:

Other

Filler Metals (QW-404) Root / Fill

F. No: /

A. No. /

Spec No. (SFA) /

AWS. No. (Class) /

JIS No. /

Size:

Deposited Weld Metal

Brand Name of Electrode or Filler Metal

Wire Type for GMAW

Electrode-Flux (Class)

Brand Name of Flux

Drying Condition: Temp oC Time hours

Other

Position (QW-405)

Position of Groove

Welding Progression : ■ Up � Down Position of Fillet

Other

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Attachment 1B

6423DA060-005-01B(0)

WELDING PROCEDURE SPECIFICATION (WPS) -

Contd/... Project name AOFP

WPS NO

Preheat:(QW-406)

�Yes ■No

Post Weld Heat Treatment ;(QW-407)

�Yes ■No

Preheat Temp: oC Post Heat Temp

oC

Interpass Temp; oC Holding Time min

Method oC Method

Other: Other

Gas (QW-408)

Shielding Gas(es) Flow Rate:

L /min

Percent Composition

% Gas Backing �Yes ■No

Trailing Shielding Gas Composition

%

Other

Electrical Characteristics & Technique (QW-409)

Tungsten Electrode Size mm Type

Mode of Metal Transfer for GMAW

Electrode Wire Feed Speed Range

Technique (QW-410)

Bead: ■ String ■ Weave Orifice or Gas Cup Size mm

Initial & Interpass Cleaning: ■ Brushing ■ Grinding � Other

Pass (per side ) ■ Multi � Single Electrode: � Multi ■ Singl

Method of Back Gouging Other

Weld Layer

Welding

Process

Filler Metal Current Travel Speed

Range

(cm/min)

Brand Class Dia: (mm) Type Polarity Amperage Range

Voltage Range

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: Attachment 2A

6423DA060-005-02A(0)

WELDING PROCEDURE QUALIFICATION RECORD

(PQR)

Project name AOFP

Project NO DZ01

Prepared by

Checked by

Certified by

PQR No. Date:

WPS No. Date:

Welding Process(es)

Type (Manual, Automatic, Semi-Auto.)

Applicable Code

Joint/ Design of Test Coupon (QW-402)

Backing No Yes

Material

BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407)

Material Spec Temperature

Type of Grade Time

P. No to P. No Other

Thickness mm

Diameter

Other

FILLER METALS (QW-404) GAS (QW-408)

Weld Metals Analysis A. No. Shielding Trailing Backing

Size of Electrode Type of Gas or Gases

Filler Metal F. No. Flow Rate

SFA Specification Composition of Gas Mixture

AWS Classification Other

Brand Name

POSITION (QW-405) ELECTRICAL CHARACTERISTICS (QW-409)

Position of Groove Current

Weld Progression (Uphill, Downhill) Polarity

Other Amps. Volts

Tungsten Electrode Type Size

PREHEAT (QW-406) TECHNIQUE (QW-410)

Travel Speed

Preheat Temp String or Weaver Bead

Oscillation

Interpass Temp. Multiple or Single Pass (per side)

Single of Multiple Electrode

Other Other

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Attachment 2B

(QW-483)

PQR No. :

Tensile Tests (QW-150)

Specimen

No.

Width

mm

Thickness

mm

Area

mm2

Ultimate

Total Load

Kg

Ultimate

unit Stress

kg/mm2

Character of

Failure &

Location

Guided Bend Tests (QW-160)

Type & Specimen No. Result

Toughness Tests (QW-170)

Specimen

No.

Notch

Location

Notch Type Test Temp. Impact

Values

Lateral Exp. Drop Weight

% Shear mm Break No Break

Fillet Weld Test (QW-180)

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

Macro-Result

Other Test

Type of Test

Deposit Analysis

Welder Name Stamp No.

Tests conducted by Laboratory Test No.

Witnessed

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 _______________________________________

(Applicable Code)

6423DA060-005-02B(0)

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Attachment 3

6423DA060-005-03(0)

Welding Procedure Qualification Test Plan

Seq.

No PQR No Base Metals(ASTM) P-No

Group

No

Filler

metals

(AWS)

PWHT

(time)

Impact

( )℃℃℃℃

Qualified thickness (mm) Type and number of tests required

Remarks Material GTAW SMAW

GTAW +

SMAW Tension

Face

bend Root bend Impact(B/W/H)

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Attachment 4

INDEX OF WPS

S/N WPS No. Supporting

PQR No.

P-NO

(GR No.)

Thickness

Range (mm) Base Metal Filler Metal PWHT

Impact

Temp.( )℃ Remarks

6423DA060-005-04(0)