Proposed Welding Procedure No.gupcO PMS SAQ QC 0001

SAQQARA FIELD DEVELOPMENT DEVELOPMENT PROJECT PROJECT

GUPCO

PMS

Gulf of Suez Petroleum Company

Petroleum Marine Services Company

SAQQARA FIELD DEVELOPMENT DEVELOPMENT PROJECT 16” SUB-S SUB-SEA EA PIPE LINE OFFSHORE - EGYPT

PROPOSED WELDING PROCEDURES

DOCUMENT REFERENCE

GUPCO-PMS-SAQ-QC-PR-0001

1

App ro ved Fo r Construction

28-01-2006

A. HAFEZ

K.YOUSEF

M. AMRO

0

ISSUE FOR APPROVAL

18/08/2005

A. HAFEZ

K.YOUSEF

M. AMRO

Rev.

Reason for Issue

Date

PMS Prepared

PMS Checked

PMS Approval

GUPCO Approval

+Contractor

Company

Petroleum Marine Services Co. (PMS)

Gulf Of Suez Petroleum Company (GUPCO)

Project

Page

SAQQARA FIELD DEVELOPMENT PROJECT 16” SUB SEA PIPE LINE

Document Title

Document Reference

PROPOSED WELDING PROCEDUR PROCEDURES ES


2/ 25 Revision

1

Date Of Issue

28/01/2006

TABL E OF CONTENTS CONTENTS CONTENT

PAGE

1. Introduction

3

2. Definitions

4

3. Reference Documents

5

4. Approved Wps's List

6

5.1 Main Welding Procedure

7

5.2 Repair Welding Procedure

8

6. Attachments

25

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3/ 25 Revision

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Date Of Issue

28/01/2006

1. INTRODUCTION

The SAQQARA Field is a sour oil reservoir located approximately 10 km offshore from Ras Shukheir in the Gulf of Suez. Saqqara will will initially be produced from an unmanned, unmanned, fixed steel platform. The full development scheme will comprise a single nine-slot platform with one 16” multiphase pipeline connecting connecting Saqqara Saqqara with onshore onshore facilities. Power, signals and chemicals from onshore facilities to the Saqqara platform will be supplied via a new umbilical. The Saqqara processing requirements will be partially satisfied by existing infrastructure. The system will be terminated at new onshore reception facilities approximately 1 km South East of the existing Ras Shukheir Plant where the gas and liquids will be separated. The gas will then be sweetened and dehydrated before transfer by existing gas pipeline to the existing Unit 104 Gas Processing Plant, Plant, for further treatment. The liquids will will be transferred via an onshore liquids pipeline from the new reception facilities to the existing Ras Shukheir Plant for final processing & export. Power for the new reception facilities will be supplied from the existing Ras Shukheir Plant.

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2. DEFINITIONS

Company

: GU GULF LF OF SUEZ PETROLEUM CO COMPANY MPANY (GUPCO (GUPCO))

Contractor

: PETROLEUM M ARINE SERVICES COMPANY (P.M.S (P.M.S))

Lay Barge

: PMS 12

Date Of Issue

28/01/2006

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Company



Project

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Document Title

Document Reference



5/ 25 Revision

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3. REFERENCE DOCUMENTS Codes & Specification: API 1104

CGOS-0258-PLN-SPE-10

Welding of Pipelines and Facilities 1999

related

Specification for pipeline welding (Revision C)

Date Of Issue

28/01/2006

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4. APPROVED WPS'S LIST F 1 4 / W I 2 4

E n P g M .A h S m Q e A d / H Q a C f e z

C e r t i f y i n g A u t h o r i t y :

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 1 2

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 1 1

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 1 0

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 9

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 8

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 7

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 6

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 5

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 4

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 3

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 2

P M S - S A Q - Q C - W P S - 1 6 " - P L - 0 0 1

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

3 2 9

D

D

D

D

D

D

D

D

D

D

D

D

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

6 0 9

R a n g ( M M )

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

G T A W & S M A W

P W r o e : c l 2 e d s i n 8 s e g / 0 s 1

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

E R - 7 0 S 3 & E - 8 0 1 8 G

P M S W I 2 4 R e v .1

. . S

: : 1 S a q q a r a X A X A X A X A X A X A A X A X A X A X A X A X A F M 6 P 6 P 6 P 6 P 6 P 6 P P 6 P 6 P 6 P 6 P 6 P 6 P i e 0 I 0 I 0 I 0 I 0 I 0 I I 0 I 0 I 0 I 0 I 0 I 0 I a / l d X 5 / X 5 / F 5 / F 5 / X 5 / X 5 5 / F 5 / F 5 / X 5 / X 5 / X 5 / X 5 t 6 L 6 L 6 L 6 L 6 L 6 L L 6 L 6 L 6 L 6 L 6 L 6 L . D 0 0 0 0 0 0 0 0 0 0 0 0 e v e l o 4 4 4 4 4 4 R p . . . . . . 8 8 8 8 8 8 a m 1 1 1 1 1 1 n ≤ ≤ ≤ ≤ ≤ ≤ e 9 9 9 9 9 9 g T . . . . . . n T T T T T T e 2 2 2 2 2 2 h t i ≤ ≤ ≤ ≤ ≤ ≤ ≤ ≤ ≤ ≤ ≤ ≤ P m k T T T T T T 1 1 1 1 1 1 r o 9 9 9 9 9 9 m .1 .1 .1 .1 .1 .1 j e c t ≤ ≤

≤ ≤

≤ ≤

≤ ≤

≤ ≤

F F F F F o o o o o r r r r r r r r ( ( m ( ( e p m ( e p e p a p i p p i a p i p i i p i p a p a p p e a e i n e i i e i r e n r t w o t w t r t w o t w o w o o e e e f l b e f l b e b l l l d a d l a d l d e d e e n i n n i n n i n i n n i n g n g g g d d g d g e g e w p w p p w p w p w r r r e o e o r r o e o l o l c l c e c d l c G C e c d d l e e d e d l ) d ) d ) e U e i ) e d ) d d u u u u u P n r r r r r e e e e e

C t O : R e p .

R E P R V O . J E W N N . O C T O P .

≤ ≤

≤

≤

≤

≤

≤ ≤

≤ ≤

≤ ≤

≤ ≤

D i m D C L . A

E l e c t r o d e s

F F F F F F F o o o o o o o r r r r r r r r r r ( ( m p e p m ( e ( m ( e ( m ( p a p p a p p p a i p p i a p p i i a p i i p i a p i i p p n e a n e i e i i e i e i r e n r e n t r t w t w o t w w t w t w t w o o e o o o o e e e f e f d l a l p e l p e l b d l l l a l p d l p d d e i i d i i i d i i n i n i i i n n p n p n p p n g n n n g g g g e g e g e g e g d e e p w w p w p w p p w p w p w r r r r r e o e o r e o e o r e o e o e o l c d l c d l c d l c l c c d d l c d l e d ) e ) e ) e d ) e d ) e d ) d ) e d d d u u u u u u u r r r r r r r e e e e e e e

R e m a r k s

O C P U G

C e r B t y i f i e d

O C P U G

C l i e n t

I T E E N T

/ 2 0 0 6

: G U P C O

A P P R O V E D B Y : G U P C O

P E T R O L I U M M A R I N E S E R V I C E S C O

A M P A P S R T O E V R E L D I S W T P F S O ’ R s

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5.1 Main Weldin g Procedur Pro cedur e For 16"X 12.7MM 12.7MM.. PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project

WPS No. Revision No. Welding Process

: Gulf Gu lf of Suez Petroleum Company Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT

Project Spec. Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipe line, line, Spool Piece Piece Supportin g PQR No. No. : PMS-QC-PQR-16"-00XXX

: PMS-SAQ-QC-WPS-16"-PL-001

TO BE QUALIFIED

:1

Date

: 28-01-06

:GTAW & SMAW

Type

: Manual

Joints :

Post Weld Heat Heat Treatment Treatment : N.A. Temp Temper erat atur ure e : N.A N.A.. T im e : N.A. Other : N.A.

Shielding Gases : Type of gas or gases Composition of gas mixture Flow rate

: Argon : 99.9% : 12-14 Lit/Min.

POSITION Type and Removal of Clamps: : Internal Remove after after : 100% 100% root root pass pass complet complet or Ex External : N.A Remo Remove ve afte afterr : N.A N.A

Position of Groove : 5G (All fixed position) W el eld Progression : ( √ UP ) Other : All Passes Uphill

B as e Met al

Fi l l er m et al

Material Spec. API 5L X60 Type or Grade Thickness of test coupon Thickness Range 4.8 mm Diameter of test coupon Diameter Range 329 mm Other :

TO API 5L X60 TO 12.7 mm TO 19.1 mm 16" (406.4 mm) TO 609 mm

Tec h n i q u e

Weld Metal Analysis ( A ) No. Size of Electrode m m Filler Metal ( F ) No. SFA Specification AW S Clasification Other

:1 :2.4 & 4m 4 mm : 3 (API 1104 Group 2) : A 5.5 & A 5.18 : ER-70S3 & E-8018G : ETC TIG SG1 : Bohler

Pr eh eat

Interpass Cleaning Stringer or W eave Multipass or single pass ( per side ) Single or Multiple Electrode

: Brush & Grinding : Both : Multi : Single

Preheat temp. (Min.) : 50°C Interpass Temp. ( max ) : 250°C Other : Drying & heating by gas torch preheat shall be measured 100mm from the edge of the weld bevel arround the circumference by tempilsticks tempilsticks or digital thermometer.where preheat is applied to heweld heweld sideonl sideonl a timedel timedela a of1 min. min. er12.7m er12.7mm m thic thickn knes ess. s. shall be applied before measuring.

Others: : prior the commencement of welding, the ends ends of pipes shall be cleaned, both inside and outside a min. of 50mm using a power wire brush or other approved method.

Electrical characteristics Current Polarity Othe Otherr

: DC : ±ve : The The curr curren entt and and vol volta tage ge ran range ges s belo below w as as per per manu manufa fact ctur urer er rec recom ommen menda dati tion on,, actu actual al val value ues s will will be be recorded from Procedure Qualification Record (PQR)- any change in heat input out side ± 10% is accepted Filler Metal

WELD Layers

Direction

Class

polar. Current range

Uphill Uphill Uphill Uphill Uphill

PM S : PMS-WI-24 REV.1

ER-70S3 ER-70S3 E-8018G E-8018G E-8018G

2.4 2.4 4 4 4

Travel Speed

Heat Input

V

range ( mm/sec)

range ( KJ/mm)

Amp

Diam mm

ROOT HOT Filling (4mm ) Filling (4mm ) CAP

Volt range

-ve -ve +ve +ve +ve

CL IENT :

min

max

min

m ax

94 94 120 160 120

144 144 180 210 180

22 22 22 22 22

32 32 32 32 32

m in

m ax

min

Remarks

m ax

THIRD PA RTY: F11-WI/24

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5.2 Repair Welding Procedure For 16"X12.7mm Pipe Line. PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


: Gu lf of Suez Petroleum Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16"-PL-002

Project Spec. Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipe line, line, Spool Piece Piece Supportin g PQR No. No. : PMS-QC-PQR-16"-00XXX TO BE QUALIFIED

:1

Date

: 28-01-06

: GTAW & SMAW

Type

: Manual

Joints :

Post Weld Heat Heat Treatment Treatment : N.A. N.A.

KINDS FOR REPAIR:-

Temp Temper erat atur ure e : N.A N.A.. T im e : N.A. Other :

A) Cap Repair ( CR).

Shielding Gases :

B) Partial Penetration Repair (PR). C) Full P enetration Repair (R). D) Repair of Repair (RR).

T ype of ga s o r gases Com position of gas m ixture

: A rg o n : 99.9%

Flow rate

: 12-14 Lit/M in.

POSITION Type and Remov Remov al of Clamps: Internal :N.A Remove Remove after after :N.A :N.A or Ex External :N .A Remove Remove after after :N.A :N.A

Position of Groove : 5G (all Fixed position) W el eld P rogression : ( √ UP ) O th e r : A l l P a ss e s U p h il l

B a s e Me t a l

Fi l l e r m e t al

Material Spec. API 5L X 60 Type or Grade Thickness of test coupon T h i ck n e s s R a n g e 4.8 m m Diam eter of test coupon Diam eter Ran ge 329 m m Other :

TO API 5L X 60 TO 12.7 mm TO 19.1 mm 16" (406.4 mm) TO 609 m m

W eld Meta l Analysis ( A ) No. Size of Electrode mm Filler Metal ( F ) No. SFA S pe cification AW S Clasif ication O th e r

: Bru sh & G rinding : Both : M ul ti : Single

100 ºC Preheat temp.(Min) : 100 Inte rpass Tem p. (Max) : 250°C O ther : Drying & heating by gas torch

T ec h n i q u e

:1 : 2.4 & 4mm : 3 (API 1104 Group 2) : A 5.18 & A 5.5 : E R 7 0 S 3 & E -8 0 1 8 G : ETC TIG SG1 & : Bohler

Pr eh eat

Interpass Cleanin g Stringer or W eave Multipass or single pass ( per side ) Sin gle or M ultiple E lectrode

circumference by tempilsticks or digital thermometer.where preheat preheat is applied to the weld side only,a time delay of 1 min.per 12.7mm thickness. shall be applied before measuring.

Electrical Electrical characteristics characteristics Current Polarity Othe Otherr WELD Layers RO OT HOT Fillin g (4m m ) Fillin g (4m m ) CAP

: DC : ±ve : The cur curre rent nt and and vol volta tage ge ran range ges s below below as as per per manuf manufac actu ture rerr reco recommen mmenda dati tion, on, actu actual al val value ues s will will be be reco record rded ed from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Volt range Travel Speed Heat Input polar. Current range Direction U p h il l U p h il l U p h il l U p h il l U p h il l

PM S : P M S -W I - 2 4 R E V . 1

Class ER-70S3 E R -7 0 S 3 E-8 018G E-8 018G E-8 018G

Amp

Diam mm 2.4 2.4 4 4 4

-ve -ve +ve +ve +ve

CL IENT :

m in 94 94 109 109 109

m ax 144 144 120 120 120

V m in 8 8 26 26 26

range ( mm/sec)

m ax 10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax

THIRD PARTY: F 1 1 - W I /2 4

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5.3 5. 3 Main Main We Weldi ldi ng Pro cedure fo r 16" X 22.2 22.2mm mm Pipe Line. PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


: Gulf Gu lf of Suez Petroleum Company Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT

Project Spec. Spec. : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipe line, line, Spool Spool Piece Supporting PQR PQR No. : PMS-QC-PQR-16"-00XXX


TO BE QUALIFIED

:1

Date

: 28-01-06

: GTAW & SMAW

Type

: Manual

Joints :

Post Weld Heat Heat Treatment Treatment : N.A. N.A. Temp Temper erat atur ure e : N.A. N.A. T im e : N.A. Other : N.A.


: Argon : 99.9% : 12-14 Lit/Min.

POSITION Type and Removal of Clamps: : Remove Remove after after : 100% 100% root root pass pass complet complet Internal or Ex External : N. N.A Remo Remove ve afte afterr : N.A N.A

Position of Groove : 5G (All fixed position) W el eld Progression : ( √ UP ) Other : All Passes Uphill

B as e Met al

Fi l l er m et al

Material Spec. API 5L Type or Grade X60 Thickness of test coupon Thickness Range 1 9 .2 m m Diameter of test coupon Diameter Range 329 mm Other :

TO API 5L TO X 60 22.2 mm TO Unlimited 16" (406.4 mm) TO 609 mm

Weld Metal Analysis ( A ) No. Size of Electrode mm Filler Metal ( F ) No. SFA Specification AW S Clasification Other


Preheat temp.(Min.) : 50°C Interpass Temp. ( max ) : 250°C Other : Drying & heating by gas torch

Tec h n i q u e

:1 : 2. 4, 4 & 5 : 3 (API 1104 Group 2) : A 5.5 & A 5.18 : ER-70S3 & E-8018G : ETC TIG SG1 : Bohler

Pr eh eat


preheat shall be measured 100mm from the edge of the weld bevel arround the circumference by tempilsticks or digital thermometer.where preheat is applied to heweldsid heweldside e onl onl a timede timedela la of1 min. min. er12.7 er12.7mmthi mmthick ckne ness ss.. shall be applied before measuring.

Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both inside and outside a min. of 50mm using a power wire brush or other approved method.


: DC : ±ve : The cur curre rent nt and and v volt oltag age e rang ranges es belo below w as per per ma manu nufac factu ture rerr reco recomme mmend ndat atio ion, n, actu actual al valu values es will will be rec recor orde ded d from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal

WELD Layers

Direction

Class




ER-70S3 ER-70S3 E-8018G E-8018G E-8018G

2.4 2.4 4/ 5 4

Travel Speed

Heat Input

V

range ( mm/sec)

range ( KJ/mm)

Amp

Diam mm

ROOT HOT Filling (4m m) Filling (5m m) CAP

Volt range

-ve -ve +v e +v e +ve

CL IENT :

m in

max

m in

max

94 94 1 20 16 0 120

14 4 14 4 180 2 10 18 0

8 8 22 22 22

10 10 32 32 32

m in

max

m in

Remarks

max

THIRD PARTY: F11-WI/24

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5.4 Repair Welding for 16" X 22.2 mm Pipe Line. PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


: Gu lf of Suez Petroleum Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16" PMS-SAQ-QC-WPS-16"-PL-004 -PL-004

Project Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipe line, line, Spool Piece : PMS-QC-PQR-16"-00XXX Supporting PQR No.

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

TO BE QUALIFIED

Joints :


KINDS FOR REPAIR:-

Temp Temper erat atur ure e : N.A. N.A. T im e : N .A. Other : N.A .

A) Ca p Repa ir (CR ).

Shielding Gases :

B) Partial Penetration Repair (PR). C) F ull Penetration Repair (R) .

T ype of gas or gas es

: A rgon

D) R epa ir of R epa ir (RR ).

C om position of gas m ix ture

: 9 9.9%

F low rate

: 12-14 Lit/M in.

POSITION Type and Removal Removal of Clamps: Remo Remove ve afte afterr :N.A :N.A Internal :N.A Remo Remove ve afte afterr :N.A :N.A or Ex External :N.A

Position of Groove W el eld Progres sio n O th er

B as e Met al

Fi l l er m et a l

Material Spec. API 5 L T ype or G rade X 60 Thickness of test coupon T hick nes s Range 19.2 m m Diam et et er of tes t c oupon Diam et er Range 329 m m O t her :

TO API 5 L TO X 60 22.2 mm TO Unlimited 16" (406.4 mm) TO 609 m m

Te c h n i q u e

: 5G (All fixed position) : ( √ UP ) : A ll P ass es U phill

W eld Me tal An alysis ( A ) No. Size of Elec tr ode m m Filler Metal ( F ) No. S F A Spec ific ation AW S Clas if ic ation O th e r

:1 : 2.4& 4 mm : 3 (API 1104 Group 2) : A 5.18 & A 5.5 : ER 70S 3 & E-8018G : ETC ETC TIG SG1 & : Bohler

Pr eh eat

Interp as s Cleaning Stringer or W eave Mu lt ipas s or single pas s ( per side ) Sing le or M ultiple Elec trode

: Brus h & G rinding : Both : M ulti : S ingle

Preheat temp.(Min.) : 100°C Interpass T em p. (m ax.) : 250°C O ther : D rying & he ating by gas torc h preheat shall be measured 100mm from the edge of the weld bevel arround the circumferenc e by tempilstic ks or digital thermometer.where preheat is applied to h e w el el d s i de de o nl nl a t im im e d e la la o f 1 m in in . e r 1 2. 2. 7m 7m m t hi hi ck ck ne ne ss ss . shall be applied before measuring.

Others: : prior the commenc ement of welding, the ends of pipes shall be cleaned, both inside and outside a min. of 50mm using a power wire brush or other approved method.

Electrical Electrical characteristics Current Polarity Other Other WELD Layers ROO T HO T F illing (4m m ) F illing (4m m ) CA P

: DC : ± ve : The The curr curren entt and and volt voltag age e rang ranges es bel below ow as as per per manuf manufact actur urer er reco recommen mmenda dati tion on,, actu actual al value values s will will be reco record rded ed from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Volt range Travel Speed Heat Input polar. Current range Direction U p h i ll U p h ill U p h ill U p h ill U phill


Class ER- 70S3 ER- 70S3 E -80 18 G E -80 18 G E-8018G

Amp

Diam mm 2.4 2.4 4 4 4

-ve -ve +ve +ve +ve

C L IE NT :

V

range ( mm/sec)

m in

m ax

m in

m ax

94 94 109 117 100

144 144 120 137 135

8 8 26 26 26

10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax


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5.5 5. 5 Main Main weldi ng pr ocedur e for Fitt ing s (Flange (Flange to Pip e Welds, Welds, thk. 22.2mm). 22.2mm). PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project

WPS No. Revision No. Welding Process Joints :

Co mpany : Gu lf of Suez Petroleum Company GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16"-PL-005

Project Spec. Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipes to Flanges Flanges Weld Supporti ng PQR No. : PMS-QC-PQR-16"-00XXX TO BE QUALIFIED

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

Post Weld Heat Heat Treatment : N.A. N.A. Temp Temper erat atur ure e : N.A. N.A. T im e : N.A. O ther : N.A.

Shielding Gases : Type of gas or gases Composition of gas mixture Flow ra te

: Argon : 99.9% : 12 -14 L it/Min .

Type and Removal of Clamps:

POSITION

Internal o r Exte rn al

Position of Groove : 5G (All fixed position) W el eld Pr ogression : ( √ UP ) O ther : All Passes U phill

:N.A :N.A

Remo Remove ve afte afterr : N.A N.A Remo Remove ve afte afterr : N.A N.A

Alignm ent will be achie ved by tac k welds which w ill be re moved d uring we lding

B as e Met a l

Fi l l er m et al

Material Spec. API 5L T ype or G rade X 60 Thickness of test coupon T hick ne ss R ang e 19.2 m m D iam e ter of te st cou pon D iam ete r R ange 32 9 m m O ther :

TO API 5L TO F6 0 22.2 mm TO Unlimited 16" (406.4 mm) TO 609 m m

Te c h n i q u e

W eld Meta l Analysis ( A ) No. : 1 : 2.4, 4 & 5 mm Size of Electro de m m Filler Metal ( F ) No. : 3 (API 1104 Group 2) SFA Specificatio n : A 5.18 & A 5.5 AW S C lasification : ER 70 S3 & E-80 18G O ther : ETC ETC TIG TIG SG1 & : Bohler

P r eh ea t

Inte rpass C lea ning Stringe r or W eave Mu ltipass or single pass ( per side ) Single or Mu ltiple Electrod e

: Brush & G r inding : Both : M ulti : Sin gle

Preheat temp. (Min.) : 50°C Interp ass T em p. ( m a x ) : 25 0°C Othe r : Dr ying & h eating by g as tor ch preheat shall be measured 100mm from the edge of the weld bevel arround the circumference by tempilsticks or digital thermometer.where thermometer.where preheat is applied to h e w e ld ld s id id e o n l a t im im e d el el a o f 1 m in in . e r 1 2 .7 .7 mm mm t hi hi ck ck ne ne ss ss . shall be applied before measuring.

Others: : prior the commencement of welding, welding, the ends of pipes shall be cleaned, both inside and outside a min. of 50mm using a power wire brush or other approved method.

Electrical characteristics Current Polarity Othe Otherr WELD

: DC : ±ve : The The curr curren entt and and volt voltag age e range ranges s belo below w as per per manu manufa fact ctur urer er rec recomme ommenda ndati tion, on, actu actual al val values ues will will be be reco recorde rded d from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Volt range Travel Speed Heat Input polar. Current range

Layers

Direction

ROOT HOT Filling (4 m m ) Filling (5m m ) C AP

U p h ill U p h ill U p h ill U p h ill U p h ill


Class ER -70S3 ER -70S3 E-8 018G E-80 18G E-8 018G

Amp

Diam mm 2 .4 2.4 4/ 5 4

-ve -ve +ve +ve +ve

CL IENT :

m in 94 94 1 09 11 7 1 00

m ax 144 144 120 137 135

V m in 8 8 26 26 26

range ( mm/sec)

m ax 10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax


+Contractor

Company



Project

Page


Document Title

12/ 25

Document Reference


Revision


Date Of Issue

1

28/01/2006

5.6 5. 6 Repair Repair weldin g pr ocedure fo r Fitt ings (F (Flange lange to Pipe Welds, thk. 22.2mm). 22.2mm). PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


: Gulf Gu lf of Suez Petroleum Company Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16"-PL-00 PMS-SAQ-QC-WPS-16"-PL-006 6

Project Spec. Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) (CGOS-0258-PLN-SP E-10) Rev. C & API 1104 Project part : Pipes to Flanges Weld Supporti ng PQR No. No. : PMS-QC-PQR-16"-00XXX

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

TO BE QUALIFIED

Joints :


KINDS FOR REPAIR:-

Temp Temper erat atur ure e Time Other

A) Cap Repair (CR).

: N.A. N.A. : N.A. : N.A.

B) Partial Penetration Repair (PR). C) Full Penetration Repair (R). D) Back W eld Repair (BW R).

Shielding Gases : Type of gas or gases Composition of gas mixture

: Argon : 99.9%

E) Repair of Repair (RR).

Flow rate

: 12-14 Lit/Min.

POSITION Type and Removal Removal o f Clamps: Remove after :N.A Internal :N.A Remove after :N.A or External :N.A

Position of Groove : 5G (All fixed position) W eld Progression : ( √ UP ) Other : All Passes Uphill

B as e Met al

Fi l l er m et al

Material Spec. API 5L Type or Grade X60 Thickness of test coupon Thickness Range 19.2 mm Diam eter of test coupon Diam eter Range 329 mm Other :

TO API 5L TO F60 22.2 mm TO Unlimited 16" (406.4 mm) TO 609 mm

Tec h n i q u e

Weld Metal Analysis Analysis ( A ) No. : 1 : 2.4, 2.4, 4 & 3.25 mm Size of Electrode mm Filler Metal ( F ) No. : 3 (API 1104 Group 2) : A 5.18 & A 5.5 SFA Specification AW S Clasification : ER 70S3 & E-8018G Other : ETC TIG SG1 & : Bohler

Pr eh eat



Preheat temp. (Min.) : 100°C Interpass Temp. ( max ) : 250°C Other : Drying & heating by gas torch preheat shall be measured 100mm from the edge of the weld bevel arround the circumference by tempilsticks or digital thermometer.where thermometer.where preheat is applied to tth he ew we eldsid l dsi de e onl onl a timedel timedela a of1 min. min. er12.7m er12.7mm m tth hic ickn knes ess. s. shall be applied before measuring.


Electrical Electrical characteristics characteristics Current Polarity Other Other

: DC : ±ve : The The curr curren entt and and voltag voltage e rang ranges es below below as per per manu manufac factur turer er reco recommen mmenda datio tion, n, actua actuall value values s will will be record recorded ed from Procedure Qualification Record (PQR) - any change change in heat input out side ± 10% is accepted Filler Metal

WELD Layers

Direction

ROOT HOT Filling (3.25) Filling (4) CAP


Class


PMS : PMS-WI-24 REV.1

2.4 2.4 3.25 4 4

Travel Speed

Heat Input

V

range ( mm/sec)

range ( KJ/mm)

Amp

Diam mm

ER-70S3 ER-70S3 E-8018G E-8018G E-8018G

Volt range

-ve -ve +ve +ve +ve

CL IENT :

min

max

min

max

94 94 109 117 100

144 144 120 137 135

8 8 26 26 26

10 10 28 28 28

m in

max

m in

Remarks

max


+Contractor

Company



Project

Page


Document Title

13/ 25

Document Reference


Revision


Date Of Issue

1

28/01/2006

5.7 5. 7 Main Main weldi ng pr ocedur e for Fitti ngs (Pipes to Bends We Welds lds , thk. 22.2 22.2mm). mm). PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


Gu lf of Suez Petroleum Company Co mpany : Gulf GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16"-PL-007

Project Spec. Spec. : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipes Pipes to Bends Bends Weld Supporting PQR No. : PMS-QC-PQR-16"-00XXX

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

TO BE QUALIFIED

Joints :

Post Weld Heat Heat Treatment Treatment : N.A. N.A. Temp Temper erat atur ure e T im e Other

: N.A N.A.. : N.A. : N.A.


: Argon : 99.9% : 12-14 Lit/Min.

Type and and Removal of Clamps :

POSITION

Internal or Ex External


:N.A :N.A

Remo Remove ve aft after er : N.A N.A Remo Remove ve aft after er : N.A N.A

Alignment will be achieved by tack welds which will be removed during welding

B as e M e t a l

Fi l l er m et al

Material Spec. API 5L Type or Grade X60 Thickness of test coupon Thickness Range 19.2 m m Diameter of test coupon Diameter Range 329 mm Other :

TO API 5L TO X60 22.2 mm TO Unlimited 16" (406.4 mm) TO 609 mm

Tec h n i q u e

Weld Metal Analysis ( A ) No. : 1 : 2.4, 2.4, 4 & 5 mm Size of Electrode mm Filler Metal ( F ) No. : 3 (API 1104 Group 2) : A 5.18 & A 5.5 SFA Specification AW S Clasification : ER 70S3 & E-8018G Other : ETC ETC TIG TIG SG1 SG1 & : Bohler

Pr eh eat






: DC : ±ve : The The curre current nt and and vol volta tage ge ran range ges s belo below w as per per manu manufa fact ctur urer er rec recomm ommen enda dati tion on,, actu actual al val value ues s will will be be reco record rded ed from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal

WELD Layers

Direction

Class




ER-70S3 ER-70S3 E-8018G E-8018G E-8018G

2.4 2.4 4/ 5 4

Travel Speed

Heat Input

V

range ( mm/sec)

range ( KJ/mm)

Amp

Diam mm

R O OT HOT Filling (4mm) Filling (5mm) CA P

Volt range

-ve -ve +ve +ve +ve

CL IENT :

m in

m ax

m in

max

94 94 109 117 100

144 144 120 137 135

8 8 26 26 26

10 10 28 28 28

m in

max

m in

Remarks

m ax


+Contractor

Company



Project

Page


Document Title

14/ 25

Document Reference


Revision


Date Of Issue

1

28/01/2006

5.8 5. 8 Repair Repair weldin g pro cedure for Fitti ngs (Pipes to Bends Welds, thk . 22. 22.2mm). 2mm). PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


: Gu lf of S uez P etroleum Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16"-PL-008

Project Spec. Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipes Pipes to Bends Bends Weld Supporting PQR No. No. : PMS-QC-PQR-16"-00XXX TO BE QUALIFIED

:1

Date Type

: GTAW & SMAW

: 28-01-2006 : Manual

Joints :


KINDS FOR REPAIR:-

Tempe Tempera ratture ure T im e Othe r

A) C ap R epa ir (C R).

: N.A. N.A. : N .A . : N.A .

Shielding Gases :

B) Partial Penetration Repair (PR). C ) F u ll P e n e trati on R e p a ir (R ). D ) B a c k W e ld R e pa ir (B W R ). E ) R e p a ir o f R e p a ir (R R ).

T yp e o f g a s o r g a s e s C o m p o s itio n o f g a s m ix tu re F lo w ra te

: A rg on : 9 9 .9 % : 1 2 -1 4 L it/M in .

POSITION Type and Removal of Clamps: Internal :N.A Remove after :N.A o r E x te rn a l :N . A Remove after :N.A

Position of Groove : 5G (All fixed position) W el eld P r o g re ss io n : ( √ UP ) O th e r : A l l P a s s e s U p h i ll

B as e Me t al

Fi l l er m et al

Material Spec. AP I 5L T yp e o r G ra d e X 60 Thickness of test coupon T h ick n e s s R a n g e 1 9 .2 m m D ia m e te r o f te st co up on D i a m e te r R a n g e 32 9 m m O th er :

TO AP I 5L TO X 60 22.2 mm TO Unlimited 16" (406.4 mm) TO 609 m m

Tec h n i q u e

W eld Met al A nalys is ( A ) N o. S ize o f E le c tro d e m m Filler Metal ( F ) No. S F A S p e c if i ca tio n A W S C l a sif ica tio n O th e r

:1 : 2.4, 2.4, 4 & 3.25 3.25 mm : 3 (API 1104 Group 2) : A 5.18 & A 5.5 : E R 7 0 S 3 & E -8 0 1 8 G : ETC ETC TIG TIG SG1 SG1 & : Bohler

P r e h ea t

In te rp a ss C le a n in g S trin g e r o r W ea ve M u ltip as s o r s in g le p as s ( p e r s ide ) S in g le o r M ul tip le E le c tro d e

: B ru s h & G rin d in g : B o th : M u lt i : S in g le

Preheat temp. (Min.) : 100°C In te rp a ss T e m p. ( m a x ) : 2 5 0 °C O th e r : D ryin g & he at in g b y ga s to rc h preheat shall be measured 100mm from the edge of the weld bevel arround the circumference by tempilsticks or digital thermometer.where preheat is applied to t he he w el el d s i de de o nl nl , a t i me me d el ela o f 1 m in in . e r 1 2 .7 .7 mm mm th ic ic kn kn es es s. s. shall be applied before measuring.


Electrical characteristics Current P o la rity Othe Otherr WELD Layers R OO T HO T F illin g (3 .2 5 ) F i ll i n g ( 4 ) C AP

: DC : ± ve : The The curr curren entt and and volt voltag age e rang ranges es bel below ow as as per per manuf manufac actu ture rerr reco recommen mmenda dati tion on,, actu actual al val value ues s will will be be reco record rded ed from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Volt range Travel Speed Heat Input polar. Current range Direction U p h ill U p h ill U p h ill U p h ill U p h i ll


Class E R -7 0 S 3 E R -7 0 S 3 E-8018G E -8 0 1 8 G E -80 1 8 G

Am p

Diam mm 2 .4 2 .4 3 .2 5 4 4

-v e -v e + ve + ve + ve

C L IE N T :

m in 94 94 10 9 117 100

m ax 144 144 120 1 37 135

V m in 8 8 26 26 26

range ( mm/sec)

m ax 10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax


+Contractor

Company



Project

Page


Document Title

15/ 25

Document Reference


Revision


Date Of Issue

1

28/01/2006

5.9 5. 9 Ma Main in weld ing pr ocedure for Fit tin gs (Flange (Flange to Pipe Welds, Welds, thk. 12.7 12.7mm). mm). PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) Company Name P r o j ec t


: Gu lf of Suez Petroleum Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-WPS-16"-PL-009

Project Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Pr o j ec t p ar t : Pipes Pipes to Flanges Flanges Weld Support ing PQR No. No. : PMS-QC-PQR-16"-00XXX TO BE QUALIFIED

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

Joints :

Post Weld Heat Heat Treatment Treatment : N.A. Temp Temper erat atur ure e : N.A. N.A. T im e : N.A. Other : N.A.


: Argon : 99.9% : 12-14 Lit/M in.

Type and Remov Remov al of Clamps:

POSITION

Internal or External

Position of Groove : 5G (All fixed position) W el eld Progression : ( √ UP ) Other : All Passes U phill

:N.A :N.A

Remov Remove e aft after er : N.A N.A Remov Remove e aft after er : N.A N.A

Alignment will be ac hieved by ta ck welds w hich will be removed during weld ing

B as e M et al

F i l l er m et a l

Material Spec. API 5L X60 Type or Grade Thickness of test coupon T hick nes s Range 4.8 m m D iam et eter of test c oupon D iam eter Range 329 m m O ther :

TO API 5L F 60 TO 12.7 mm TO 19.1 mm 16" (406.4 mm) TO 609 m m

Tec h n i q u e

We ld Metal Analys is ( A ) N o. Size of Electrode mm Filler Metal ( F ) No. SFA Specif ication AW S Clasification Other

:1 : 2.4 & 4mm : 3 (API 1104 Group 2) : A 5.18 & A 5.5 : ER 70S3 & E- 8018G : ETC TIG SG1 & : Bohler

P r eh eat

Interpass Cleaning Stringer or W eave M ultipass or single pas s ( per side ) Single or Multiple Electrode

: Brush & G rinding : Both : Multi : Single

Preheat temp. (Min.) : 50°C Interpass T em p. ( m ax ) : 250°C Other : Dr ying & heating by gas torch preheat shall be measured 100mm from the edge of the weld bevel arround the circumfere nce by tempilstic ks or digital thermometer.w here preheat is applied to t he he w el el d s i de de o nl nl a t im im e d e la la o f 1 m in in . e r 1 2. 2. 7m 7m m t hi hi ck ck ne ne ss ss . shall be applied before measuring.

Others: : prior the commenc ement of welding, the ends of pipes shall be c leaned, both inside and outside a min. of 50mm using a power wire brush or other approved method.

Electrical characteristics Current Polarity Other Other WELD Layers RO OT HOT Filling (4m m ) Filling (4m m ) CAP

: DC : ±ve : The The curr curren entt and and voltag voltage e rang ranges es below below as per manufac manufactu turer rer recommen recommendat dation ion,, actu actual al value values s will will be record recorded ed from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Volt range Travel Speed Heat Input polar. Current range Direction U p hil l U p hil l U p hi l l U p hi l l Uphill


Class ER -70S3 ER -70S3 E-8018G E-8018G E-8018G

Amp

Diam mm 2.4 2.4 4 4 4

- ve - ve +ve +ve +ve

CL IEN T :

m in 94 94 109 117 100

m ax 144 144 120 137 135

V m in 8 8 26 26 26

range ( mm/sec)

m ax 10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax

T H IR D PA R T : F11-WI/24

+Contractor

Company



Project

Page


Document Title

16/ 25

Document Reference


Revision


Date Of Issue

1

28/01/2006

5.10 5. 10 Re Repair pair weldi ng pr ocedure for Fit tin gs (Flange (Flange to Pipe Welds, Welds, thk. 12.7 12.7mm). mm). PRODUCTION WEL DING PROCEDURE SPECIFICATION ( W.P.S ) Company Name Project


: Gu lf of Suez Petroleum Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SAQ-QC-W PS-16"-PL-010 PS-16"-PL-010

Project Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipes to Flanges Weld Supporting PQR No. No. : PMS-QC-PQR-16"-00XXX TO BE QUALIFIED

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

Joints :


KINDS FOR REPAIR:-

A) C ap Re pair ( CR). CR) .

Temp Temper erat atur ure e T im e Other Oth er

B) Partial Penetration Repair (PR). C ) F ull Pen etra tio n R epa ir (R ). D ) B ac k W eld R ep air ( BW R ). E ) R epair of R epa ir (R R ).

T ype of ga s or gas es C om pos ition of gas m ix tu re F low ra te

: N.A. N.A. : N .A . : N.A .

Shielding Gases : : Ar go n : 99.9% : 12- 14 Lit/M in.

POSITION Type and Removal of Clamps: Internal :N.A Remove after :N.A Remove after :N.A o r E xternal :N .A

Position of Groove : 5G (All fixed position) W el eld Pr ogr ess io n : ( √ UP ) O the r : A ll P as s es U phill

B as e Me t a l

Fi l l er m e t a l

M aterial S pe c . AP I 5L TO A P I 5L T ype or G rad e X 60 TO F 60 T h ic k nes s of te s t cou pon 12.7 m m T h ic k nes s R ang e 4.8 m m TO 19.1 m m D iam e ter of te st c ou pon 16" ( 406.4 m m ) D iam ete r R ange 32 9 m m TO 609 m m O ther :

W e ld M etal Ana lys is ( A ) N o. S ize o f Ele c trode m m F ille r M eta l ( F ) N o. S F A S pec ific a tion A W S Clas if ica tion O th er

Te c h n i q u e

Pr eh e a t

Inte rpas s C leaning S tringe r or W eav e M u ltipas s or s ingle pas s ( per s id e ) S ingle o r M ultiple E lec trod e

: Br ush & G rind ing : B o th : M u lti : Sin gle

:1 : 2.4, 2.4, 4 & 3.25 3.25 mm : 3 ( AP I 11 04 G ro up 2) : A 5.18 & A 5.5 : E R 70S 3 & E -80 18G : ETC ETC TIG TIG SG1 & : Bohler

Preheat temp. (Min.) : 100°C Inter pas s T em p. ( m ax ) : 2 50° C O ther : D rying & heating by gas tor c h preheat shall be measured 100mm from the edge of the weld bevel arround the circumference by tempilsticks or digital thermometer.where preheat is applied to h e w e ld ld s id id e o n l ,a ti me me d el el a o f 1 m in in . e r 1 2 .7 .7 mm mm t hi hi ck ck ne ne ss ss . shall be applied before measuring.

Others: : prior the commencem ent of welding, the ends of pipes shall be cleaned, both inside and outside a min. of 50mm using a power wire brush or other approved method.

Electrical characteristics Current P olarity Other Other WELD Layers RO O T HO T F illing (3.25) F illing (4 ) C AP

: DC : ± ve : The The curr curren entt and and volt voltag age e rang ranges es bel below ow as as per per manuf manufact actur urer er reco recommen mmenda dati tion, on, actua actuall val values ues will will be reco recorde rded d from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Volt range Travel Speed Heat Input polar. Current range Direction U p h ill U p h i ll U p h il l U p h il l U p h ill

PMS : P M S- W I-24 R EV .1

Class E R -70S 3 E R -70S 3 E- 801 8G E- 801 8G E-8 018 G

Am p

Diam mm 2.4 2.4 3.2 5 4 4

-ve -ve +ve +v e +ve

CLIENT :

m in 94 94 109 117 100

m ax 144 144 120 137 135

V m in 8 8 26 26 26

range ( mm/sec)

m ax 10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax

THIRD PARTY: F 1 1-W I/24

+Contractor

Company



Project

Page


Document Title

17/ 25

Document Reference


Revision


Date Of Issue

1

28/01/2006

5.11 5. 11 Ma Main in w elding proc edure for Fitti ngs (Pipes to Bends Welds, thk . 12. 12.7mm). 7mm). PRODUCTION PRODUCTION W ELDING PROCEDUR PROCEDURE E SPECIFICATION ( W .P.S ) Company Name P r o j e ct

WPS No. Re vision vision No. Welding Welding Proces s

: Gu lf of S uez P etroleum Company Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT : PMS-SA Q-QC-WPS Q-QC-WPS -16"-PL-0 -16"-PL-011 11

Project Spec. Spec . : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 P r o j e c t p a r t : Pipes to Bends Weld : PM S-QC-PQR-16"-00XX S-QC-PQR-16"-00XXX Support ing PQR No. No.

:1

Date

: 28-01-2006 28-01-2006

: GTAW & SMAW

Type

: M anual anual

Joints :

TO BE QUALIFIED

Pos t Weld Weld Heat Treatment Treatment : N.A. Tempe emperratur ature e Ti m e O t her

: N.A. N.A. : N. A . : N. A .

Shielding Shielding Gases Gases : Type of gas or gases Composit ion of gas mix ture F l ow rat e

: Argon : 99.9% : 12-14 Li t / M i n.

POSITION

Type and Removal of Clamps:

Pos ition of Groove Groove : 5G (All fixed position) W el el d P rogres s ion : ( √ UP ) : A l l P as s es Uphi l l Alignment will be ach ieve d by t ack welds w hich will be remove d during we lding O t her

Internal o r Exte r na na l

:N.A : N. N.A

Remove Remove after : N.A Remove Remove after : N.A

B a s e Me t a l

F i l l er m e tal

Material Spec. AP I 5L Type or Grade X6 0 Thickness of test coupon Thi c k nes s Range 4. 8 m m Di am et et er of t es t c ou oupon Di am et er Range 329 m m O t h er :

TO AP I 5L TO X6 0 12.7 mm TO 19.1 mm 16" (406.4 mm) TO 609 m m

T ec h n i q u e

W eld Met al A naly sis si s ( A ) No : Size of Electrode mm : Filler Metal ( F ) No. : S F A S pec i fi c at i on : A WS W S Cl as ifific at at i on : Ot her : :

1 2.4 & 4 mm 3 (API 1104 Group 2) A 5.18 & A 5.5 E R 70S 3 & E -8018G ETC T IG SG1 & Bohler

P r eh e a t

Int erpas s Cl eani ng S t ringer or W eave M ul t ipas s or s ingl e pas s ( per s i de ) S i ngl e or M ul t i pl e E l ec t rode

: : : :

B rus h & G ri nding B ot h M ul t i S ingl e

Preheat temp. (Min.) : 50°C Int erpas s Tem p. ( m ax ) : 250°C Ot her : Dry i ng & heat ing by gas t orc h

preheat preheat shall be measured 100mm f rom the edge of the weld bev bev el arround arround the circumf erence by by t empilsticks or digital thermometer.where preheat is Others: : prior the commencem ent of welding, the ends ends of pipes shall be be cleaned, both a lied t o t he h e weld s id ide onl a t im e de d ela of 1 m in in er 12 7m m t hi hi c k n e s s inside and outside a min. of 50mm us ing a power power wire wire brush or other approved met hod. shall be applied before m easuring.

Electrical ch aracteristics Current Current P olari t y Other Other WELD Layers

: DC : ±ve : The The curre current nt and and voltage oltage range ranges s below below as per per manuf manufacturer acturer recommen recommendati dation, on, actual actual valu values es will will be recor recorded ded from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal Travel Travel Speed Heat Input polar. Current range Volt range Direction

Class

Am p

Diam mm

ROOT HOT F i ll ing (4m m ) F i ll ing (4m m ) CA P

Uphi l l Uphi l l Uphil l Uphil l Uphi l l

P MS : PMS-WI-24 REV.1

E R-70S 3 E R-70S 3 E -8018G E -8018G E -8018G

2. 4 2. 4 4 4 4

-ve -ve + ve + ve + ve

CL I ENT :

V

range ( mm/sec)

m in

m ax

m in

m ax

94 94 109 117 100

144 144 120 137 135

8 8 26 26 26

10 10 28 28 28

m in

m ax

range ( KJ/mm)

m in

Remarks

m ax


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5.12 5. 12 Re Repair pair w elding pro cedure for Fitti ngs (Pipes to Bends Welds, thk . 12.7 12.7mm). mm). PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S ) : Gulf Gu lf of Suez Petroleum Company Co mpany GUPCO : SAQQARA FIELD DEVELOPMENT PROJECT

Company Name Project


Project Spec. Spec. : KBR Specs No. (CGOS-0258-PLN-SPE-10) Rev. C & API 1104 Project part : Pipes Pipes to Bends Bends Weld : PMS-QC-PQR-16"-007R Supporti ng PQR No. No.


TO BE QUALIFIED

:1

Date

: 28-01-2006

: GTAW & SMAW

Type

: Manual

Joints :


KINDS FOR REPAIR:-

Temp Temper erat atur ure e Time Other

A) Cap Repair (CR).

: N.A N.A.. : N.A. : N.A.

B) Partial Penetration Repair (PR). C) Full Penetration Repair (R). D) Back W eld Repair (BW R).

Shielding Gases Gases : Type of gas or gases Com position of gas m ixture

: Argon : 99.9%

E) Repair of Repair (RR).

Flow rate

: 12-14 Lit/Min.

POSITION Type and and Removal of Cl amps: Internal :N.A Remove after :N.A or External :N.A Remove after :N.A


B as e Met al

Fi l l er m et al

Material Spec. API 5L Type or Grade X60 Thickness of test coupon Thickness Range 4.8 m m Diameter of test coupon Diameter Range 329 m m Other :

TO API 5L TO X60 12.7 mm TO 19.1 mm 16" (406.4 mm) TO 609 m m

Tec h n i q u e

Weld Metal Analysis ( A ) No. : 1 : 2.4, 2.4, 4 & 3.25 3.25 mm Size of Electrode mm Filler Metal ( F ) No. : 3 (API 1104 Group 2) : A 5.18 & A 5.5 SFA Specification AW S Clasification : ER 70S3 & E-8018G Other : ETC ETC TIG SG1 & : Bohler

Pr eh eat






: DC : ±ve : The The curre current nt and and vol volta tage ge ran range ges s belo below w as per per manu manufac factu ture rerr recom recommen menda dati tion on,, actu actual al val value ues s will will be be reco record rded ed from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted Filler Metal

WELD Layers

Direction

Class




ER-70S3 ER-70S3 E-8018G E-8018G E-8018G

2.4 2.4 3.25 4 4

Travel Speed

Heat Input

V

range ( mm/sec)

range ( KJ/mm)

Amp

Diam mm

R O OT HOT Filling (3.25) Filling (4) CA P

Volt range

-ve -ve +ve +ve +ve

CL IENT :

m in

max

m in

m ax

94 94 109 117 100

144 144 120 137 135

8 8 26 26 26

10 10 28 28 28

m in

max

m in

Remarks

m ax


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19/ 25 Revision

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Date Of Issue

28/01/2006

Repair w eldi ng pro cedu re fo r WPS No.PMS-SAQ-QCNo.PMS-SAQ-QC-WPSWPS-16” 16” -PL-001, -PL-001, 003, 005, 005, 007, 007, 009 and 0011 REV.1

1- SCOPE This repair welding Procedure shall be used for the unacceptable weld defect which has been welded using approved Main welding procedures specifications 2- GENERAL GENERAL a) In case of partial penetration weld repairs maximum of 30% of the weld circumference, the joint shall be cut out. b) In case of full penetration penetration weld repairs maximum of 20% of the weld circumference, circumference, the joint shall be cut out. repair and performance of NDT found that the c) If, after completion of the second repair repair section contains imperfection exceeding the acceptability limit, the weld shall be cut out. d) Removal of defect by using grinding only only according to the depth of the defect defect with minimum excavation length of 300 mm. e) The minimum allowable repair length shall be 50mm (2 Inch) at the bottom bottom of the groove). f) The portion of the weld cut out for repair shall be be tapered at the the sides and ends to give adequate access for re-welding. Metal may be removed by thermal gouging followed by grinding. Grinding shall be used for the last 3mm (1/8 Inch) through to the root. g) When arc gouging is used, used, the gouged area shall be cleaned by grinding to a bright finish. h) When a root repair weld in a pipelines fails to comply with the requirements of of acceptance criteria, the entire circumferential weld shall be cut out, and the pipe ends re-bevelled and re-welded, where necessary a second repair may be attempted for all regions a part from the root. If the second repair fails to meet the equipments of acceptance criteria, the entire circumferential weld shall be cut out (2nd repair permitted for partial penetration weld only). i) Weld repairs repairs to pipe ends ends shall not not be permitted. 3- REPAIR PROCEDURE 1- The defect carefully will be removed and re-welded re-welded using the attached WPS WPS No. PMSSAQ-QC- WPS-16”-PL-002,004, 006, 008, 010 and 0012 Rev.1 2- Repair of cracks: Welds cracks: Welds with cracks (other than small creater cracks ≤ 4mm in length) shall be removed from the pipeline, remedial measures implemented to prevent further occurrence. – No cracks other than crater cracks are allowed to be repaired. o Small crater crater cracks shall be removed by local local grinding and repaired repaired 3. For the repair repair of Arc Bu rns: the rns: the repair of the arc burns shall be carefully grinding or filing until all visible signs of the arc burn are removed, welding shall not be used to remove arc burns. The dressed area shall blend smoothly into the surrounding base

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20/ 25 Revision


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Date Of Issue

28/01/2006

metal and shall be examined by VT & MT to ensure freedom from defects and the remaining wall thickness shall be checked with UT. o If blending to remove the defects of arc burns reduces the wall thickness thickness below the specified minimum, the defective pipe section shall be cut out and the pipe rebevelled and re-welded. 4. Preheat & Interpass temperature: temperature: shall be applied by propan preheating torches, induction heating coils or other approved method. Welding or cutting torches shall not be used for preheating purposes and care shall be taken to avoid damage to any coating. Preheating shall be applied uniformly on both sides of the joint preparation around the entire periphery and shall be measured at four circumferential locations, each approximately 90° apart. Interpass temperature shall be measured on the parent material at the edge of the weld bevel near the weld start location and shall be measured once per complete revolution around the weld circumference. o Temperature indicating crayons which melt on attaining the specific temperature may be used to check preheat and Interpass temperature, but shall not be marked on weld bevels, weld beads or surfaces to be welded. Temperature indicating crayons or paints which indicate temperature by colour change shall not be used, alternatively, suitably attached (calibrated) thermocouples, or calibrated contact or optical pyrometers may be used to check preheat and Interpass temperatures. 4- Inspection Excavations associated with the partial thickness repair of planer flaws shall be tested t ested by MT to confirm complete removal of the flaw. f law. Inspection Inspection and treatment treatment of bevels: bevels: on pipe which is to be cut back, a zone extending 100mm (4 In.) from the proposed position of the new field bevel shall be examined by VT and UT. In case of existing of arc strikes. It shall be removed by grinding, and the area shall be Checked for the soundness by magnetic particles inspections

PMS PMS QA/QC QA/QC Eng.

Eng. Ahmed Hafez

Client

Certi Certi fyi ng Aut hori ty

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A) Qu ali fi cat io n f or Main Weldin Weld in g Pr oc edures edu res

Qualification shall be carried out in accordance with the specification for pipe line welding (Specs. No. CGOS-0258-PLN-SPE-10 Rev.C) and the reference standard API 1104. After welding the suitable no. of 16 inch welded pipe pipe nipples nipples (min. 1m length) length) to cover the mechanical test requirement the following will be done. •

•

•

Where adjoining pipe pipe have different thickness thickness (12.7mm, 22.2mm) the largest thickness will be transitioned with a 1:4 taper. All welded pipe nipples will be subjected to 1. 100% Radiographic Radiographic inspection according according to the radiographic radiographic inspection testing procedure no. GUPCO-PMS-SAQ-QC-PR-0003. 2. 100% Ultrasonic inspection according according to the ultrasonic inspection test test procedure no. GUPCO-PMS-SAQ-QC-PR-0004. 3. 100% Magnetic particles inspection according to the magnetic particles inspection testing procedure no. GUPCO-PMS-SAQ-QC-PR-0002. 4. 100% Visual inspection according according to the visual inspection inspection testing procedure No. GUPCO-PMS-SAQ-QC-PR-0005.

Mechanical test for main procedure Welding Procedure Qualification Test Sampling and Distribution: WALL THICKNESS ≤ 12.7 Type and number of test specimens for qualifi cation of w elding procedure CVN ¹

Type of Test

Cross Tensile

AWT

Nick Break

Root Bend

Face Bend

(Set of 3)

No. Of Specimens

4

1

4

4

4

5

Macro / HV10²

CTOD ³

3

2

(Set of 3)

WALL THICKNESS > 12.7 Type and number of test specimens for qualifi cation of w elding procedure Type of Test

Cross Tensile

No. Of Specimens

4

AWT

Nick Break

Side Bend

1

4

8

CVN ¹ (Set of 3)

5

Macro / HV10²

CTOD ³

3

2

(Set of 3)

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28/01/2006

Notes:1. CVN will comprise of Weld metal (WM), fusion line (FL) and and FL+2mm machined machined 2mm from the inside diameter. 2. A photograph will be taken of each macro macro following hardness testing. testing. 3. The sample distribution distribution and orientation will be as indicated in the figure 1. 4. Location of hardness hardness transverses transverses as indicated indicated in figure 2. 5. Location of charpy charpy impact tests tests specimens as indicated in figure 3.

Figure 1: Location of Te Test st Pieces from a But t Weld in Pipe

Figure 2 Indicates The Location Of Hardness Hardness Transverse Transverses s For Full Penetration Penetration Butt We Welds. lds.

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28/01/2006

Figure 3 location of c harpy impact tests specimens. B) Qualification for Repair Welding Procedures •

•

Will be qualified by by welding a suitable number of 16” welded pipe nipples nipples there will be subjected to the same non-destructive testing as mentioned above at point (A) (qualification for main welding procedure). Weld repairs repairs will will qualify for the following cases (As per per KBR Specification)

see figur e 4 1. Cap Repair (CR). 2. Partial Penetration Repair (PR). 3. Full Penetration Repair (R). 4. Back Weld Repair (BWR). 5. Repair of Repair (RR).

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28/01/2006

Welding Procedure Qualification Test Sampling and Distribution: Side Bend

CVN

Macro

CTOD

(Set of 3)

HV 10

(Set of 3)

1

---

1

---

1

1

3

1

---

1

1

1

3

1

2

---

---

1

---

---

1

---

1

1

1

1

3

1

2

Repair Type

Cross Tensile

CR

---

PR

Root Bend

Face Bend

---

---

1

1

R

1

BWR RR

For thk. ≥ 12.7mm

Figure 4A Full Penetration Repair

Figure 4B Partial Penetration Repair

NOTES: a b

Original weld fusion line Original weld heat-affected zone

Notes:t Wall Thickness of test pipe

Figure Figu re 4C Cap Cap Repair

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28/01/2006

1. CVN will comprise of Weld metal (WM), fusion line (FL) and and FL+2mm machined machined 2mm from the inside diameter. 2. A photograph will be taken of each macro macro following hardness hardness testing. testing. 3. One set of SSC test shall be conducted on Through Thickness repair welding procedure and main welding procedure. 4. The sample distribution distribution and orientation will be as indicated in the figure 1. 5. NDT will be carried out 24 hours following weld completion and visual weld acceptance. 6. Minimum of 2 passes shall shall be made for cap and back weld repairs. 7. CTOD will consist of WM and FL and will be performed performed at the minimum design temperature. 8. CTOD test pieces may be taken from any position around the weld weld where spare material is available. 9. Longitudinal weld weld seams will be separated by a minimum of 250 mm or or 90° whichever is the smaller and will both lie in the top half of the pipe circumference. 10. Prior to commencement of the welding, the ends of the pipes shall be cleaned, both inside and outside a minimum of 50mm using a power wire brush or other approved method. 11. Welding of the parent material on the outside and inside of the pipe body shall not be permitted. 12. Heat or hammering shall not be used to aid alignment. 13. When weld cannot be completed in one continuous welding operation, a minimum of 4 passes shall be deposited. 14. All start and stops shall be cleaned by grinding together with any weld undulation prior to depositing the next pass. 5. ATTACHMENTS: • • •

Material Certificates. Welding Consumables Certificates. Equipment Calibration Certificates.

Proposed Welding Procedure No.gupcO PMS SAQ QC 0001

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