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SAQQARA FIELD DEVELOPMENT PROJECT

GUPCO PMS
Gulf of Suez Petroleum Company Petroleum Marine Services Company

SAQQARA FIELD DEVELOPMENT PROJECT

16” SUB-SEA PIPE LINE

OFFSHORE - EGYPT

PROPOSED WELDING PROCEDURES

DOCUMENT REFERENCE
GUPCO-PMS-SAQ-QC-PR-0001

Approved For
1 28-01-2006 A. HAFEZ K.YOUSEF M. AMRO
Construction

0 ISSUE FOR APPROVAL 18/08/2005 A. HAFEZ K.YOUSEF M. AMRO

PMS PMS PMS GUPCO


Rev. Reason for Issue Date
Prepared Checked Approval 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 2/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

TABLE OF 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
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 3/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 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 initially be produced from an unmanned, fixed steel platform. The full
development scheme will comprise a single nine-slot platform with one 16” multiphase
pipeline connecting Saqqara with 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, for further treatment. The liquids 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.
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 4/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

2. DEFINITIONS

Company : GULF OF SUEZ PETROLEUM COMPANY (GUPCO)


Contractor : PETROLEUM MARINE SERVICES COMPANY (P.M.S)
Lay Barge : PMS 12
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 5/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

3. REFERENCE DOCUMENTS

Codes & Specification:

API 1104 Welding of Pipelines and related


Facilities 1999

CGOS-0258-PLN-SPE-10 Specification for pipeline welding (Revision C)


28/01/2006
Date Of Issue
6/ 25

MASTER LIST FOR


Page

APPROVED WPS’s
Gulf Of Suez Petroleum Company (GUPCO)

PETROLIUM MARINE SERVICES CO


Revision

PROJECT :Saqqara Field Development Project CLIENT :GUPCO APPROVED BY : GUPCO


GUPCO-PMS-SAQ-QC-PR-0001

REV. NO. :1 DATE : 28/01/2006


SAQQARA FIELD DEVELOPMENT PROJECT

W.P.S Thik Dim. Welding Certified


Mat. Electrodes Remarks Client
NO. Range mm Rang (MM) Processes By
API 5L For main welding procedure
PMS-SAQ-QC-WPS-16"-PL-001 4.8 ≤ T ≤ 19.1 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/X60 (pipe to pipe weld)
Document Reference

API 5L For repair welding procedure


PMS-SAQ-QC-WPS-16"-PL-002 4.8 ≤ T ≤ 19.1 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
16” SUB SEA PIPE LINE

X60/X60 (pipe to pipe weld)


API 5L For main welding procedure
PMS-SAQ-QC-WPS-16"-PL-003 19.2 ≤ T 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/X60 (pipe to pipe weld)
API 5L For repair welding procedure
Company

PMS-SAQ-QC-WPS-16"-PL-004 19.2 ≤ T 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/X60 (pipe to pipe weld)
API 5L For main welding procedure
PMS-SAQ-QC-WPS-16"-PL-005 19.2 ≤ T 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/F60 (pipe to flange weld)
API 5L For repair welding procedure

GUPCO

GUPCO
PMS-SAQ-QC-WPS-16"-PL-006 19.2 ≤ T 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/F60 (pipe to flange weld)
API 5L
For main welding procedure
PMS-SAQ-QC-WPS-16"-PL-007 API 5L 19.2 ≤ T 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
PROPOSED WELDING PROCEDURES

(pipe to bend weld)


X60/X60
Petroleum Marine Services Co. (PMS)

API 5L For repair welding procedure


PMS-SAQ-QC-WPS-16"-PL-008 19.2 ≤ T 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/X60 (pipe to bend weld)
API 5L For main welding procedure
4. APPROVED WPS'S LIST PMS-SAQ-QC-WPS-16"-PL-009
X60/F60
4.8 ≤ T ≤ 19.1 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
(pipe to flange weld)
API 5L For repair welding procedure
PMS-SAQ-QC-WPS-16"-PL-010 4.8 ≤ T ≤ 19.1 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/F60 (pipe to flange weld)
API 5L For main welding procedure
PMS-SAQ-QC-WPS-16"-PL-011 4.8 ≤ T ≤ 19.1 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/X60 (pipe to bend weld)
API 5L For repair welding procedure
PMS-SAQ-QC-WPS-16"-PL-012 4.8 ≤ T ≤ 19.1 329 ≤ D ≤ 609 GTAW & SMAW ER-70S3 & E-8018G
X60/X60 (pipe to bend weld)
PMS QA/QC Certifying Authority : Client :
Eng.Ahmed Hafez GUPCO Rep.

Document Title
+Contractor

F14/WI-24 PMS-WI-24 Rev.1


Project
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 7/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.1 Main Welding Procedure For 16"X 12.7MM.


PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipe line, Spool Piece
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-001 TO BE QUALIFIED
Revision No. :1 Date : 28-01-06
Welding Process :GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
Time : N.A.
Other : N.A.
Shielding Gases :
Type of gas or gases : Argon
Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :√ Remove after : 100% root pass complet Weld Progression : ( √ UP )
or External : N.A Remove after : N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. :1
Type or Grade X60 TO X60 Size of Electrode mm :2.4 & 4mm
Thickness of test coupon 12.7 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 4.8 mm TO 19.1 mm SFA Specification : A 5.5 & A 5.18
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER-70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 50°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be
recorded from Procedure Qualification Record (PQR)- any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 22 32
HOT Uphill ER-70S3 2.4 -ve 94 144 22 32
Filling (4mm) Uphill E-8018G 4 +ve 120 180 22 32
Filling (4mm) Uphill E-8018G 4 +ve 160 210 22 32
CAP Uphill E-8018G 4 +ve 120 180 22 32
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 8/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.2 Repair Welding Procedure For 16"X12.7mm Pipe Line.


PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipe line, Spool Piece
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-002 TO BE QUALIFIED
Revision No. :1 Date : 28-01-06
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
KINDS FOR REPAIR:- Time : N.A.
A) Cap Repair (CR). Other :
B) Partial Penetration Repair (PR). Shielding Gases :
C) Full Penetration Repair (R). Type of gas or gases : Argon
D) Repair of Repair (RR). Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (all Fixed position)
Internal :N.A Remove after :N.A Weld Progression : ( √ UP )
or External :N.A Remove after :N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4 & 4mm
Thickness of test coupon 12.7 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 4.8 mm TO 19.1 mm SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp.(Min) : 100 ºC
Stringer or Weave : Both Interpass Temp. (Max) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
preheat shall be measured 100mm from the edge of the weld bevel arround the
Single or Multiple Electrode : Single circumference by tempilsticks or digital thermometer.where preheat is applied to
the weld side only,a time delay of 1 min.per 12.7mm thickness.
shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4 +ve 109 120 26 28
Filling (4mm) Uphill E-8018G 4 +ve 109 120 26 28
CAP Uphill E-8018G 4 +ve 109 120 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 9/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.3 Main Welding Procedure for 16" X 22.2mm Pipe Line.


PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipe line, Spool Piece
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-003 TO BE QUALIFIED
Revision No. :1 Date : 28-01-06
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
Time : N.A.
Other : N.A.
Shielding Gases :
Type of gas or gases : Argon
Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :√ Remove after : 100% root pass complet Weld Progression : ( √ UP )
or External : N.A Remove after : N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. :1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4, 4 & 5
Thickness of test coupon 22.2 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 19.2 mm TO Unlimited SFA Specification : A 5.5 & A 5.18
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER-70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp.(Min.) : 50°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4/ +ve 120 180 22 32
Filling (5mm) Uphill E-8018G 5 +ve 160 210 22 32
CAP Uphill E-8018G 4 +ve 120 180 22 32
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 10/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.4 Repair Welding for 16" X 22.2 mm Pipe Line.


PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipe line, Spool Piece
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-004 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
KINDS FOR REPAIR:- Temperature : N.A.
Time : N.A.
A) Cap Repair (CR). Other : N.A.
B) Partial Penetration Repair (PR). Shielding Gases :
C) Full Penetration Repair (R). Type of gas or gases : Argon
D) Repair of Repair (RR). Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :N.A Remove after :N.A Weld Progression : ( √ UP )
or External :N.A Remove after :N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4& 4 mm
Thickness of test coupon 22.2 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 19.2 mm TO Unlimited SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp.(Min.) : 100°C
Stringer or Weave : Both Interpass Temp. (max.) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4 +ve 109 120 26 28
Filling (4mm) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 11/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.5 Main welding procedure for Fittings (Flange to Pipe Welds, thk. 22.2mm).
PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Flanges Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-005 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
Time : N.A.
Other : N.A.
Shielding Gases :
Type of gas or gases : Argon
Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
Type and Removal of Clamps: POSITION
Internal :N.A Remove after : N.A Position of Groove : 5G (All fixed position)
or External :N.A Remove after : N.A Weld Progression : ( √ UP )
Alignment will be achieved by tack welds which will be removed during welding Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO F60 Size of Electrode mm : 2.4, 4 & 5 mm
Thickness of test coupon 22.2 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 19.2 mm TO Unlimited SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 50°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4/ +ve 109 120 26 28
Filling (5mm) Uphill E-8018G 5 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 12/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.6 Repair welding procedure for Fittings (Flange to Pipe Welds, thk. 22.2mm).
PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Flanges Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-006 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
KINDS FOR REPAIR:- Temperature : N.A.
Time : N.A.
A) Cap Repair (CR). Other : N.A.
B) Partial Penetration Repair (PR). Shielding Gases :
C) Full Penetration Repair (R). Type of gas or gases : Argon
D) Back Weld Repair (BWR). Composition of gas mixture : 99.9%
E) Repair of Repair (RR). Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :N.A Remove after :N.A Weld Progression : ( √ UP )
or External :N.A Remove after :N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO F60 Size of Electrode mm : 2.4, 4 & 3.25 mm
Thickness of test coupon 22.2 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 19.2 mm TO Unlimited SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 100°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (3.25) Uphill E-8018G 3.25 +ve 109 120 26 28
Filling (4) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 13/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.7 Main welding procedure for Fittings (Pipes to Bends Welds, thk. 22.2mm).

PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )


Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Bends Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-007 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
Time : N.A.
Other : N.A.
Shielding Gases :
Type of gas or gases : Argon
Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
Type and Removal of Clamps: POSITION
Internal :N.A Remove after : N.A Position of Groove : 5G (All fixed position)
or External :N.A Remove after : N.A Weld Progression : ( √ UP )
Alignment will be achieved by tack welds which will be removed during welding Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4, 4 & 5 mm
Thickness of test coupon 22.2 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 19.2 mm TO Unlimited SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 50°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4/ +ve 109 120 26 28
Filling (5mm) Uphill E-8018G 5 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 14/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.8 Repair welding procedure for Fittings (Pipes to Bends Welds, thk. 22.2mm).

PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )


Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Bends Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-008 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
KINDS FOR REPAIR:- Temperature : N.A.
Time : N.A.
A) Cap Repair (CR). Other : N.A.
B) Partial Penetration Repair (PR). Shielding Gases :
C) Full Penetration Repair (R). Type of gas or gases : Argon
D) Back Weld Repair (BWR). Composition of gas mixture : 99.9%
E) Repair of Repair (RR). Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :N.A Remove after :N.A Weld Progression : ( √ UP )
or External :N.A Remove after :N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4, 4 & 3.25 mm
Thickness of test coupon 22.2 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 19.2 mm TO Unlimited SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 100°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (3.25) Uphill E-8018G 3.25 +ve 109 120 26 28
Filling (4) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 15/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.9 Main welding procedure for Fittings (Flange to Pipe Welds, thk. 12.7mm).
PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Flanges Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-009 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
Time : N.A.
Other : N.A.
Shielding Gases :
Type of gas or gases : Argon
Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
Type and Removal of Clamps: POSITION
Internal :N.A Remove after : N.A Position of Groove : 5G (All fixed position)
or External :N.A Remove after : N.A Weld Progression : ( √ UP )
Alignment will be achieved by tack welds which will be removed during welding Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. :1
Type or Grade X60 TO F60 Size of Electrode mm : 2.4 & 4mm
Thickness of test coupon 12.7 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 4.8 mm TO 19.1 mm SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 50°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4 +ve 109 120 26 28
Filling (4mm) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PART:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 16/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.10 Repair welding procedure for Fittings (Flange to Pipe Welds, thk. 12.7mm).
PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )
Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Flanges Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-010 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
KINDS FOR REPAIR:- Temperature : N.A.
Time : N.A.
A) Cap Repair (CR). Other : N.A.
B) Partial Penetration Repair (PR). Shielding Gases :
C) Full Penetration Repair (R). Type of gas or gases : Argon
D) Back Weld Repair (BWR). Composition of gas mixture : 99.9%
E) Repair of Repair (RR). Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :N.A Remove after :N.A Weld Progression : ( √ UP )
or External :N.A Remove after :N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO F60 Size of Electrode mm : 2.4, 4 & 3.25 mm
Thickness of test coupon 12.7 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 4.8 mm TO 19.1 mm SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 100°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (3.25) Uphill E-8018G 3.25 +ve 109 120 26 28
Filling (4) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 17/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.11 Main welding procedure for Fittings (Pipes to Bends Welds, thk. 12.7mm).

PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )


Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Bends Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-00XXX
WPS No. : PMS-SAQ-QC-WPS-16"-PL-011 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
Temperature : N.A.
Time : N.A.
Other : N.A.
Shielding Gases :
Type of gas or gases : Argon
Composition of gas mixture : 99.9%
Flow rate : 12-14 Lit/Min.
Type and Removal of Clamps: POSITION
Internal :N.A Remove after : N.A Position of Groove : 5G (All fixed position)
or External :N.A Remove after : N.A Weld Progression : ( √ UP )
Alignment will be achieved by tack welds which will be removed during welding Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No : 1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4 & 4 mm
Thickness of test coupon 12.7 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 4.8 mm TO 19.1 mm SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 50°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single preheat shall be measured 100mm f rom the edge of the weld bev el arround
the circumf erence by tempilsticks or digital thermometer.where preheat is
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
applied to the weld side only a time delay of 1 min per 12 7mm thickness
inside and outside a min. of 50mm using a power wire brush or other approv ed method. shall be applied bef ore measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (4mm) Uphill E-8018G 4 +ve 109 120 26 28
Filling (4mm) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 18/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

5.12 Repair welding procedure for Fittings (Pipes to Bends Welds, thk. 12.7mm).

PRODUCTION WELDING PROCEDURE SPECIFICATION ( W.P.S )


Company Name : Gulf of Suez Petroleum Company Project Spec. : KBR Specs No.
GUPCO (CGOS-0258-PLN-SPE-10) Rev. C & API 1104
Project : SAQQARA FIELD DEVELOPMENT Project part : Pipes to Bends Weld
PROJECT Supporting PQR No. : PMS-QC-PQR-16"-007R
WPS No. : PMS-SAQ-QC-WPS-16"-PL-012 TO BE QUALIFIED
Revision No. :1 Date : 28-01-2006
Welding Process : GTAW & SMAW Type : Manual
Joints : Post Weld Heat Treatment : N.A.
KINDS FOR REPAIR:- Temperature : N.A.
Time : N.A.
A) Cap Repair (CR). Other : N.A.
B) Partial Penetration Repair (PR). Shielding Gases :
C) Full Penetration Repair (R). Type of gas or gases : Argon
D) Back Weld Repair (BWR). Composition of gas mixture : 99.9%
E) Repair of Repair (RR). Flow rate : 12-14 Lit/Min.
POSITION
Type and Removal of Clamps: Position of Groove : 5G (All fixed position)
Internal :N.A Remove after :N.A Weld Progression : ( √ UP )
or External :N.A Remove after :N.A Other : All Passes Uphill
Base Metal Filler metal
Material Spec. API 5L TO API 5L Weld Metal Analysis ( A ) No. : 1
Type or Grade X60 TO X60 Size of Electrode mm : 2.4, 4 & 3.25 mm
Thickness of test coupon 12.7 mm Filler Metal ( F ) No. : 3 (API 1104 Group 2)
Thickness Range 4.8 mm TO 19.1 mm SFA Specification : A 5.18 & A 5.5
Diameter of test coupon 16" (406.4 mm) AWS Clasification : ER 70S3 & E-8018G
Diameter Range 329 mm TO 609 mm Other : ETC TIG SG1 &
Other : : Bohler
Technique Preheat
Interpass Cleaning : Brush & Grinding Preheat temp. (Min.) : 100°C
Stringer or Weave : Both Interpass Temp. ( max ) : 250°C
Multipass or single pass ( per side ) : Multi Other : Drying & heating by gas torch
Single or Multiple Electrode : Single 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
Others: : prior the commencement of welding, the ends of pipes shall be cleaned, both
the weld side only,a time delay of 1 min.per 12.7mm thickness.
inside and outside a min. of 50mm using a power wire brush or other approved method. shall be applied before measuring.

Electrical characteristics
Current : DC
Polarity : ±ve
Other : The current and voltage ranges below as per manufacturer recommendation, actual values will be recorded
from Procedure Qualification Record (PQR) - any change in heat input out side ± 10% is accepted
WELD Filler Metal polar. Current range Volt range Travel Speed Heat Input
Layers Direction Diam Amp V range ( mm/sec) range ( KJ/mm) Remarks
Class
mm min max min max min max min max
ROOT Uphill ER-70S3 2.4 -ve 94 144 8 10
HOT Uphill ER-70S3 2.4 -ve 94 144 8 10
Filling (3.25) Uphill E-8018G 3.25 +ve 109 120 26 28
Filling (4) Uphill E-8018G 4 +ve 117 137 26 28
CAP Uphill E-8018G 4 +ve 100 135 26 28
PMS : CLIENT : THIRD PARTY:
PMS-WI-24 REV.1 F11-WI/24
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 19/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

Repair welding procedure for WPS No.PMS-SAQ-QC-WPS-16”-PL-001, 003, 005, 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
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 weld repairs maximum of 20% of the weld circumference,
the joint shall be cut out.
c) If, after completion of the second repair and performance of NDT found that the
repair section contains imperfection exceeding the acceptability limit, the weld shall
be cut out.
d) Removal of defect by using grinding only according to the depth of the defect with
minimum excavation length of 300 mm.
e) The minimum allowable repair length shall be 50mm (2 Inch) at the bottom of the
groove).
f) The portion of the weld cut out for repair shall be tapered at 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, 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
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 to pipe ends shall not be permitted.

3- REPAIR PROCEDURE

1- The defect carefully will be removed and re-welded using the attached WPS No. PMS-
SAQ-QC- WPS-16”-PL-002,004, 006, 008, 010 and 0012 Rev.1
2- Repair of 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 cracks shall be removed by local grinding and repaired

3. For the repair of Arc Burns: 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
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
Project Page
SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 20/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 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 below the
specified minimum, the defective pipe section shall be cut out and the pipe re-
bevelled and re-welded.

4. Preheat & Interpass 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 by
MT to confirm complete removal of the flaw.
Inspection and treatment of 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 QA/QC Eng. Client Certifying Authority

Eng. Ahmed Hafez


+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
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SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 21/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

A) Qualification for Main Welding Procedures

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 nipples (min. 1m length) to
cover the mechanical test requirement the following will be done.

• Where adjoining pipe have different 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 inspection according to the radiographic inspection testing
procedure no. GUPCO-PMS-SAQ-QC-PR-0003.
2. 100% Ultrasonic inspection according to the ultrasonic inspection 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 to the visual 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 qualification of welding procedure
CVN ¹ Macro
Type of Cross Nick Root Face CTOD ³
AWT /
Test Tensile Break Bend Bend (Set of 3) (Set of 3)
HV10²
No. Of
Specimens
4 1 4 4 4 5 3 2

WALL THICKNESS > 12.7

Type and number of test specimens for qualification of welding procedure


CVN ¹ Macro
Type of Cross Nick CTOD ³
AWT Side Bend /
Test Tensile Break (Set of 3) (Set of 3)
HV10²
No. Of
Specimens
4 1 4 8 5 3 2
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
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SAQQARA FIELD DEVELOPMENT PROJECT
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Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

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

Figure 1: Location of Test Pieces from a Butt Weld in Pipe

Figure 2 Indicates The Location Of Hardness Transverses For Full Penetration Butt Welds.
+Contractor Company

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
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Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

Figure 3 location of charpy impact tests specimens.


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

Petroleum Marine Services Co. (PMS) Gulf Of Suez Petroleum Company (GUPCO)
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SAQQARA FIELD DEVELOPMENT PROJECT
16” SUB SEA PIPE LINE 24/ 25

Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

Welding Procedure Qualification Test Sampling and Distribution:


Side Bend CVN Macro CTOD
Repair Cross
For thk. ≥ Root Bend Face Bend
Type Tensile (Set of 3) HV 10 (Set of 3)
12.7mm

CR --- --- --- 1 --- 1 ---


PR 1 1 1 1 3 1 ---
R 1 1 1 1 3 1 2
BWR --- --- 1 --- --- 1 ---
RR 1 1 1 1 3 1 2

Figure 4A Full Penetration Repair

Figure 4B Partial Penetration Repair

NOTES:

a Original weld fusion line Figure 4C Cap Repair


b Original weld heat-affected zone

Notes:-
t Wall Thickness of test pipe
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Document Title Document Reference Revision Date Of Issue

PROPOSED WELDING PROCEDURES GUPCO-PMS-SAQ-QC-PR-0001 1 28/01/2006

1. CVN will comprise of Weld metal (WM), fusion line (FL) and FL+2mm machined 2mm
from the inside diameter.
2. A photograph will be taken of each macro following hardness testing.
3. One set of SSC test shall be conducted on Through Thickness repair welding
procedure and main welding procedure.
4. The sample 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 be made for cap and back weld repairs.
7. CTOD will consist of WM and FL and will be performed at the minimum design
temperature.
8. CTOD test pieces may be taken from any position around the weld where spare
material is available.
9. Longitudinal weld seams will be separated by a minimum of 250 mm 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.

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