WASKITA - GXED/TKL

D/TKL CONSORTIUM

Document No. Rev.: 1

WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
Page 1 of 10
 WASKITA - GXED/TKL CONSORTIUM

Document No. Rev.: 1

WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005 (PENSTOCK)
Page 2 of 10

Table of Content

I. General Description 3
II. Welding procedures 4
III. W elder and Operator 7
IV. Strand of metal welding 8
V. Reinforcement of Welding 8
VI. Tide welding and extension 8
VII. Transient welding 9
VIII. Erection of weld strand 9
IX. Data 10
X. Repair of Welding 10
XI. Test and Welding Inspection 10
Attachments
1. WPS / PQR
2. P. Number
3. F. Number
4. A. Number
5. Welder list
6. Welding map
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Document No. Rev.: 1

WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005 (PENSTOCK)
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I. General Description

A. All of welding process of Penstock for maintenance and erection process at project of
Genyem Hydroelectric Power will be executed as according to standard of ASME
Code Section IX "QUALIFICATION STANDARD FOR WELDING AND BRAZING
PROCEDURES, WELDERS, BRAZERS, AND WELDING AND BRAZING
OPERATORS" Employer will inform the specification of material of each work items to
be adopted, and hereinafter Contactor will determine usage of its Electrode.
Contractor have ever executed the similar work as follows:
1. Project of Musi HEPP in Bengkulu ( 2000).
2. Project of Balambano in Soroako Sul-Sel(1997)
3. Project of Telaga Tunjung in Tabanan Bali(2006)
4. Project of Batubulan in Sumbawa ( 2002).
5. Project of Bili-Bili in South Sulawesi(1997)
6. Project of PLTU Tarahan in Lampung (Chimney).(2007)
7. Etc.
Electrode (Materials Filler) will according to the specification of material which have
approved by consultant (Engineer), before execution of work, Contractor will propose
the welding procedure as attachment - 1 (WPS and PQR)

B. Contractor will accountable for make WPS and determine the welder.
Welding standard which is often used as follows:
1. American Petroleum Institute ( API)
2. American Society Mechanical Engineer of ( ASME)
3. Japanese Industry Standard ( JIS)
4. Deutsches Institute Norm(DIN)
5. American Welding Society ( AWS)

Welding procedure will be executed by Contractor with the following sequences:

1. Installation of Tools and Equipment
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D/TKL CONSORTIUM

Document No. Rev.: 1

WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
Page 4 of 10

2. Welding Process:
a. Hope to be paid attention to basic metal .(QW - 403)
b. Hope to be paid attention to Metal filter.(QW - 404)
c. Hope to be paid attention to welding position (QW- 461)
d. Hope to be paid attention to Post Weld Heat Treatment (PWHT)(QW- 407)
e. Hope to be paid attention to its preheat (QW-406).

II. Welding procedures

Welding Procedure will be executed by Contractor with the following sequences:

A. Install the tools and equipments.

1. Before
ore welding process conducted, install the temporary tool which used to water
down at the time of welding and give cover above material to welded by blue sheet
( deklit ) if the location of welded material reside in terrain or is open.
2. Placing tool (welding machine) on course the nearby material to weld.

B. Welding Process.
Before welding process,
process Contractor willl make "Technical and Execution of Welding"
Welding in
using at project of Genyem Hydroelectric Power to be approved to consultant
(Engineer) see attachment - 1.
In welding process, there is some requirement which to be paid attention:
a. Hope to be paid attention to basic metal.(QW - 403)
Before welding process, please look at the WPS and PQR which have approved,
hereinafter hope to be paid attention to the basic metal from welded material with
WPS which have made available.
available
Basic metal classified in a group called P. the number,
umber, seen in attachment - 2 (P
NUMBER)
b. Hope to
o be paid attention to its metal filter.(QW - 404)
Before welding process, please look at the WPS and PQR which have
approved, hereinafter hope to be paid attention to metal filter from welded
material with WPS which have made available
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D/TKL CONSORTIUM

Document No. Rev.: 1

WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
Page 5 of 10

Metal filter classified

clas as according to ability of its characteristic and used to
relate according to F Number
Number. seen in attachment- 3 F NUMBER
Something else needed to determine welded metal will conducted according to
its analysis chemistry relate according to: A NUMBER, seen in attachment - 4.

c. Hope to be paid attention to welding position

The following are the kind of welding position
Welding Position level off ( 1 G)

1G
1 G - Rotated

Welding position of horizontal basic metal which can only be welded from the
top, this matter happened if welding at plate type and for the type of pipe metal
will be placed is same welded part positioned in circle,, and welding also can
only be conducted from the top.

Horizontal Welding Position ( 2 G)

2G
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WELDING PROCEDURE
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05 (PENSTOCK)
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Welding position of vertical basic metal, if the material are pipe or plate only
can be conducted by horizontal welding and then for the pipe because of its
position cannot be moved / changed for momentary welding

Vertical Welding Position ( 3 G )

3G

This welding position conducted at plate only and plate material positioned
position
vertically and welding can be conducted in vertical

Welding Position above Head ( 4 G )

Position welding is only done at the plate and position it horizontally positioned
plate material and welding can be done from the bottom.

Assorted Position ( 5 G )

5G
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WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
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This welding position conducted at pipe only and pipe material positioned
horizontally and welding can be conducted without twiddling of pipe

Assorted Position ( 6 G )

45 Deg + 5
Deg

This welding position conducted at pipe only and at pipe material positioned
at angle 450 and welding can be conducted without twiddling of pipe.

d. Hope to be paid attention to Post Weld Heat Treatment (PWHT)(QW

WHT)(QW - 407)
In this procedure do not be required.
e. Hope to be paid attention to its preheat(QW
preheat - 406)
Before the welding started ,the material shall be preheat with 500c at the welding
position area.
After finishing of welding process, will be continued by inspection and test

III. Welder and Operator

Besides welding operational and technical, Contractor will execute efficiency test to
welder and operator called PWQT (Performance Welder Qualification Test), which have
aimed to get the expert of Welder and operator as according to ASME Section IX.
Intention off PWQT is to determine ability of weld
welder
er mechanic or operator in operating
equipments to make the soft welding ( is not handicap ) see attachment-
attachment 5 list of the
expert welder with their certificates.
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WELDING PROCEDURE
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HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
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IV. Strand of metal welding

All of welding are including weld repair at Genyem Hydroelectric Powe
Power made by Low
Hydrogen welded strand of metal which have been adapted by section IX and Section II
part of C from ASME Code.
Contractor submit welded strand of metal to used at Project of Genyem to Engineer to get
the approval

V. Reinforcement of Welding
All result of welding reinforcement at tuning extension of pipe before welded, will be
cleaned with this matter hand grinding to specify the V path form (Grove) step by step
This
his matter will be conducted when early welding

Hand Grinding

cleaned up finish

VI. Tide welding and extension

Tide welding and Extension will be executed as according to the thickness of each
plate in such a way till to form di
distortion
stortion as minimum as possible,
possible this matter will be
conducted at welding adjustment to give the underhand welding . All extension at
metal will adjust Dye Penetrant at T extension. Executing the extension at butt-
welded, All the welding of the cracked will in gouging back hereinafter in Dye
Penetrant , if tack weld used in groove welding, every weld tack will change before
executing of welding ( see attachment 6 )
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WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
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Edge Welding (Fillet Weld) the thickness of filler will be made in 4 mm with two or
more pass. By multiple pass welding,
welding weld strand
d of metal to be used by Diameter
2.6 mm up to 4 mm at its passes root

After admission filling every boras will be cleaned with weld (TETEK) and strand of
metal become militant to eliminate slag and scale,, and will be cleaned is deeper if
needed. Henceforth
orth conducting the welding at metal which have been cleaned

All welding will clean in such a way till free from flux
fl

VII. Transient welding

All transient installation will be conducted by side welding or grove welding and this
welding have the same quality with the major welding, transient installation like (lugs,
(
supports and tie downs) will weld at the metal body except place appliance lift , seen
sketch

Some temporary mounting materials needed in the installation work, is an integral part

VIII. Protection
tion of weld strand
Contractor will provide the ware house and chain block as according to required in
AWS D.1.1
Contractor will apply the metal strand and placed by weld thermos as according to
required temperature
If weld strand have not in wearing, weld strand will be kept at dry place
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Document No. Rev.: 1

WELDING PROCEDURE
Page Number
HPP-GYM-PP-ENG-EP-005
05 (PENSTOCK)
Page 10 of 10

IX. Data
Contractor will arrange the from start of welding process until finishing work in each
welding location as according to the drawing, welding type , repair of welding result
from Dye penetrant according to the required by Owner

X. Repair of Welding
Contractor will repair all defect welding
Welding of the detected cracks will be replace in a way to ciping or gouging, and adds
metal to weld on a part is detected content in the welding repair, welding
weldi will be done
by adding filler metal. After all repairs done to re-Examined
re Examined using methods that have
set the appropriate type of welding.

XI. Test and Welding Inspection

Test to make sure that all of its surfaces is good from the material defect, such
as under cut, crack and porosity will be conducted :
100 % ultrasonic examination, by a laboratory approved by the
employers representative for a welds made in penstock.
In the area of any defect detected by ultrasonic examination including a
length of weld 100 mm either side of the defect side of the defect will be
check by Radiographic examination
Ten percent (10%) of circumferential and longitudinal welds (T-Joint)
(T
in the penstock shell with by radiographic (x-ray)
ray) in accordance with have
been determined by the Employers Representative.
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