PELATIHAN INSPEKTUR PIPA PENYALUR

WELDING PROCEDURE SPECIFICATION (WPS)

&
PROCEDURE QUALIFICATION RECORD (PQR)

PURWIDIATMO
June 2010
 DEFINITION

WELDING :
A joining process that produces coalescence of
materials by heating them to the welding
temperature with or without the application of
temperature,
diatmo

pressure or by pressure alone, and with or

without the use of filler metal.
Purwid

(by AWS A3.0)

 WELD
WELD METAL
BASE METAL
diatmo
Purwid

T wm > T bm
 WELDING CODE

Provide
Rules, requirements, tolerances, etc. to assure
that the production weld will comply with code
requirements.
requirements
diatmo
Purwid
 WELDING OF PIPELINES
ASME B31.8 a 2000 – CHAPTER II

823.1 Hoop stress less than 20% of SMYS

• Welders shall be qualified as per 823.21 or Appendix G

823.2 Hoop stress 20% or more of SMYS

diatmo

8.23.21 Welding Procedures & Welders shall be qualified as per

ASME sect. IX or API 1104
Purwid

8.23.22 Welders qualified under API 1104 ( that are employed on

compressor station piping), qualification shall be based
on mechanical
o ec a ca test requirements
equ e e ts

823.3 Welder re-qualification required :

• When there is specific reason to question welder's ability
• When the welder does not weld in 6 months or more
• All Welder shall be re-qualified at least once a year
 WELDING OF PIPELINES

Welding of Pipelines and

Related
e ated Facilities
ac t es
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Purwid

API STANDARD 1104

TWENTIETH EDITION, NOVEMBER 2005
 1. GENERAL

1.1 SCOPE
• Gas & arc welding of : Butt, Fillet and Socket welds
• Carbon and Low-alloy steel piping use in compression,
pumping and transmission of crude, petroleum product,
DARD 1104

fuel gas
gas, . . ….
• New construction and in-service welding
• SMAW
SMAW, SAW,
SAW GTAW,
GTAW GMAW,
GMAW FCAW,
FCAW PAW,
PAW OAW and Flash
PI STAND

butt welding or combination of these processes. (Manual,

mechanized or automatic – or combination of these
techniques)
q )
AP

• Units : either inch-pond or SI – do not combine the units

 2. REFERENCED PUBLICATIONS

• API
• ASNT
• ASTM
DARD 1104

• AWS
• BSI
PI STAND
AP
 3. DEFINITION OF TERMS

AWS A 3.0, with addition and modifications given in 3.2

• Automatic Welding
• Branch Connection
DARD 1104

• Defect
• Imperfection
• Position welding
PI STAND

• Qualified Welder
• Qualified Welding Procedure
AP

• Etc.
 4. SPECIFICATIONS

4.2 Materials
Pipes and fittings shall conform to:
• API Spec 5L
• Applicable ASTM specifications
DARD 1104

• Also applies to materials with chemical and mechanical

properties that comply with one of above specifications
PI STAND

Filler Metal
• AWS A5.1
• AWS A5.2
AP

• . . . . AWS A5.29
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.1 Procedure Qualification

• Prior to production welding, detailed procedure
specification shall be established and qualified
• Quality of welds shall be determined by destructive
DARD 1104

testing

5.2 Record
Suggested
gg form Æ Fig.
g 1&2
PI STAND
AP
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.3 Procedure Specification

Shall include information:
• Welding process and technique (manual, auto. , etc)
• Pipe & Fitting Material
DARD 1104

• Diameter
Di & Wall
W ll thick.
hi k
• Joint design
• Filler metal & number of Beads
PI STAND

• Electrical characteristic
• Flame characteristic
AP

• Position
• Direction of welding
• Time between passes
• . . . Etc. Æ Fig. 1 & 2
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.4 Essential Variables

When any of essential variables listed in 5.4.2 are changed
Æ the welding procedure must be re-established (new
qualification shall be made)
DARD 1104
PI STAND
AP
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.5 Welding of test joints-butt welds

2 (two) pipe nipples shall be joined

5.5 Testing of welded joints-butt welds

DARD 1104

• Specimens
p shall be cut at the location shown in Fig.3
g
• Type & number of tests Æ Table 2.
• Specimen preparation Æ Fig. 4, 5, 6 or 7
PI STAND

• For pipe < 2.375

2 375 in.
in (60.3
(60 3 mm) OD
OD, 2 (two) test weld required
• For pipe < 1.315 in. (33.4 mm) OD, one full sec. specimen maybe
substituted for the 4 (four) reduce section Nick-break and root
bend specimens
p
AP
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.6.2 Tensile Strength Test

• Specimen preparation Æ Fig. 4
• Method Æ Specimen shall be broken under tensile load
Æ Tensile Strength = Ultimate load / Cross section
Ts = F/A
DARD 1104

• Requirements
9 Tensile Strength of Weld > SMTS of pipe material
(including fusion zone)
9 If breaks in the weld or fusion Zone Æ shall also meet
PI STAND

soundness
d requirement.
i t 5.6.3.3
5633
AP
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.6.3 Nick-break Test

• Specimen preparation Æ Fig. 5
• Method Æ Specimen shall be broken by pulling in tensile
machine
Æ The exposed area of the fracture shall be at least
DARD 1104

3/4 in.
in (19 mm) wide)

• Requirements
9 Exposed surface shall show complete penetration and
PI STAND

f i
fusion
9 Gas pocket < 1/16 in (1.6 mm)
9 Sum of gas pocket < 2% of exposed area
9 Slagg inclusion : Depth
p < 1/32 in ((0.8 mm))
AP

Length < 1/8 in (3 mm) or ½ nom thk

(whichever is smaller)
9 Adjacent slag inclusions shall be separated by at least
½in Measurement Æ Fig.
½in. Fig 8
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

5.6.4 Root and Face-bend Test

• Specimen preparation Æ Fig. 6
• Method Æ Specimen shall be bent to U-shape in guided jig
(Fig. 9)
• Requirements
DARD 1104

9 No crack or other imperfection > 1/8 in

in. (3 mm) or ½ nom
thk.- whichever is smaller.
9 Crack at corner < ¼ in. (6 mm) shall not be considered
unless caused by imperfection
PI STAND

5.6.4 Side-bend Test

Similar to Root and Face-bend Test
AP
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES
DARD 1104

LATIHAN SOAL
PI STAND
AP
 5. QUALIFICATION OF WELDING PROCEDURE FOR
WELDS CONTAINING FILLER METAL ADDITIVES

Lihat WPS No. M0025.

Apakah WPS tersebut dapat digunakan untuk produksi las berikut:
(Catatan : Welding variable yang lain sama)
DARD 1104

p 10 NPS,, API 5L X52,, Single

1. Pipa g bevel joint
j 450, SMAW.
2. Pipa 12.750 in OD x 0.875 in Thk, single V 600, SMAW.
3. Pipa 16.000 in OD x 0.750 in Thk, single V 600, FCAW.
PI STAND

4 Pipa 14.000
4. 14 000 in OD x 0
0.750 Thk single V 600, SMAW,
750 in Thk, SMAW sumbu pipa
vertical.
5. Pipa 12.750 in OD x 0.750 in Thk, API 5L X65, single V 600, SMAW,
Filler metal E 8016-G.
AP

6. Pipa 12.750 in OD x 0.750 in Thk, single V 600, SMAW, Preheat Temp.

500 C.
7. Pipa g V 600, SMAW,,
p 12.750 in OD x 0.750 in Thk,, API 5L X65,, single
Filler metal E 8018-G, DCEP.
8. Pipa 12.750 in OD x 0.750 in Thk, single V 600, SMAW, arah las turun
(down hill)
 6. QUALIFICATION OF WELDERS

6.1 General
• Purpose Æ To determine welder’s
welder s ability to make sound
welds using qualified procedure.
• Prior to production welding, Welder shall be qualified
DARD 1104

according to 6.2 ~ 6.8

• Welder who complete the procedure qualification Æ is a
qualified welder.
PI STAND

• The welder qualification test shall be conducted in the

presence of company representative.
• Welder shall make test on segments or on full size of pipe
AP

nipples (if test on segment , shall covers typical flat

nipples. flat,
vertical & overhead positions)
 6. QUALIFICATION OF WELDERS

6.2 Single Qualification

6.2.1 General
• Shall follow qualified procedure
• Make a test on pipe nipples or segment of pipe nipples
DARD 1104

• Shall make butt weld in rolled or fixed position

(fix position shall be horizontal, vertical or inclined 450)
PI STAND
AP

450

• Change in the essential variable 6.2.2 Æ require re-

qualification of the welder
welder.
• Weld accepted if meet requirements 6.4 and either 6.5 or
6.6
 6. QUALIFICATION OF WELDERS

6.2 Single Qualification

6 2 2 Scope
6.2.2 S
• Welder shall b e qualified within the limit of essential
variable
DARD 1104

• Any change of essential variable will require re-

qualification of welder. Æ 6.2.2 a. ~ g
PI STAND
AP
 6. QUALIFICATION OF WELDERS

6.3 Multiple Qualification

6 3 1 General
6.3.1
Welder shall make 2 (two) test
• 1st Test
DARD 1104

9 Butt weld in fixed position (either horizontal or inclined 450)

9 Pipe OD > 6.625 in. (68.3 mm)
9 Thickness > 0.250 in. ((6.4 mm))
PI STAND

9 No backing strip
9 The weld shall meet reqmn’t of 6.4 and either 6.5 or 6.6
AP
 6. QUALIFICATION OF WELDERS

6.3 Multiple Qualification

• 2nd Test
9 Branch-on pipe connection
9 Pipe OD > 6.625 in. (68.3 mm)
DARD 1104

9 Nom Thick.
Thick > 0.250
0 250 in
in. (6
(6.4
4 mm)
9 Weld shall have
o Uniform workmanlike appearance
o Complete penetration
PI STAND

o No burn-through < ¼ in. (6mm), sum of burn-through in any

12 in. length of weld < ½ in. (13mm).
9 4 (four) nick-break test required and shall meet the
AP

requirement of 5.8.3
583

Nick-break test locations

 6. QUALIFICATION OF WELDERS

6.3 Multiple Qualification

6 3 2 Scope
6.3.2
• A Welder who passed the tests on pipe OD > 12.750 in. (323.9
mm), shall be qualified :
DARD 1104

9 In all positions
9 All wall thicknesses
9 All joint designs & fittings
PI STAND

9 All pipe diameters

• A Welder passed the test on pipe OD < 12.750 in. (323.9 mm),
shall be q
qualified :
AP

9 In all positions
9 All wall thicknesses
9 All joint designs & fittings
9 All pipe diameters < OD of pipe used in qualification test.
 6. QUALIFICATION OF WELDERS

6.4 Visual Examination

• Free from : crack, incomplete penetration & burn through
• Shall have neat workman-like appearance
• Undercut
DARD 1104

9 max depth Æ the smaller 1/32 in. (0.8

(0 8 mm)) or 12.5%
12 % wall thk.
9 Sum of undercut < 2 in. (50 mm) in any continuous 12 in. (300
mm) length of weld.
PI STAND
AP
 6. QUALIFICATION OF WELDERS

6.5 Destructive Test

6 5 1 Sampling
6.5.1 S li off Test
T t Butt
B tt Welds
W ld
• Full circum test Æ Specimens shall be cut at the location
shown in Fig.12
DARD 1104

• Segment test Æ equal number of specimens shall be removed

from each segment
• Type & number of tests Æ Table 3
PI STAND

• Pipe OD < 1.315 in.(33.4 mm) Æ one full section test may
substitute for root-bend & nick-break tests
AP
 6. QUALIFICATION OF WELDERS

6.5 Destructive Test

6 5 2 Tensile
6.5.2 T il Strength,
St th Nick-break
Ni k b k&B
Bend-test
dt t
• Specimen preparation and tests shall be as per 5.6 (similar to
procedure qualification)
DARD 1104

• No need to calculate the tensile strength

6.5.3 Tensile Strength Test requirements Æ 5.6.3.3

PI STAND

6.5.4 Nick-break Test requirements Æ 5.6.3.3

6.5.5 Bend Test requirements
q Æ 5.6.4.3 or
AP

5.6.5.3
 6. QUALIFICATION OF WELDERS

6.6 Radiography – Butt welds only

6 6 1 General
6.6.1
At company’s option, Radiography may be used in lieu of
destructive test
DARD 1104

6.6.2 Requirements
• The test weld shall meet requirements of 9.3
• Radiography shall not be used to locate the sound area
PI STAND

6.7 Retesting
• Welder fails because of unavoidable conditions Æ 2nd
opportunity
AP

• No further retest unless the welder has proof sufficient

training acceptable to Company.

6.8 Records
• Suggested form Æ Fig. 2
• A Welder may be required to re-qualify if there is a reason to
question his ability
FACE BEND

ROOT BEND

SIDE BEND