wps - 020

###

WELDING PROCEDURE APPROVAL RECORD

WPAR : 020 REV : 00 Sheet : 03 of 03

TECHNIQUE

String or Weave Bead : String & Weave Bead Single/Both Side : Single SideOrifice / Cup Size : N/A Maximum Weave : 3 x Core Dia of ElectrodeInterpass Cleaning Method : Brushing & Grinding Joint Type : Butt WeldMethod of Back Gouging : N/AOscillation : N/A Code/Testing Standard : BSEN 288-3Multiple/Single Pass : Multipass Other Applicable Codes : MITS-12

TENSILE TESTMark No. Type Dimensions Area UTL UTS Fracture Comments/Location

mm mm2 kN N/mm2 Position

356A Cross Weld 22.3 x 24.8 553.0 275.1 497 Pm 1 - 2 O'clock

357A Cross Weld 22.7 x 25.0 567.5 281.2 496 Pm 4 - 5 O'clock

BEND TESTMark No. Type Bend Angle Former Diameter Result Comments/Location

358 Side Bend 120° 38 Acceptable 1 - 2 O'clock359 Side Bend 120° 38 Acceptable 7 - 8 O'clock360 Side Bend 120° 38 Acceptable 4 - 5 O'clock361 Side Bend 120° 38 Acceptable 10 - 11 O'clock

CHARPY IMPACT

Mark No. Location Dimensions Absorbed Energy Average Temperature °C Commentsmm Joules, J J

364 WCL 10 X 10 90 66 96 84 0 3 O' Clock 365 FL 10 X 10 100 252 156 164 0 3 O' Clock 366 FL + 2 10 X 10 208 220 160 196 0 3 O' Clock 367 FL + 5 10 X 10 46 72 140 86 0 3 O' Clock

TEST HOUSE LABORITORY : BODYCOTE, Abudhabi, UAE Report No. AD01204A

Visual Examination : Satisfactory Fillet Weld Fracture Test : N/ASurface NDT : Satisfactory Charpy Vee Notch Test : SatisfactoryUltrasonic Testing : Satisfactory Hardness Test : Refer Report No.Tensile Test : Satisfactory OVERALL TEST RESULTBend Test : Satisfactory AD01204AMacro Examination : Satisfactory AcceptableTests carried out in accordance with the requirement of : BS EN-288-3 Test results were acceptable.Laboratry Report Reference No: AD01204A Test Carriedout in the presence of Bureau Veritas, Abudhabi.

MANUFACTURER TEST BODY

NAME : R. Vairamani NAME : C. SivakumarSIGN : SIGN :DEPT : QA/QC DEPT : Bureau VeritasDATE : DATE :

FORM NO. QAF/029/PQR Sht. 2 Rev. (A)

The Madina Group W.L.L - Mechanical DivisionThe Madina Group W.L.L - Mechanical Division

Company Name The Madina Group W.L.L., Mechanical Division

KEY INFORMATION QUESTIONS ANSWERS

File Reference File Details KH/Excel/Welding/WPS003

Reviews & Approvals Prepared ByDepartmentDate PreparedReviewed By R. VAIRAMANYDepartment QA / QCDate Reviewed 09-NOV-98Approved By C.SIVAKUMARDepartment BUREAU VERITASDate Approved

Welder Details Welder ID MW00072Employee No. 00072Name THOMAS MATHEWLocation of Test SALWA, QATAR

Original PQR Details WPS No. 003Revision No. 001Supporting PQR 003A, 004Welding Process SMAWProcess Type ManualTesting Code AWS D1.1Others MITS - 12

Welding Details Weld Direction UPHILLMaximum Bead Width 3 x Core DiaMulti / Single Pass MULTIPASSManual / Automatic MANUAL

Technique WeavingTechnique STRING / WEAVESingle/Both Sides SINGLEMultiple/Single Electrode SINGLEOscillation N/AOther NOT APPLICABLE

Joint on Qualification Test Joint Type BUTT WELDMethod of Preparation FLAME CUT &/OR GRINDIncluded Angle 37.5 Deg Material Thickness 23.01mmRoot Gap 2.5 - 3.5 mm (rg)Root Face 1.5 - 2.5 mm (rf)Backing NONE

Base Metal Details Material Specification ASTM A106Type or Grade GRADE BFrom - P No. GROUP ITo - P No. GROUP IDiameter of Test Coupon 8"Other NONE

Welding Consumables Electrode Brand ESABSize of Filler Metal 2.5 mm & 3.2 mmSFA / AWS No 5.1Classification E7016 & E7018Type of Flux NOT APPLICABLEOther NONE

Inert Gas Details Gas Type N/AGas Flow Rate N/AGas Mixture N/AOriface / Cup Size N/ABacking Gas N/ABacking Flow Rate N/ABacking Gas Mixture N/A

Preheat Details Pipe to Pipe 70°CPipe to Fittings 127°CFitting to Fitting AMBIENTSpare Line 1Spare Line 2

Interpass Temperature Interpass Temperature MAX 127°

PWHT Details Temperature NOT APPLICABLETime NOT APPLICABLEEquipment Type NOT APPLICABLEOther NOT APPLICABLELine 5

PQR Material Details (QW 403) Qualified ANY METAL ASSIGNED TOCode/Testing Standard AWS D1.1Other Codes/Standards NOT APPLICABLEP No. / Group No. GROUP-I TO GROUP-I

Plate & Pipe Ranges ASME IX 4.7 mm - UNLIMITEDOTHERS NOT APPLICABLEDiameter 4" & OVERPQR Filler Metal F Nos. F4PQR Filler Metal A Nos. N/AInterpass Cleaning Method GRINDING & BRUSHINGMethod of Back-Gouging NOT APPLICABLETungsten Type NOT APPLICABLETungsten Size NOT APPLICABLE

WPSPASS WELDING ELECTRODE CURENT TYPE ACTUAL WPS ACTUAL WPS TRAVEL TRAVEL ACTUAL INTERNUMBER ELECTRODE DIA (mm) & POLARITY AMPS AMPS VOLTS VOLTS SPEED SPEED KJ/mm Temp°CPass No. 1.1 SMAW - E7016-1 2.5 mm Direct +Ve 75.0 19.0 50.00 1.71 70Pass No. 1.2 SMAW - E7016-1 2.5 mm Direct +Ve 76.0 21.0 74.00 1.29 70Pass No. 1.3 SMAW - E7016-1 2.5 mm Direct +Ve 75.0 21.0 58.00 1.63 70Pass No. 1.4 SMAW - E7016-1 2.5 mm Direct +Ve 73.0 21.0 66.00 1.39 70Pass No. 1.5 SMAW - E7016-1 2.5 mm Direct +Ve 68.0 20.0 75.00 1.09 70Pass No. 1.6 SMAW - E7016-1 2.5 mm Direct +Ve 60.0 19.0 68.00 1.01 70Pass No. 1.7 SMAW - E7016-1 2.5 mm Direct +Ve 59.0 20.0 57.00 1.24 70Pass No. 1.8 SMAW - E7016-1 2.5 mm Direct +Ve 69.0 20.0 48.00 1.73 70Pass No. 1.9 SMAW - E7016-1 2.5 mm Direct +Ve 67.0 20.0 60.00 1.34 70Pass No. 1.10 SMAW - E7016-1 2.5 mm Direct +Ve 71.0 20.0 60.00 1.42 70Pass No. 1.11 SMAW - E7016-1 2.5 mm Direct +Ve 67.0 20.0 72.00 1.12 70Pass No. 1.12 SMAW - E7016-1 2.5 mm Direct +Ve 59.0 68.25 21.0 20.17 63.00 62.58 1.18 70Pass No. 2.1 SMAW - E7016-1 2.5 mm Direct +Ve 73.0 21.0 116.00 0.79 71Pass No. 2.2 SMAW - E7016-1 2.5 mm Direct +Ve 73.0 22.0 100.00 0.96 71Pass No. 2.3 SMAW - E7016-1 2.5 mm Direct +Ve 71.0 22.0 78.00 1.20 71Pass No. 2.4 SMAW - E7016-1 2.5 mm Direct +Ve 71.0 23.0 88.00 1.11 71Pass No. 2.5 SMAW - E7016-1 2.5 mm Direct +Ve 77.0 24.0 70.00 1.58 71Pass No. 2.6 SMAW - E7016-1 2.5 mm Direct +Ve 81.0 23.0 87.00 1.28 71Pass No. 2.7 SMAW - E7016-1 2.5 mm Direct +Ve 78.0 24.0 92.00 1.22 71Pass No. 2.8 SMAW - E7016-1 2.5 mm Direct +Ve 78.0 23.0 84.00 1.28 71Pass No. 2.9 SMAW - E7016-1 2.5 mm Direct +Ve 74.0 75.11 26.0 23.11 93.00 89.78 1.24 71Pass No. 3.1 SMAW - E7018 3.2 mm Direct +Ve 104.0 22.0 93.00 1.48 75Pass No. 3.2 SMAW - E7018 3.2 mm Direct +Ve 118.0 23.0 84.00 1.94 75Pass No. 3.3 SMAW - E7018 3.2 mm Direct +Ve 123.0 24.0 83.00 2.13 75Pass No. 3.4 SMAW - E7018 3.2 mm Direct +Ve 118.0 23.0 90.00 1.81 75Pass No. 3.5 SMAW - E7018 3.2 mm Direct +Ve 122.0 24.0 73.00 2.41 75Pass No. 3.6 SMAW - E7018 3.2 mm Direct +Ve 127.0 118.67 24.0 23.33 87.00 85.00 2.10 75Pass No. 4.1 SMAW - E7018 3.2 mm Direct +Ve 124.0 25.0 125.00 1.49 127Pass No. 4.2 SMAW - E7018 3.2 mm Direct +Ve 126.0 24.0 112.00 1.62 127Pass No. 4.3 SMAW - E7018 3.2 mm Direct +Ve 127.0 26.0 111.00 1.78 127Pass No. 4.4 SMAW - E7018 3.2 mm Direct +Ve 116.0 24.0 96.00 1.74 127Pass No. 4.5 SMAW - E7018 3.2 mm Direct +Ve 129.0 24.0 93.00 2.00 127Pass No. 4.6 SMAW - E7018 3.2 mm Direct +Ve 127.0 26.0 96.00 2.06 127Pass No. 4.7 SMAW - E7018 3.2 mm Direct +Ve 127.0 125.14 25.0 24.86 115.00 106.86 1.66 127Pass No. 5.1 SMAW - E7018 3.2 mm Direct +Ve 131.0 25.0 63.00 3.12 127

Pass No. 5.2 SMAW - E7018 3.2 mm Direct +Ve 131.0 23.0 59.00 3.06 127Pass No. 5.3 SMAW - E7018 3.2 mm Direct +Ve 136.0 25.0 68.00 3.00 127Pass No. 5.4 SMAW - E7018 3.2 mm Direct +Ve 136.0 26.0 69.00 3.07 127Pass No. 5.5 SMAW - E7018 3.2 mm Direct +Ve 121.0 24.0 49.00 3.56 127Pass No. 5.6 SMAW - E7018 3.2 mm Direct +Ve 122.0 23.0 62.00 2.72 127Pass No. 5.7 SMAW - E7018 3.2 mm Direct +Ve 132.0 26.0 55.00 3.74 127Pass No. 5.8 SMAW - E7018 3.2 mm Direct +Ve 130.0 24.0 54.00 3.47 127Pass No. 5.9 SMAW - E7018 3.2 mm Direct +Ve 134.0 130.33 23.0 24.33 91.00 63.33 2.03 127Pass No. 6.1 SMAW - E7018 4.0 mm Direct +Ve 157.0 22.0 110.00 1.88 90Pass No. 6.2 SMAW - E7018 4.0 mm Direct +Ve 159.0 22.0 96.00 2.19 90Pass No. 6.3 SMAW - E7018 4.0 mm Direct +Ve 159.0 24.0 100.00 2.29 90Pass No. 6.4 SMAW - E7018 4.0 mm Direct +Ve 161.0 21.0 92.00 2.21 90Pass No. 6.5 SMAW - E7018 4.0 mm Direct +Ve 163.0 25.0 102.00 2.40 90Pass No. 6.6 SMAW - E7018 4.0 mm Direct +Ve 167.0 161.00 24.0 23.00 161.00 110.17 1.49 90Pass No. 7.1 SMAW - E7018 4.0 mm Direct +Ve 163.0 23.0 40.00 5.62 90Pass No. 7.2 SMAW - E7018 4.0 mm Direct +Ve 160.0 23.0 48.00 4.60 90Pass No. 7.3 SMAW - E7018 4.0 mm Direct +Ve 161.0 23.0 70.00 3.17 90Pass No. 7.4 SMAW - E7018 4.0 mm Direct +Ve 169.0 26.0 99.00 2.66 90Pass No. 7.5 SMAW - E7018 4.0 mm Direct +Ve 166.0 23.0 57.00 4.02 90Pass No. 7.6 SMAW - E7018 4.0 mm Direct +Ve 167.0 23.0 85.00 2.71 90Pass No. 7.7 SMAW - E7018 4.0 mm Direct +Ve 173.0 165.57 24.0 23.57 109.00 72.57 2.29 90Pass No. 8.1 SMAW - E7018 4.0 mm Direct +Ve 173.0 25.0 68.00 3.82 100Pass No. 8.2 SMAW - E7018 4.0 mm Direct +Ve 173.0 25.0 96.00 2.70 100Pass No. 8.3 SMAW - E7018 4.0 mm Direct +Ve 171.0 24.0 109.00 2.26 100Pass No. 8.4 SMAW - E7018 4.0 mm Direct +Ve 163.0 23.0 72.00 3.12 100Pass No. 8.5 SMAW - E7018 4.0 mm Direct +Ve 165.0 23.0 67.00 3.40 100Pass No. 8.6 SMAW - E7018 4.0 mm Direct +Ve 164.0 168.17 23.0 23.83 85.00 82.83 2.66 100Pass No. 9.1 SMAW - E7018 4.0 mm Direct +Ve 160.0 24.0 69.00 3.34 90Pass No. 9.2 SMAW - E7018 4.0 mm Direct +Ve 164.0 24.0 81.00 2.92 90Pass No. 9.3 SMAW - E7018 4.0 mm Direct +Ve 167.0 23.0 82.00 2.81 90Pass No. 9.4 SMAW - E7018 4.0 mm Direct +Ve 164.0 24.0 70.00 3.37 90Pass No. 9.5 SMAW - E7018 4.0 mm Direct +Ve 164.0 24.0 71.00 3.33 90Pass No. 9.6 SMAW - E7018 4.0 mm Direct +Ve 164.0 24.0 83.00 2.85 90Pass No. 9.7 SMAW - E7018 4.0 mm Direct +Ve 164.0 163.86 24.0 23.86 86.00 77.43 2.75 90Pass No. 10.1 SMAW - E7018 3.2 mm Direct +Ve 109.0 24.0 80.00 1.96 88Pass No. 10.2 SMAW - E7018 3.2 mm Direct +Ve 110.0 24.0 105.00 1.51 88Pass No. 10.3 SMAW - E7018 3.2 mm Direct +Ve 121.0 26.0 112.00 1.69 88Pass No. 10.4 SMAW - E7018 3.2 mm Direct +Ve 124.0 26.0 95.00 2.04 88

Pass No. 10.5 SMAW - E7018 3.2 mm Direct +Ve 122.0 25.0 91.00 2.01 88Pass No. 10.6 SMAW - E7018 3.2 mm Direct +Ve 122.0 26.0 79.00 2.41 88Pass No. 10.7 SMAW - E7018 3.2 mm Direct +Ve 123.0 118.71 25.0 25.14 130.00 98.86 1.42 88Pass No. 11.1 SMAW - E7018 3.2 mm Direct +Ve 130.0 23.0 100.00 1.79 80Pass No. 11.2 SMAW - E7018 3.2 mm Direct +Ve 111.0 24.0 123.00 1.30 80Pass No. 11.3 SMAW - E7018 3.2 mm Direct +Ve 113.0 24.0 118.00 1.38 80Pass No. 11.4 SMAW - E7018 3.2 mm Direct +Ve 113.0 24.0 96.00 1.70 80Pass No. 11.5 SMAW - E7018 3.2 mm Direct +Ve 112.0 24.0 100.00 1.61 80Pass No. 11.6 SMAW - E7018 3.2 mm Direct +Ve 111.0 115.00 22.0 23.50 112.00 108.17 1.31 80Pass No. 12.1 SMAW - E7018 3.2 mm Direct +Ve 133.0 26.0 112.00 1.85 105Pass No. 12.2 SMAW - E7018 3.2 mm Direct +Ve 133.0 25.0 129.00 1.55 105Pass No. 12.3 SMAW - E7018 3.2 mm Direct +Ve 133.0 24.0 130.00 1.47 105Pass No. 12.4 SMAW - E7018 3.2 mm Direct +Ve 134.0 24.0 132.00 1.46 105Pass No. 12.5 SMAW - E7018 3.2 mm Direct +Ve 134.0 23.0 126.00 1.47 105Pass No. 12.6 SMAW - E7018 3.2 mm Direct +Ve 134.0 133.50 23.0 24.17 148.00 129.50 1.25 105Pass No. 13.1 SMAW - E7018 3.2 mm Direct +Ve 124.0 23.0 116.00 1.48 110Pass No. 13.2 SMAW - E7018 3.2 mm Direct +Ve 129.0 24.0 145.00 1.28 110Pass No. 13.3 SMAW - E7018 3.2 mm Direct +Ve 121.0 22.0 123.00 1.30 110Pass No. 13.4 SMAW - E7018 3.2 mm Direct +Ve 124.0 23.0 132.00 1.30 110Pass No. 13.5 SMAW - E7018 3.2 mm Direct +Ve 121.0 123.80 23.0 23.00 125.00 128.20 1.34 110Pass No. 14.1 SMAW - E7018 3.2 mm Direct +Ve 122.0 23.0 110.00 1.53 115Pass No. 14.2 SMAW - E7018 3.2 mm Direct +Ve 121.0 24.0 140.00 1.24 115Pass No. 14.3 SMAW - E7018 3.2 mm Direct +Ve 127.0 24.0 138.00 1.33 115Pass No. 14.4 SMAW - E7018 3.2 mm Direct +Ve 124.0 23.0 118.00 1.45 115Pass No. 14.5 SMAW - E7018 3.2 mm Direct +Ve 124.0 23.0 133.00 1.29 115Pass No. 14.6 SMAW - E7018 3.2 mm Direct +Ve 124.0 24.0 139.00 1.28 115Pass No. 14.7 SMAW - E7018 3.2 mm Direct +Ve 96.0 23.0 141.00 0.94 115Pass No. 14.8 SMAW - E7018 3.2 mm Direct +Ve 99.0 22.0 242.00 0.54 115Pass No. 14.9 SMAW - E7018 3.2 mm Direct +Ve 100.0 22.0 196.00 0.67 115Pass No. 14.10 SMAW - E7018 3.2 mm Direct +Ve 102.0 23.0 166.00 0.85 115Pass No. 14.11 SMAW - E7018 3.2 mm Direct +Ve 102.0 23.0 188.00 0.75 115Pass No. 14.12 SMAW - E7018 3.2 mm Direct +Ve 102.0 111.92 24.0 23.17 221.00 161.00 0.66 115

Test Results Visual Examination Surface NDT NOT APPLICABLERadiography Tensile Test Bend Test

Macro Examination Fillet Weld Fracture Test NOT APPLICABLECharpy Vee Knotch Test Other Tests NOT APPLICABLEOVERALL TEST RESULT

### The Madina Group W.L.L., Mechanical DivisionWELDING PROCEDURE SPECIFICATION - No. :020 REV. :00

WPS Details Welding Consumables Base Metals

WPS No. : 020 Electrode Brand : ESAB or Equialant Material Qualified Any Metal AssignedRevision No : 00 SFA / AWS No : 5.1 to Group No. : 1 to Group 1Supporting PQR : WPAR 020 Classification : E7016 & E7018Welding Process : MMAW (111) Type of Flux : Basic Thickness & Diameter of Groove weldProcess Type : Manual Gas Type : Not Required Thickness : 11.5mm to 46mmTesting Code : BS EN 288-3 Gas Flow Rate : Not Required Diameter : Plate & Pipe over Dia 109.5mmTest Body : Bureau Veritas Backing Gas : Not Required Fillet : All Thickness & Diameter

Technique Preheat Details Deg C PWHT Details

Weld Direction : UPHILL Temperature : NOT APPLICABLEMax Bead Width : 3 x Core Dia AMBIENT : Min 70°C Time : NOT APPLICABLEMulti / Single Pass : MULTIPASS Equipment : NOT APPLICABLEManual Automatic : MANUAL Other : NOT APPLICABLEWeaving Technique : STRING / WEAVEOscillation : N/A Interpass Temperature : MAX 205°C

Joint Design Welding Sequence

### Angle : 35 - 38 DegreeRoot Gap : 2.5 - 3.5 mm (rg)Root Face : 1.5 - 2.5 mm (rf)Backing : NONE

POSITION QUALIFIED - ALLRefer Drg WPS-D-01 for qualified joint configuration

Pass Welding Process Electrode Current Type Amps Volts Travel Speed Number Welding Electorde Diameter & Polarity (a) (v) mm / min

Pass No. 1 MMAW - E7016-1 2.4 mm Direct +Ve 61 - 83 18 - 24 55 - 68Pass No. 2 MMAW - E7016-1 2.4 mm Direct +Ve 71 - 96 20 - 27 96-118Pass No. 3 MMAW - E7018 3.2 mm Direct +Ve 90-135 20 - 27 60-100Pass No. 4 MMAW - E7018 3.2 mm Direct +Ve 90-135 19 - 26 120-140& above MMAW - E7018 4.0 mm Direct +Ve 140-190 19 - 26 60-100

Other Informations Additional Notes

1. Method of Prepartion : FLAME CUT &/ OR GRIND2. Interpass Cleaning Method : GRINDING & BRUSHING3. Tungsten Type : NOT APPLICABLE4 Back Gauging : Air Arc & or when required

Grinding

PREPARED BY REVIEWED BY APPROVED BYNameName : R. MUTHUKUMAR Name : R. VAIRAMANI Name : C.SIVAKUMAR

Sign : Sign : Sign :

Dept : QA / QC Dept : QA / QC Dept : BUREAU VERITAS

Date : 6/12/2000 Date : 7/12/2000 Date : 7/12/2000

The Madina Group W.L.L. - Mechanical Division

WELDING PROCEDURE APPROVAL RECORD FORM (WPAR)

WPAR : 020 REV. 00 SHEET: 01 OF 03

WELDING PROCEDURE APPROVAL TEST CERTIFICATE

Manufacturer's Welding Procedure : 020 Rev. : 00 Examiner or test body : Bureau Veritas

Manufacturer : Madina Mechanical Reference No : 00.102.40

Address : Street No.: 45, Salwa Indl. Area, Qatar

Code/ Testing Standard : BSEN 288-3

Date of Welding : 15.06.2000

EXTENT OF APPROVAL

Welding Process : MMAW (111)

Joint Type : Butt Weld (BW)

Parent Metal (s) : Group - 1

Metal Thickness (mm) : 23.1 mm

Outside Diameter (mm) : 8" Dia (219.07mm)

Filler Metal Type : Basic Covering

Filler Metal Classification : E7016 & E7018 (B)

Type of Welding Current : Dirrect

Welding Positions : HLO 45 (Upward)

Preheat : 70°C

Post - Weld Heat Treatment and/or ageing : Not Applicable

Other informations : Not Applicable

Certified that test welds prepared, welded and tested satisfactorily in accordance with the requirements of the code/testing standard

indicated above.


NAME : R. Vairamani NAME : C.Sivakumar

SIGN : SIGN :

DEPT : QA/QC DEPT : Bureau Veritas

DATE : 07.12.2000 DATE : 07.12.2000

The Madina Group W.L.L., Mechanical Division

PROCEDURE QUALIFICATION RECORD

PQR : 020 REV : 00 Sheet : 1 of 2

Company Name : The Madina Group W.L.L., Mechanical Division

Original Procedure Qualification Record No : 020 Date : 15-June-2000

Original WPS No. : 020 Welder ID : MW00072

Welding Process : MMAW Name : THOMAS MATHEW

Type (Manual / Automatic / Semi-Automatic) : MANUAL Location : SALWA, QATAR

JOINTS

##################### Angle : 37.5 Deg

Thickness : 23.01mm (t)Root Gap : 3.0 mm (rg)Root Face : 1.5 mm (rf)Backing : NONE TEST POSITION - 6G

BASE METAL POSTWELD HEAT TREATMENT

Material Specification : ASTM A106 Temperature : NOT APPLICABLEType or Grade : GRADE B Time : NOT APPLICABLE

From Group No.: I to Group No. I Equipment Type : NOT APPLICABLEThickness of Test Coupon : 23.01mm Other : NOT APPLICABLEDiameter of Test Coupon : 8"Heat / Cast No. : 59090

FILLER METAL GAS

SFA Specification : 5.1 Percent CompositionAWS Specification : E7016-1 & E7018 Type Gas(es) Mixtures Flow RateFiller Metal F No. : F4 Shielding N/A N/A N/AWeld Metal Analysis A No. : N/A Trailing - - -Weld Metal Deposit Thickness : 23.01mm Backing - - -Size of Filler Metal : 2.4 mm & 3.25mm Other - - -Batch / Lot Nos. : E7016-8381631

E7018-2.5 9411671E7018-3.2 9411691

POSITION ADDITIONAL NOTES

Position of Groove : 6GWelding Progression : UPHILLOther : NOT APPLICABLE

PRE - HEAT

Pre-Heat Temperature : 70°CInterpass Temperature : MAX 127°Equipment Type : NOT APPLICABLEOther : NOT APPLICABLE

WELDING PROCEDURE APPROVAL RECORD FORM (WPAR)WPAR : 020 REV. 00 SHEET: 02 OF 03

DETAILS OF WELD TEST

Location : Madina Workshop Examiner or Test Body : Bureau VeritasManufacturer's Welding Procedure : 020 Rev. - 0 Method of Preparation : By Grinding

WPAR No : 020 Parent Materials Specification : SA106GRB

Manufacturer : Madina Mechanical Materials Thickness (mm) : 23.1

Welder's Name : Thomas Mathew (MW 072) Outside Diameter (mm) : 219.07 (8")

Welding Process : MMAW Welding Position : HL045 (Upward)

Joint Type : BW

Weld Preparation Details : See Sketch

JOINT DESIGN WELDING SEQUENCES

WELDING PARAMETERS

Run Process Size of Current Voltage Type of Current/ Wire Feed Travel Heat InputFiller Metal A V Polarity Speed Speed*

REFER ANNEXURE - 1

WELDING CONSUMABLES OTHER INFORMATION

Filler Metal Classification : E7016 & E7018

Trade Name : ESABAny Special Baking or Drying : 300°C - 2 1/2 Hours Joint Design:Gas/flux : Shielding : Not Required

Backing : Not Required Angle : 35 Degree Gas Flow Rate - Shielding : Not Required Root Gap : 3.0 mm

Backing : Not Required Root Face : 1.5 mmTungsten Electrode Type/Size : Not RequiredDetails of Back Gouging / Backing : Not Required

PRE - HEAT & POST WELD HEAT TREATMENT

Post Weld Heat Treatment : Not ApplicablePre-heat temperature : 70°C Interpass Temperature : Max.205°CTime, Temperature, Method : N/AHeating and Cooling Rates: : N/A


NAME : R. Vairamani NAME : C. Sivakumar

SIGN : SIGN :

DEPT : QA/QC Inspector DEPT : Bureau Veritas

DATE : DATE :

FORM NO. QAF/029

The Madina Group W.L.L - Mechanical DivisionThe Madina Group W.L.L - Mechanical Division

The Madina Group W.L.L., Mechanical Division

PROCEDURE QUALIFICATION RECORD

PQR : 020 REV :00 Sheet : 2 of 2

TECHNIQUE

String or Weave Bead : STRING / WEAVE Single/Both Side : SingleOrifice / Cup Size : N/A Maximum Weave : 3 X Core DiaInterpass Cleaning Method : GRINDING & BRUSHING Joint Type : Butt WeldMethod of Back Gouging : NOT APPLICABLE Method of Preparation : Flame & Grind & MachiningOscillation : NOT APPLICABLE Code and testing standard : AWS D1.1 - 1996Multiple/Single Pass : MULTIPASS Other Application Code : Maersk MITS - 12

Pass Welding Electrode Electrode Current Type Amps Volts Heat Input Travel Interpass Number Welding Class Diameter & Polarity (a) (v) Kj / mm mm / min Temp°C

TENSILE TEST TEST SPECIFICATION : AWS D1.1Mark No. Type Dimensions Area UTL UTS Fracture Position Comments

mm mm2 KN N/MM2 Location 356 Cross-weld 22.7 X 19.0 431.3 217.7 505 Parent Metal 12 o' clock357 Cross-weld 21.2 X 19.3 409.2 206.8 505 Parent Metal 6 o' clock

BEND TEST TEST SPECIFICATION : AWS D1.1Mark No. Type Bend Angle Formar Diameter Result Comments/Location

358 Side Bend 180° 38 Acceptable 1-2 o' clock 359 Side Bend 180° 38 Acceptable 7-8 o' clock 360 Side Bend 180° 38 Acceptable 4-5 o' clock 361 Side Bend 180° 38 Acceptable 10-11 o' clock

CHARPY IMPACT TEST SPECIFICATION - ASTM E23 Mark No. Location Dimensions Absorbed Energy Average Temperature Comments

mm Joules, J J 364 WCL 10 X 10 90 66 96 84.0 0 3 o'clock 365 FL 10 X 10 100 252 156 169.0 0 3 o'clock 366 FL+2 10 X 10 208 220 160 196.0 0 3 o'clock 367 FL+5 10 X 10 46 72 140 86.0 0 3 o'clock

TEST HOUSE LABORITORY : BODYCOTE - MTS, ABU DHABI, U.A.E. Report No: AD 01204 Rev. 0WITNESSED BY : BUREAU VERITAS, INTERNATIONAL REGISTER, ABU DHABI, U.A.E.

Visual Examination : Satisfactory Fillet Weld Fracture Test : Not ApplicableSurface NDT : Satisfactory Charpy Vee Notch Test : Satisfactory

Radiography / Ultrasonic : Satisfactory Other Tests : Hardness O.KTensile Test : Satisfactory OVERALL TEST RESULT ACCEPTABLEBend Test Satisfactory We certify that the statements in the record above areMacro Examination : Satisfactory correct in accordance with the standard indicated above.

PREPARED BY REVIEWED BY APPROVED BYName : A.N. SENTHIL KUMAR Name : R. VAIRAMANI Name : C.SIVAKUMAR


Dept : QA/QC Dept : QA / QC Dept : BUREAU VERITAS

Date : 26-JUNE-2000 Date : 26-JUNE-2000 Date : 26-JUNE-2000

Madina Trading & Contracting Est. - Mechanical DivisionANNEXURE - 1 PROCEDURE QUALIFICATION RECORD PAGE 01 OF 02 PQR : 020 REV : 00


Pass No. 1.1 SMAW - E7016-1 2.5 mm Direct +Ve 75 19 1.71 50 70Pass No. 1.2 SMAW - E7016-1 2.5 mm Direct +Ve 76 21 1.29 74 70Pass No. 1.3 SMAW - E7016-1 2.5 mm Direct +Ve 75 21 1.63 58 70Pass No. 1.4 SMAW - E7016-1 2.5 mm Direct +Ve 73 21 1.39 66 70Pass No. 1.5 SMAW - E7016-1 2.5 mm Direct +Ve 68 20 1.09 75 70Pass No. 1.6 SMAW - E7016-1 2.5 mm Direct +Ve 60 19 1.01 68 70Pass No. 1.7 SMAW - E7016-1 2.5 mm Direct +Ve 59 20 1.24 57 70Pass No. 1.8 SMAW - E7016-1 2.5 mm Direct +Ve 69 20 1.73 48 70Pass No. 1.9 SMAW - E7016-1 2.5 mm Direct +Ve 67 20 1.34 60 70Pass No. 1.10 SMAW - E7016-1 2.5 mm Direct +Ve 71 20 1.42 60 70Pass No. 1.11 SMAW - E7016-1 2.5 mm Direct +Ve 67 20 1.12 72 70Pass No. 1.12 SMAW - E7016-1 2.5 mm Direct +Ve 59 21 1.18 63 70Pass No. 2.1 SMAW - E7016-1 2.5 mm Direct +Ve 73 21 0.79 116 71Pass No. 2.2 SMAW - E7016-1 2.5 mm Direct +Ve 73 22 0.96 100 71Pass No. 2.3 SMAW - E7016-1 2.5 mm Direct +Ve 71 22 1.20 78 71Pass No. 2.4 SMAW - E7016-1 2.5 mm Direct +Ve 71 23 1.11 88 71Pass No. 2.5 SMAW - E7016-1 2.5 mm Direct +Ve 77 24 1.58 70 71Pass No. 2.6 SMAW - E7016-1 2.5 mm Direct +Ve 81 23 1.28 87 71Pass No. 2.7 SMAW - E7016-1 2.5 mm Direct +Ve 78 24 1.22 92 71Pass No. 2.8 SMAW - E7016-1 2.5 mm Direct +Ve 78 23 1.28 84 71Pass No. 2.9 SMAW - E7016-1 2.5 mm Direct +Ve 74 26 1.24 93 71Pass No. 3.1 SMAW - E7018 3.2 mm Direct +Ve 104 22 1.48 93 75Pass No. 3.2 SMAW - E7018 3.2 mm Direct +Ve 118 23 1.94 84 75Pass No. 3.3 SMAW - E7018 3.2 mm Direct +Ve 123 24 2.13 83 75Pass No. 3.4 SMAW - E7018 3.2 mm Direct +Ve 118 23 1.81 90 75Pass No. 3.5 SMAW - E7018 3.2 mm Direct +Ve 122 24 2.41 73 75Pass No. 3.6 SMAW - E7018 3.2 mm Direct +Ve 127 24 2.10 87 75Pass No. 4.1 SMAW - E7018 3.2 mm Direct +Ve 124 25 1.49 125 180Pass No. 4.2 SMAW - E7018 3.2 mm Direct +Ve 126 24 1.62 112 180Pass No. 4.3 SMAW - E7018 3.2 mm Direct +Ve 127 26 1.78 111 180Pass No. 4.4 SMAW - E7018 3.2 mm Direct +Ve 116 24 1.74 96 180Pass No. 4.5 SMAW - E7018 3.2 mm Direct +Ve 129 24 2.00 93 180Pass No. 4.6 SMAW - E7018 3.2 mm Direct +Ve 127 26 2.06 96 180Pass No. 4.7 SMAW - E7018 3.2 mm Direct +Ve 127 25 1.66 115 180Pass No. 5.1 SMAW - E7018 3.2 mm Direct +Ve 131 25 3.12 63 127Pass No. 5.2 SMAW - E7018 3.2 mm Direct +Ve 131 23 3.06 59 127Pass No. 5.3 SMAW - E7018 3.2 mm Direct +Ve 136 25 3.00 68 127Pass No. 5.4 SMAW - E7018 3.2 mm Direct +Ve 136 26 3.07 69 127Pass No. 5.5 SMAW - E7018 3.2 mm Direct +Ve 121 24 3.56 49 127Pass No. 5.6 SMAW - E7018 3.2 mm Direct +Ve 122 23 2.72 62 127Pass No. 5.7 SMAW - E7018 3.2 mm Direct +Ve 132 26 3.74 55 127Pass No. 5.8 SMAW - E7018 3.2 mm Direct +Ve 130 24 3.47 54 127Pass No. 5.9 SMAW - E7018 3.2 mm Direct +Ve 134 23 2.03 91 127Pass No. 6.1 SMAW - E7018 4.0 mm Direct +Ve 157 22 1.88 110 90Pass No. 6.2 SMAW - E7018 4.0 mm Direct +Ve 159 22 2.19 96 90Pass No. 6.3 SMAW - E7018 4.0 mm Direct +Ve 159 24 2.29 100 90Pass No. 6.4 SMAW - E7018 4.0 mm Direct +Ve 161 21 2.21 92 90Pass No. 6.5 SMAW - E7018 4.0 mm Direct +Ve 163 25 2.40 102 90Pass No. 6.6 SMAW - E7018 4.0 mm Direct +Ve 167 24 1.49 161 90Pass No. 7.1 SMAW - E7018 4.0 mm Direct +Ve 163 23 5.62 40 90Pass No. 7.2 SMAW - E7018 4.0 mm Direct +Ve 160 23 4.60 48 90Pass No. 7.3 SMAW - E7018 4.0 mm Direct +Ve 161 23 3.17 70 90Pass No. 7.4 SMAW - E7018 4.0 mm Direct +Ve 169 26 2.66 99 90

PREPARED BY REVIEWED BY APPROVED BY Name : R. Muthukumar Name : R. VAIRAMANI Name : C. SIVAKUMAR


Dept : QA/QC Dept : QA/QC Dept : QA/QC

Date : Date : Date :

Madina Trading & Contracting Est. - Mechanical DivisionANNEXURE - 1 PROCEDURE QUALIFICATION RECORD PAGE 02 OF 02 PQR : 020 REV : 00


Pass No. 7.5 SMAW - E7018 4.0 mm Direct +Ve 166 23 4.02 57 90Pass No. 7.6 SMAW - E7018 4.0 mm Direct +Ve 167 23 2.71 85 90Pass No. 7.7 SMAW - E7018 4.0 mm Direct +Ve 173 24 2.29 109 90Pass No. 8.1 SMAW - E7018 4.0 mm Direct +Ve 173 25 3.82 68 100Pass No. 8.2 SMAW - E7018 4.0 mm Direct +Ve 173 25 2.70 96 100Pass No. 8.3 SMAW - E7018 4.0 mm Direct +Ve 171 24 2.26 109 100Pass No. 8.4 SMAW - E7018 4.0 mm Direct +Ve 163 23 3.12 72 100Pass No. 8.5 SMAW - E7018 4.0 mm Direct +Ve 165 23 3.40 67 100Pass No. 8.6 SMAW - E7018 4.0 mm Direct +Ve 164 23 2.66 85 100Pass No. 9.1 SMAW - E7018 4.0 mm Direct +Ve 160 24 3.34 69 205Pass No. 9.2 SMAW - E7018 4.0 mm Direct +Ve 164 24 2.92 81 205Pass No. 9.3 SMAW - E7018 4.0 mm Direct +Ve 167 23 2.81 82 205Pass No. 9.4 SMAW - E7018 4.0 mm Direct +Ve 164 24 3.37 70 205Pass No. 9.5 SMAW - E7018 4.0 mm Direct +Ve 164 24 3.33 71 205Pass No. 9.6 SMAW - E7018 4.0 mm Direct +Ve 164 24 2.85 83 205Pass No. 9.7 SMAW - E7018 4.0 mm Direct +Ve 164 24 2.75 86 205Pass No. 10.1 SMAW - E7018 3.2 mm Direct +Ve 109 24 1.96 80 88Pass No. 10.2 SMAW - E7018 3.2 mm Direct +Ve 110 24 1.51 105 88Pass No. 10.3 SMAW - E7018 3.2 mm Direct +Ve 121 26 1.69 112 88Pass No. 10.4 SMAW - E7018 3.2 mm Direct +Ve 124 26 2.04 95 88Pass No. 10.5 SMAW - E7018 3.2 mm Direct +Ve 122 25 2.01 91 88Pass No. 10.6 SMAW - E7018 3.2 mm Direct +Ve 122 26 2.41 79 88Pass No. 10.7 SMAW - E7018 3.2 mm Direct +Ve 123 25 1.42 130 88Pass No. 11.1 SMAW - E7018 3.2 mm Direct +Ve 130 23 1.79 100 80Pass No. 11.2 SMAW - E7018 3.2 mm Direct +Ve 111 24 1.30 123 80Pass No. 11.3 SMAW - E7018 3.2 mm Direct +Ve 113 24 1.38 118 80Pass No. 11.4 SMAW - E7018 3.2 mm Direct +Ve 113 24 1.70 96 80Pass No. 11.5 SMAW - E7018 3.2 mm Direct +Ve 112 24 1.61 100 80Pass No. 11.6 SMAW - E7018 3.2 mm Direct +Ve 111 22 1.31 112 80Pass No. 12.1 SMAW - E7018 3.2 mm Direct +Ve 133 26 1.85 112 105Pass No. 12.2 SMAW - E7018 3.2 mm Direct +Ve 133 25 1.55 129 105Pass No. 12.3 SMAW - E7018 3.2 mm Direct +Ve 133 24 1.47 130 105Pass No. 12.4 SMAW - E7018 3.2 mm Direct +Ve 134 24 1.46 132 105Pass No. 12.5 SMAW - E7018 3.2 mm Direct +Ve 134 23 1.47 126 105Pass No. 12.6 SMAW - E7018 3.2 mm Direct +Ve 134 23 1.25 148 105Pass No. 13.1 SMAW - E7018 3.2 mm Direct +Ve 124 23 1.48 116 110Pass No. 13.2 SMAW - E7018 3.2 mm Direct +Ve 129 24 1.28 145 110Pass No. 13.3 SMAW - E7018 3.2 mm Direct +Ve 121 22 1.30 123 110Pass No. 13.4 SMAW - E7018 3.2 mm Direct +Ve 124 23 1.30 132 110Pass No. 13.5 SMAW - E7018 3.2 mm Direct +Ve 121 23 1.34 125 110Pass No. 14.1 SMAW - E7018 3.2 mm Direct +Ve 122 23 1.53 110 115Pass No. 14.2 SMAW - E7018 3.2 mm Direct +Ve 121 24 1.24 140 115Pass No. 14.3 SMAW - E7018 3.2 mm Direct +Ve 127 24 1.33 138 115Pass No. 14.4 SMAW - E7018 3.2 mm Direct +Ve 124 23 1.45 118 115Pass No. 14.5 SMAW - E7018 3.2 mm Direct +Ve 124 23 1.29 133 115Pass No. 14.6 SMAW - E7018 3.2 mm Direct +Ve 124 24 1.28 139 115Pass No. 14.7 SMAW - E7018 3.2 mm Direct +Ve 96 23 0.94 141 115Pass No. 14.8 SMAW - E7018 3.2 mm Direct +Ve 99 22 0.54 242 115Pass No. 14.9 SMAW - E7018 3.2 mm Direct +Ve 100 22 0.67 196 115Pass No. 14.10 SMAW - E7018 3.2 mm Direct +Ve 102 23 0.85 166 115Pass No. 14.11 SMAW - E7018 3.2 mm Direct +Ve 102 23 0.75 188 115Pass No. 14.12 SMAW - E7018 3.2 mm Direct +Ve 102 24 0.66 221 115

PREPARED BY REVIEWED BY APPROVED BY Name : R. Muthukumar Name : R. VAIRAMANI Name : C. SIVAKUMAR


Dept : QA/QC Dept : QA/QC Dept : QA/QC

Date : Date : Date : ###

wps - 020

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