WELD PROCEDURE DATA WPS: WEI-30-1 Rev. 0 Application: Branch and Lap (Sleeve) Connections on non-flowing, gas lines which are either pressured or non-pressured. Supporting PQR: WEI-30-1-1 (Branch) Qualification Limits: Carrier Pipe Diameter (D): 25.4 mm < D = 1067 mm (Design) Carrier Pipe Thickness (WT): 6.4 mm < WT = 31.8 mm (Design and CSA Z662 Cl. 7.9.16.1) Branch Diameter: < 60.3 mm (CSA Z662 Table 10.2 and SP-51-32-OM) Branch Thickness: 4.8 mm < WT = 25.4 mm (ASME Sec. IX QW 450) Sleeve Thickness : As per design requirements Material Grade: < Grade 483 (ASME Sec. IX QW-153). CE: 0.45 (Lab Test & CSA Z662 Cl. 10.9.2.2). Electrodes: Classification: E7018-1 Size: 3/32, 1/8 and 5/32 Service: Sweet and sour Special Requirements: Qualification Code: Welding limited to non flowing condition CSA Z662, Cl. 10.9, and ASME Sec. IX. 1
QW-482 WELDING PROCEDURE SPECIFICATIONS (WPS) (Section IX, ASME Boiler and Pressure Vessel Code) WPS-WEI-30-1 REV 0 Company Name: Westcoast Energy Inc By: H. M. Yamauchi Welding Procedure Specification: WEI-30-1 Date: Feb. 20, 2004 Supporting: PQR 30-1-1, 48.3 mm Branch Welding Process(es): SMAW JOINTS (QW-402) Joint Design Groove, Fillet Backing: Nil Backing Material (Type): Nil BASE MATERIALS (QW-403) S-1 Group 1 to S-1 Group 1. Typical Materials: API 5L X52, ASTM A333 Gr. 6 Qualification: Carrier Pipe Thickness Limitation > 6.4 mm Branch Thickness: 4.8 mm < WT < 17.4 mm Sleeve Thickness: As per design requirement. FILLER METALS (QW-404) Spec. No. (SFA): 5.1 AWS No. (Class): E7018-1 F-No: 4 A-No: 1 Size of Filler Metals 3/32,1/8 Deposited Weld Metal Groove: 5.1 mm Fillet: min. 6.0 mm, max branch WT 2
QW-482 WELDING PROCEDURE SPECIFICATIONS (WPS) (Section IX, ASME Boiler and Pressure Vessel Code) WPS-WEI-30-1 REV 0 POSITIONS (QW-405) Position(s) of Weld Joint: Welding Progression: Position(s) of Fillet: Branch 6G. Header Horizontal 5G Slightly uphill for branch. All PREHEAT (QW-406) Preheat Temp. Min: 120 C Inter-pass Temp. Max: 120 C - 300 C Instructions: POSTWELD HEAT TREATMENT (QW-407) Temperature Range: N/A Time Range: -- TECHNIQUE (QW-410) Number of welders: One, or two for branch, two for sleeves. Type of line-up clamps: Mechanical Length of time line-up clamps to be held: Until weldment is tacked String or Weave Bead: String, weave up to 3X electrode diameter. Initial and inter-pass cleaning: Brush and grind weld metal to clean metal. Filler Metal Weld Layers Class Dia. Type Polar. Current Amp. Range Volt Range Travel Speed Range cm/min Heat Input KJ/mm 1 E7018-1 3/32 DCEN/EP 70-110 20-24 5.0 12.0 1.65 3.5 1 E7018-1 1/8 DCEN/EP 90 160 20-25 7.0 12.0 1.65 4.0 2, 3, 4. E7018-1 1/8 DCEP 90-160 22-25 7.0 12.0 2.0 4.0 5+ E7018-1 5/32 DCEP 130-210 22-26 7-14 2.2 5.0 The minimum heat input shall not be less than that outlined above. The weld beads should be deposited in near sequential order as indicated on sketch. The temper bead, where employed, shall be deposited on top of last pass on the header wall, as close as possible to the extremity, without impinging on the header wall. After temper bead has cooled to room temperature temper bead shall be ground to acceptable weld profile. 3
QW-483 Procedure Qualification Record (PQR) QW-201.2, Section IX, ASME Boiler and Pressure Code PQR WEI-30-1-1 Company: Westcoast Energy Inc Procedure Qualification Record: WEI-30-1-1, Branch Weld Date: Feb. 16, 2004 WPS WEI-30-1 Welding Process(es): SMAW Types (Manual, Automatic, Semi-Auto) Manual Joints Base Metals Postweld Heat Treatment (QW-407) Material: Header 762 mm OD x 9.5 mm API 5L X52 CE. 0.43 Temperature: N/A Time Branch 48.3 mm OD x 5.1 mm WT ASTM A333 Gr.6 CE. 0.27 S-1 Grp. 1 to S-1 Grp 1 Gas (QW-408) Shielding Trailing Backing Percent Composition Gas(es) (Mixture) Flow Rate N/A Filler Materials (QW-404) Electrical Characteristics (QW-409) SFA Specification: 5.1 Electrode Polarity Amps Volts cm/min kj/mm AWS Classification: E7018-1 3/32 DCEN 105-110 21-23 6.0 10.0 1.6 2.5 Filler Metal F-No 4 1/8 DCEP 135-140 22-24 7.5-12.0 2.0 2.7 Weld Metal Analysis A-No 1. Size of Filler Metal: 3/32, 1/8 Technique (QW-410) Deposited Weld Metal: 8.6 mm groove + fillet Travel Speed: 6.0 13.0 cm / min. String or Weave Bead: String with slight wave (3 X electrode) Position (QW-405) Oscillation: -- Position: Header Horizontal, Branch 6G Multi-pass or Single Pass (per side): Multi-pass Weld Progression: Essentially uphill Single or multiple electrodes: N/A Preheat (QW-406) Preheat Temp: Min 120 C Interpass Temp: Max 300 C 4
QW-483 Procedure Qualification Record (PQR) QW-201.2, Section IX, ASME Boiler and Pressure Code PQR WEI-30-1-1 Tensile Test (QW-150) Specimen No. Width Thickness Area Ultimate Total Load (lb) N/A Ultimate Unit Stress (psi) Type of Failure and Location Guided-Bend Tests (QW-160) CSA Z662, Clause 10.9.2.2.2.1.1 Type and Figure No. Result Passed -see attached Bacon Donaldson File# A0460400076 March 05, 2004 Report #4 Rev. 1 Hardness Tests and Macroexamination Fillet-Weld Test (QW-180) CSA Z662 clause 10.9.2.2.2.2 Hardness Passed, see attached Bacon Donaldson File #A0460400175, May 3, 2004 Report #1 Rev. 1 Macro- Passed, see attached Bacon Donaldson File #A0460400076 March 5, 2004 Report #4 Rev. 1 Tests Chemistry : (Header 0.45): 0.43 See attached file # A0460400062 Report 12 Rev. 1 Welder s name: Mike Doll Clock No. Stamp No. Tests conducted by: Canspec (Bacon Donaldson) Laboratory Test No. We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of CSA Z-662 Code Date Mar. 16.2004 Approved By: Henry Yamauchi 5
Bacon Donaldson Phone: (604) 277-2322 12271 Horseshoe Way Fax: (604) 274-7235 Richmond, BC, Canada V7A 4V4 Consulting Engineers A Rockwood Company FILLET WELD HARDNESS TEST REPORT DUKE ENERGY 1333 West Georgia Street Vancouver, BC V6E 3K9 Attention: HENRY YAMAUCHI Date: May 3, 2004 File No: A0460400175 P.O. No: Report No: 1 Description: 1½" Ø Branch on Ambient Header (WPS #30-1) WPS #: 30-1, PQR #30-1-1 Name of Welder: Randall Roberts Reg. #: 21128 Hardness Test Method: ASTM E 92-82 Test Specification: CSA Z662-03, Clause 10.9.2.2.2.2 Scale: Vickers Hardness Number (1 Kg Load) HARDNESS READING (HV) Sample ID WPS# Location 1 2 3 4 5 6 7 Average (of 1 to 5) MM2 HAZ on Pipe 174 175 171 175 182 154 153 175 MM2 HAZ on Attachment 187 195 149 196 193 202 176 184 MM3 HAZ on Pipe 174 198 184 165 180 160 158 180 MM3 HAZ on Attachment 194 188 199 207 221 199 168 202 Province of British Columbia authorized testing agency for boiler, pressure vessel and pressure piping: No. TA-15. Test machine calibrated to ASTM E4 and CSA A23.2-9C specifications. Specimens will be disposed of after 30 days unless alternate provisions are made. Reported by: Reviewed by: Wesley Narciso, E.I.T. David Kwong, C.Tech SCOPE OF SERVICES: The agreement of Bacon Donaldson to perform services extends only to those services provided for in writing. Under no circumstances shall such services extend beyond the performance of the requested services. It is expressly understood that all descriptions, comments and expressions of opinion reflect the opinions or observations of Bacon Donaldson based on information and assumptions supplied by the owner/operator and are not intended nor can they be construed as representations or warranties. Bacon Donaldson is not assuming any responsibilities of the owner/operator and the owner/operator retains complete responsibility for the engineering, manufacture, repair and use decisions as a result of the data or other information provided by Bacon Donaldson. In no event shall Bacon Donaldson's liability in respect of the services referred to herein exceed the amount paid for such services. STANDARD OF CARE: In performing the services provided, Bacon Donaldson uses the degree, care, and skill ordinarily exercised under similar circumstances by others performing such services in the same or similar locality. No other warranty, expressed or implied, is made or intended by Bacon Donaldson. 6
Bacon Donaldson Phone: (604) 277-2322 12271 Horseshoe Way Fax: (604) 274-7235 Richmond, BC, Canada V7A 4V4 Consulting Engineers A Rockwood Company WELDER QUALIFICATION TEST DUKE ENERGY P.O. Box 1150 Hope, BC V0X 1L0 Attention: BARRY WESTGATE Date: March 5, 2004 File No: A0460400076 P.O. No: 13012242 Report No: 4, Revision 1 Sample Description: 1½" Branch onto ambient header Lab Sample ID: K Procedure No: WPS # 30-1, PQR # 30-1-1 Welding Process: Base Material: Carbon Steel Filler Material: Test Sample Size: 1½" Pipe Welder ID: Randall Roberts Reg. # 21128 Test Specification: CSA Z662-03 Specimen Identification Type of Bend Results *BEND TEST Specimen Identification Type of Bend Results KF1 Face Acceptable KF2 Face Acceptable * As per CSA Z662 - Clause 10.9.2.2.2.1 **MACROSECTION TEST MACRO EXAM AND HARDNESS TEST Specimen Identification Results Specimen Identification Results KM2 KM3 Acceptable Acceptable ** As per CSA Z662 - Clause 7.7.8 Province of British Columbia authorized testing agency for boiler, pressure vessel and pressure piping: No. TA-15. Test machine calibrated to ASTM E4 and CSA A23.2-9C specifications. Specimens will be disposed of after 30 days unless alternate provisions are made. Reported by: Reviewed by: David Kwong, CTech Murray Swayze, P.Eng. SCOPE OF SERVICES: The agreement of Bacon Donaldson to perform services extends only to those services provided for in writing. Under no circumstances shall such services extend beyond the performance of the requested services. It is expressly understood that all descriptions, comments and expressions of opinion reflect the opinions or observations of Bacon Donaldson based on information and assumptions supplied by the owner/operator and are not intended nor can they be construed as representations or warranties. Bacon Donaldson is not assuming any responsibilities of the owner/operator and the owner/operator retains complete responsibility for the engineering, manufacture, repair and use decisions as a result of the data or other information provided by Bacon Donaldson. In no event shall Bacon Donaldson's liability in respect of the services referred to herein exceed the amount paid for such services. STANDARD OF CARE: In performing the services provided, Bacon Donaldson uses the degree, care, and skill ordinarily exercised under similar circumstances by others performing such services in the same or similar locality. No other warranty, expressed or implied, is made or intended by Bacon Donaldson. 7
Bacon Donaldson Phone: (604) 277-2322 12271 Horseshoe Way Fax: (604) 274-7235 Richmond, BC, Canada V7A 4V4 Consulting Engineers A Rockwood Company CHEMICAL ANALYSIS REPORT DUKE ENERGY 1333 West Georgia Street Vancouver, BC V6E 3K9 Attention: HENRY YAMAUCHI Date: February 20, 2004 File No: A0460400062 P.O. No: Report No: 12, Revision 1 Description: 1.5", 4", Header with CE 0.45 and Header Sample for WPS # 16-1, 30-1 Sample ID: Test Method: Spectrographic Analysis TEST RESULTS Element Chemical Composition (%) 1.5" 4" Header (.45) Header Carbon Manganese Phosphorous Sulphur Silicon Nickel Copper Chromium Molybdenum Niobium Vanadium Aluminum Boron 0.13 0.86 0.007 <0.002 0.18 0.05 0.08 0.05 0.02 0.0002 0.062 1.02 0 <0.002 0.17 8 0.02 0.06 0.05 0.0002 0.26 0.89 0.009 0.021 0.02 0.05 0.10 0.03 1 0.0002 0.059 1.49 6 <0.0002 0.25 0.21 0.02 0.06 0.04 0.07 <0.0002 Caron Equivalent (CE) 0.27 0.17 0.43 0.22 Reported by: David Kwong, CTech Reviewed by: SCOPE OF SERVICES: The agreement of Bacon Donaldson to perform services extends only to those services provided for in writing. Under no circumstances shall such services extend beyond the performance of the requested services. It is expressly understood that all descriptions, comments and expressions of opinion reflect the opinions or observations of Bacon Donaldson based on information and assumptions supplied by the owner/operator and are not intended nor can they be construed as representations or warranties. Bacon Donaldson is not assuming any responsibilities of the owner/operator and the owner/operator retains complete responsibility for the engineering, manufacture, repair and use decisions as a result of the data or other information provided by Bacon Donaldson. In no event shall Bacon Donaldson's liability in respect of the services referred to herein exceed the amount paid for such services. STANDARD OF CARE: In performing the services provided, Bacon Donaldson uses the degree, care, and skill ordinarily exercised under similar circumstances by others performing such services in the same or similar locality. No other warranty, expressed or implied, is made or intended by Bacon Donaldson. Attach 4 - WPS 30-1 Rev0.doc