KBR tui:LJ rilillulaJUcJiki9in

TRANSMITTAL No.

Saudi Kayan Olefins ProjectKBR Job-6484

Document Transmittal Sheet6484-GC-021 -SC-008-T0054 DATE: 21 February 2008

Transmittal of Welding WPS & PQR’s

Nasser S. Al Hajri Corp.D. Han Kumar

The attached items are transmitted for the reason indicated below:

For incorporation into Contract

— For comment/coordination: please respond by:

For Information Only. No response required.

LW Other (Provide Reason)I I I Returned with commentsATTACHMENTS:1 NSH-KBR-SKOP-WPS-1 1 -P12 SH-KBR-SKOP-WPS-1 1 -P23 NSH-KBR-SKOP-WPS-1 1 -P34 NSH-KBR-SKOP-WPS-1 1-P4

Transmittal prepared by: Be abiona Jr.

PLEASE ACKNOWLEDGE RECEIPT BY SIGNING AND RETURNING A

21 February 2008

SUBJECT:

ToATTN:

NASSE S AL ;‘ k C0R’

ID! •‘ •‘OJ!T

.jiJRA

All comments can be referenced using Saudi Kayan approved document title: Welding, PWHT &NDE of Plant Piping document number 000-85S-0005

NSH-KBR-SKOP-WPS-11-Pi1. WPS lists multiple brands of GTAW and SMAW electrodes as per Consumables — General8.4.12. Amp range for GTAW and SMAW on WPS exceed Amp range qualified on PQR perWelding Procedure Specifications 9.23. Maximum Brinell hardness values allowed for P1 material are 200 PQR values on testingcertificate do not reflect whether these are Brinell or Vickers reading in any case the highestreading is 247 which is above the limit on Brinell or Vickers conversion. Welding ProcedureQualifications 10.1.24. Heating and cooling rates used on both WPS and PQR exceed the required maximum statedin POSTWELD HEAT TREATMENT 11.175. As called for in POSTWELD HEAT TREATMENT 11.19 temprature range as called for P1material 600C to 620C WPS and PQR call for 593C to 640C

NSH-KBR-SKOP-WPS-1 1-P21. WPS lists multiple brands of GTAW and SMAW electrodes as per Consumables — General8.4.1

NSH-KBR-SKOP-WPS-1 1-P31. WPS lists multiple brands and grade of GTAW wire PQR was performed with ESABER7OS-2 as see Consumables — General 8.4.12. Amp and Volt range exceed those set on PQR Welding Procedure Specifications 9.2

NSH-KBR-SKOP-WPS-1 1-P41. WPS lists multiple brands and grade of GTAW wire PQR was performed with ESABER7OS-2 as see Consumables — General 8.4.12. Maximum Brinell hardness values allowed for P1 material are 2O0.jQRalues on.iest—certificate are in Vickers the highesF lsilS allowing for conversion to Brinell thehighest reading would be approx. 230 which is above the limit allowed for P1 material asstipulated in Welding Procedure Qualifications 10.1.2

âJj rmIII-IiuiIi !J9dfl

KBR

MAStER

24-Sep-08

24-Feb-08

17-Feb-08

DatePrepared by

(NSH QNQC Engr.)Checked by Reviewed by Approved by

(NSH QA!QC Mgr.) (KBR QAIQC Mgr.j(Saudi Kayan)

Base Metal Thickness is changedas per PQR & As per PWHT

Requirement as per B31 .3 Table331.1.1 Edition 2006

For Approval

For Approval

Reason For Issue

tso91 xIe

OHI I$I# I: im

Nasser S. AI-Hajri Corporation

Welding Procedure Specification (WPS)

Page 1 of 4

Common for all NSHProcedures

jecevatioi

Numbering System for WPS and PQR

WPS Welding Procedure SpecificationPQR Procedure Qualification Record*

*Note N/A for Previously Qualified PQR’s &Pre-Qualified as per AWS D1.1

Document No.: NSH-KBR-SKOP-WPS-I I-P2—

P Numbers of two joining

S = Structural, C = Civil, M =

Mechanical or attachment weldsother than Piping & P = Piping

udure No. 4

MASTER

Page 2 of 4

Nasser S. Al-Hajri Corporation ‘J ‘U’‘%.._ . . duJi !I9JflWelding Procedure Specification (WPS)

ISO9i1 iOO01110$ 1101: 10$

WPS No.: NSH-KBR-SKOP-WPS-1 1 -P2 Rev.: 2 Date.: 24-Sep-08Supporting PQR No.: NSH-PQR-11-P2 Rev.: 0 Date.: 29-Nov-03

Welding Process: GTAW+SMAW Type: Manual

Code: — ASME IX ASME B31.3 ASME B31.1 U AWS D1.1 U OTHER

JOINTS DESIGN (QW-402)

. .

JOINT DETAILSJoints Design : See Sketch-

Backing : GTAW - N:

Backing Material Type: Weld Metal for SMAW \\

A = 750 ±5° LTB = 4.8 mm to 20.00 mm \> 7C = 1.6±0.8 mm ROOTFACE ZJ1.LROoTGAP

0 = 3.2±0.8mm

BASE METALS (QW-403)

P-No.: 1 Group No.: I to P-No.: 1 Group No.:OR

Specification type and Grade : ASTM A671 GR.CC6O A 672 Gr. B 60, A 106 Gr. B, API 5L Gr. B etc or equivalentto Specification type and Grade : ASTM A671 GR.CC6O A 672 Gr. B 60, A 106 Gr. B, API 5L Gr. B etc or equivalent

OR

Chem.Analysis and Mech.Prop. : As per ASME Sec II A or Project Requirementto Chem Analysis and Mech.Prop. : As per ASME Sec II A or Project Requirement

Base Metal Thickness Groove : 4.8 mm to 20.00 mm Max Fillet : UnlimittedPipe Dia Range Groove : 2 7/8” OD & Over Fillet : UnlimittedOthers :

FILLER METALS IQW-404)

GTAW SMAWSpec. No. (SFA) 5.18 5.1AWSNo. (Class) / Trade ER 70S.-2 I S-3 E 7018

2.5 mm & 3.2 mm (4mm shall be used forSize of Filler Metals 2.4 mm supports & other attachment welds)Deposit Weld Metal Thickness Range:

Groove No pass greater than 5 mm No pass greater than 5 mmFillet All All

Electrode-Flux (Class) N/A Low Hydrogen TypeFlux & Electrode Name:

/\ ESAB, LINCOLN or any other brand approved by ESAB, LINCOLN or any other brand approved byclient, client.

Consumable Insert N/A N/AOthers

--

Page 3 of 4

vT_Vi

CUrNflt Travel SpeedDia T e Polan Amp Ran e Volt Range Range mmlmln

1st (Root)]7TAW1 ER 70S-2 2.4mm DCSP 110-115 50- 1002nd (Hot) GTAW ER 70S-2 2.4 mm DCSP 130 - 135 10- 13 75 - 125

3rd(Fill) E7018 2.5&3.2 mm DCRP 85-130 22-27 75-125

Final (Cap)

__________

E 7018 2.5&3.2 mm DCRP 116-120 23-27 75- 125

We undersigned certify that the information stated on this WPS conforms to the requirements of ASME Sec.IX-2004

____________________________________________________

Saudi_Kayan

________________________________________________

QA1QC MANAGERQAIQC ENGINEER QAIQC MANAGER

Name 4V3ST1N &NA

Signature

Date j

WPS No.: NSH-KBR-SKOP-WPS-11-P2 Rev.: 2 Date.: 24-Sep-U

POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407)Position (s) Groove : All

/ Temperature Range : N/AWelding Progression : Uphill V’ Downhill Time Range : N/A

Position (5) of fillet : All Heating Rate : N/A

Cooling Rate : N/A

PREHEAT (QW-406) GAS (QW-408)Preheat Temp.Min. : 10°C Mm. (See the Note Below) Shielding Gas(es) : Arg.nInterpass Temp. Max. : 250°C Max Percent Composition :

Preheat Maintenance : 10°C Max Flow Rate : S - 15 ( LI Mm.)Others : If the ambient temperature is less than 10°C, .Joint Gas Backing : N/A

should be pre-heated. Trailing Sheilding Gas Composition : N/A

ELECTRICAL CHARACTERISTICS (QW-409)Current AC or DC : DC Polarity : GTAW (SP) + SMAW (RP)

Amps. Range : 88 - 135 Volts Range : 10 - 27

(Amps and Volts range should be recored for each electrode size, position and thickness etc. This infirmati.n sh•ull be listed in the tabular f.rmshown below)

Tungsten Electrode Size and Type : 2.4 mm dia, 2% Thoriated

TECHNIQUE (QW-410)String or Weave Bead : Root : String Max. Weave Width: Limited to 3 times the electrode diameter.

Filling / Capping : String & Weaving

Orifice or Gas Cup Size : 4, 5 & 7

Initial and interpass cleaning (Brushing, Grinding, etc..) : Brushing and Grinding NIASTERMethod of Back Grouging : N/A

Oscilation : N/A

Contact tube to work distance : N/A

Multiple or Single Pass (per side) : Multiple

Multiple or Single Electrode : Single

Travel Speed (Range) : See Table

Peening : N/AOthers : For 24’ NPS (61 0mm) pipe, if access permits weIdin is allowed from

both sides. Shall be permitted to use for pipe attachment welding also.

FiIIer Metal-Pass Process Class Other

Page 4 of 4

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AL HOTY-STANGER LTD. Co.

Independent Laboratories & Malerials Testing

&bL1 -5— .1’ !i-’

Jk_.-il _-..

PROCEDURE QUALIFICATION RECORD (PQR)

Company Name NASSER S. AL HAJRI CORPORATIONProcedure Qualification Record No. NSH-PQR- 11 -P2WPS No. NSH-MTC-1 1-P2 REV. C - -

Welding Process (es) GTAW + SMAW — - —

Types (Manual, Automatic. Semi-Auto) MANUAL -- -. - -

CODE: ASMEIX 0JOINTS (QW-402)

a= 70°

b= 0.43?c= 0.126d= 0.06?

WELD DEPOSIT THICKNESSGTAW = 0.099”SMAW = 0.333”

d%TLE

Report Ref. No.: JB.N-3558

Date 29 NOVEMBER 2003

API 1104 fJ AWSDI.IQ Other LI

—‘I

Joint Design Used

BASE METALS (QW-403) I PREHEAT (QW-406)Material Spec. SA-10_

_____ _________________

Preheat Temp. 28 °CType of Grade Gr.B

_______________________J

Interpass Temp. 212 °CP No. 1 to P No. 1 Other NIAThickness 0.432’

- 1Diameter 6 -__________________________

Other N/A

_____________

-.

GAS( )Type of Gas or Gases ARGONComposition of Gas Mixture 99.99%Other SHIELDING GAS FLOW =

LFILLER METALS (QW-404)eld Metal Analysis A-No. 1e of Electrode 3/32w, 1I8 0rMetalFNo. 6,4

iFA Specification 5.18.5.1AWS Classification ER7OS-2. E7018Other FILLER WIRE: LINCOLN I ELECTRODE: ESAB

POSITION (QW-405) TECHNIQUE (QW-410)Position of Groove 6G Travel Speed 3-5 INCH/MINUTEWeld Progression (Uphill, Downhill) UPHILL String or Weave Bead BOTH STRING & WEAVE BEADOther NIA Oscillation NIA

________________________ _____________________

Multipass or Single Pass (per side) MULTIPASS

__________________ _________________

Single or Multiple Electrodes SINGLE

_______________ ________________

Other N/A

10—13 2—4130—135 10—1385—89 22—25

112—116 23—27126—130 23—27116—120 23—27

Test Wtnessed By: JAGANNIVASAN

Ls!i L—

•AL HOTY STANGERNASSER S. AL HAJRI CORP.

ate of Report. 29 Nov. 2:03

ample No. JB.N-3558

VICKERS HARDNESS (HV-1O) TEST RESULTS

NSH-PQR-1 1 -P2

(SAUDI ARAMCO STANDARD DRAWING W-AB-036386)

I \23\5

A - SINGLE - SIDED BUTT WELDNEAR 6 O’CLOCK POSITION

P05 AREA HARDNESS POS AREA HARDNESS

I BASE METAL 150 11 BASE METAL 153

2 HEAT 157 12 HEAT 142

3 AFFECTED 166 13 AFFECTED 165ZONE ZONE

4 160 14 161

5 19J 15 195WELD METAL WELD METAL

6 177 16 190

‘ HEAT 182 17 HEAT 166

8 AFFECTED 172 18 AFFECTED 168ZONE ZONE

9 167 19 160

10 BASE METAL 136 20 BASE METAL 151

isorFor Al Hoty-Stanger Ltd. Co./a’

This report relates onh- to the sample (ested and shall on/v be reprn!uced in full :th tire written appro a! oJAHS testing laboratory.

INDEPENDENT LABORATORIES & MATERIALS TESTINGP.O.BOX 1122 AL-KHO8AR 31952 -TEL: (03) 8891C00 (11 LINES)! 89809581 8642539

kta Tel. (03)341-6191- HoU Te O3, 8S-3210.Ryai Te (01) 37 J292-J TI43)660-1924 -Yanj Tel: -4)322-5 Cha Tel: C55422: - Crbai Tel. (04)3472201 - Jebel Ah Tel: (04)8ii-1

(ic)61

ie edit”

-s-s--3-6mm--- -, -

TYPE

II 12 15‘ •)

13

0 5-t 0mm

(ACROSS FINAL PASS)TYPE

6 78, 10--0 —:- 0-- -0 -

WED METAL ..

- BASE METAi.

.‘

16 2C

I?

a

LMED SAFARULLAAsst. Regional ManagerFor Al Hoty Starger Ltd. Co.

L HOTY-STANGER LTD. CO. J $°J ‘7

ndependent Lacatcs & Vaterials Testing‘—

WELDING PROCEDURE QUALIFICATION RECORD (WPQR)

w.P.S. #NSH-MTC-11-P2 REV. 0 P.Q.R. #NSH-PQR-11 P2 Issue Date: 29 NOVEMBER 2003

TENSILE TEST

Identification Result Identification Result

Face Berd— : Satisfactory

Face Bend — 2 Satisfactory

Root Bend — I Satisfactory

Root Bend —2 Satisfactory

IMPACT TOUGHNESS TEST (N!A) FILLET WELD (N/A)

Specimen Size J Notch Test ImpactTemp. i Values Result — Satisfactory YES j NO El

No. I Location(° F) Li• lbs.)

Penetration into YES J NO ElParent Metal

P. 1,2,3 -- I P.M.

1-- -—

W. I ;2,3 H — I W.M. Macro - Results : SATISFACTORY

H. 1.2,3—— I H.A.Z. -

Other Tests : RADIOGRAPHY

HARDNESS TEST RESULT (SEE ATTACHED)

Parent Metal Ave I-ti Low Hardness

Weld Ave Hi Low

Haz Ave Hi Low

Welders Name : MOHAN )CUMAR

Test Conducted By : LEO FRANCIA I Laboratory No. JB.N-3558

WE CERTiFY THAT THE STATEMENTS IN THIS RECORD ARE CORRECT AND THAT THE TEST SPECIMENS WERE PREPARED

AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF WELDING SPECIFICATION ASME IX 2001.

Witness .JAGANNIVASAN

Date : 19 NOVEMBER 2003

11anufacturer

By

NASSER S. AL HAJRI CORP.

Mr. BIJU G.

xiL

GUIDED BEND TEST

R

‘‘4.

AL H1TY- STANGERM.S. AL SUWAIDI IND’L. SERVICES

VICKERS HARDNESS (HV-1O) TEST RESULTS

NSH-PQR-1 1-P2

ate of Retort: 2 Nc; 2CC3

ample ND. JB.N-355

(SAUDI ARAMCO STANDARD DRAWING W-AB-036386)

-&---

I \i\—3.6mm)--.--

TYPE \WELD METAL

0 5-1 0mm(ACROSS FINAL PASS)

TYPE

0--•’

/4k’

/ BASE METAL

16 18 200, 0 -

I?

A - SINGLE - SIDED BUTT WELDNEAR 12 O’CLOCK POSITION

POS AREA HARDNESS POS AREA HARDNESS

I BASE METAL 162 11 BASE METAL 160

1702 HEAT 12 HEAT 171

3 AFFECTED181

13 AFFECTED 170ZONE 185 ZONE

4 14 165

5 197 15 158WELD METAL WELD METAL

6 209 16 158

7 HEAT 188 17 HEAT 160

8 AFFECTED 173 18 AFFECTED 162ZONE ZONE

9 165 19 158

10 BASE METAL 154 20 BASE METAL 162

MASTER

MOHAMED SAFARULLAAsst. Regional ManagerFor Al Hoty Stanger Ltd. Co.

This report relotes onl w :‘e sample tested and shall oisli- h rc;rociiiced in full with the written approval ofAHS testing laboratory.

INDEPENDENT LABORATORIES & MATERIALS TESTINGP.0.BOX 1122 AL-KHOBAR 31952-TEL: (03)6891000(11 LINES) (8980958 ‘8642539

.kadTe: C3)34I-791 -HoM: ‘-J-RyhTe 2’l223L

8a

*

MASTER

AP’

For Al Hoty-Stanger Ltd. Co.I.’

Nasser S Al Hajri CorporationIndustrial ContractorsCR 2060006231P 0. Box 495, Dhahran Airport31932,Kingdom of Saudi ArabiaTel No. ÷966-3-865-0009(10 Lines)Fax No. +966-3-898-4211

Kellog Brown 8 Root Saudi Ltd.

Mr. Brad BradfleldDeputy Project DirectorKBR Olefins Plant

THE FOLLOWING • PRINTS

ARE TRANSMITTED HEREWITH FOR

Q INFORMATION

Q REVIEW

Q RECORD

D REPRODUCIBLE COPIES

• APPROVAL Q CONSTRUCTION

D ACTION Q QUOTATION

Q BIDDING Q APPROVED

Q ORIGINAL

0 REFERENCE

Q FINAL

= IIIIIUI.i,

TO

ATTN:

Issue Date Wednesday, September 24, 2008

Ref. No. : NSH-KBR-T-0678

Job No. 6484-GC-021-SC-0086484-AB-Ol 2-SC-Cog

Document Submittal

Rev..• Remarks

No. ofDocument No.

No.copies

NSH-KBR-SKOP-WPS-1.2 Welding Procedure Specification (WPS)P2

Attachments enclosed

kE.ESIGNED BY:

ECT MANAGERINTERNALI%UFdIMI

NSH KBR

REMARKS

NOTE 0 = ORIGINAL R = REPRODUCIBLE

• RECEIPT REQUIRED (PLEASE ACKNOWLEDGE THE RECEIPT ON THE DUPLICATE AND RETURN)THE ABOVE DOCUMENTS RECEIVED BY.

Mr. Irshad A. Tirmizi

_______

Sr. Subcontracts Administrator DATE

C = COPIES

SIGNATURE

Saudi Kayan Olefins

.iiudikdydn ProjectTransmittal_Sheet

Our Transmittal#: SKOT- KBR - T- 0078

DATE : 29/ 09/ 2008

Date: TRANSMITTAL TITLE Ret#: KBRSL-SKOr-GEN-T-0102

27/09/2008

Welding Procedure Søecification

REMARKS OR SPECIAL INSTRUCTION:

Approved

TO DATE REQUIRED ACTION

C Approval

LI Review & CommentsMr. Beethoven Sabiona 29/ 09/ 2008

Information

C Others: For Action

PLEASE ACKNOWLEDGE RECEIPT BY SIGNING AND RETURNING A COPY OF THIS TRANSMITTAL

SLV

71SJLUD8

REcöBY 3y. -

Pis. Return to: Control #:CARLOS J. SALVADORDocument ControllerContracting l)ept.

::X1 carlosj.salvador@kbr.com

ARLO S-OS