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Instructions for the Preparation and Writing of Procedure Qualification Records Red Book Number: 831-1 Revised: 13/12/2005 Issuing Authority: Tom J. Landon/Plainfield/CBI Maintenance & Review: Corporate Welding & QA Technology 0.1 Scope: This standard provides instructions for the preparation and writing of Procedure Qualification Records (PQR) to ASME Section IX. ¶¶¶ 0.2 Introduction: A Procedure Qualification Record is a certified document giving complete information on how a particular test plate or set of plates was welded and the results of any required testing thereon. A copy of all Procedure Qualification Records should be sent to Corporate Welding and QA Technologies (CWT) for inclusion in the Lotus Notes PQR Search Database. This includes all U.S. and international locations. The Procedure Qualification Record shall be composed of as required: 1 WL 20D Essential Variables 2 WL 154 Welding Variables 3 WL 253 Impact Test Data 4 WL 20G Dropweight Test Data 5 WL 1 Vickers Hardness Report 6 WL 10 Brinell Hardness Report 0.3 Microsoft Excel Templates (PQR Forms): The forms listed in Section 0.2 above are available from Corporate Welding and QA Technologies (CWT) as Microsoft Excel Templates. Contract CWT for the latest versions of the templates. ¶¶¶ 1.0 WL 20D ESSENTIAL VARIABLES: (Figure 1.0) This form should be used to record all essential variables, the welding procedure, and test results for the test plate. A separate form should be used for each position. 1 2 3

Page: Leave blank. Contract: Leave blank. PQR No.: Refer to numerical index kept by Corporate Welding for determination of this number for all U.S. PQR's. For special applications, show the following letters after the PQR number to be used for information retrieval on computer printouts: ¶¶¶ AApplied Lining Weld BWelding Procedure with Butter t CCorrosion Resistant Weld Metal Overlay Qualification DTemper Beads EBritish Standards FFillet Weld Qualification Test GHalf bead technique HHigh Temperature Tensiles JComposite Weld KPQR with Drop Weight Tests (ASTM E208) LExxon Lap Welding Qualification Test MHard Facing Weld Metal Overlay Qualification

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Post Weld Flame Softening Qualification Welding Position Restricted Stud Weld Tapco Filler Powder PQR Typed on AWS Form Military Procedures PQR Witnessed and Signed by a Third Party organization Repairs without PWHT

Process: Use AWS Abbreviations or write out in full. SMAW - Shielded Metal Arc GMAW - Gas Metal Arc, MIG SAW - Submerged Arc Welding, Auto Girth, Auto Flat Down, Strip Overlay. Put SA1, SA2, SAT, AG1, AG2, SAO, AGO or SAS in parentheses. EBW - Electron Beam Welding FCAW - (Flux Cored Wire, Innershield, Dualshield) GTAW - Gas Tungsten Arc, TIG, GTH EGW - Auto Vert & Electrogas Welding ESW - Electroslag Welding SW Stud Welding PAW - Plasma Arc Welding Material Specification: Give the ASME, ASTM or AISI designation. If proprietary materials that meet, ASME, ASTM or AISI requirements are used, reference the proprietary name in remarks. If two different materials are welded together, give the ASME, ASTM or AISI designations of each. If materials are used for which there are no ASME, ASTM or AISI designations, give the proprietary names. For aluminum material, show the temper for the allow used. ASME P. no.: Give the P-number and group number for each of the pieces. If materials are used for which there is not ASME designation, state that the P-number and group number are similar to that of a comparable ASME material as "Sim. P-1, Gp. 1." Thickness: Give the thickness of the material ed. If pieces of different thicknesses are ed, list both thicknesses. If pipe is the material ed give pipe diameter and the wall thickness. Metric values may be used. Always use inch or millimeter marks. F-no.: Give the F-number(s) of the electrode(s) used in welding. If electrodes are used that do not conform to an AWS-SFA specification, state that the F-number is similar to a comparable U.S. electrode as "Sim. F-4." If no F No., state "None". A-no.: (Applicable only to ferrous metals). Give the A-number(s) of the weld deposit(s) when the weld deposit is ferrous metal. In lieu of an A-number designation, the nominal chemical composition of the weld deposit may be indicated. Designation of nominal chemical composition may also be by reference to the AWS classification (where such exists). For nonferrous metals state "N/A". ASME specification no.: Give the SFA designation(s) of the electrode(s), i.e. SFA 5.1, SFA-5.5, and SFA-5.17. If electrodes are used that do not conform to an SFA specification, state that the electrode is similar to SFA specification as "Sim SFA-5.xx". AWS specification no.: Same as (11) except use A-5.xx instead of SFA-5.xx. Manual , Machine , Automatic , Semi-Automatic: Place an "X" in the box of the appropriate technique. Flux trade name: If flux is required, give the trade name. When a flux is not used state N/A. Provide the AWS Flux-Electrode Designation (Classification) only when it is applicable and available from the flux manufacturer or from previous CB&I test to AWS A5.17 or A5.23. List the AWS Flux-Electrode Designation in the Remarks. Inert gas composition: Give the percentage composition of the shielding gas, if any is used. Otherwise state "N/A". Flow rate: Give the flow rate of the shielding gas, if any is used. Otherwise state "N/A". Preheat temperature range: (Examples): If no preheat was used, enter "70-500°F (IPT)". The maximum IPT is usually 500°F. For those cases where a different maximum IPT is required, enter it accordingly.

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If preheat was used, enter "200 to 500°F (IPT)". Enter preheat and/or IPT as required depending on the material being welded. Postheat treatment: Enter the actual temperature used and actual time in hours and/ or minutes. Single or Multiple : State whether a single or multiple es were used. Single or multiple arc: State whether a single arc or a multiple arc was used per . The AG1 is considered as a single arc per . The AG2 is considered as multiple arc per . Position of groove: State 1 G, 2G, 3G, 4G, 5G or 6G. Mode transfer for GMAW: Place an "X" in the appropriate box to describe the mode of transfer used for GMAW welding. Filler Metal for GTAW or PAW: Give the SFA-AWS Classification of the filler metal(s) used for GTAW or PAW welding. Reference the brand name(s) in the remarks. If no classification is available use the proprietary name. Filler metal diameter: Give the diameter of the filler metal in inches or millimeters. Add inch or millimeter marks. Electrode: Give the SFA-AWS Classification of electrode(s). Reference the brand name(s) in the remarks. If no classification is available use the proprietary name. Electrode diameter: Give the diameter of the electrode(s) in inches or millimeters. Add inch or millimeter marks. Type of backing: State the type of backing if backing was used. This could be an insert, a tape, a gas purge, bars or temporary bars, or parent plate. If metallic backing is used the type should also be stated. If no backing is required, state "None Required". Welding current: State the current type used and whether the electrode was negative or positive. Indicate "Straight Polarity" or "Reverse Polarity" in parentheses. Example: "Direct current/Electrode Positive" (Reverse Polarity) Specimen No.: Enter the specimen number. Width: Give the width of the specimen to three decimal places with a preceding zero if the specimen is less than 1 inch wide. If metric values are used give millimeter values to two decimal places. Always use inch or millimeter marks. Thickness: Same as (31) If round specimens are used give the diameters to the same decimal place. Area: Use the same number of decimal places as in width and thickness. Ultimate Total Load: Give the ultimate total load in pounds. Other units (such as kilograms) may be used if the change is noted. Ultimate Unit Stress KSI: Give the ultimate unit stress in KSI. Ultimate Unit Stress MPa: Give the ultimate unit stress in MPa. Character of Failure and Location: Give the character (brittle or ductile) of failure and the location, (Plate, Haz or weld metal). Type of Bend: State the number and type of bends (4 transverse side bends, 2 transverse root bends, 2 transverse face bends, 2 longitudinal root or 2 longitudinal face bends). Results: Give results of bends identified in (37). Welder's name: Fill in name of person or persons who welded test plate. SS Number: Fill in social security number of person or persons who welded test plate. If welder does not have a SS number, show company ID number. Welder's symbol: Fill in welder's initials, number or symbol. Work Order (Orig. WPS) No.: Fill in number of work order including revision number. Date: Date PQR is signed. By: Typed name and signature of person writing PQR. Remarks: Add any pertinent comments which are necessary and comments form other areas of the PQR. Corrections: Corrections of data such as typographical errors, arithmetical errors or others shall be updated to the latest form. The explanation will be: updated to the new form, your initials, and the date of the update. All dates already on the PAR will remain the same. Any prior explanations or update will not be put on the latest form.

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If any areas are not filled in, the space should not be left blank but rather "N/A" typed in to signify that the space has been reviewed and that there is no answer applicable.

2.0 WL 154 WELDING VARIABLES (Figure 2.0) This form should be used to record the welding parameters. 1 Page: Leave blank. 2 Contract: Leave blank. 3 Drawing of t: Make a drawing of the t that was welded. The drawing should be full size and to scale with the land, gap, thickness, and bevels dimensioned. Show the exact sequence, in most cases, with each identified by number. Weld beads (es) are to be drawn as closely as possible to scale. In the cases of very thick or thin materials a scale factor (noted on the WL 154 form) may be used for the drawing of the t. 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Side: Side welded (1 or 2). : Number the es. Electrode type: Give the SFA-AWS designation of the electrode for each line listed. If no designation is available, use the proprietary name. Electrode Size In: Give the wire size for each electrode type in inches. Electrode Size mm: Give the wire size for each electrode type in millimeters. Amps: Give the amperage at which the or es were welded. If several es are grouped together, give the amperage at which these were welded. Do not use ranges. Volts: Give the voltage at which each or group of es was welded. Do not use ranges. Round off volts to the nearest who number. Travel Speed in/mm: Give the travel speed in inches per minute for each or group of es. Travel Speed cm/min: Give the travel speed in centimeter per minute for each or group of es. Heat Input KJ/in: Give the heat input in kilo joules per inch for each or group of es. Heat Input KJ/cm: Give the heat input in kilo joules per centimeter for each or group of es. Remarks: List any special remarks such as gas composition and flow, flux or anything else which will clarify the line. For vertical welding show direction of welding for each or group of es. Qualification No.: Fill in the same number used on WL 20D. Date: Give date PQR is signed. By: Typed name and signature of person writing PQR.

3.0 WL 253, IMPACT TEST DATA (Figure 3.0) This page shall be used whenever impacts are to be reported on a PQR. If impacts were taken at several temperatures, a separate page should be written for each temperature. If this is done, the PQR can be used for qualification at different temperatures and only the applicable data need be used for a given contract. 1 Page: Leave blank. 2 Contract: Leave blank. 3 W/O No: Enter the work order number. The type of notch placed in the impact specimens has been included here a "Vee". Change in necessary. 4 Spec. No.: Identify the specimens or groups of specimens in some manner so that each individual specimen can be traced back to the work order. 5 Spec. Orient.: Give the orientation of the specimen, whether longitudinal or transverse. Weld metal impacts do not have an orientation. Do not give the side or depth of specimen. 6 Spec. Size: Give the size of the specimens. For 10 x 10 mm specimens, write "FULL," and for other cross section dimensions write 7.5 x 10mm, 6.7 x 10mm, 3.3 x 10mm or 2.5 x 10mm.

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Notch Location: State where the notch was placed (PL, WM or HAZ). Side: State the side impact were taken from (1 or 2). Depth: State depth where impacts were taken from (1/16", 1/4T, 1/2T). Test Temp Deg F.: Give temperature in degrees F at which specimens were tested. If heading changed to Degree C, the temperature may be given in degrees C. Energy Ft.-lb.: Give absorbed energy required to break specimens in foot-pounds. Energy J: Give the absorded energy required to break the specimens in Joules. Lateral Expansion Mils: State the amount of lateral expansion at the broken surface in mils. This unit may be given in decimal millimeters if the change is noted. Percent Shear: Give the percent shear of the broken surfaces. Remarks: Give any pertinent comments which are needed. Qualification No.: Enter the number of the qualification. Date: Give the date form is signed. Signature and typed name of person completing form.

4.0 WL 20G, DROPWEIGHT TEST DATA (Figure 4.0) This form shall be used whenever dropweight data is to be reported. One form shall be used for each test plate. 1 Page: Leave blank. 2 Contract: Leave blank. 3 P: Give the number of the type of specimen (1, 2 or 3). 4 Plate: Give the plate material. 5/10/15 Location: Give the location (depth) at which the specimens were obtained. 6/11/16 Test Temp F: Give the temperature(s) at which the specimens were tested. 7/12/17 Results: Give the test results for each specimen. 8 Plate TNDT: Give the plate NDT temperature. 9 Heat Affected Zone: Give the heat affected zone material (same as 5). 13 Heat Affected Zone TNDT: Give the HAZ NDT temperature. 14 Weld Metal: Give the weld metal by ASW-SFAA classification or proprietary name if no classification exists. 18 Weld Metal TNDT: Give the weld metal NDT temperature. 19 Qualification No.: Give the number of the qualification. 20 Date: Give date form is signed. 21 By: Signature and typed name of person completing form. If two dropweight specimens are tested in a go-no-go situation and both have a no break performance state in 9, 14 and/or 19 that TNDT is " F or below."

5.0 ADDITIONAL REQUIREMENTS If other information is required on the PQR by customer specifications, type this information in the remarks section of a copy of WL 20D or make separate sheets. The original WL 20D should not contain any hardness, impact, or NDT information. If his procedure is followed, the PQR can be used on other contracts where this information is not required, without reworking the PQR or supplying information that is not required. Hardness testing, if required for the PQR , is to be recorded on Form WL1 (Vickers Hardness Report) or Form WL10 (Brinell Hardness Report). Hardness report form WL 120 (see Standard 801-4-4 ) should never be part of a PQR.

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Fig. 1.0 - Sample Copy of Form WL 20D Fig. 2.0 - Sample Copy of Form WL 154

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Fig. 3.0 - Sample Copy of Form WL 253 Fig. 4.0 - Sample Copy of Form WL 20G ******* ©Chicago Bridge & Iron Company, 2006. All Rights Reserved. For Internal Use Only. NOTICE: THIS DOCUMENT, AND ALL TEXT, DRAWINGS, DETAILS AND DATA SHOWN HERETO, IS THE SOLE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY, AND SHALL NOT BE REPRODUCED IN ANY MANNER OR USED FOR ANY PURPOSE WHATSOEVER EXCEPT BY EXPRESS WRITTEN PERMISSION OF CHICAGO BRIDGE & IRON COMPANY.