KONTRAKTOR : INNOSEVEN SDN BHD

PROJEK : PEMBINAAN BANGUNAN TAMBAHAN

HOSPITAL SEGAMAT, JOHOR (REKA DAN BINA)
NO KONTRAK : JKR/IP/CKUB/79/2018

Method of Statement – Welding jointing

1. Title
Method Statement Welding of Piping and Structural Components

2. Methodology
1. Welders shall only work within the limit of their qualification range.

2. Welding supervisor/welders shall ensure that “Welding Procedure Specification”

(WPS) selection is taken from the approved matrix for each specific line class/application
accompanying each WPS.

3. Withdraw consumables only from designated welding stores and endorse initials on the
“Welding Consumables Distribution Form” maintained by the issue clerk.

4. Withdraw only sufficient quantities of welding consumable for a four (4) hour period
of work.

5. All low-hydrogen welding electrodes shall be maintained in heated “portable rod

caddies”. The lid of the caddie should be closed following the withdrawal of each
withdrawal electrodes.

6. Low-hydrogen electrodes shall only be conveyed to the job site in heated “portable rod
caddies”.

7. At shift change, all “rod caddies” must be returned to the originating welding store for
checking. All issued and unused low-hydrogen electrodes shall be scrapped.

8. The technical requirements of the “Welding Procedure Specification” (WPS) must be

followed at all times.

9. Pre-heat and inter pass temperatures shall be monitored using “Tempil Stiks” or
calibrated “digital” temperature by pyrometers. greater than the nominal wall thickness.
ii) For flanges, use the thickness corresponding to two (2) higher wall thickness ranges
greater than the nominal wall thickness.

10. Pre-heat values shall be taken calculated and WPS assuming a value of 0.42 CE
(Carbon Equivalent). Wall thickness values shall be selected as follows:
a) For pipe-pipe, use the actual wall thickness.

b) For pipe-to-fitting or fitting-to-fitting.

c) For fittings (other than flanges), use the next higher wall thickness range a sufficient
period of time to ensure an Oxygen content of less than 0.5%. When available, “purge
monitoring devices” shall be used.

d) Back purge shall be maintained for a minimum of four (4) passes. Pipe bungs (purge
dams) shall be left in place until completion of the joint.

e) The end of partly used filler wire shall be snipped off prior to use.

f) Maintain the tip of the filler rod within the gas shroud during welding to avoid
contamination.

g) Inter pass temperatures for these materials is critical. The welder shall check the
temperature prior to the next pass. All austenitic stainless welds on this project will be
tested for “Ferrite” content therefore, cleanliness during fabrication and monitoring of
inter pass temperatures will have a direct effect on test results.

h) Only approved “iron-free” cutting and grinding disks shall be used.

i) Only approved marking materials (sulphur, chlorine free etc.) are to be used.

j) All material handling devices and equipment shall be adequately protected/lined, to

prevent the possibility of carbon “pick-up” (i.e. workbench, transport trucks, supports
etc.).

k) Wherever possible, tools shall be colour coded to prevent cross-use with other material
types.

11. Pre-head shall be applied through the full thickness of the joint and checked from the
opposite side wherever possible.

12. For repair welds, the pre-heating temperature shall be 500 C (1220 F) above that used
for the original weld. Maximum pre-heat for repair welding is 1500 C (3020 F).

13. Approved WPS. Internal misalignment for butt joints shall not exceed 1.5 mm
(1/16”).

14. Deposit the root pass and six (6) successive passes or 1/3 of the weld volume prior to
interruption (allowing to cool to ambient temperature).

15. Buttering (build-up) is permitted as follows: a) Buttering shall not exceed the lesser
of 10 mm or 1/3 base metal thickness. b) If buttering will exceed 10 mm or 1/3 base
metal thickness then this shall be witnessed by the customer and the area shall be tested
by PT/MT following completion of buttering but before final welding of the joint.

16. Back welding is permissible for all applications, so long as the same electrodes and
process is used as for the fill pass.

17. The following points shall be observed when fabricating/welding stainless and non-
ferrous materials:

a) Weld preps and filler materials shall be degreased using an appropriate solvent.

b) Weld prep surfaces shall be buffered using flapper wheels.

c) Argon hoses shall be checked for any loose connections or leakage etc.

d) Fit up geometry shall be in accordance with the applicable, approved WPS.

e) Bridge tacks to be used. Avoid tacking directly on to the adjacent pipe wall. Bridge
tack within the fusion faces of the joint wherever possible.

f) Prior to welding, the back purge shall be set up in accordance with the approved WPS
for a sufficient period of time to ensure an Oxygen content of less than 0.5%. When
available, “purge monitoring devices” shall be used.

g) Back purge shall be maintained for a minimum of four (4) passes. Pipe bungs (purge
dams) shall be left in place until completion of the joint.

h) The end of partly used filler wire shall be snipped off prior to use.

i) Maintain the tip of the filler rod within the gas shroud during welding to avoid
contamination.

j) Inter pass temperatures for these materials is critical. The welder shall check the
temperature prior to the next pass. All austenitic stainless welds on this project will be
tested for “Ferrite” content therefore, cleanliness during fabrication and monitoring of
inter pass temperatures will have a direct effect on test results.

k) Only approved “iron-free” cutting and grinding disks shall be used.

l) Only approved marking materials (sulphur, chlorine free etc.) are to be used.

m) All material handling devices and equipment shall be adequately protected/lined, to

prevent the possibility of carbon “pick-up” (i.e. workbench, transport trucks, supports
etc.).
n) Wherever possible, tools shall be colour-coded to prevent cross-use with other material
types.