WELDING PROCEDURE SPECIFICATION No. EPI-11

WELDING PROCEDURE SPECIFICATION No. EPI-11- WP9 Rev. 1 January 29, 2012

Company: Enbridge Pipelines Inc., PO Box 398, 10201 Jasper Avenue, Edmonton, AB T5J 2J9 Scope: This welding procedure specification details the procedure to be followed for Thru-Wall or

Partial Wall Repair Welding of pipe as required by CSA Standard Z662-11 Oil and Gas Pipeline Systems.

Service Restrictions: Sweet or Sour Temperature Restrictions: Notch Toughness Tested to -5°C (23°F)

Note: This revision added supporting PQR (EPI-08-WP9) to extend welding parameter range to cap pass only.

1. WELDING PROCESS & METHOD

Shielded Metal Arc Welding (SMAW) - Manual Method

2. JOINT GEOMETRY

a) Joint Type: Groove – Single Vee Butt b) Bevel Angle: See Drawing c) Root Face: 1.6 mm (0.063 in.), ±0.8 mm (0.032 in.) d) Root Gap: 1.6 mm (0.063 in.), ±0.8 mm (0.032 in.)

The surfaces to be welded shall be smooth, uniform, free of fins, laminations, tears, scale, slag, grease, paint or other foreign matter, which may adversely affect the welding.

3. BASE MATERIAL

a) Composition: This specification applies to pipe and/or component material manufactured in accordance with, or listed as “Acceptable Alternative Materials” in any of the following standards:

CSA Z662, Oil and Gas Pipeline Systems CAN/CSA-Z245.1 Steel Line Pipe CAN/CSA-Z245.11, Steel Fittings CAN/CSA-Z245.12, Steel Flanges CAN/CSA-Z245.15, Steel Valves

b) Material Grades 483 MPa (SMYS) or less c) Wall Thickness Qualified: 4.0 to 27.8 mm (0.157 to 1.10 in.) inclusive d) Pipe Diameter Qualified: 457 mm (18 in.) OD minimum e) CSA Carbon Equivalent: 0.32 maximum for >Gr.386 (SMYS)

4. FILLER METAL CLASSIFICATION & SIZE

a) Root Pass: E6010; 4.0 mm (5/32 in.) b) Hot Pass: E8010-G; 4.0 mm or 5.0 mm (5/32 or 3/16 in.) c) Fill Pass (es): E8018-C3; 2.4, 3.2 or 4.0 mm (3/32, 1/8 or 5/32 in.) d) Cap Pass (es): E8018-C3; 2.4, 3.2 or 4.0 mm (3/32, 1/8 or 5/32 in.)

5. POSITION & DIRECTION OF WELDING

a) Position: 5G (Pipe Horizontal, Fixed Position) b) Direction of Welding: Vertical Down

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6. PREHEATING, INTERPASS TEMPERATURE & CONTROLLED COOLING

a) A minimum preheat temperature of 120°C (250°F) shall be applied to an area of at least 150 mm (6 in.) from any point to the area to be repaired. Note: The entire girth weld will be preheated to 38°C (100°F) prior to grinding repair and maintained once welding starts until repair completion.

If the interpass temperature falls below the minimum preheat temperature, the entire weld repair area shall be heated to the minimum preheat temperature prior to starting the next weld pass.

The maximum interpass temperature shall not exceed 204°C (400°F).

Preheating may be applied by oxy-fuel torch, propane torch, electrical induction coils or any other method approved by Enbridge.

Preheat temperature shall be checked using temperature indicating crayons, thermocouple pyrometers or other suitable method approved by Enbridge to determine that the required preheat temperature is obtained prior to, and maintained during the welding operation.

Where applicable, precautions shall be taken through the use of insulating covers or other means to control the cooling rate of the weld after any pass.

7. POST WELD HEAT TREATMENT

Welds prepared in accordance with this specification shall not be subjected to post-weld heat treatment.

8. ELECTRICAL CHARACTERISTICS

a) Current Type: Direct Current, Reverse Polarity (DCRP) b) Amperage, Voltage and Travel Speed: See TABLE # 1 c) Heat Input: See TABLE # 1

9. TECHNIQUE

a) Minimum number of root & hot pass welders: One b) Stringer or Weave Bead:

Root & Hot Pass: String; Fill & Cap Pass: String or Weave

Number of Weld Layers: Four weld layers minimum for full thru-wall repair.

c) Cleaning methods: Hand or power tools may be used. Each pass shall be thoroughly cleaned and free of slag and scale prior to depositing the next weld layer. The completed weld shall be brushed and free of spatter.

d) Filler and Finish Beads and Finish to be Achieved: Weld repairs shall be completed in a full operation without stopping. The completed welds shall have a substantially uniform cross-section for its entire circumference. The crown of the weld shall not be below the surface of the adjacent base material.

10. REMOVAL AND REPAIR OF DEFECTS

Repairable defects shall be removed by grinding. The minimum length of any repair shall be 50.8 mm (2.0 in.). Welding shall be performed following the details outlines in this specification.

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11. ATTACHMENTS a) Procedure Qualification Test Records: EPI-11-WP-9 & EPI-08-WP9-1 b) Laboratory Test Reports: E11-1117.3 & E08-213.18 c) NDT Examination Results: RTD AUT Report No. 7 17-11-2011 RTD RT Report No. PS12805 & Report No’s 12522 & 2585 d) Material Test Report: PCK Heat # 11201828 & Evraz Heat # 591747

TABLE # 1 WELDING PARAMETERS

Bead Number

Electrode Welding

Progression

Amperage Range

amperes

Voltage Range volts

Travel Speed mm/min (in./min)

Heat Input J/mm (J/in.)

Size mm (in.)

AWS Class

Root 4.0 (5/32) E6010 Down 92 – 144 21 – 34 127 – 241 (5.0 – 9.5) 0.80 – 1.35

(20,415 – 34,171)

Hot 4.0 (5/32)

or 5.0 (3/16)

E8010-G Down 113 – 190 22 – 35 258–467 (10.2 – 18.2) 0.57 – 0.85

(14,389 – 21,704)

Fill(s) 2.4 (3/32)

or 3.2 (1/8)

E8018-C3 Up 78 – 169 17 – 31 41 – 127 (1.6 – 5.0) 1.11 – 4.13

(27,936 – 105,336)

Cap 2.4 (3/32)

or 3.2 (1/8)

E8018-C3 Up 98 – 186 18 – 28 34 – 107 (1.2 – 4.2) 1.92 – 4.68

(48,836 – 122,760)

Note – The use of stripper passes is optional.

JOINT COMPLETION AND PASS SEQUENCE:

~3.5 mm

1.6 mm±0.8 mm

1.6 mm±0.8 mm

PQR # EPI-11-Wp-9 ELECTRODE LINCOLN 5 P+ E6010 Root Pass

DATE LINCOLN 8P+ E8010-G HP

WELDERS Brooks Aitken Not Available E8018-C3 Fill & Cap

Kevin O'Brien POWER SUPPLY Not Available

BASE MATERIAL CSA Z245.1

PIPE GRADE 483 Cat. 1 POLARITY Direct Current, Reverse Polarity

PIPE MANUFACTURER PCK

HEAT # 11201828 NOTES:

CSA Z662 CARBON EQUIVALENT 0.27 Weld Parameters sampled per full side completed

DIMENSIONS NPS 36" X 22.2mm Preheat checked - Contact Thermocouple, Tempil Stick, IR Thermometer

WELDING PROGRESSION Downhill Interpass Cleaning, Grind or Powerbrush as required

POSITION 5G Time between Bead and HP: 10 mins

PRE HEAT / MIN INTERPASS 149°c minimum Time between HP & First Fill: 7 - 34 mins

MAX INTERPASS 200°C maximum Time between Fill & Cap: 4 - 9 mins

Root Opening 1.6 - 2.4 mm

WELD PARAMETERS

Preheat

(Celcius)

in. mm High Low High Low Distance Time (s) IPM Celcius High Low

Bead-T E6010 5P+ 1/8 3.2 #DIV/0! 140 #DIV/0! #DIV/0!

Bead-B E6010 5P+ 1/8 3.2 #DIV/0! 140 #DIV/0! #DIV/0!

HP-T E8010-G 5/32 4.0 #DIV/0! 135 #DIV/0! #DIV/0!

HP-B E8010-G 5/32 4.0 #DIV/0! 135 #DIV/0! #VALUE!

Fill 1-T E8018-C3 3/32 2.4 #DIV/0! 140 #DIV/0! #DIV/0!

Fill 1-B E8018-C3 3/32 2.4 #DIV/0! 130 #DIV/0! #DIV/0!








Cap 1-T E8018-C3 1/8 3.2 #DIV/0! 130 #DIV/0! #DIV/0!

Cap 1-B E8018-C3 1/8 3.2 #DIV/0! 135 #DIV/0! #DIV/0!

SEE LUDWIG WELDING DATA SHEET REF:

E11-1117.3

Heat Input (KJ/mm)

Class

Diameter

Pass

Electrode Voltage Amperage Travel Speed

ENBRIDGE PROCEDURE QUALIFICATION TEST REPORT

17-Nov-11

JOINT DESIGN

Joint Geometry and Fit-Up Joint Completetion and Pass Sequence

ENBRIDGE PIPELINES INC. Weld Parameter Calculations

Weld PQR: EPI-11-WP-9Pass Class Size (mm) Amperage Voltage mm/min in/min kJ/mm J/inch

Root-T E6010 3.2 120 28.0 201 7.9 1.00 25,519 Heat Input Calculated by using:

Root-B E6010 3.2 115 26.0 159 6.3 1.13 28,476

Hot-T E8010-G 4.0 158 29.0 389 15.2 0.71 18,087 Average Recorded Amps x Average Recorded Volts x 60

Hot-B E8010-G 4.0 141 27.0 323 12.7 0.71 17,986

Fill-1-T E8018-C3 2.4 100 26.0 106 4.2 1.47 37,143

Fill-1-B E8018-C3 2.4 97 21.0 88 3.5 1.39 34,920

Fill-2-T E8018-C3 2.4 110 25.0 89 3.5 1.85 47,143

Fill-2-B E8018-C3 2.4 104 22.0 51 2.0 2.69 68,640

Fill-3-T E8018-C3 3.2 141 24.0 99 3.9 2.05 52,062

Fill-3-B E8018-C3 3.2 128 22.0 63 2.5 2.68 67,584

Fill-4-T E8018-C3 3.2 141 23.0 82 3.2 2.37 60,806

Fill-4-B E8018-C3 3.2 133 22.0 51 2.0 3.44 87,780

Fill-5-T E8018-C3 3.2 141 23.0 52 2.1 3.74 92,657

Fill-5-B E8018-C3 3.2 133 22.0 51 2.0 3.44 87,780

Cap-1-T E8018-C3 3.2 136 23.0 55 2.2 3.41 85,309

Cap-1-B E8018-C3 3.2 124 22.0 42 1.6 3.90 102,300

Class Size (mm) Minimum Maximum Minimum Maximum

ROOT E6010 3.2 92 144 21 34 127 241 5.0 9.5 0.80 1.35 20415 34171

HOT E8010-G 4.0 113 190 22 35 258 467 10.2 18.2 0.57 0.85 14389 21704

FILL-1 E8018-C3 2.4 78 120 17 31 70 127 2.8 5.0 1.11 1.77 27936 44571

FILL-2 E8018-C3 2.4 83 132 18 30 41 107 2.0 4.2 1.48 3.23 37714 82368

FILL-3 E8018-C3 3.2 102 169 18 29 43 119 2.0 4.7 1.64 3.22 41649 81101

FILL-4 E8018-C3 3.2 106 169 18 28 41 98 1.6 3.8 1.90 4.13 48645 105336

FILL-5 E8018-C3 3.2 106 160 18 26 41 61 1.6 2.4 2.75 4.13 70224 105336

CAP-1 E8018-C3 3.2 99 163 18 28 34 66 1.2 2.6 2.73 4.68 68247 122760

Actual Arc Speed

PROCEDURE QUALIFICATION RECORD-WELDING PARAMETERS VALUES-MANUAL SMAW WELDING

Insert Actual

Values Here

CSA Tolerance

Amps,Volts &

Arc Speed,

Heat Input; +/-

20%)

Weld Pass

Electrode Amperage Voltage

Arc Speed Heat Input

Minimum

(mm/min)

Maximum

(mm/min)

Minimum

(in/min)

Maximum

(in/min)

Minimum

(kJ/mm)

Maximum

(kJ/mm)

Minimum

(J/inch)

Maximum

(J/inch)

Electrode Arc Speed Heat Input

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huntleyb

Rectangle

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WELDING PROCEDURE SPECIFICATION No. EPI-11

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