PQR AWSPROCEDURE QUALIFICATION RECORDSTRUCTURAL WELDING CODE- AWS D1.1Doc NoPQ7-GM-16Mo3-B1GeneralManufacturer:Turnmill Proquip Engineering (PTY)Ltd.PWPS Number:GM-16Mo3-B1PQR No.:PQ7-GM-16Mo3-B1PWPS Revision:0Welder (1):J.A. Oosthuizen (3G Plate position)Stamp NoV33PWPS Date:13/04/2011Welder (2):M. Horn (2G plate position)Stamp NoV33:PQR Edit No:014/10/2014Code / Test Standard:AWS D1.1 2008Base MetalsMaterial 1:EN10028-2; 1992 16Mo3 (Cast No: 611695)P No.:Unassigned materialMaterial 2:EN10028-2; 1992 16Mo3 (Cast No: 611695)P No.:Unassigned materialThickness:25mmDiameter:N/A - Plate materialBacking:YesBacking Type:Weld metalInserts/Retainers:NoneWelding ConsumablesProcess:GMAWProcess Type:Semi-automaticFiller Specification:AWS A 5.28Filler Classification No.:ER80S-D2 ( ESAB OK Aristorod 13.08)Filler F-Number:F6Machine Current type:Constant Voltage (CV)Consumable Backing:N/AFlux Trade Name:N/ASup. Filler / Powder:NoneFlux Type:N/AFlux Wire Combination:N/ABacking:Weld metalProcess thickness:25mm MaxPreheat & Interpass TemperatureShielding & Backing GasPreheat Temperature:41C (3G) 46C (2G) minimumType:Coogar 84Heat Method:Propane Gas heating torch% Composition:13%CO2 3%O2 84%ArTemperature Check:Digital ThemometerFlow Rate:17-22L/minuteInterpass Temperature:169C (3G) 194C (2G) maximumOrifice Size:18mmHeat Area:100mm either side of the weldTrailing Gas:NoneP.H. Maintenance:NoneBacking Gas:NoneOther:NoneFlow Rate:N/AJoint DesignPass & Location SequencePreperation Method:Machine and GrindingMax. Run Thick:7mmInitial Clean:Ground/Wire brushGouge Method:Arcair gouge and grindMax. Run Type:GMAWInterpass Clean:Grind & Wire brushProcessPass No.Consumable TypeFiller Size (mm)Weld PositionAmps (A)Volts (V)Travel Speed (mm/min)Prog.I Type/ PolarityWire Speed (m/min)Heat Input (Max)OtherGMAW1 to 12ER80S-D21.20 mmVertical2102348.7-180UphillDC EP7.9201.605 - 5.950Non pulsedBackgouge grind and reweldGMAW13ER80S-D21.20 mmVertical21023116UphillDC EP7.9202.494Non pulsedGMAW1 to 18ER80S-D21.20 mmHorizontal170-26025-26162-516N/ADC EP6.24-10.980.772-1.620Non pulsedBackgouge grind and reweldGMAW19 to 21ER80S-D21.20 mmHorizontal25726368-602N/ADC EP11.3400.666-1.088Non pulsedWelded in the 3G positionWelding TechniqueSingle/Multiple Arc:Single arcElectrode Spacing:N/ASingle/Multi Pass:MultipassTransfer Mode:Globular TransferSides Welded:Both side weldedOscillation:NoneString/Weave Bead:String and weavePeening:NoneFiller Added(GTAW):N/ACTWD:19mmSAW Recrushed Slag:Not usedTungsten Type:N/ASolid/Tubular Wire:Solid for GMAWTungsten Size:N/APost Weld Heat TreatmentHeating Rate:N/ACooling Rate:N/AHolding Temperature:N/AMethod:N/AHolding Time:N/AOther:No PWHTNon-Destructive Examination (Ref)Radiography (RT):Acceptable -see Philver Services Report No: DF-0130Ultrasonics (UT):NoneMagnetic Particle (MT)NoneDye Penetrant (PT):NoneVisual (VT):100 % AcceptableDestructive Testing - METLAB Report no: 11-2375 A1 AmendedTensile Test (4.8.3.4 and Fig 4.14)MarkWidth (mm)Thickness (mm)Area (mm)Ultimate Load (KN)Tensile Strength (Mpa)Fracture Location & Appearance120.0625.23506.11251.70497Parent Metal / Ductile220.1125.15505.77252.60499Parent Metal / DuctileComments:- Two reduced section Tension tests per 4.8.3.4 and Fig 4.14 See METLAB Report No: 11-2375 A1 AmendedRound Tensile Test:NoneMarkDiameter (mm)Area (mm2)Ultimate Load (KN)Tensile Strength (Mpa)Yield Strength (Mpa)0.2 % Proof Stress (Mpa)Elong %Gauge Length (mm)Reduction in area %Bend Test (4.8.3.1 and Fig 4.13)Bend Angle:180OFormer Size:38mmTypeResultTypeResultsSide Bed1Acceptable No Visible DefectsSide Bend 3Acceptable No Visible DefectsSide Bed2Acceptable No Visible DefectsSide Bend 4Acceptable No Visible DefectsComment:- See METLAB Report No: 11-2375 A1 Amended . The size of the former is based on Figuree 4.15Impact Tests:NoneSize:NoneTest Temp.NoneMarkLocationImpact Strength (J)Lateral ExpansionShear Fracture %(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)RemarksComments1.) Macro Examination Conducted METLAB Report No: 11-2375 A1 - Acceptable (3 off)2.) Hardnes Vickers done on crossection of the weld for information only. See METLAB Report No: 11-2375 A1 Amended3.) Hardness Brinell done on both top and bottom surfaces of the weld for information only. See METLAB Report No: 11-2375 A1 AmendedWe Certify that the welds were prepared, welded and tested and that the statements in this record are in accordance withsection 4 of ANSI/AWS D1.1-2008 Structural Welding code-SteelAPPROVALSManufacturerKusile Power ProjectHitachi AfricaEskomMoody InternationalDesignationWelding EngineerWelding EngineerNameRodwell BaloyiPeter SmithDate15-10-2014Stamp & SignatureStatusEdit 1Welded in the 2G positionWelding TechniqueSingle/Multiple Arc:Single arcElectrode Spacing:N/ASingle/Multi Pass:MultipassTransfer Mode:Root: Short Circuit. Fill & Cap: Globular/Spray TransferSides Welded:Both side weldedOscillation:NoneString/Weave Bead:StringPeening:NoneFiller Added(GTAW):N/ACTWD:18mmSAW Recrushed Slag:Not usedTungsten Type:N/ASolid/Tubular Wire:Solid for GMAWTungsten Size:N/APost Weld Heat TreatmentHeating Rate:N/ACooling Rate:N/AHolding Temperature:N/AMethod:N/AHolding Time:N/AOther:No PWHTNon-Destructive Examination (Ref)Radiography (RT):Acceptable -see Philver Services Report No: DF-0134 AUltrasonics (UT):NoneMagnetic Particle (MT)NoneDye Penetrant (PT):NoneVisual (VT):100 % AcceptableDestructive Testing - METLAB Report no: 11-2477 A1 AmendedTensile Test (4.8.3.4 and Fig 4.14)MarkWidth (mm)Thickness (mm)Area (mm)Ultimate Load (KN)Tensile Strength (Mpa)Fracture Location & Appearance120.1825.27509.95254.10498Parent Metal / Ductile220.1425.15506.52255.10504Parent Metal / DuctileComments:- Two reduced section Tension tests per 4.8.3.4 and Fig 4.14 See METLAB Report No: 11-2477 A1 AmendedRound Tensile Test:NoneMarkDiameter (mm)Area (mm2)Ultimate Load (KN)Tensile Strength (Mpa)Yield Strength (Mpa)0.2 % Proof Stress (Mpa)Elong %Gauge Length (mm)Reduction in area %Bend Test (4.8.3.1 and Fig 4.13)Bend Angle:180OFormer Size:38mmTypeResultTypeResultsSide Bed1Acceptable No Visible DefectsSide Bend 3Acceptable No Visible DefectsSide Bed2Acceptable No Visible DefectsSide Bend 4Acceptable No Visible DefectsComment:- See METLAB Report No: 11-2477 A1 Amended . The size of the former is based on Figuree 4.15Impact Tests:NoneSize:NoneTest Temp.NoneMarkLocationImpact Strength (J)Lateral ExpansionShear Fracture %(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)(1) (2) (3)RemarksComments1.) Macro Examination Conducted METLAB Report No: 11-2477 A1 - Acceptable (3 off)2.) Hardnes Vickers done on crossection of the weld for information only. See METLAB Report No: 11-2477 A Amended3.) Hardness Brinell done on both top and bottom surfaces of the weld for information only. See METLAB Report No: 11-2477 A Amended.We Certify that the welds were prepared, welded and tested and that the statements in this record are in accordance withsection 4 of ANSI/AWS D1.1-2008 Structural Welding code-SteelAPPROVALSManufacturerKusile Power ProjectHitachi AfricaEskomMoody InternationalDesignationWelding EngineerWelding EngineerNameDick WuisPeter SmithDate26-01-2012Stamp & SignatureStatusEdit 1

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PRS AWSPARAMETER RECORD SHEETDoc NoPQ-GM-16Mo3-B1Ref. No.Manufacturer:Turnmill Proquip Engineering (PTY)Ltd.Welders Name:J.A. Oosthuizen (3G Plate position)Identity No.:720217 5039 085Stamp No.:Y:M. Horn (2G plate position)Identity No.:750919 5217 081Stamp No.:MEdit No.:4Date:26-01-2012Shop/Field:ShopCode:AWS D1.1 2008ProcessRun No.Elec. No.Size (mm)Length (mm)Volts (V)Amps (A)Preheat CR.O.L. (mm)R.O.T. (Secs)Run width (mm)Run Thick (mm)Stub Length (mm)Wire feed Speed m/minWeld Speed (mm/min)Heat input (kJ/mm)Test plate welded in the Vertical up position by Welder J.A. OosthuizenGMAW1-1.20-2321042C31217885-7.92105.22.756GMAW2-1.20-2321043C316166103-7.92114.22.537GMAW3-1.20-2321060C319249163-7.9276.93.770GMAW4-1.20-2321091C317388174-7.9249.05.912GMAW5-1.20-2321086C313104124-7.92180.61.605GMAW6-1.20-23210106C312190154-7.9298.52.941GMAW7-1.20-23210123C319393234-7.9248.75.950GMAW8-1.20-23210109C316156114-7.92121.52.384GMAW9-1.20-23210133C31413394-7.92141.72.046GMAW101.20-23210144C312123104-7.92152.21.904GMAW111.20-23210169C322174103-7.92111.02.610GMAW121.20-2321041C30511472-7.92160.51.805Second sideGMAW131.20-2321042C30615875-7.92116.22.494Test plate welded in the Horizontal position by Welder M.HornGMAW1-1.20-2517046C30111185-6.24162.71.567GMAW2-1.20-2625093C301709.55-10.20258.01.512GMAW3-1.20-26250100C30175116-10.20240.81.620GMAW4-1.20-26250119C30170115-10.20258.01.512GMAW5-1.20-26250124C3015211.55.5-10.20347.31.123GMAW6-1.20-26250142C30174107-10.20244.11.598GMAW7-1.20-26250157C30159105-10.20306.11.274GMAW8-1.20-26250148C30163115-10.20286.71.360GMAW9-1.20-26250165C30141116-10.20440.50.885GMAW10-1.20-26250137C30150117-10.20361.21.080GMAW11-1.20-26250152C3014185-10.20440.50.885GMAW12-1.20-26260171C30140115-10.98451.50.898GMAW13-1.20-26260194C3013595-10.98516.00.786GMAW14-1.20-25200180C29850102.5-7.80357.60.839GMAW15-1.20-25200143C29846112.5-7.80388.70.772GMAW16-1.20-25200170C2984611.53-7.80388.70.772GMAW17-1.20-25200137C29850113-7.80357.60.839GMAW18-1.20-25200166C29861113-7.80293.11.023Second sideGMAW19-1.20-26257113C30149104-11.34368.61.088GMAW20-1.20-26257157C30130102-11.34602.00.666GMAW21-1.20-26257165C30147123-11.34384.31.043Process:GMAWType:Semi-automatic*Remarks: NoneManufacturerKusile Power ProjectHitachi AfricaEskomMoody InternationalDesignationWelding EngineerWelding EngineerNameDick WuisPeter SmithDate26-01-2012Stamp & SignatureStatus

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WQR 1 AWSWelder/Welding Operator or Tack Welder Performance Qualification RecordAWS D1.1 Structural Welding Code - SteelWELDER'S DETAILEmployer:Turnmill Proquip Engineering (PTY) Ltd.Welder:J.A. Oosthuizen (3G Plate position)Designation:WelderIdentity No.:720217 5039 085Stamp Number:YCertification No.:21/02/11A-(AWS D1.1)Identification Method:I.D. DocumentDate of Birth:17/02/1972Place of Birth:No recordJob Knowledge:Not testedCode / Testing Standard:AWS D1.1 2008WELDING DETAILSWelding Process:GMAWProcess Type:Semi AutomaticWPS Followed:WP GM-16Mo3-B1Material 1:EN10028-2; 1992 16Mo3Thickness:25mmMaterial 2:EN10028-2; 1992 16Mo3Thickness:25 mmVARIABLESACTUAL VALUEQUALIFICATION RANGEBacking:GMAW - YesGMAW - With backingMaterial 1 P-No.:EN10028-2; 1992 16Mo3 - Unassigned material.Unassigned materials of similar chemical comp.Material 2 P-No.:EN10028-2; 1992 16Mo3 - Unassigned material.Unassigned materials of similar chemical comp.Diameter:N/A (Plate mat'l)609mm O.D. and above in Flat position.Filler A No & AWS No.:A 5.28; AWS ER80S-D2A 5.28; AWS ER80S-D2 onlyMachine Current Type:Constant VoltageConstant VoltageWire feed speed:7.92m/minute7.128-8.712m/minuteNo of Electrrodes:SingleSingle onlyConsumable Insert:NoneWithout insertsDeposit Thick./Process:GMAW-25mmTotal weld thickness 3mm-UnlimitedWeld Position:VerticalVertical up and FlatWeld Progression:UphillUphill onlyWeld Type:GrooveGrooves and filletsGas /Flux Type:Mixed gas. (Cougar 84)Mixed gas. (Cougar 84) - onlyTransfer Mode GMAW:Globular & SprayGlobular and SprayCurrent Type:Direct Current (DC)Direct Current (DC) - onlyPolarity:Electrode +veElectrode +ve - onlyControl Method:N/AN/AJoint Tracking:Direct visualDirect visualRemarks:Welder qualified as part of the PQR PQ-GM-16Mo3-B1TEST DETAILSBend test:METLAB Report No 11-2375 A1Bend Angle:180Former Size:38mmTypeResultTypeResultsSide bend 1AcceptableSide bend 2AcceptableSide bend 3AcceptableSide bend 4AcceptableVISUAL Examination:100% AcceptableRADIOGRAPHY TEST:100% to QW 191 See Philver RT Report No:- DF 0130Result:AcceptableFILLET WELD TEST:NoneFracture Test (1):N/AFracture Test (2):N/ADefect Length (mm):N/ADefect %:N/AMacro Test Fusion:N/AAppearance Test Fusion:N/AAppearance Fillet Size (Leg) (mm x mm) (1):N/AAppearance Fillet Size (Leg) (mm x mm) (2):N/AConvexity (mm):N/AConcavity (mm):N/ACERTIFICATIONWE THE UNDERSIGNED, CERTIFYTHAT THE STATEMENTS IN THIS RECORD ARE CORRECT AND THAT THE TEST WELDS WERE PREPARED, WELDED, ANDTESTED IN CONFORMANCE WITHTHE REQUJIREMENTSOF CLAUSE 4 OF AWS D1.1/D1.1M, ( 2008 ) Structural Welding Code - SteelManufacturerKusile Power ProjectHitachi AfricaEskomMoody Int S.A.DesignationWelding EngineerWelding EngineerNameDick WuisPappy MwilambweDate02/11/2011Stamp & SignatureStatusWELDER'S DETAILEmployer:Turnmill Proquip Engineering (PTY) Ltd.Welder:J.A. Oosthuizen (3G Plate position)Designation:WelderIdentity No.:720217 5039 085Stamp Number:YCertification No.:21/02/11AIdentification Method:I.D. DocumentDate of Birth:17/02/1972Place of Birth:No recordJob Knowledge:Not testedCode / Testing Standard:AWS D1.1 2008DATENAMESIGNATURECERTIFIED BYSIGNATURESTAMPREMARKSWE, THE ABOVESIGNED, DECLARE THAT THE WELDER NAMED ABOVE HAS BEEN REGULARLY AND SATISFACTORYEMPLOYED ON WORK COVERED BY THIS TEST CERIFICATE DURING THE SIX MONTHS PRECEEDING THE DATE OF OURSIGNATURES.

WQR 2 AWSWelder/Welding Operator or Tack Welder Performance Qualification RecordAWS D1.1 Structural Welding Code - SteelWELDER'S DETAILEmployer:Turnmill Proquip Engineering (PTY) Ltd.Welder:M. Horn (2G plate position)Designation:WelderIdentity No.:750919 5217 081Stamp Number:MCertification No.:21/02/11AIdentification Method:I.D. DocumentDate of Birth:19/09/1975Place of Birth:No recordJob Knowledge:Not testedCode / Testing Standard:AWS D1.1 2008WELDING DETAILSWelding Process:GMAWProcess Type:Semi AutomaticWPS Followed:WP GM-16Mo3-B1Material 1:EN10028-2; 1992 16Mo3Thickness:25mmMaterial 2:EN10028-2; 1992 16Mo3Thickness:25 mmVARIABLESACTUAL VALUEQUALIFICATION RANGEBacking:GMAW - YesGMAW - With backingMaterial 1 P-No.:EN10028-2; 1992 16Mo3 - Unassigned material.Unassigned materials of similar chemical comp.Material 2 P-No.:EN10028-2; 1992 16Mo3 - Unassigned material.Unassigned materials of similar chemical comp.Diameter:N/A (Plate mat'l)609mm O.D. and above in Flat position.Filler A No & AWS No.:A 5.28; AWS ER80S-D2A 5.28; AWS ER80S-D2 onlyMachine Current Type:Constant VoltageConstant VoltageWire feed speed:6.24-11.34m/minute5.616-12.474m/minuteNo of Electrrodes:SingleSingle onlyConsumable Insert:NoneWithout insertsDeposit Thick./Process:GMAW-25mmTotal weld thickness 3mm-UnlimitedWeld Position:HorizontalHorizontal and FlatWeld Progression:N/AN/AWeld Type:GrooveGrooves and filletsGas /Flux Type:Mixed gas. (Cougar 84)Mixed gas. (Cougar 84) - onlyTransfer Mode GMAW:Globular & SprayGlobular and SprayCurrent Type:Direct Current (DC)Direct Current (DC) - onlyPolarity:Electrode +veElectrode +ve - onlyControl Method:N/AN/AJoint Tracking:Direct visualDirect visualRemarks:Welder qualified as part of the PQR PQ-GM-16Mo3-B1TEST DETAILSBend test:METLAB Report No 11-2477 A1Bend Angle:180Former Size:38mmTypeResultTypeResultsSide bend 1AcceptableSide bend 2AcceptableSide bend 3AcceptableSide bend 4AcceptableVISUAL Examination:100% AcceptableRADIOGRAPHY TEST:100% to QW 191 See Philver RT Report No:- DF 0134 AResult:AcceptableFILLET WELD TEST:NoneFracture Test (1):N/AFracture Test (2):N/ADefect Length (mm):N/ADefect %:N/AMacro Test Fusion:N/AAppearance Test Fusion:N/AAppearance Fillet Size (Leg) (mm x mm) (1):N/AAppearance Fillet Size (Leg) (mm x mm) (2):N/AConvexity (mm):N/AConcavity (mm):N/ACERTIFICATIONWE THE UNDERSIGNED, CERTIFYTHAT THE STATEMENTS IN THIS RECORD ARE CORRECT AND THAT THE TEST WELDS WERE PREPARED, WELDED, ANDTESTED IN CONFORMANCE WITHTHE REQUJIREMENTSOF CLAUSE 4 OF AWS D1.1/D1.1M, ( 2008 ) Structural Welding Code - SteelManufacturerKusile Power ProjectHitachi AfricaEskomMoody Int S.A.DesignationWelding EngineerWelding EngineerNameDick WuisPappy MwilambweDate02/11/2011Stamp & SignatureStatusWELDER'S DETAILEmployer:Turnmill Proquip Engineering (PTY) Ltd.Welder:M. Horn (2G plate position)Designation:WelderIdentity No.:750919 5217 081Stamp Number:MCertification No.:21/02/11AIdentification Method:I.D. DocumentDate of Birth:19/09/1975Place of Birth:No recordJob Knowledge:Not testedCode / Testing Standard:ASME IX 2010DATENAMESIGNATURECERTIFIED BYSIGNATURESTAMPREMARKSWE, THE ABOVESIGNED, DECLARE THAT THE WELDER NAMED ABOVE HAS BEEN REGULARLY AND SATISFACTORYEMPLOYED ON WORK COVERED BY THIS TEST CERIFICATE DURING THE SIX MONTHS PRECEEDING THE DATE OF OURSIGNATURES.