This document summarizes the welding procedure qualification record for oxy-fuel welding of carbon steel. It includes 3 key points: 1) The welding process qualified was oxy-fuel welding of a single-V groove weld in the horizontal position using an RG 60 filler metal between 3.5mm thick carbon steel plates. 2) Mechanical testing was performed including tensile and bend tests, which met the requirements of ASME Section IX. Macro examinations also showed acceptable results. 3) Hardness testing found the weld metal had an average hardness of 186.5 HV, while the HAZ areas were 155.5 HV and the base metal was 143 HV, demonstrating acceptable hardness across the joint.

1. Page 1 of 2
PQR0.DOC
PQR Cat No: 0 PROCEDURE QUALIFICATION RECORD (PQR)
Procedure Details
PQR No : SP1-1-A-6-2
Company Name: Sasol PQR Date: 1992-10-09
Welding Process(es) Additional Information: N/A Joints (QW–402)
Root: OFW This is a special procedure with limited application Joint Design: Single-V groove weld
Main: OFW Backing: No
Cap: OFW Code/Standard: ASME IX, SP90-1, SP90-2 Type: N/A
Weld Preparation Bead Sequence
Base Metal (QW-403) Filler Metals (QW-404)
Type: Carbon Steel to Carbon Steel Process: OFW
P-No: 1 Gr No: 1 to P-No: 1 Gr No: 1 SFA Specification: 5.2
Spec: Type & Grade: SA 179 AWS Classification: RG 60*
Spec: Type & Grade: SA 179 Filler Metal F-No: 6
Thickness range: ASME: 3.5mm to 3.5mm Weld Metal A-No: 1
Diameter: 31.8mm Weld Metal “t”: Groove: 3.5mm
Heat Number: Not Recorded Trade Name: Not Recorded
Pass “t” (Max.): All passes were  10mm thick Solid / FluxCored: Solid
Other comments: N/A Batch number: Not Recorded
Consumable Handling: As per manufacturers recommendation
Other: *Special Proc
Position (QW-405)
Electrical Characteristics (QW-409) Gas (QW-408) Type % Composition Flow Rate
Position: Horizontal (2G) Tungsten Size: N/A Shield: GTAW N/A N/A N/A
Welding Progression: N/A Tungsten Type: N/A OFW Oxy-Acetylene Neutral-Oxi As Required
Other: N/A Transfer Mode: N/A Backing: N/A N/A N/A
Wire feed speed: N/A Other: N/A
Preheat (QW-406) Technique (QW-410)
Preheat Temperature: 5 °C Minimum Bead Type: Stringer/Weave Oscillation: N/A
Interpass Temperature: 200 °C Maximum No of Passes/Side: 3 Passes No of Electrodes: Single
Preheat Maintenance: No Back Gouging: None Peening: No
Other: N/A Orifice/Gas cup size: GTAW: N/A mm ID FCAW: N/A mm ID
Post Weld Heat Treatment (QW-407) CTWD: GTAW: N/A mm FCAW: N/A mm
Temperature Range: N/A °C ± N/A °C Initial Cleaning/Prep Method: Machining
Time Range: N/A Interpass Cleaning: Grinding/Brushing
Heating & Cooling Rates: N/A GTAW out of chamber: N/A GTAW with / without filler: N/A
Other: No PWHT Other: N/A
PQR Qualified with impact Testing: No Test Temperature: N/A °C Other: N/A
Weld Layer/Passes: 1 to 3 Other relevant Information:
Process: OFW This procedure was totally rewritten from another format to
standardise the format of SASOL SYNFUELS procedures to be
effective 011 November 2002. The original procedure information
is attached to the original package. For conformance to the
relevant codes, editorial corrections were made and the WPS was
issued with the next revision, but the catalogue number remained
the same. The PQR catalogue number also remained unchanged.
See page 2 of 2 for any additional information and test results.
Filler Metal: Classification: RG 60
Diameter: 2 mm
Polarity: N/A
Current: N/A
Voltage: N/A
Travel Method: Manual
Heat Input / Run Out Ratio: N/A
Other Comments: N/A
1mm
70°°
T = 3.5mm
1-3mm
OFW = 3.5mm

2. Page 2 of 2
PQR0.DOC
Cat No: 0
PROCEDURE QUALIFICATION RECORD (PQR)
2. Test Results
PQR No. SP1-1-A-6-2
Date: 1992-10-09
Tensile Tests (QW-150); (QW462)
Specimen
No:
Width
(mm)
Thickness
(mm)
Area
(mm2
)
Ultimate Load
(kN)
Ultimate Tensile
Strength (MPa)
Type of
Failure
Location of
failure
Other
1 10 3.3 33 12.9 390 Ductile Base Material None
2 10 3.3 33 12.6 382 Ductile Base Material None
3 10 3.3 33 13.7 415 Ductile Base Material None
N/A N/A N/A N/A N/A N/A N/A N/A N/A
ASME II part A requirements 325 Min
All Weld Tensile Test (QW-150)
Specimen
No:
Diameter
(mm)
Area
(mm2
)
Ultimate Load
(kN)
Ultimate Tensile
Strength (MPa)
Type of
Failure
Location of
failure
Other
N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A
Guided Bend Tests (QW-160); (QW-462) Fillet Weld Test (QW-180); (QW-462) Non Destructive Examination:
Macro done at 10 x magnification Type: Status: Report No:
Bend Angle: 180° Bend Former Size: 10mm Number of Fillet Weld Tests: 0 RT: N/A N/A
Bend number: Type: Type of bend: Results: Result Satisfactory (Yes/No): N/A UT: N/A N/A
1 Transverse Face bend Acceptable Penetration in Base Metal (Yes/No): N/A MPI: N/A N/A
2 Transverse Face bend Acceptable Macro Results Acceptable (Yes/No): N/A PT: N/A N/A
3 Transverse Root bend Acceptable Comments: N/A Visual: N/A N/A
4 Transverse Root bend Acceptable Other: N/A N/A
Impact Tests (QW-170): Notch Type: N/A Size: N/A Test Temperature: N/A °C
Specimen No: Notch Location: Impact Energy (J): Ave (J): Lateral Expansion (mm): % Shear fracture: Other:
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Hardness tests: Type: Vickers (HV) Load: 5 kg Lab. No: 87/485 Remarks: N/A
1st
2nd
3rd
Ave. Location of Hardness Measurements
Base Material 1 126 160 - 143.0
HAZ Material 1 154 157 - 155.5
Weld Metal 177 194 - 186.5
HAZ Material 2 154 157 - 155.5
Base Material 2 126 160 - 143.0
Additional Information: N/A
We certify that the statements in this record are correct and that the test welds were prepared, welded and tested in accordance with the requirements of Section IX of the ASME
Code and the Sasol SP Specifications.
By: Peter Smith
Signature:
Designation: Senior Welding Engineer
Date: 01 November 2002
Peter Smith
Name Print Stamp
Sasol Synfuels Welding Technology Date: Approved Inspection Authority Date:
Weld
HAZ 2
Base Mat. 2Base Mat. 1
HAZ 1
+
+ ++
+ +
+ +++
+
++ ++