CORGNATING COMPARE Consolidated Contracting Engineering & Procurement S.A.L. Offshore [DOCUMENT NUMBER: KED1-B0-000-CC-Q-PR-0032-000 ‘CONTRACT DESCRIPTION: Hook-up, pre-commissioning & commissioning Assistance Project ‘AGIPKCOCONTAACT NO: 2009-0363 ‘CONTRACTOR'S 108 NO: ‘SHEET NO, 10F 15, ‘CONTRACTOR'S DOCUMENT NUMBER: QCP-1035-101 DocuMENT nie: QCP for Weld Consumables Control - Piping ABSTRACT: The purpose of this document Is to define the minimum requirements for receiving, storage, issuing and treatment of welding consumables as applicable to CCC scope of work for the Hook-up, pre-commisstoning & commissioning Assistance Project aby tae commer by CC KASHACAN EP OFFSHORE PROJECT AGIPKCO COMMENTS MASTER, APPROVED - NO COMMENTS, ‘Contractor wil evubsuit thi document at au approved (Sor Co revisit level far sigotury by tne COMPANY and tn upd ints IMIS. "APPROVED - WITH COMMENTS 2, | Cantraser will she the document tinchude way commen snd revubmi this decaunent ut an approved (Ao € res at Bevel or the COMPANY and thea upload ints IMS REJECTED - WITH COMMENTS 3. | (eutrastr will revise the document inehide snp comments und revubind this deceeat through EMIS 1 the wext pruiiinary revision 1 evel for furter review by the COMPANY FOR INFORMATION ONLY — This document does not require review by the CUMEANY, Cemtnactor D | seit resus tts document tsa appn COMPANY telealy sta plead ive MIS YOU NAME: COSIGN: ip RCD review wr acceptance chal waters away alg PepamsTBiiTy wad aa rok ‘relieve the contactor foo eas contractual respensbalitis. ST hina p01 | 28-05-2010 ISSUE FOR REVIEW lon Steltan Tivichi REV DATE REASON FOR ISSUE PREPAREDhom, Kazakhstan North Caspian Operating Company N.V Doc Ni Hook-up, pre-commissioning & commissioning assistance project lo. KE01-B0-000-CC-0-PR-0032-000 QCP for Weld Consumables Control REVISION DESCRIPTION SHEET Sheet 2 i Pot Hold No Rev Para. Revision Description pon Issue for review Para. Description of HoldBe, scesithcran Neath caapteni Ne. ; cent ; Doc ‘Anip Kazakhstan North Caspian Operating Company NV | reo1.50 000.6007 Hook-up, pre-commissioning & commissioning assistance projcet QCP for Weld Consumables Control Sheet 3 Rev, Pot WELD CONSUMBLES CONTROLBaveKco . . DOC No. ‘Agip Kazakhstan North Caspian Operating Company N.V E01 co 20: Hook-up, pre-commissioning & commissioning assistance project QCP for Weld Consumables Control Sheet 4 Rev. P01 1. SCOPE PURPOSE REFERENCES DEFINITIONS. RESPONSIBILITIES pw ke OD PROCEDURE ATTACHMENTS 2Mist, carakantan North Caspian Operating C NV i sip 8 North Caspian Operating Company N.V | veo, cnn Hook-up, pre-commissioning & commissioning assistance project QCP for Weld Consumables Control Sheet 5 Rev. POt 1. SCOPE 1.1 The scope of this procedure is specifics the minimum requirements for receiving. storage, issuing and treatment of welding consumables. In the context of this procedure, welding consumables are electrodes, welding wires, fluxes and welding grade gasses as applicable to CCEP scope of work for the Hook-up, Pro-commissioning, and commissioning assistance project in full compliance with Ref. 3.1, 3.2, 33, 3.4 and 3.5 below. 2, PURPOSE 2.1 The purpose of this procedure is to ensure that welding consumables are received, stored issued and treated in a controlled manner. Control of welding consumables is important in order to assure the quality of the welding process. 2.2. Additionally the purpose of this Quality Procedure is to address and cover the requirements of ISO 9001:2008 paragraphs 6 3, 6 4, 7.5 1 and 7 5 2 dealing with Process Control 3. REFERENCES 3.1 ASME IX Welding and Brazing Qualifications 3.2 ASME B31.3 ASME Code for Process Piping 3.3 ASME Section II Part C ‘Specifications for Welding Rods, Electrodes and Filler Metals 3.4 KE01-00-000-KD-V-SS-0018-000 Specification for Welding of Piping & Fittings 3.5 KEOI-B4-000-KD-V-ST-0002-000 High Pressure Piping Welding & Fabrication Specification 3.6 KEO1-B0-000-CC-Q-PR-0031-000/QCP-1035-100) Weld Control - Piping 3.7 KE01-D0-000-CC-Q-PR-0055000(/OMP-1 035-010) Inspection Measurement and Testing Equipment 4. DEFINITIONS 4.1 COMPANY Agip Kazakhstan North Caspian Operating Company N.V. 42 CCEP Consolidating Contracting Engineering & Procurement SAL Offshore 4.3 QCP Quality Control Procedure 4a TTP Inspection & Test Plan 4.5 WPS Welding Procedure Specific 46 GTAW Gas Tungsten Are Welding 47 SMAW Shielded Metal Arc Welding, 4.8 AWS ‘American Welding Sovicty 49.9C Quality Controt 410 LH Low Hydrogen 5. RESPONSIBILITIES 5.1 Welding/QC EngincerBom ‘Agip Kazakhstan North Caspian Operating Company N.V Hook-up, pro-commissioning & commissioning assistance project BOC No. KE01-B0-000-CC-Q-PR-0032-000 QCP for Weld Consumables Control | Sheet 8 Rev. Pot $2 53 SA The Welding/QC Engineer is responsible for monitoring and adherencs to the present procedure. More specifically he is responsible for: a) _ Establishing stock levels of welding consumables, as appropriate, in order to ‘meet production requirements, ) _ Reviewing requisitions of consumable purchase orders in order to safeguard adherence to the project specifications. ©) Reviewing and accepting/rejecting the accompanying welding consumables certificates upon consumables arrival, or proferably an advance copy of the certificates as per Project's Welding Specifications ) g Assessing the condition of welding consumables which may be found to be LZ damaged on receipt and decide whether to accept, reject or recondition as appropriate ©) Guiding the welding Foreman/Supervisor for the correct applications of the relevant WPS. ) Establishing cle baking/holding tomperatures and times as appropriate. Homo, Recon , ® Using the welding program statistical reports to establish tronds of welding faults caused by possible had storage, issuing, treating or use of the welding consumables and provides appropriate remedies. Welding Foreman/Superviser ‘The Welding Foreman/Supervisor is responsible for:~ a) The correct implementation of all parameters in the WPS’s used on site with respect to the consumables. The approved copy of WPS shall be made available at job site in the immediate area of the welding activities, b) The monitoring of baking/holding temperatures/times of the ovens and the appropriate use of the quivers for LH electrodes. He may also appoint a ‘nominee for this task. 5) Welding consumables traceability throughout @) The guidance of the welders as appropriate for the use of the consumables, Welding Inspectors ‘Welding Inspector is responsible for monitoring all the activities listed in 5.2 a, b and e ‘StorekeepersBom, Kazakhstan North Caspian Operating Company N.V Hook-up, pre-commi DOC No. KE01-80-000-CC-Q-PR-0032-000 ioning & commissioning assistance project QCP for Weld Consumables Control Sheet 7 Rev. POt 6 61 62 63 ‘The storckeeper is responsible for: ) Incoming inspection of the welding consumables (damaged, inappropriate packing and so on), ») Ensuring the correct - according to this procedure - storage, treatment, logging. and issue of all welding consumables, PROCEDURE General For the purpose of this project each tin or packet of clectrades/wvires or flux must be clearly marked with the respective loVbatch number and manufacturer's certificates must state ‘compliance with the appropriate AWS Designation for each lot/baich. Certificates must provide the actual chemical composition as well as mechanical composition, Aspecis such FN, Ni content, etc, must be monitored in order to safeguard compliance with Projects Specifications and pertinent WPSs. All purchased consumables shall be of the same brand and AWS type as those indicated in the approved WPS. ‘Welding consumables receipt 62.1 Storekeeper receives welding consumables and checks them against the purchase order. Any severe damage of the packaging will be reported to the Welding/QC Enginees. The Weldiny/QC Engineer (or in his absence a Welding Inspector) will 622 Electrodes that are found to be bent. have damaged coatings, have been contaminated, have lost their identification shall be discarded 62.3 All welding consumables received shall be provided with actual Batch/Heat Lot certificate as per applicable AWS Designation. Consumables not provided by Batch certificates shall be withhold by QC Storage 63.1. Storage and handling of filler metals and fluxes will be as per Ref 3.4 paragraph 5.3; Ref 3.5 paragraph 3.3.2and mamufacturers’ recommendation. 6.3.2. Consumables must be stored in their original packing in a dry place adequately protected from the effects of weather and in accordance with the manufacturer's recommendations, For all consumables, the following principle -is valid: First-in first-out. This means that the consumables first received should be consumed first. 6.3.3 When stored, SMAW electrodes will be stacked as shipped or as per the specific manufacturer's recommendations. As a guide: © Cans will be stacked in layers of 4 cans high maximum, © Cartons will be stacked in layers of $ cartons high maximum 7Bavnco DOC No. Agip Kazakhstan North Caspian Operating Company N.V | peo, cecoche oot c0i Hook-up, pre-commmissioning & commissioning assistance project QCP for Weld Consumables Control Sheet 8 Rev. Pot 63.4 Electrodes will be stored per AWS classification, size, batch number and brand with ‘Proper identification tags to facilitate retrieval. 63.5 Welding wires and cored wires (if required) must be suitably stored to guard against damage. They should be kept in their original bundle or package 63.6 Flux Gf required) supplied normally in bags with polythene inner lining will be stored as supplied. If the composition of the flux is such that special treatment before usc is recommended, details of such treatment must be followed according to ‘the manufacturer's recommendations. 64 Issuing 6.4.1 Issuing of welding consumables to the fabrication shops and site will be in large enough quantities fo maintain adequate supply to the welders, It is the responsibility of the welding foreman to issue a consumables requisition Form No. FM-1035- 101D to the stores and request the type and quantities required. The consumables received will be treated as per section 6.5 below. = 642. Issuing of consumables to the site will be the responsibility of the site-welding, foremen, 6S Treatment of welding consumables 65.1 The Welding/QC Engineer (or in his absence a Welding Inspector), and in accordance with the consumables’ manufacturer recommendations, establishes the requirements for treatment. However, the procedure described herein forms the basis for the treatment of consumabies. 6.5.2 Collulosic electrodes will be issued for welding without any form of treatment. ‘These electrodes can be used directly from their packaging without insertion to quivers. Sce Flow Chart in Form FM-1035-101E. 65.3. Basic (low hydrogen) electrodes will be subjected to a treatment depending on their use and as per the manufacturer's recommendations. Attachment No.l shows in iagrammatic form an indicative treatment of basic clectrodes before use and requirement for low hydrogen moisture content in the electrode flux. 6.54 Form FM-103S-101A provides the contro! of treating the LH electrodes whereas form FM-1035-101C provides the control of issuing the LH electrodes from the ‘ovens to the quivers. All unused LH. electrodes will be retumed to the holding ovens, after color marking (see Form FM-1035-101A) at the end of each shift. All unused cellulosic electrodes will be returned to the storage containers at the end of each shift. No electrodes to be left out (or in quivers) overnight 66 — Ovens/Quivers, for basic-Low Hydrogen-electrodes 6.6.1 Two types of ovens shall be utilized for electrodes: Baking (drying) ovens and holding ovens (storing). Their use is described in Attachment No.1Bopnco DOG No. ‘Agip Kazakhstan North Caspian Operating Company N.V cc. — ‘Hook-up, pre-commissioning & commissioning assistance project QCP for Weld Consumables Control Sheet Rev. Poi 6.6.2 Baking and holding ovens may be physically one and the same unit which can be ‘used for both applications. 6.6.3 Ovens will be used to treat or store one type (per AWS classification) of electrode Different types of electrodes will not be mixed in the same oven at any one time. Each size of the same type of electrode will be stored in a different tray in the oven. 6.64 Holding ovens must be operational on a 24-hour basis and must be equipped with calibrated temperature indicators. 7 6.6.5 Electrodes in the baking ovens shall not be stacked in more than 4 layers 6.6.6 Electrodes in the holding ovens will be fed/consumed on the firstin first-out principle. 6.6.7 Electrode ovens will be operated and controlicd by the consumables controller assigned for this task under the supervision of the welding foreman. 66.8 To cusure that welding ovens operate at the correct temperature range, daily temperature checks will be made by Q.C. ‘These measurements shall be recorded and documented as appropriate. 6.6.9 Fluxes (if required) shall be treated in special fux ovens as per manufacturer's instructions. Minimum holding temperature 70°C or as otherwise suggested by the Flux Manufactorer. 6.6.10 Quivers will be operating at a temperature of 80 deg. C as a minimum. Quivers must be checked, for functional operation, daily and appropriate record must be Kept. Quivers will be switched on at least one hour prior to the commencement of a shift. Quiver’s cover shall always be closed during welding work 6.6.11 Ovens and quivers shall be adjusted as per the welding consumables manufacturers* instruction, 7. ATTACHMENTS. ‘© Attachment No. I; Treatment of Basie Electrodes Form 101A © Attachment No.2: Consumable Baking Log Form 101B ‘® Attachment No.3 Consumable Holding Log Form 101C ‘+ Attachment No. 4 Welding Consumables Requisition Control Form 101D ‘© Attachment No.5 Approved Vendor List Note; A) When filling forms do not leave any blanks. If something is not applicable for specific case denote N/A. B) Use of Blanco, Tipp-ex et, is forbidden.Dow DOC No. ‘gin Kazakdstan North Caspian Operating Company NV | cos enlonszienn Hook-up, pre-commissioning & commissioning assistance project QCP for Weld Consumables Control Sheet 10 Rev. PO1 ‘This documeat is CCC intellectual property and may not be referred or copied in whole or in part without CCC written approval. 10oes ig mow Tem Z 129 TO 150 dep © icant TatFarm Ne PUTOSE TOTS s Agip KCO | xastacanrieto peveLorment EXPERIMENTAL [Rev No. POI PROGRAM Owner CP-4025-101 lHand Class: GENERIC RATCH AT [PRNITTAL ‘OVEN DETAILS ‘NUMBER OR WEIGHT OF ELECTRODES BAKING. OVEN Ne. tc REBAKE ‘CALIBRATION DUE DATE ns DATE: ELECTRODE DETAILS TMENTOBAKE | FMEOUT TPs BATCH Ne, "MANUFACTURER DIAMETER arcu aT [PaNITAL ‘OVEN DETAILS NUMBER OR WEIGHT OF ELECTRODES BAKING OvENNo nc [ REBAKEE ‘CALIBRATION DUE DATE Rs. DATE ELECTRODE DETAILS TIME INTO BAKE: TIMEOUT Tyre BATCH Ne. (MANUFACTURER DIAMETER RATCHAT: — [PINTTIAL ‘OVEN DETAILS ‘NUMBER OR WHIGHT OF ELECTRODES. BAKING OVEN Ne, *REBAKE CALIBRATION DUE DATE ERS. DATE ELECTRODE DETAILS [TIME INTO BAKE TMEOoT TPE ‘BATCH Ne. BATCHING ‘OVENDETAIS TNUNBER OF WEIGHT OF ELECTRODES BAKING OVENNe.. FREBAKE ‘CALIBRATION DUE DATE: "DELETE AS APPROPRIATE F1ato96-1018-ReviPer)-Beking Log(Bh 40p Kco ELECTRODE DETAILSLUN KASHAGAN FIELD DEVELOPMENT EXPERRIENTAL, CONSUMABLES HOLDING AND ISSUING Loc From ne? ParOaS Tore Row No. P01 (Owmar-CP-1035-101 Hand Class : GENERIC Pope: OF. ‘OVEN DETATES a ‘MANUFACTURE ‘DIAMETER, ‘BATCH. OVEN Ne HOLDING TEMPERATURE” + ‘CALIBRATION DUE DATE TSSUETO | DATE wiper iment | ISsuED TNE] NUMER OR WHRGITT OF ws ISSUED. ELECTRODES ISSUED, ‘WELDING FOREMANS SIGNATURE Patcaesore-RenPor sree ogWOd ‘TOWLNOD NOTLISINOTY STTAVINASNOD ONIGTIM WVUSOUd TYINAWWAXA LNIWdOTIAIG CTala NVOVHSWGegptca Azip Kazakhstan North Caspian Operating Company N.V ]DOC No. Hook-up, pre-commissioning & commissioning assistance project _| KeQ3-B0-DOO-CC-O-PR-0041-000 QCP for Weld Consumables Control Attachment | Rev. Pot LW Approved Vendor’s List ‘WELDING CONSUMABLES COUNTRY OF ORIGIN FRANCE AUSTRIA SWEDEN 4 HOLLAND USA ¢ | Merrove \ \ UK 7 HOBART ~ Wot Kir Ry. % \ USA 8 LINCOLN ELECTRIC \ USA 1 ° Kose L¢o | JAPAN NIPPON JAPAN THYSSEN GERMANY ELLETTRPTER.ACIO,OCA SRL > Er, ITALY WELDING ALLOYS UK ELGA AB OERLIKON INCO ALLOYS INTERNATIONAL