CONSTRUCTION OF SOCIAL APARTMENTS

PROJECT

WELDING CONTROL PROCEDURE

DOC No: KON-8.2-QA-PRO-0020

REVISION & APPROVAL STATUS:

C1 Approved for Construction A.Salmanov

A1 Issued for internal comment A.Salmanov

PREPARED CHECKED APPROVED

REV. DATE DESCRIPTION
by by by
Welding Control Procedure KON-8.2-QA-PRO-0020

CONTENTS

1.0 Purpose...................................................................................................................................... 3
2.0 Scope......................................................................................................................................... 3
3.0 Definitions................................................................................................................................. 3
4.0 Responsibilities........................................................................................................................ 3
4.1 QA/QC Manager...................................................................................................................... 3
4.2 Production Supervision............................................................................................................ 4
4.3 QC Inspector............................................................................................................................ 4
5.0 Process...................................................................................................................................... 4
5.1 Welder and Procedure Qualification......................................................................................... 4
5.1.1 Weld Procedure Specifications............................................................................................. 4
5.1.2 Weld Procedure Qualification............................................................................................... 5
5.1.3 Welder Qualification and Training......................................................................................... 5
5.2 Qualification Period.................................................................................................................. 6
5.3 Documents and Certification.................................................................................................... 7
5.4 Qualification of Tack Welders.................................................................................................. 7
5.4.1 Piping................................................................................................................................... 7
5.4.2 Structural.............................................................................................................................. 7
5.4.3 Inspection and Testing......................................................................................................... 8
5.4.4 Re-tests................................................................................................................................ 8
5.4.5 Qualification Period.............................................................................................................. 8
5.4.6 Documentation..................................................................................................................... 8
5.5 Welder Identification and Traceability......................................................................................8
5.6 Storage and Issue of Welding Consumables...........................................................................8
5.6.1 General................................................................................................................................. 8
5.6.2 Consumable Certification..................................................................................................... 9
5.6.3 Welding Consumable Issue - Structural...............................................................................9
5.6.4 Welding Electrode Issue (Vac Pack)....................................................................................9
5.6.5 Welding Wire Issue............................................................................................................... 9
5.6.6 Submerged Arc Welding Flux.............................................................................................10
5.6.7 Consumables Issue for Pipework.......................................................................................10
5.6.8 Re-Baking of Electrodes and Flux......................................................................................10
5.7 Receipt, Storage and Issue of Gasses for Welding & Purging...............................................11
5.8 Pre-Heat and Interpass Temperature Control........................................................................11
5.9 Weld Repair Analysis............................................................................................................. 11
5.10 In Process Monitoring............................................................................................................ 12
List of Forms....................................................................................................................................... 12
List of Attachments............................................................................................................................ 13
Associated Procedures...................................................................................................................... 13

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Welding Control Procedure KON-8.2-QA-PRO-0020

1.0 Purpose
To ensure that all welding activities are carried out in accordance with the requirements of the
contract and specification requirements during projects execution.

2.0 Scope
This procedure applies to all welding related activities for “KONTINENT Inshaat” construction of
social apartments Project in Khatai district.

3.0 Definitions
Project: “KONTINENT Inshaat” construction of social apartments Project in
Khatai district.
Contractor: “KONTINENT Inshaat”
Company: “KONTINENT Inshaat” Main Office
Standards: All technical standards or codes referenced in Project QMS
Documents.
Drawing &Specifictions: Technical specifications and drawings issued by “KONTINENT
Inshaat” or third party

Approved: The revision of the related Contractor’s Procedure, Plan, or other

documents, which were approved by Construction Director.
WPS: Weld Procedure Specifications
ITP: Inspection & Test Plan
WPQR: Weld Procedure Qualification Record
PWHT: Post Weld Heat Treatment
GTAW: Gas Tungsten Arc Welding
SAW: Submerged Arc Welding
GSFCAW: Gas Shielded Flux Core Arc Welding
SMAW: Shielded Metal Arc Welding

4.0 Responsibilities
The responsibility for co-ordinating welding controls detailed in this procedure is divided
between the QA/QC Manager, Production Supervision and the QC department. Their prime
responsibilities are as follows:
4.1 QA/QC Manager
 The development of Weld Procedure Specifications (WPS).
 Supervising the qualification, NDT and specifying the type and quantity of mechanical
testing of weld procedures.
 Controlling welder qualification tests ensuring all welder qualification tests are
witnessed by the QC Dept / Welder Trainers and carried out in accordance with the
applicable Code of Practice.
 Provide production supervision with verified qualified welder lists.
 Check manufacturers’ consumable certificates for compliance endorse as approved
and distribute copies to stores as an approval to issue.

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Welding Control Procedure KON-8.2-QA-PRO-0020

 To review the weekly weld repair status and implement corrective action as
necessary.
 Evaluation of welding failures and implementing corrective actions.
 Assessment of materials for their weld ability.
 Review and approval of sub contractors’ welding procedure specifications, welding
procedure qualification records and welder qualifications.
 Implementation of the programme for daily weld audits, review of audit results and
preparation of the monthly welder audit summary report.
 Liaison with Company on a regular basis and providing Company with updated
reports and documentation as agreed.
4.2 Production Supervision
To ensure all work is carried out in a safe and proper manner in accordance with
“KONTINENT Inshaat”
 HSE Procedures.
 To supervise all welding activities to ensure that work is carried out in accordance with
the relevant procedures and specifications.
 Use verified qualified welder lists for allocating welding personnel to tasks for which
they are qualified.
 To check that there is a suitably approved WPS for the work prior to starting.
 To ensure that the welding personnel are issued with a copy of the project welding
procedures and associated documents are updated with any revisions.
 To provide good access and environmental protection to all welding activities prior to
starting the work, including inspection.
 To ensure work is completed to the required visual acceptance standard in
accordance with applicable project specifications and record all completed weld
acceptance before release to QC inspection.
 To notify QC for inspection points in accordance with I&TP.
 To monitor and ensure that all personnel involved in the welding, cutting and gouging
operations, comply fully with the minimum technical requirements of the project
procedures, WPS and project specifications.
 Notification to the Company of specific inspections, Witness or Hold points as defined
in the ITP.
4.3 QC Inspector
 To carry out fit up inspection and monitor material preparation methods.
 To carry out daily surveillance inspection on welding, checking welder qualification,
consumables used, material welded, welding parameter checks and compliance with
welding procedures, recording findings on KON-8.3-QF-041 Welding Audit Report.
 Carry out final visual inspection and endorse visual reports.
 Monitor PWHT of welds and review reports.
 Monitor welder Qualification.
 Monitor consumable control.
 Call for dimensional control checks on areas of difficult fit-up, etc.

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Welding Control Procedure KON-8.2-QA-PRO-0020

5.0 Process
5.1 Welder and Procedure Qualification
5.1.1 Weld Procedure Specifications
The QA/QC Manager shall produce WPSs to cover the scope of the contract. Where
possible, pre-qualified Weld Procedure Qualification Requirements (WPQR) will be used
as the basis for the development of project specific WPS. All WPS and WPQR will be
approved by the Company.
Where pre-qualified WPQRs are unsuitable or do not exist, WPS proposals shall be
developed for qualification.
The latest revision of all WPS and Registers shall be available to all computer users in
PDF format in the “Easy Access Program’ on the project-shared drive.
The QA/QC Manager shall notify all personnel of any changes and revisions to these
documents. It is the responsibility of those departments to distribute and replace all
revisions of these documents as required.
5.1.2 Weld Procedure Qualification
Weld Procedure Qualification Tests shall be prepared, welded and tested in accordance
with the WPS proposal, relevant project specifications, and applicable National /
International standards. Any deviations made during qualification shall be recorded on
the As Run form and reflected in the WPQR. (Weld Procedure Qualification Record)
All welding parameters, Material identification, joint dimensions, consumables and any
other relevant details shall be recorded during the performance of the Weld Procedure
Qualification Test and recorded on the WPQR as Run Form.
The Company shall be given 24hrs notices to witness all welding procedure qualification
tests.
Mechanical testing shall be performed at an independent testing laboratory or Company
approved test house.
The welding procedure qualification documentation shall be compiled and approved by
the QA/QC Manager.
Each WPQR shall be documented in a separate folder with a unique identity and will
contain the following as a minimum:
 Welding Procedure Specification front sheet.
 Welding Procedure Proposal Specification.
 Welding Procedure Qualification Welding Record.
 Actual “As Run” welding parameters and run sequence sheet.
 PWHT Report, Calibration Certificates and Temperature Records (as applicable).
 NDE Records.
 Mechanical/Corrosion testing reports. (Including photo-macrographs /
micrographs).
 Welding Consumable Test Certificates.
 Material Test Certificates.
5.1.3 Welder Qualification and Training
Where the term “Welder” is used this also refers to the term “Welding operator” as
applicable.
“Welder trainers” shall have previous welding experience in the processes being taught
and shall be assessed and approved by the QA/QC Manager.
Welders shall be given a period of training sufficient to bring them up to the necessary

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welding standard. Daily assessments of their ability shall be recorded, and when the
welder trainer is satisfied that the welder could confidently use the process he shall be
allowed to sit a qualification test. During training and testing, a Tool Box Talk shall be
conducted where the WPS requirements are fully explained to the welder.
For the training of welders for Stainless Steels, Duplex and Super Duplex, the training
period shall be at least 2 weeks and the welder shall have previously had GTAW welding
experience. During this training period the welder shall receive Tool Box Talk lectures
and practical demonstrations, where the requirements of WPS are fully explained and
understood.
All welder qualification tests shall be witnessed and welding parameter checks shall be
carried out by the welder trainers to ensure compliance with the WPS.
The Company shall be invited to witness all welder qualification tests and a daily
notification list of all welders on test shall be available.
Visual inspection of welder qualification tests shall only be done by a qualified Welding
Inspector.
Welder qualification tests shall be carried out in accordance with the contract referenced
edition of the following national standards:-
Structural - AWS D.1.1
Process Piping - ASME Section IX
Each test piece shall be identified with the welder’s identification number, except where a
welder is being assessed for employment where his full Identity Card or passport name
shall be used. The date, process used material type dia / thickness and position tested
shall be recorded on the daily visual report and entered into the Welder Qualifications
database.
All material used for welders’ tests should have a material certificate traceable to the test
piece.
All welder qualification tests shall be subjected to 100% Radiography testing, Ultrasonic
may be substituted with permission where radiography is not practical.
Re-tests
Any welder, who for any reason fails to meet specification requirements, may at the
discretion of the Welder Trainer be immediately re-tested in accordance with relevant test
code.
In the event that the re-test is considered unacceptable, no further re-testing shall be
permitted until the welder has completed a further period of re-training and shows
significant improvement.
Where a Qualified welder has been found to have a poor production record in a particular
process or position the welder or operator shall be given a suitable period of training
targeting the actual problem with NDE testing to show evidence of improvement, if the
welder fails to show improvement after the training period his qualification shall be
withdrawn.
5.2 Qualification Period
A welder’s certificate shall lapse and full re-qualification testing shall be required if after
any six consecutive months the welder has not carried out any production welding using
the applicable process.
The welder’s qualification expiry date for the process used is automatically extended for
a further 6 months in the weld history data base when satisfactory visual and NDE testing
results are input, the minimum requirement for re-validation is Visual plus MPI/DPI
testing. Current welder qualification registers will be available in CERTIFICATION to all
“KONTINENT Inshaat”

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network users.
To re-validate a welder before the qualification expiry date if he has not been using a
particular process, the welder may be put onto work that will be NDE tested or the welder
may be given a ‘Welder Qualification Update Test’. This is a single test demonstration
with a single or combination of processes on plate or pipe. After successful NDE, all of
the welders qualifications for that process or processes used in the test shall be
extended for a further 6 months. One or more of the following tests shall be used for a
‘Welder Qualification Update Test’
Structural
 3G plate 10mm thick x 200mm long all passes made with SMAW, this will update
all SMAW qualifications for any thickness
 3G plate 10mm thick x 200mm long with ceramic backing for root pass, all passes
made with GSFCAW, this will update all GSFCAW qualifications
 3G plate 15mm x 200mm, pass root, hot pass and 3rd run with SMAW and fill and
cap with GSFCAW, this will update all structural qualifications for SMAW and
GSFCAW including 6G and 6GR.
 1G plate with steel backing 10mm X 300mm long all runs with SAW, this will
update their SAW qualifications.
Piping
 6G pipe 6” x 10.97mm (sch XS) thick on any material, using GTAW SMAW, this
will update all GTAW and SMAW qualifications.
 6G pipe 6” x 10.97mm (sch XS) thick on any material, using GTAW GSFCAW,
this will update all GTAW and GSFCAW qualifications.
 1G rotated, plate with steel backing 10mm X 300mm long all runs with SAW, this
will update their SAW qualifications.
5.3 Documents and Certification
Welder Qualification Certificate (KON-8.3-QF-062) will be issued to the qualification test
performed and shall be approved by the QA/QC Manager and Company. Third party
inspection authority approval may be sought where required.
Live registers of structural and piping welders’ qualifications will be available as ‘read-
only’ registers from the CERTIFICATION database to all “KONTINENT Inshaat” network
users.
These registers shall summarise all the materials, processes, thickness and diameters
that the welder is qualified to use.
5.4 Qualification of Tack Welders
5.4.1 Piping
Only qualified pipe welders shall perform all tack welding of pipe work.
5.4.2 Structural
Tacking tests for structural shall be carried out in accordance with AWS D1.1. Chapter 4,
Part 'C', section 4.31.
Tacking tests shall be carried out to an approved welding procedure for fillet welds.
Test pieces shall be cut from 12mm thick plate 100mm x 100mm square and set up as a
fillet weld see AWS D1.1. Fig.4.38. Section 4.19.2
A 50mm tack weld shall be applied to one side of each plate in the 2F, 3F and 4F
positions.
Each test piece shall be identified with the tack welders name, position tested and
process used, this information shall also be transferred on to the tack welder’s register.

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Following visual acceptance, each test weld shall be subjected to a fillet weld break test.
Where tack welding is to be done by personnel with no previous welding experience then
they shall be given a period of training in fillet welding in all positions on 300mm long
plates. The tack welders shall demonstrate their ability to the welder trainer to produce
good quality single pass and multi pass fillet welds in all positions prior to being allowed
to sit the Tacking tests.
5.4.3 Inspection and Testing
Acceptance criteria (see AWS D1.1 section 4.30.4.1)
The finished weld shall have a uniform appearance with an even leg length of approx
6mm, no cracks overlap or porosity; minor undercut is acceptable.
The fracture surface shall show good fusion and penetration into the corner of the test
plates with no inclusions or porosity greater than 2.5mm.
A Welding Inspector shall monitor all tack welding qualification tests and witness all fillet
weld fractures.
5.4.4 Re-tests
Any tack welder who fails to meet the requirements of the specification may be permitted
two re-tests without additional training.
5.4.5 Qualification Period
Tack welders who pass the test shall be considered qualified indefinitely unless there is
specific reason to question their ability, in which case, they shall be re-tested.
5.4.6 Documentation
An up to date register of qualified tack welders shall be maintained.
5.5 Welder Identification and Traceability
Each welder is allocated a unique identification mark that is retained throughout the
welder's employment. There must not be any re-issue of the same welders identification
marks issued to other welders throughout the project.
Welders shall be identified with a “P” prefix e.g. P001
Each welder shall mark his unique identification number, time and date on the work piece
adjacent to all production welds using an approved type of marker. Where different
welders have partly completed a weld then each welder shall identify each portion of the
weld he is responsible for.
The identification marks are recorded from the work piece by the Production Supervisor,
or his appointed deputy, and transferred to the Visual Inspection report; following visual
acceptance and NDE all information shall be input to the CERTIFICATION database.
5.6 Storage and Issue of Welding Consumables
5.6.1 General
All welding consumables including fluxes shall be purchased in vacuum-sealed
containers.
All welding consumables including fluxes shall be initially received into the main
consumable warehouse, which has a controlled environment; a daily record of
temperature and humidity shall be recorded on KON-8.3-QF-064. The recommended
minimum storage temperature is 18ºC and maximum relative humidity is 60%; situations
where these conditions cannot be maintained shall be brought to the attention of the
QA/QC Manager.
All consumables shall be stored on open rack shelves; electrodes shall be stacked no
higher than 6 cartons or as per manufacturers’ recommendations.

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No unauthorised personnel are allowed into the main consumable warehouse or satellite
stores and only the Store man is allowed to issue welding consumables. The control of
satellite consumable stores remains the responsibility of the store man and welding
supervision.
The Welding inspector shall carry out random checks on the storage and issue of
welding consumables. Shelf life of welding consumables recommended by manufacturer
shall be strictly controlled.
All GTAW Filler wires shall be supplied hard stamped or printed with their type identities.
All electrodes shall have their type and identity stencilled on the flux.
Only approved welding consumable identified in the project WPSs shall be used, no
substitution of consumables brand name or type is allowed without formal approval on an
engineering query.
A copy of this procedure shall be retained in all consumable stores.
5.6.2 Consumable Certification
All consumables shall be supplied and certified in accordance with the Manufacturers
product data sheet.
On receipt of consumables into the stores the store man shall inspect the consumables
for damage verify that their batch numbers and consumable type corresponds with the
batch certificates supplied and complete the first part of KON-8.3-QF-039. This form is
then presented to the QA/QC Manager or appointed QA/QC representative along with
the Batch certificate for approval or in the case of defective consumables a corrective
course of action.
The QA/QC Manager shall verify that the consumable mechanical properties and
chemical analysis are in accordance with the manufacturers product data sheet
All consumables shall remain on Hold until the storeman receives a signed accepted
KON-8.3-QF-039 from the QA/QC Manager.
After review and approval by the QA/QC Manager or an appointed QA/QC
representative, the certificate shall be endorsed and a copy shall be forwarded to the
consumable storeman to enable release of the consumables for production. All original
certificates are held on file by the QA/QC department.
Consumables received without certification are quarantined until certificates are received
and approved by the QA/QC Manager.
5.6.3 Welding Consumable Issue - Structural
All consumables shall be issued by the store man and recorded on a Consumable Issue
Sheet (See KON-8.3-QF-040). These issue sheets are periodically reviewed by the
Welding Inspector and are held in the relevant welding stores. The welder shall
determine from the relevant WPS which consumable is required, confirmed if necessary
by the supervisor / foremen or Welding Inspector.
5.6.4 Welding Electrode Issue (Vac Pack)
Electrodes will be issued as shown in Attachment 1.
All electrodes will be received in hermetically sealed vacuum packs (vac packs) and the
storeman shall check the seal is tight on Vac Pac electrodes prior to their issue, any
packet showing signs of leakage shall be put into the returns container for re-baking.
The external aluminium foil seal shall be opened by the Storeman at the time of issue.
He will legibly note the date and time of issue together with the welder's number on the
internal plastic container.
All Vac Pack consumables shall also be recorded on a Consumable Issue Sheet, (KON-
8.3-QF-040)

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Once the vac-pack is opened, the welder has 12 hours maximum to use the electrodes.
Any electrodes not used at the end of the working shift will be returned in the original
carton to the Stores and will be put into the returns area for re-baking.
5.6.5 Welding Wire Issue
Welding wire for SAW, and GSFCAW welding processes shall be issued by the Store
man and recorded on the consumable issue sheet KON-8.3-QF-040
All GSFCAW and SAW wire spools shall be covered at all times to protect the wire from
dust and environmental conditions. At the end of each shift or if not in use for more than
6 hours, unused SAW and GSFCAW consumables shall be returned to the welding
consumable stores.
5.6.6 Submerged Arc Welding Flux
Issue of Flux
All flux shall be received in hermetically sealed bags, the store man shall check each bag
for perforation, any bag which is damaged or leaking shall be put to one side for baking.
The Storeman shall issue flux to the welder in unopened bags and shall record the
quantity, date and batch numbers of all issues on the issue sheet (KON-8.3-QF-040) as
applicable.
Flux Usage
Flux can be used in one of 2 ways;
 Directly form sealed bags, once opened the flux shall be used within a 5-hour
period, after that it shall be returned for re-baking @ 350ºC for 2 hrs.
 Issued directly from a sealed bag into a heated hopper at 150ºC and stored
indefinitely, the welder can take flux as required to fill the welding machine hopper
where it shall be used within 10 hours; this is the recommended method.
Used flux shall be retrieved either by using a vacuum type recovery unit or by manual
collection; it shall not be recovered from the ground or from the floor. The used flux shall
be sieved (3mm mesh) to remove slag, mill scale or other extraneous matter. The
retrieved flux is returned to the machine hopper, which shall be continually topped up
with new flux to give a 50 / 50 mix. During the shift the welder shall monitor the condition
of the flux and replenish as necessary. The welding machine hopper shall be emptied at
the end of each shift and that flux shall be scrapped.
5.6.7 Consumables Issue for Pipework
Carbon Steels
In the pipe shop or main build the welder shall determine from the relevant WPS which
consumable is most suitable for the job at hand, confirmed if necessary by the supervisor
/ foremen or Welding Inspector.
Note. There is only one set of consumables for the welding of all types of carbon steels
pipework so the consumables cannot be mixed up.
All piping consumable issues shall be issued and recorded by the storeman on the pipe
welding consumable issue sheet (KON-8.3-QF-040) detailing date, make, size, quantity,
batch of consumables, welders identification, isometric and piping material class.
5.6.8 Re-Baking of Electrodes and Flux
When a sufficient amount of electrodes have been returned they shall be re-baked in
accordance with the manufacturers recommendations, see Table 1, A record of this re-
baking shall be kept by the Storeman on the baking record sheet. (KON-8.3-QF-040)
After re-baking, the consumable shall be marked at the end with a permanent dye or
paint by the Storeman to show they have been re-baked once. These electrodes can
then be transferred to holding ovens in accordance with the manufacturer's instructions,

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e.g. 150ºC.
Re-baked electrodes shall be re-issued to production in one of 2 ways:
 Issued to a heated quiver at 70ºC for a maximum of 12 hours from issue, this is
the preferred method.
 Each shift a batch of electrodes can be removed from the holding oven and
allowed to cool to ambient temperature inside the consumable store, these
consumables will then be transferred into plastic vac pack containers and the time
of removal from the oven recorded on each packet, these electrodes can then be
issued in the same manner as for Vac pack electrodes except that the maximum
time shall be 12 hours from the time of removal from the oven, at the end of that
shift all unused electrodes shall be scrapped.
Any electrodes returned from production to the store marked with dye or paint shall be
scrapped.
Any electrodes, which cannot be supplied in Vac Packs, will be baked and held in
accordance with Fig 2 and issued into heated quivers at 70ºC, electrodes not used after
12 hours will be scrapped.
Submerged arc flux shall be baked on shallow trays with flux no deeper than 50mm at a
temperature and time in accordance with Table 1. Baked flux shall be transferred to a
heated hopper and held at 150ºC.
Table 1: Electrode and Flux Re-Baking
BAKING BAKING HOLDING
MAKER TYPE FLUX TYPE COMMENT
TEMP 0 C TIME TEMP 0 C
BASIC LOW
FILARC 88S 350 2 Hrs 1500 C
HYDROGEN
OP121TT BASIC
OERLIKON 350 2 Hrs 1500 C
FLUX AGGLOMERATED
ULTRAMET
METRODE RUTILE 200 - 300 2 Hrs 1000 C
316L
ULTRAMET
METRODE RUTILE 200 - 300 2 Hrs 1000 C
309L
BASIC LOW
METRODE 2205 XKS 200 - 300 2 Hrs 1000 C
HYDROGEN

5.7 Receipt, Storage and Issue of Gasses for Welding & Purging
Stores personnel shall check that gasses supplied are as specified on the relevant
purchase order / delivery note documentation and are supplied with a purity certificate.
Gasses shall be handled and stored in accordance with “KONTINENT Inshaat” HSE
requirements.
The Warehouse Manager shall check that the gasses are the correct type and purity for
the intended welding process and sign the gas purity certificate prior to release to
production.
The welder shall double check that the gas is correct type according to the applicable
WPS.
5.8 Pre-Heat and Interpass Temperature Control
The pre-heat and interpass temperatures shall be as identified on the applicable WPS.
The maximum inter-pass temperature for structural welding shall be 250C.
Temperatures shall be checked using tempilstiks or digital temperature measuring
devices.
Interpass temperature shall be checked immediately prior to commencement of the weld
pass adjacent to the start and intended stop positions.

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5.9 Weld Repair Analysis

All rejected welds shall be reported to the QC department and the Company on an NDE
report detailing drawing number, weld number, defect type, length and location from a
known datum. QA/QC Manager shall review all rejected welds and endorse the NDE
report where required; corrective and preventive actions shall be implemented as
necessary.
A repair Register for Piping and Structural is available from the certification database. A
welding repair status shall be issued on a weekly basis from the certification weld history
database to all relevant departments and the Company.
This repair status and repair register allows early identification of adverse trends in order
that they can be investigated further and appropriate action taken where necessary. (e.g.
welder re-training or equipment repairs, revision of welding procedures)
The target linear repair rate should not exceed 2% where the total repair length shall be
divided by the total length of weld tested x 100, note that where 2 separate volumetric
NDE methods are used on a single weld only one single weld length shall be considered.
A separate repair status shall be kept for Structural and each material type in piping.
The weld repair register shall include, weld number, drawing number, welder ident, date,
defect length and type, reject report number and repair close out date.
The Pipework repair weld numbering system shall be in accordance with Attachment 2,
all NDE repairs and re-welds shall be included in the repair rate statistics, dimensional
and modification welds will not be included in the repair statistics.
Repair rates per welders shall also be monitored. Toolbox talk will be conducted to
welders with repair rates above 2%.
5.10 In Process Monitoring
The welding supervisor shall check the work prior to allocating the welder and ensure
there is safe access, a permit (where required), environmental protection and the joint fit
up accepted by the QC Inspector. The foreman shall instruct the welder which WPS shall
be used after consideration of the material type and welder qualification required, the
foreman shall consult other trade supervisors and or QC inspection department as
necessary.
The QC Inspector shall continuously monitor fit ups and welders’ performance to ensure
that all fabrication and welding work is carried out in compliance with the Contract
specification and procedure requirements.
The QC Dept shall carry out regular welder audits on each welding process per shift to
ensure compliance with the project WPS. These audits shall be recorded on the welding
audit sheet (KON-8.3-QF-041) for records. Where a welder is found to be working
marginally outside the requirements of the WPS the Welding Inspector shall bring this to
the attention of the welding foreman who shall instruct the welder how to bring the
welding back into conformance with the WPS, the inspector shall then repeat the audit to
ensure compliance and report this action on the lower part of the form, all non
compliances shall be detailed to the QA/QC Manager for corrective action.
On a monthly basis the QA Engineer shall issue a welding audit summary.

List of Forms
KON-8.3-QF-038 Fit-up Approval Sheet
KON-8.3-QF-039 Welding Consumable Approval Sheet
KON-8.3-QF-040 Welding Consumable Issue Sheet
KON-8.3-QF-041 Welding Audit Report

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Welding Control Procedure KON-8.2-QA-PRO-0020

KON-8.3-QF-062 Welder Qualification Certificate

KON-8.3-QF-063 Visual Examination Report for Welder Qualification Tests
KON-8.3-QF-064 Consumable Store Temperature and Humidity Record
KON-8.3-QF-067 Welder Qualification Register

List of Attachments
Attachment 1 Consumable Control Flowchart
Attachment 2 Pipe work weld repair numbering

Associated Procedures
XXX Project Quality Plan
XXX Inspection & Test Plan
KON-8.2-QA-PRO-0003 Material Control Procedure
KON-8.2-QA-PRO-0011 Steel Structure Fabrication and Installation Procedure
AWS D1.1 Structural Welding Code - steel
ASME B 31.3 Process Piping

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Attachment 1 KON-8.2-QA-PRO-0020

Consumable Control Flowchart

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Attachment 2 KON-8.2-QA-PRO-0020

PIPEWORK WELD REPAIR NUMBERING

PREFIX WELD No SUFFIX
001 ORIGINAL WELD
001 R1 NDE REPAIR 1
001 RW1 NDE RE-WELD 1
001 RW1-R1 NDE REPAIR ON NDE RE-WELD
DW1 001 DIMENSIONAL RE-WELD 1
MW1 001 MODIFICATION WELD 1
MW1 001 R1 REPAIR1 ON A MODIFICATION WELD
DW1 001 RW1 RE-WELD 1 ON A MODIFICATION WELD

NOTE'S
1 PREFIX IS FOR MODIFICATIONS & DIMENSIONAL ERRORS
2 SUFFIX IS FOR NDE REPAIRS ONLY
3 REPAIR IS WHERE PART OF THE WELD IS REMOVED DUE TO WELDING DEFECTS FOUND BY NDE
4 RE-WELD IS WHERE THE WHILE WELD IS CUT OUT DUE TO WELDING DEFECTS FOUND BY NDE
MODIFICATION WELD IS WHERE DUE TO A CHANGE OR REVISION IN THE ISOMETRIC, EXISTING PIPE BUTT
5
WELDS NEED TO BE CUT OUT AND RE-WELDED
DIMENSIONAL WELD IS WHERE A WELD HAS TO BE CUT OUT AND RE-WELDED DUE TO A DIMENSIONAL
6
ERROR IN THE SPOOL
THE NUMBER AFTER THE PREFIX OR SUFFIX SIGNIFIES HOW MANY TIMES THE WELD HAS BEEN REPAIRED
7
OR RE WELDED
ONLY 2 ATTEMPTS ARE ALLOWED ON A LOCAL WELD "REPAIR", AFTER THAT THE WELD SHALL BE CUT OUT
8 AND THE PARENT MATERIAL CUT BACK BY 5mm EITHER SIDE TO REMOVE THE HAZ OR THE PARENT
MATERIALS REPLACED.
IF THE WELD IS CUT OUT AND THE HAZ REMOVED AS ABOVE THERE IS NO LIMIT TO THE NUMBER OF RE-
WELDS ALLOWED AND 2 FURTHER "REPAIR ATTEMPTS WOULD ALSO BE ALLOWED ON THIS RE-WELD AS
9
IT WOULD BE THE SAME AS AN ORIGINAL WELD. A CUT OUT AND RE-WELD ALSO CANCELLS OUT ANY
PREVIOUS "REPAIR" HISTORY.

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