‘Transmittal No, Date 0: FROM: Contract Name: Projet Tie \ontrac No Location: ‘Saud Aramco Approval Status Code: Approved “correct & Resubmit *For Information *Other as Noted *Rppraved with Comments *Not Approved * No Comments *For Action PSAL Reference No: Document No | Rev Subject status | avy | Remarks 03 | WELDER AND WPS QUALIFEATION AND aerRavED | (CONTROL PROCEDURE-REV 03 “Transmitted by Received BY: Wecelved Date10. “1. 12. WELDER AND W.P.S. QUALIFICATION [AND CONTROL PROCEDURE SCOPE PURPOSE DEFENITION REFERENCE RESPONSIBILITIES WELDING PROCEDURE SPECIFICATION WELDER AND WELDING OPERATOR PERFORMANCE QUALIFICATION TEST WELDER JOB CLEARANCE CARD (JCC) PRODUCTION WELD QUALIFICATION DETAILS WELDER CONTROL PROCEDURE RENEWAL OF QUALIFICATION ATTACHMENTS: Page? of 10WELDER AND W.P.S. QUALIFICATION ‘AND CONTROL PROCEDURE. 1. SCOPE, ‘This procedure specif outline the requirements for welding procedure ‘quatncation, weder qualieation test and welder control procedure in the ‘ccordance with the applicable code/standards and SAUDI ARAMCO Project requirements 2. PURPOSE ‘This procecure shall be aplied to all construction of the project where Welding Is Involved. 3. DEFENITION, WrS- Welding Procedure Specification PQR-Procedure Qualification Record ARFL-Request for Irspection WaT-Welder Quaiation Test 4. REFERENCES [ASME SEC.IK Welding and Brazing Qualiteations [ASME SEC.II,Part C: Specification for welding rods, electrodes and filer metals ASME Sec V Nondestructive examination ASME 831.3 Process Pping aws Dit Structural Welding Code ~ Stee! ‘SAES-W-011 Wielding Requirements for On-Plt Piping ‘SAEP-352 + Welding Procedures Review and Approval ‘SAEP-326 Ccerticaton Review and Registration of Project Welders SAEP-1160, + Tracking and Reporting of Welding, NOT and pressure Testing for captal projects sA4758 ob Clearance Card saz318 ‘Welder qualification record Page 3 of 10WELDER AND W.P.8. QUALIFICATION [AND CONTROL PROCEDURE [SCHEDULE Q ualty requirements 5. RESPONSIBILITIES 51 QC Manay 5.1.1 Approval ef welding procedure specifications, and performance qualification procedure of welders and welding operators In accordance with Saul Aramco specification, ASME Section IX and AWS D1. 5.1.2 Approving that only properly qualified welding procedure specication, Welders and welding operators are used in any construction or repair welding. ‘54. Monitoring welding sctivtes for compliance as well as provide taining to Improve welder performance. ‘544. Publishing of weekly welder repair rate as per requirement: Root cause analysis of welder repair rate for the cases exceeding the project limit. “Tracking welder tralning/alsquaifation. 5.2 Welding Supervisor 5.241 Preparing and reviewing Welding Procedure Specification (WPS) and verifying ‘qualification test and maintain WPS with thelr procedure qualification record (POR) and welder qualification Test (WAN). 5.2.2 Witnessing the mechanical tests / other tests which shall be performed by ‘approves third party test laboratories. 15.2.3 Reporting ll ofthese mentioned above to the Site QC Manager for review or approval '5.2.4 Preparation of weekly welder repair rate and monitoring welder training. erate eae eee emia Nees eterna 5.3 Welding Inspector / Third Party Welding Inspector ‘5.3.4 The Quali welding Inspector shall be present for the entire duration of the test Page 4 of 10WELDER AND W.P.8. QUALIFICATION ‘AND CONTROL PROCEDURE 5.3.2 The welding inspector shall have authority to terminate the test at any time it he feels that welder is unable to dlsplay the skis necessary to produce satisfactory results as per approved welding procedure requirements. 15.3.3 The welding Inspector Is responsible for verifying the identification number/ symbol of the welders taking the test against the welder performance ‘documents. Al test coupons shall be identified before welding stars 5.3.4 The welding Inspector shall have Identification stamp using palnt marker in the welders test coupons. 53.5 Montoro of ele peromance after retaing NGS i cha tah eee ce 6. WELDING PROCEDURE SPECIFICATION Welding procedure qualification test shall be In accordance with ASME section 1X 8 SAEP-352 & SAES-W-011, (6.1 WELDING BOOTH PREPARATION: Wielding booth shall have clean and proper wind protection, Each booth shall have suficien: space, exhaust system, and proper lights. 6.2 PREPARATION OF TESTS: The number of test specimen to be prepared shall be In accordance with QW- 451.1 of ASME section IX. Mechanical test specimens shall be removed from Welded pipes end steel plates In accordance with QW-463.1 (d) or QW-463.1(¢) ‘and QW-462,1(b), QU 463.1(2), (b) or 462.1(c), QW-462,3(a), respectively, of [ASME section IK. In addition shall be comply SAES-W-011 Para.7. Welding and testing of Spetial conosion-resstance materials which are Austenite stainless stool (excludina304/3041/316/316L oF nickel haced alloys) plex stsinlers steal ‘and high alloyed steels, etc shall comply SAES-W-016, 6.3 TESTS. Al procecure quaifation mechanical tests and examination shall be performed by 180 17025 certified test laboratory and as per Company's approved Ist. Page Sof 10WELDER AND W.P.S, QUALIFICATION [AND CONTROL PROCEDURE, Mechanica test shall be performed in accordance with ASME TX, and the result of tension test and guided bend test shall meet the accaptance criteria of ASME section IX, Other test lke hardness test, corosion test etc. shall be performed ‘according to ASME Sec. IX and SAES-W-011, 6.4 WITNESS: ‘8, The preparation and welding of procedure test coupon shall be conducted by NSH under the witness of approved third pary/PIL/Company as per the TTP. b, Machanicaltasts and other tests of procedure test coupon shall be performed by an approved third-party under the witness of NSH/PIL/Company as per the 1. NSH shall be ralsed RFI for POR inspection 4, All welding details and actual readings shall be recorded on PQR run sheet 6.5 Test recordet 2, Test records shall be prepared using formats as per the code. (See the sattachment-3) . WPS log will maintain for approval status. AWS D1.3 prequalified procedure can use for structural steel welding 6.6 WPS Submission and approve 2, All Welding shall indude the welding procedure request form (SAES-W-011 ‘tachment A), Welding Procedure Specification (WPS), POR, and Weld and Line Description Tables (SAES-W-011 Attachment 8) ». All WPS shall be submitted to PIL/Company for review and approval 7. Welder and welding Operator Performance Qualification Test 7.4 THIRD PARTY'S WELDER QUALIFICATION PROCEDURE 2) Third partys welder qualification procedure shall be approved prior to start welder qualification test. Page 60 10WELDER AND W.P.S, QUALIFICATION AND CONTROL PROCEDURE 7.2 SELECTION OF WELDER AND WELDING OPERATOR ) NSH wil mebiize the welders as per the “Welder Quolifction Test plan” (See the Attachrent-12),For Welders mobilization, NSH Planning Dept. wil inform ‘to NSH Administration dept. two months before rem the mobilization date, ©) Al fetd 8 s1op welders shall be qualified before beginning work in accordance With ASME Section x or AWS D1.1/approved WPS. 4) All welders shall be qualified by approved third party. Welder continuity can bbe acceptable If continuity is from Saud Aramco projects, ©) Continulty record shall be supported by a permanent NOT report ~ RT or UT 1 Certiicatiors of contractor welders shall be reviewed by the PID inspector prior to the start of work and Issued a JCC.A roster shall be provided, 7.3 WELDING BOOTH PREPARATION: ‘Welding booth shall have clean and proper wind protacton. Each booth have suclent space, exhaust system, end proper lighting. ». Qualifying WPS shal be displayed in the welding booth 7.4 PREPARATION FOR TEST COUPONS 2) The test coupons shall be prepared as per ASME Section Dx(QW-302.2,01- 302.3,QW-310 &QW-303) & AWS D1.1(4.20,4.24 & 4.31) ) Ones the test piece is in te fixed postion, It shall not be altered or changed Until the conpltion of the test. ©) Welder Idenfication number and test coupon number (WOT number) shell be clearly stamp/punch on the test coupon, 7.5 Welder Training 2) All welders shall he sufficiently glven traning prior to Welder Qualiftation ‘Test. WAT Welder foreman shall be the responsible for all traning to welders. All raining shall be logged in attached format (Attachment-11). 7.6 ACCEPTANCE REQUIREMENTS OF THE TEST COUPON Page 7 of 10WELDER AND W.P.S. QUALIFICATION 'AND CONTROL PROCEDURE 7.6.4 VISUAL Performance test coupon shall show complete joint penetration with complete fusion of weld metal and base metal, weld reinforcement, root penetration, ‘smooth weld profile, etc as per ASME Sec IX/AWS D1.1/SAES-W-011. 7.6.2 MECHANICAL TESTING Where Mechanical testing Is requested, the test coupon shall be prepared and tested in accordance with the ASME Section IX (QW-462 & QW-466) oF AWS L.A by an spproved third Party as per ASME Sec IX/AWS D1.1/SAES-W-011, 7.6.3 RADIOGRAPHIC TESTING Whore Radography tasting s raqured the tachniques stated In the relevant codes / NOT standards shall be applied. Acceptance criteria shall be as per [ASME Secton IX & AWS D1.1.and shall be interpreted only by a qualified RIF. ‘TEST COUPON VISUAL & RADIOGRAPHY EXAMINATION RECORD. Prior to testall welders and qualification test coupon data shall be filed In Welder performance qualifcation record (see Attachment-4). 8. Welder Job Clearance Card (JCC) {) ICC shall be submitted to PSAL (Petrofac Saudi Arabia) / Saudi Aramco for approval b) ICC shall be prepared according SAEP-324 Appendix IL(See Attachment -6). ©) ICC shall be surrender to NSH Quality department when welder revoked/vacation/site transfers. Finally all orginal ICC chal be eurrender to Saud Avameo whan the welder wae revoked/trasfersite/exit or terminate thelr contact. - PRODUCTION WELD QUALIFICATION DETAILS. 2. Welder shall be given three (3) welder initial production joints after the Page 8 of 1010. Fr WELDER AND W.P.S. QUALIFICATION ‘AND CONTROL PROCEDURE, ‘approval of Cc. '. RT, decision and training shall be taken as per the SAEP-324 Appendbx ttt (See Attochment-1). ‘6. No welding in production prior to obtalning the NDT results, WELDER CONTROL PROCEDURE '9) All welders shall be trained @s per NSH weld performance lesson learned and |Implementtion file (See attachment-10) prior ta weld inal production joint. All pipe welters shall be classified as per SAEP-324 Appendix -Table for welder criteria (See Attachment-1) ©) Welders shall be qualified and monitored as per the attached flow chart (Merged SAEP-324 Appendix I and Appendix Il} (See Attachment-1) «) Tack welding shall be performed by qualified welder €) Saual Aram inspector shall have the right to require removal or retest of ‘any welder at any time due to unsatisfactory work or poor performance as dentited In SAEP-324 Appendix 1 welder performance guidelines. NSH wil issue ‘Welder passport’ to all welders for monitoring welder performance (See the atachment-8) 9) NSH wil previde rewards to high performance welder periacally, fn) Based on the welder performance NSH wil provide training to welders Whenever necessary. 1D Repair rate of welder shall be published as per the requirement of SAES-W- 118 SAEP-1160, 2D. Pxeweding repair rata chal be eubjected to root couse ansiysis, ‘RENEWAL OF QUALIFICATION: Page 9 of 1012. WELDER AND We. AND CONTROI ‘QUALIFICATION {OCEDURE 2) Renewal ofthe welder and welding operator qualifcation Is requlred in the following ceses (Ref.QW-322 of ASME Section ix & AWS D1.1 Para 4.1.3 for steel structure.) ) When the welder and welding operator has not welded with a process during 2 period of sik months or more, his quaifcation that process shal expire. Continuity record forall welders shall keep In NSH database and in each welder fle, -ATIACHNENTS Attachment: Welder Qualification and Control Flo chart _Attachment#2; Welding Procedure specication [Attachment#3: Procedure Qualification Record ‘Attachment? 4: Welder Performance Qualification Record (SATR-W-2003) {elder Performance Qualification Test Record (third party) ‘Attachment? 6: Job Clearance Card (3CC) ‘Attachment#7: Weld and Line Description Matrix ‘Attachment [Attachment 10: Weld Performance Lesson learned and implementation ‘Attachment 11: Welder Training Record ‘Attachment12: Welder Qualification Test Plan Page 10 of 10| ! tHane ans en SSeS Sa SS SeWor stan Tat lan Fawaaee eats om [roe] wectwann | sinerwar | exawar | ren |dmetmen | saterner | em erwar tet [ome |= | cour | weer o | een sac vet | mo | on | www | omen 2 | eww | wae a a coe se «| eae | moc oe © [een | ane men | cor [eve [sae e soo Total] 1316753 | 53s 129