SF boy 7ADNA DEMON #88? Petrofac @ ‘ADMA OPCO Document No. | AD203-600-6-00088 [ADMA-OPCO Contract No. 159500 Budget Ref. SOE Projeetind. | Area | Section | SubSection | Number | Revision | Volume ‘aoz03_ | 600 6 PRG ‘00088 4 Satah Al Razboot (SARB) Field Development Project — Package 3 EPC Work Welder Qualification and Control Procedure Job No. 10603 Sub Contract /P.O. No.PIL-OCP-DYM-0S00001-002 Construction Engineering, Fabrication, Load out and Sea Fastening of Structures & | on Sep3 Final issue 3 | 17-Jul-13 For Review and Approval 2 | o7dub-13 For Review and Approval | 25dune-13, For Review and Approval Rev | date DescriptionSPlzod rie - ee ee 1.0 2.0 3.0 40 5.0 6.0 7.0 10.0 ‘Walder Qualifiation & Control INDEX Page No, OBJECTIVE 3 SCOPE 3 REFERENCES 3 RESPONSIBILITIES 3 QUALIFICATION PROCEDURE 3-5 RETEST 6 WELDER CONTROL 6 WELDER IDENTIFICATION NUMBER. 7 SKILL / EXPERIENCE QUALIFICATION 7 RECORDS 7 Pego2ot7[Welder Qualification & control Lod rocedure é ASA | ray | MUllLit Petrofac 10 20 30 40 4a 42 43 50 5A OBJECTIVE This procedure isto be used as a guideline for qualification of Welders and Welding Operators who perform the welding activites to meet the applicable specification of structural Code and standard for Satah Al Razboot Field Development Project (SARB 3) ‘SCOPE ‘The scope of this procedure is to estabish the test and certification for qualification of the Welders / Welding operators who work at the DENHOLM YAM fabrication shop land construction site in accordance with approved relevant Welding Procedure ‘Speetication REFERENCES sT0-103, Approval of Welding Procedures and Welder’s Performance EEMUA-158 The Engineering Equipment and Materials Users Association Construction Specification For Fixed Offshore Structures in he North Sea AWS 1.1 ‘Structural Welding code - Stee! RESPONSIBILITIES Welding Inspector He shall be responsible to identify the welders for qualification. He shall train the welders end arrange for the welder / welding operator qualification. NDE Coordinator He shall be responsible to coordinate with NDE subcontractor to carry out radiograph testing forthe test specimen, QNQC Engineer He shall be respensible forthe preparation of Welder / Welding operator qualification record once the welder passed the test QUALIFICATION PROCEDURE Welder performance qualification tests are intended to determine the ability of welders to make sound welds using specific types of electrodes as specified in the approved WPS.‘Welder Qualification & Control 'A0203-600-G-000 | ree | I petoe © 52 53 54 55 56 87 5a 59 6.10 6a 5.12 5.14 515 Welder performance qualification shall be performed in accordance with AWS D1.1 for structural and EEMUA-158, Test piece shall be plate, pipe or other product which conform to the applicable code, standard and WPS, End preparation of test piece for qualification test shall be made by machining, ‘oxygen-acetylene flame cutting or other proper methods, and cleaned to a bight surface, For the purpose of recognizing the welder who wants to be qualified (‘applicant” hereafte), the applicant number and positon to trace shall be marked on the surface ofthe test piace kefore welding, “The root gap (root opening) of tes piece for qualification test shall maintain by strip or tack welding For the prepared iest piece, the welding inspector shall assure the following: © To assure that the thickness of test piece for qualification test and nominal diameter meet the requirement of WPS. ‘+ Toassure the type of groove including groove angle, root gap are suitable. + Toassure thatthe position of test piece meets the test postion to be qualified. Welder qualification tests. shall be subject to witness and approved by CONTRACTOR and COMPANY or COMPANY Representative, Welders for qualifction shall have his own identification card or resumes with photo to prove his identiication in the testing area, Approved WPS which apples tothe tes, shall be provided inthe testing area. All welding accessories for qualification as well as a welding rod shall be in accordance with fhe relevant WPS. Welding electrodes for qualification shall be kept in quiver with required temperature. ‘The type of gas and the degree of purity to be used for shielding and purging shall be ‘same as specifiec in WPS, Welding inspector shall monitor untl finishing ofthe welder test If an applicant has a lack of abilty, welding Inspector can stop the qualification test even not finishing the welding When welding of test piece is finished, the weldment shall be subjected to the visual inspection by the welding inspector.5.16 617 6.18, 5.19 5.20 521 522 523 Welder Qualification & Control Loy rocedure | SR | MLA extn 6) Acceptance criteria for visual inspection + No surface crack and no undercuts shall be present on the weldment. ‘= Root bead shall not show lack of fusion and penetration. ‘© The shape of surface bead shall be uniform and a steep prominence shall not be permite. + Other ingpestion criteria shall be in accordance with the applicable code and standards + Undercut Sight intermittent undercut permitted, depth should not exceed approximately 0.5 mm. + Excess peretvation : 3 mm maximum. Occasional local slight excess is allowable. + Reinforcement shape : The reinforcement shall blend smoothly with the parent ‘metal, Dressing is not normally required provided the shape does not interfere uit the spesified nondestructive testing techniques. Overlap : Net permitted + Linear misalgnment : - for double-sided joints: the smaller of 6 mm of 10% of the joint thickness, except that a 2 mm misalignment is permitted regardless of thickness, For single-sided joints: the smaller of 3 mm or 10% of the joint thickness, except that a 2 mm misalignment is permitted regardless of thickness. ‘Once the test piece has passed the visual inspection, it shall be subjected to the radiograph testing. If the test piece has to be machined for destructive testing if necessary, test specimen shall be prepared in accordance with the applicable standard, Machined test specimen shall be marked with welders ID No. and Test ID. No shall bbe correlated to welders .D., WPS, Test piece dimensions, welding position and other details {QC Engineer shal prepare welder performance qualification record with the results of radiograph test, The welder performance qualification record is subject to CONTRACTOR epproval QC Engineer shal maintain the welder qualification records and the corticates of the qualified welders. Each qualified welder shall be provided by welder ID card and he carries his {qualification card whenever he perfoims welding activity. No welder or Wetting operator shall be allowed to work without welder’s ID and shall be endorsed by CONTRACTOR Welding Engineer. Pago Sof?‘Welder Qualification & Contral ‘A0202-600-G-00088, | SAR recast Petrotac 6] 70 7A 72 73 74 RETEST Welders who failed the test, may be retested after minimum 2 days training subject to the assessment of Welding Supervisor. Personnel who fall tests for automatic welding air carbon arc gouging or tack welding ‘may undertake two repeat tests immediately. If both are acceptable, the welder or ‘operator shall be qualified WELDER CONTROL When a qualifiec welder has not performed the welding process for 8 months or ‘more, his qualification for that welding process shall be considered as expired. QC Engineer car limit the welder’s production welding if he decides that the welder has a lack of abilty In this case, the welder shall be re-trained for minimum 2 days before requalifieaion, Welding inspector shall periodically review the welders qualification validity and performance. Existing Welder's Qualification in accordance with project specification shall be accepted subjectto the following ‘Welder performance reports for previous projects involving a similar standard of work will be submited to CONTRACTOR for approval if required, along with repair percentage / periormance record of last three months with valid certification or shall be working with DENHOLM YAM for past six months with valid certificates. and meeting the project performance rate requirements The test cortiicate shall be an ori acceptable to the contractorcompany. ial, endorsed by an independent witness: It the test was welded more than 6 months previously, the certificate shall have been te-endorsed by the Contractor at intervals not exceeding 6 months to indicate that the welder has continuously used the process in production welding with satisfactory results. ‘The tect ehall have beon woldod using welding consumablca with the came welding consumable grouping as stipulated in AWS D1-1 and electical characteristics as will be used in production. Failure to meet any ofthe requirements above requires requalfcaton,Welder Qualification & Control Ay rosea DEMMOIM aM Petrofac €| 'AD203-600-G-00088 80 9.0 ot 92 93 100 10.41 10.2 WELDER IDENTIFICATION NUMBER, QC Engineer shall provide a welder identification number in uniform numbering system to identify and trace all the welders. SKILL / EXPERIENCE QUALIFICATION ‘All welders employed on the project shall have passed the appropriate welder ‘qualification test applicable tothe Project and approved by contractor. For structural work, Welder/Welding operator who shall exceed 1.5 % by liner length ‘shall be disqualifed and shall undergo training and qualification. Contractor has right to remove the welder/Welding operator who is not suitable for the work from the work. Necessary training and qualification shall be given to the personal before deployment forthe jb, RECORDS Welding inspecter shall give permanent welder identification number according to pre-determine to Kentify welders. This permanent welders identification number shall not be given to any other welder for the duration of project. Pogo Tot?