OML58 Upgrade Phase 1 Project

TRANSMITTAL SHEET

FROM : CPY ~~ Company Contract n° : TO : SPD ~ SAIPEM PONTICELLI DESICON

Name : Transmittal N° : TNO-CPY-SPD-000033 Attn :

Address : Total E&P Nigeria Limited Issue Date : 2-Sep-10 Address : 1/7 Avenue San Fernando
Plein Jour, 12 bis rue Jean Jaurès Montigny le Bretonneux
PUTEAUX 92800 Remarks : 78 884 SAINT QUENTIN EN YVELINES Cedex
Tél. : 01 47 44 84 17 Tél. : 01 61 37 69 36
CD Acknowledgement of receipt :
E-mail Date :
Courier Signature : 03/09/2010
DMZ X

We are pleased to deliver to your Company the following documents. For CPY ~ Company
Prior to be sent, these documents have been checked as per contract requirements.
Information included in this transmittal for each document is in accordance with the document itself.

Name & signature

Approval Class
CONTRACTOR

Return Code

Remarks
DocNber
Document Number Rev Stat. Rev. Date Title Disc. Type

NG22-282-CST-PSL-100017 C0 IFR 9-Jul-10 PROCEDURE FOR VISUAL EXAMINATINO AND WELDING/ NDT CST PRC 2 2
NG22-282-CST-PSL-100018 C0 IFR 13-May-10 WPS / PQR QUALIFICATION PROCEDURE FOR OBITE TC STORAGE TANK CST PRC 2
NG22-282-CST-PSL-100020 C0 IFR 10-Jul-10 PROCEDURE FOR MANAGEMENT OF WELDING CONSUMABLES FOR CST PRC 2 2
NG22-282-CST-PSL-100019 C0 IFR 12-Aug-10 Procedure For Welder Qualification For Obite TC Storage Tanks Erection CST PRC 2 2
NG22-282-CST-PSL-100011 C0 IFR 29-Jun-10 WELDING BOOK FOR OBITE TC TANK ERECTION CST BOK 2
NG22-282-CST-PSL-100014 C0 IFR 7/72010 INSPECTION AND TEST PLAN FOR BASE MATERIAL RECEIVING FOR CST PLN 2 2
NG22-282-CST-PSL-100033 C0 IFR 12-Aug-10 Mobilization Plan For Obite TC Storage Tanks Erection CST PRC 2 2
NG22-282-CST-PSL-100007 C0 IFR 12-Aug-10 Project Quality Plan For Obite TC Storage Tanks Erection QUA PLN 2 2
 Comments Summary for document
NG22-282-CST-PSL-100019_revC0 Rev. C0
Date of comments : Aug. 31 2010
Comments performed / validated by: QC Head
Return Code is 2 ~ Proceed with comments

There are 40 annotations following

 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 7 of 21

4. RESPONSIBILITIES
 Project Manager: He will be responsible to make sure this Procedure is well
implemented . He will also be responsible to make sure the needed equipment ,
material , personnel are available
 Project HR Coordinator : He will be responsible to contact the test candidates , to
take them to the test area , to issue the list of candidates, to give the list to the QC
supervisor, to Employ each test candidate that passes the test ( employment after
PM Approval ) .
 QA/QC Coordinator : He will be responsible to identify all the requirements ( Base
Metals and filler metals ) , the required Project WPS to which the welder shall be
qualified within the ranges in accordance to ASME IX / API 650 for plate and Piping.
The welder’s requirements, the required NDT and Destructive Test. He is also
responsible for the issuing of the appropriate WPS in accordance to contract
requirements and relevant standards, to ensure that all personnel are aware of the
testing and acceptance criteria. To coordinate all testing and inspection activities
and to liaise with Certifying authority / Client. He is also responsible for the
preparation of welder qualification records, and issuance of welder qualification
records for the Certifying authority / Client endorsement.
 NDT Coordinator : He will be responsible to perform the NDT and to issue the NDT
report .
 QC Supervisor : He will be responsible to issue to contractor/client, the Inspection
notice, the Identification of each welder (name and Photo), and assign the CID, the
Weld Summary, and NDT request. He is also to issue any Destructive test request,
assign the Candidate CID, assign the Welder ID, issue the Welder’s Record for
Client approval and keep an updated welder Log. Issue the welder ID card, collect
and file the WPS , the Welder Photo , the Weld Summary, the NDT request , the
NDT report , the Welder record , the ID card , the welder Log.
 Welding Inspector : He will be responsible to monitor the testing of the welder , to
make sure that all activity are done in accordance to the approved WPS, to help
the QC supervisor in preparing all foreseen request and documents, he is also
responsible for visual inspection in accordance with the requirements of the relevant
code and acceptance criteria .
 Third Party: will be responsible to endorse all Welder qualification documents and
Approve the welder Qualification Records.
 Material Coordinator: He will be responsible for the storage of the base material
and welding consumable for welder qualification. The material coordinator will also
be responsible for issuance of the same in accordance with the applicable WPS.

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 9 of 21

7.2. Filler Metals for Qualification

FILLER METAL MATRIX

Filler
Welder
AWS Metal Welding
S/N AWS Class Qualif. Remarks
Specification Size Process F No A No
Code
( mm )
1 A 5.1 E6010 2.5 SMAW ASME IX 4 1

SMAW 4 1
2 A 5.1 E6010 3,2 ASME IX

3 A 5.1 E6010 4,0 SMAW ASME IX 4 1

SMAW 4 1
4 A 5.1 E 7018 2,5 ASME IX
SMAW 4 1
5 A 5.1 E 7018 3,2 ASME IX
SMAW 4 1
6 A 5.1 E 7018 4,0 ASME IX

7.3. Base Metal Coupon List

BASE METAL TEST COUPON MATRIX

Base metal Range of
Actual
Material Actual Material Qualification (All Diam.)
Qualif. test Weld WPS to be
S/N Spec / Type THK P No–S No
Code Diam. Process (ASME IX) Min. Max. P No. Qualified
Grade ( mm )
(“) Thk. Thk. or
(mm) (mm) S No
ASTM A 283 ASME WPS PQR
1 Plate N/A 9.5 SMAW P1 5 10 P1 / S1
Gr C IX 01
ASME WPS PQR
2 ASTM A 106 Pipe
IX
6 7 SMAW P1 3,91 12,54 P1 / S1
02

Remarks:

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 10 of 21

8. WELDER QUALIFICATION MATRIX

WELDER QUALIFICATION MATRIX

Size Qualified
Base Base Nominal
Weld Thick. Weld Nom.
S/N Code Material Material Diam. WPS Thk. Remarks
Book ( mm ) Process Diam.
Spec. Type (“) ( mm )
(“)

1 100011 ASME IX CS Plate N/A 10 WPS-PQR-01 SMAW N/A 10

2 100011 ASME IX CS Pipe 6 7 WPS-PQR-02 SMAW 6 16

Remarks :
1. Welding Position for Plate = 3G / Welding Position for Pipes test = 6G.
2. The welders shall be Qualified by Visual and Radiographic test

9. TEST COUPON PREPARATION

 Test Coupon shall be cut and bevelled.
 Diameter and thickness shall be in accordance with the WELDER
QUALIFICATION MATRIX.
 Coupon Length shall be = 2 x 200mm minimum and shall be sufficient to allow
full size mechanical test specimens to be taken in accordance with the relevant
code.

10. WPS
 The Actual Approved WPS used for the training or for the test shall be displayed at
the welding Test Workshop.

11. WELDER
 The welder Candidate may be assigned a Training Program.
 Based on the training result it will be decided if the welder can perform the
qualification test.
 The test coupon shall be inspected against the acceptance criteria of ASME IX AND
API 650. A Daily welding Report will be issued for proper monitoring and proper
traceability of the activities.

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 11 of 21

12. SEQUENTIAL ACTIVITY

 It is necessary to follow a sequence of activities to qualify a welder.
 Each welder may be trained in advance, and if judged as good he/she will be
required to take the official test.

WELDER QUALIFICATION ACTIVITY LIST

Sequential Who
Activity Remarks
No is Responsible
1 Issue the WPS QA/QC Coordinator Approved By Client
2 Identify the Qualification ranges QA/QC Coordinator
Issue the list of required material
3 QA/QC Coordinator
( Base metal and Filler metal )
4 Provide an efficient test area Project Manager
Provide the equipment in accordance
5 Project manager
to the approved WPS
Identify welder candidates for the
6 HR
welding test
Take the candidates inside the test
7 area ( it will be necessary to provide HR
each candidate with proper PPE )
Provide the candidates list to QC
8 HR
Supervisor
QC Supervisor / Welding
9 Identify each candidate
Inspector
QC Supervisor / Welding
10 Take the Photo of each candidate
Inspector
Assign to each candidate the
QC Supervisor / Welding
11 temporary ID ( it will be call CID =
Inspector
Candidate ID )
QC Supervisor / Welding
12 Proceed to log each candidate
Inspector
Issue to the Client the Test Inspection
13 QC Supervisor Approved By Client
Notice
Assign each candidate a welding QC Supervisor / Welding
14
booth Inspector
Distribute to each candidate the
15 QA/QC Coordinator
respective base materials
Distribution to each candidate the
16 Material Coordinator
respective Filler materials
Display at each Welding Booth the QC Supervisor / Welding
17
actual Applicable WPS Inspector
Surveillance checks
18 Tack weld the Test Coupon Candidate by Contractor
Inspector.
Inspection of tack-welded test coupon
QC Supervisor / Welding
19 , and ensuring that materials and
Inspector
consumables are the correct ones
20 Welding of test Coupon Candidate
21 Inter-pass and parameters check QC Supervisor / Welding Surveillance checks

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 12 of 21

Inspector by Contractor
Inspector.
QC Supervisor / Welding Approved By
22 Visual Inspection of Complete weld
Inspector Contractor / Client
QC Supervisor / Welding
23 Issue a Visual test Report
Inspector
QC Supervisor / Welding
Issue a Daily welding summary report
Inspector
Issue an NDT Request for those QC Supervisor / Welding
24
Candidates that pass the visual test Inspector
QC Supervisor / Welding
25 Log the Result
Inspector
Take the test Coupon to the NDT
26 QA/QC Coordinator
area
27 Perform the NDT NDT Coordinator
Review the Film and issue the NDT Approved By
28 NDT Coordinator
Report Contractor / CPY
QC Supervisor / Welding
29 Log the Results
Inspector
Send the test Coupon for Destructive QC Supervisor / Welding
30
test Inspector
Issue to the Client the Test Inspection Approved By
31 QC Supervisor
Notice Contractor / CPY
Perform the Destructive Test and Third Party Laboratory or Approved By
32
Issue related Report CTR Welding Eng. Contractor / CPY
QC Supervisor / Welding
33 Log The Result
Inspector
Assign to each welder that passes
QC Supervisor / Welding
34 the test ID ( a Permanent
Inspector
Identification )
Issue the Welder Record and the ID
QC Supervisor / Welding Approved By CTR,
35 Card, Update the Qualified Welder.
Inspector TPY then CPY.
Log
The Welder Records , the Visual Report , the NDT report , the Destructive test report shall be
Approved by the TPY
In case of Re-Tests, all process shall be understood same as test.

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 13 of 21

13. WELDER QUALIFICATION

 Qualification of welder and welder operator shall be valid for 6 months from the last
qualification performance date , however a validity period of 2 years may be
considered if sufficient evidence is shown ( NDT reports ) that the related welder
has regularly used the same welding process and materials with no interruption
exceeding 6 month. Welders and welders operator are subject to requalification
when the quality of their work, during fabrication, appears to be below acceptable
standard for example, high and /or frequent NDT reject rates.
 Upon Agreement with CPY , a welder may undergo to a Training Period (Before
Requalification , the Training period shall be agreed with CPY , and in any case
shall be sufficient to enable the welder to produce good acceptable welds) .
 Any Qualification Re-validation of Approval shall also be indicated on the Welder
Record.
 The welder qualification log (see annex 6) shall also indicate the Qualification Re-
Validation date.
 The welder qualification log (electronic copy) shall be issued to CPY on weekly
basis, unless the document remains unchanged.
 The welder qualification documents shall be stamped by a third party such as
Mudiame Intl. Ltd.

14. TACK WELDER

 Tack welder for tanks carbon steel can Be qualified as tack welder ( this will be
indicated on the proper ID Card ) .

TACK WELDER QUALIFIED FOR TANKS

Weld
Process Pipe Pipe
Material to be Diam. ( Thick. Position WPS Range of Qualify.
used for Inches ) (mm )
tack
All Tack , in all Position ,should
CS SMAW N/A 10 3G VBW 01 consider the Preheat requirements
of the WPS to be applied

All Tack , in all Position ,should

CS SMAW 6 7 6G PBW 01 consider the Preheat requirements
of the WPS to be applied

Type of test , same as normal qualification ( Visual , RT , Bend )

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 15 of 21

16. ANNEX
Visual Inspection Report

NDT Request

Welder Record

Welder ID card

WELDERS Qualification Log

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR WELDER QUALIFICATION FOR OBITE TC NG22-282-CST-PSL-100019
STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : 0 Rev. Date : 17-July-2010
Page 16 of 21

Annex Visual Inspection Report

“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
NG22-282-CST-PSL-100019_C0
 JOB UNIT
COMPANY TOTAL E&P NIGERIA LIMITED
DATE
PLANT LOCATION QC CODE PROGRESS N.
RC326229
PETRA SERVICES LIMITED PROJECT TITLE OML 58 UPGRADE PHASE 1 ITP REF.

VISUAL INSPECTION REPORT FOR TANKS (Welder Qualification Test)

TAG/ITEM ENGINEERING DOCUMENT No. SUPPLIER DOCUMENT No. CODE/SPECIFICATION

IDENTIFICATION OF MONITORING AND MEASURING DEVICES PAGE 1 OF 1

REPORT
WELD APPEARANCE
Mat'l WELDER ID
Joint Diam.Ø in. Thk. ROOT CAP BASE METAL
S/N LINE N˚. DRG N°. SHT. N°. Weld NO. (CS,SS & WPS No. RESULT (1)
Type Pipe/Plate (mm) DSS) Width of Width of Height of
Root/ Hot Fill/Cap I/P B/T Reinforced Reinforced
Overlap U/Fill Pore U/C Spatter M/A
Pass

LEGEND (1) A=ACCEPTABLE; NT=TO BE CUT; R=REJECT; I/P=INCOMPLETE PENETRATION; B/T=BURNTHROUGH; PORE=POROSITY; U/FILL=UNDERFILL; U/C=UNDER CUT; M/A=MISALIGNMENT.
NOTES: √ = Accept INSPECTION NOTIFICATION REFERENCE

RFI No.
ISSUE DATE
PREPARED BY:
QC Supervisor/ Manager CONSTRUCTION
QC Welding CONSTRUCTION SUB-CONTRACTOR COMPANY
CONTRACTOR
NAME :- NAME :- NAME :-

SIGNATURE :- SIGNATURE:- SIGNATURE :-

DATE:- DATE:- DATE :-

Form code: MDT.WL.CDQ.0151 Sh.01/Rev.00.07
 OML 58 Phase 1 Project TANK ERECTION
WELDERS QUALIFICATION LOG
Test Details Qualification Range REPORTS
WELDER DATE WPS CODE / Material Size of Diamete Material Test Qualification Qualification Re-
S/N WELDER NAME Candidate CID
Thick. Welding Filler Thickne Filler Visual Visual NDT NDT Welder Destructive Destructive
ID TESTED USED SPEC Location Expire date validation date
Weld No P/S/ Coupon Position r(OD) Process Position P/S/ DWR
(mm) Process Metals ss mm Metal Report Result Report Result Record No. Test Report Test Result
Group No (") Inch Group No

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