Classification: Internal #

Project Title: CT798 - NORTH FIELD EXPANSION (NFXP) OFFSHORE

Mr. Waldi

Item
Description
No

RCA Team

List the team involved in the RCA investigation members from different department/ disciplines to provide
1
comprehensive perspective of the issue in hand

Welding Operators

Welding operatives qualification certificates available and valid . Confirm knowledge of WPS, pipe rig expie
1 of camera monitoring system etc. Confirm if Project specific awareness sessions were conducted prior to P
needs,requirements and expectations

Deposition of the 1st and subsequent clad layers, operators indents, are they fully traceable with respect t
2 defective barrel. Verify if there is a correlation between specific welders and repairs . Why were so many o
involved in the welding of the barrels, upto 7 on occasion

Is Welders’ KPI performance tracked and monitored. Identify Welders training, cladding experience, any ne
3
operators used, any operators used with historically high repair rates /required re training as a consequenc

Materials and Welding Consumables

1 Does barrel base material meet Project requirements, chemically/physically/dimensionally

Classification: Internal #

Was Barrel surface preparation prior to overlay free from scale, paint, oil, rust, dirt, oxides, and other forei
2 Blasting used, was it conducted thoroughly, i.e in accordance with SA 2.5 profile standard. Confirm the dur
barrel blasting and overlay for each?

3 Confirm if Welding consumable /Filler metal size, type classification / brand conform with the approved cla

Weld Consumable control/ storage, was wire returned to the store at weekends/ the wire covered /protec
4
of the process ?

Welding Machine/Equipment

Verify that all the pipe cladding rig equipment were fully calibrated and in good working condition, not limi
• Welding power sources
• Pipe rotating equipments/rollers/ wire rope system/step back
• Arc Voltage Control Unit
2 • Twin or single welding head . Weld torch mounting
• Twin wire or single wire and hot wire current application
• Camera monitoring and housing
Verify if any breakdowns were reported during the barrel production window . Confirm if the identified rep
unique to one pipe clad rig station.

2 Was each barrel set up in accordance with requirements, chuck system, aligned and trued up
Environment Conditions
1 Environmental conditions during production welding, protected with shielding/drafts /factory doors open/
Welding Process / Procedures and Techniques

1 Welding execution -Any issues raised by operators during 1st layer deposition. Any interim repairs conduct

2 Approved Welding Procedure (WPS) available at site/copy provided/awareness of the WPS used
Classification: Internal #

Preheat Controls before and during all overlay activities. Was propane gas used, how was it applied, period
time ? Preheat temp (32deg) , where are the temperatures checked (OD only), verified by whom? How wa
3
thickness temp acheived and maintained How was preheating managed during breaks, lunch, shift change
working etc. All records to be collated

Overall WPS compliance with critical weld parameters, sequences, step back/overlap, hot wire current/ wi
4 speed , interpass temp,gas shielding , clad deposit thicknesses etc What verifiable records are available an
inputs . Was autogenous welding carried out on any of these areas?

Was a tungsten grinder used to sharpen all tungstens in all cases. How often were the tungsten sharpened
6
welders advised on the importance of the angle / sharpness requirements of the tungsten

Wire changes - Was each of the station weld torchs repositioned in the exact same location which the we
7 terminated prior to any wire change, how is this marked. Wire positioning, relative to tungsten, is a gauge
Is there a correlation between the wire changes and the location of the clad defects .

Detail exactly the differing surface preparation which would have achieved complete bonding between the
8 backing material when comparisons are made ? Why was this retrospective preparation not considered as
practice?

Having passed all the required WPS /PQR qualification tests with comparable surface preparation,, althoug
9
variables are met, is the procedure robust enough to successfully weld substrates of this magnitude

QC/NDT

1 State the QC inputs before ,during and after welding, compliance to WPS and ITP

Project specific ITP awareness -QC knowledge of Project Quality requirements, noting NDE was not perform
2
deposition of 1st clad layer
Verify UT Technicians qualifications. How many were involved. Cross checking expierence and performanc
3
recruits
Verify technicians understanding of Project NDE requirements, technique, material thickness/nominal any
4
sessions conducted
5 Operatives understanding of the materials to be scanned
6 Calibration/validation block used for equipment set up and preparation prior to applying UT scanning
7 Was scanning area adequate to cover scanning technique as per procedure
8 Was the UT technique applied in accordance with the procedure?
9 Was the correct calibration block selected
Is the calibration sensitivity, probe angle, actual probe angle performed correctly prior to carrying out UT s
10
applications
11 Was the sensitivity correctly used by NDT technician during UT scanning processes
12 Was the transfer correction value checked prior to all scanning applications?
13 Was the Rolling direction of material verified before each scanning application
Classification: Internal #

14 What sizing techniques applied during defect identification and evaluation

15 Were the correct probe angles used (0 Degree inspection to check disbondment )
UT Set Equipment
1 Are all the UT sets used calibrated with valid certificates

2 Is all the equipment regulary checked/ functionally fit for purpose, any faults reported during the productio

UT Reporting

1 UT reports, was the correct information based on the actual UT scanning application recorded

2 Considering the criticality level, were the reports verified by UT Level 3

Clarify what has been used as tge datum, is this the distance from the end of the barrel? Circumferential l
3
circumference, need to know where location is compared to 12 o’clock position

4 Provide actual WT of base material as well as depth of LOB indications in report

5 Weld defect characterisation and reported location , interlayer versus lack of interface disbondment dispa
 Classification: Internal #

RCA Investi
XPANSION (NFXP) OFFSHORE

Description

RCA investigation members from different department/ disciplines to provide a

of the issue in hand

tion certificates available and valid . Confirm knowledge of WPS, pipe rig expierence c/w use
m etc. Confirm if Project specific awareness sessions were conducted prior to Production on
ectations

bsequent clad layers, operators indents, are they fully traceable with respect to each
re is a correlation between specific welders and repairs . Why were so many operators
he barrels, upto 7 on occasion

tracked and monitored. Identify Welders training, cladding experience, any newly qualified
rs used with historically high repair rates /required re training as a consequence

meet Project requirements, chemically/physically/dimensionally

 Classification: Internal #

on prior to overlay free from scale, paint, oil, rust, dirt, oxides, and other foreign matter. If
ted thoroughly, i.e in accordance with SA 2.5 profile standard. Confirm the durations between
or each?

ble /Filler metal size, type classification / brand conform with the approved clad WPS

torage, was wire returned to the store at weekends/ the wire covered /protected at all stages

ing rig equipment were fully calibrated and in good working condition, not limited too;

ts/rollers/ wire rope system/step back

t
ead . Weld torch mounting
and hot wire current application
housing
re reported during the barrel production window . Confirm if the identified repairs were
tation.

cordance with requirements, chuck system, aligned and trued up

uring production welding, protected with shielding/drafts /factory doors open/closed

echniques

es raised by operators during 1st layer deposition. Any interim repairs conducted

e (WPS) available at site/copy provided/awareness of the WPS used

 Classification: Internal #

during all overlay activities. Was propane gas used, how was it applied, periodically or full
) , where are the temperatures checked (OD only), verified by whom? How was through
d maintained How was preheating managed during breaks, lunch, shift change, weekend
be collated

h critical weld parameters, sequences, step back/overlap, hot wire current/ wire angle , travel
hielding , clad deposit thicknesses etc What verifiable records are available and level of QC
lding carried out on any of these areas?

to sharpen all tungstens in all cases. How often were the tungsten sharpened. Are the
ortance of the angle / sharpness requirements of the tungsten

the station weld torchs repositioned in the exact same location which the weld arc was
change, how is this marked. Wire positioning, relative to tungsten, is a gauge used to verify?
en the wire changes and the location of the clad defects .

urface preparation which would have achieved complete bonding between the WO and
parisons are made ? Why was this retrospective preparation not considered as a standard

ed WPS /PQR qualification tests with comparable surface preparation,, although essential
cedure robust enough to successfully weld substrates of this magnitude

during and after welding, compliance to WPS and ITP

ss -QC knowledge of Project Quality requirements, noting NDE was not performed after

cations. How many were involved. Cross checking expierence and performance . Any new

ding of Project NDE requirements, technique, material thickness/nominal any awareness

the materials to be scanned
used for equipment set up and preparation prior to applying UT scanning
e to cover scanning technique as per procedure
ed in accordance with the procedure?
block selected
probe angle, actual probe angle performed correctly prior to carrying out UT scanning

used by NDT technician during UT scanning processes

value checked prior to all scanning applications?
material verified before each scanning application
 Classification: Internal #

ed during defect identification and evaluation

es used (0 Degree inspection to check disbondment )

rated with valid certificates

checked/ functionally fit for purpose, any faults reported during the production window

information based on the actual UT scanning application recorded

vel, were the reports verified by UT Level 3

s tge datum, is this the distance from the end of the barrel? Circumferential length is <full
w where location is compared to 12 o’clock position

aterial as well as depth of LOB indications in report

n and reported location , interlayer versus lack of interface disbondment disparity

Classification: Internal #

RCA Investigation Checklist

PO Number: 00116700

Manufacturer: PT. Cladtek Bi-Metal Manufacturing

Finding / Verified

Enclosed the list of the team involved

1. Welding Operator Certification.

2. All welding machine using the same setup.
3. Camera monitor are available every welding machine station.
4. Project specific awarness session was not conducted due to commmon practice weld overlay identified in the initial
stage.

1. Yes. Enclosed sample welding survailance record for this project.

2. No. The weld overlay was carried out by machanized welding process and certified welding operator.
3. Due to the size of the barrels, long duration to complete weld overlay is around 7 - 10 days (Both shift) which require
multiple welding operator involved

1. There is no welding operator KPI perfomance with regard to weld overlay method due to the difficulty of
measurement. The repair of weld overlay shall be calculated based on area instead of component quantity.

2. Yes, all the welding operator are trained and monitored the welding performance based on the live project. The
priodic monitoring is in accordance with ASME IX. Welding operator validity is updated every 6 months.

This material is free issued by customer. NOV to reconfirm.

Classification: Internal #

1. Surface preparation prior to weld overlay was carried out based on ITP SR# 13 that is in accordance with SA 2.0 as
blast condition only.

2. It is expected around 1 to 3 days after blasting by achieving SA 2.0

Confirmed.

Cladtek has internal procedure to control the wire consumable. This procedure is available at Cladtek premises and can
be reviewed by customer on site.
No welding consumable returned to the store. Welding was carried out continuosly both shift and over the week end
24/7.

1. Enclosed the validation certificate for Welding power sources, Pipe rotating equipments/rollers/ wire rope
system/step back, Arc Voltage Control Unit.
Twin or single welding head (Weld torch mounting), Twin wire or single wire and hot wire current application and
Camera monitoring and housing are in the good condition.

2. Any break down during the weld overlay will be reported by break down record. In regard to repair identification
from break down case, the repair type mostly in the form of tungtens inclusion and/or start stop welding.

Yes.

Environmental conditions was preserved.

No.

Yes.
Classification: Internal #

1. Preheat temperature is checked at OD and verified by Cladtek OQ Inspector

2. No propane gas inspection priodically

1. Yes
2. Yes. Enclosed sample welding survailance record for this project.
3. Yes, Autogenus welding on the start stop area as per approved WPS.

1. Yes, all the tungsten condition has been monitored periodically.

2. Yes, all tungstens are sharpened in all cases in accordance with Internal Cladtek Procedure (WI-73)
3. Yes, the tungsten angle was written in the procedure. The welding operators are aware of the angle and sharpness
requirements of the tungsten.

1. Change of wire was carried out in accordance with the approved the WPS and all the positions are the same since
the welding equipment setup are typical and the same for all welding machine stations. Please refer to approve WPS
page 2 of 2 (QW-410).
2. No.

Refer to remark in row #16

Submitted and approved WPS / PQR was considered 3.0 mm FBH with 80% FSH while the new project requirement is
3.0 mm FBH with 50% FSH. This gap is due to the unclear requirement during project hand over. Also, Cladtek
understands that the UT LD is not required as per approved CT798-ITP-001 Rev. 2

No input the Quality prior to start, during and after weld overlay until new ITP revision received which is require UT LD.
Unfortunately all the barrels has been complete weld overlay.
Yes, project specific requirement which is desciribe at the approve ITP has been aknowladge to quality member at the
shop floor.

All UT technicians are qualified and certified according to Cladtek writen practice procedure.

Yes
Yes
Yes
Yes
Pulse Echo technique with probe twin crystal (contact testing) and UT digital thickness gauging to measure the total
thickness (CS+CRA)
Yes, Calibration block was made from similar material which is provided by customer (NOV).
Yes, before scanning NDE technician was perform calibration. Only 0 degree (straight beam) applicable for UT
lamination and disbondment and the activity is witnessed by customer.
3.0 mm FBH set to 80% FSH mentioned as 100% reference level
No. Transfer correction is not required, since the thickness/material specification of calibration block is similar with the
actual barrels.
No
Classification: Internal #

6 db drop as per applicable procedure

Yes, following the teorytical normal probe will perpendicular to disbondment defect orientation.

Confirmed.

Yes, following the calibration shall be performed prior daily inspection activity and witnessed by customer.

Yes, the activity is witnessed by customer.

Yes

Yes, Cladtek datum always started from R side with 0 degree 12 o'clock position located at exact position of the
hardstamp with clockwise calculation for circumferential.

The actual thickness cannot provide at the LOB location. However, the actual thickness was taken before weld overlay
with interval 500mm along the pipe

Yes, understod. Defect position between carbon steel interface to CRA layer is call as lack of bonding, defect position
CRA layer to CRA layer is call as lack of fusion or interrun fusion. UT thickenss before weld overlay as reference to
decide the LOB defect considering depth of defect not exceeding thickness before weld overlay.
Classification: Internal #

Evidence Remarks

Attachment 1

Attachment 2 for Point No. 1

Attachment 3 for Point No. 1

(Sample)

Attachment 4 for Point No. 2

N/A
Classification: Internal #

1. Cladtek notes that to fulfill the UTLD requirements, it is

strongly advised to employ a combination of blasting and
grinding.

In addition,The absence of intermediate cleaning stages was

noted. Owing to the large dimensions of the materials involved,
the welding process tends to exceed standard duration
expectations. This extended time frame may result in the
N/A
inadvertent accumulation of particles on the carbon steel
surfaces.

2. The absence of intermediate cleaning stages was noted. Owing

to the large dimensions of the materials involved, the welding
process tends to exceed standard duration expectations. This
extended time frame may result in the inadvertent accumulation
of particles on the carbon steel surfaces.

Attachment 5

N/A

Attachment 6 for Sample Welding

Machine Validation Certificate

N/A

N/A

No UT disbondment requirement in the initial stage which has

N/A
been verified by approved CT798-ITP-001 Rev. 2.
Cladtek internal document (Job Instruction Sheet) is available and
N/A
can be reviewed on site.
Classification: Internal #

Attachment 3 for Point No. 1

(Sample)

Attachment 3 & 7 for Point No. 2 &

3

Cladtek internal procedure WI-73 is available and can be

N/A
reviewed on site.

Attachment 7 for Point No. 1

Refer to row #16

Attachment 8

Attachment 8

Attachment 8

Cladtek internal procedure is available and can be reviewed on

N/A
site.
Attachment 9
Attachment 9
Attachment 10
Attachment 9
Attachment 11
Attachment 10

Attachment 11

Attachment 9 & 11
N/A
N/A
Classification: Internal #

Attachment 9
Attachment 9

Attachment 12

N/A

Attachment 11

Attachment 13

N/A Following by paint marker on the surface pipe.

Attachment 11

Attachment 11