Provision of Flow lines and

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EBS1 FSFA11 SAPR PRIS 1001 D01

Field Welding Control Procedure

Contract No.: 031-SC-21
Date Sign
Code I Information only Submission - Accepted
Code R Rejected – Major Comments – Data Provider to revise and re-
submit. Work should NOT proceed in the affected areas until
comments are resolved.
Comments Returned – Data provider to revise and re-submit for
Code C the further review.
Code A Accepted – Approved – No further submission required
Review Code and Status

2022.08.30

D01 17-08-2022 IFA Yousef Ahmed Haythem

D00 21-06-2022 IFA Yousef Ahmed Haythem

REV Date Issue Status Prepared By Checked By Approved By
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DOCUMENT REVISION HISTORY SHEET

REVISION DATE
Rev DESCRIPTION ISSUED UPDATE / AMENDMENT DETAILS
Field Welding
D00 21/06/2022 Issue For Approval
Control Procedure
Field Welding
D01 17/08/2022 Issue For Approval
Control Procedure
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Contents

1- PURPOSE ……………………………………………………...……4

2- SCOPE ……………………………………………………………....4

3- REFERNCES ………………………………………………………….….4

4- DEFENTIONS …………………………………………………..…. 4

5- PROCEDURE ………………………………………………………..…….5

5.1 WELDING PROCEDURE SPECIFICATIONS (WPS) ……………....5

5.2 WELDER QUALIFICATION ………………………………………...5

5.3 WELDER PERFORMANCE ……………………………………….…6

5.4 MATERIAL INSPECTION ………………………………………...…6

5.5 FABRICATION AND PREPRATION ………………………….….…7

5.6 PREPRATION PRIOR WELDING ………………………………….. 8

5.7 WELDING PROCSSES ……………………………………………....10

5.8 INSPECTION……………………………………………………….... 15

6- RESPONSBILITIES OF QA/QC ENGINEER & QC INSPECTOR ……..19

7- FILLER WIRE & ELECTRODES CONTROL……………………….…..19

8- DOCUMENTATION, RECORD & REPORTING……………………..…20

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1- PURPOSE
This purpose describes the general requirements for control of welding activities to ensure all
production welds are in good quality.

2- SCOPE

This procedure covers all stages of work before welding, which include selection of WPS,
welder qualification, material identification, visual inspection, welding sequence and inspection
during and after welding.

3- REFERENCES

This procedure complies with the following contract specifications and international codes:
— ASME Section IX Welding and Brazing Qualification
— ASME B 31.3 Process Piping
— ASME B 31.4 Pipeline Transportation Systems for Liquids and Slurries
— API 1104 Welding of Pipelines and Related Facilities

4- DEFENITIONS

- PWPS Preliminary Welding Procedure Specification

- WPS Welding Procedure Specification

- PQR Procedure Qualification Record

- WPQ Welder Performance Qualification

- VT Visual Test

- NDE None Destructive Examination

- NDT None Destructive Testing

- AWS American Welding Society

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5- PROCEDURE

5.1 WELDING PROCEDURE SPECIFICATIONS (WPS)

5.1.1 Prior to fabrication, ALMUTAA shall identify from the pre-accepted welding procedure
specifications, the applicable WPS for the work, the list of the applicable WPS shall be
submitted to EBS / PMT for review and approval.

5.1.2 If additional WPS is required, the additional WPS shall be qualified in accordance with
the latest edition of AWS D.1.1 for structural, ASME section IX for piping specifications.

5.1.3 It is the duty of the ALMUTAA Welding Engineer to formulate WPS applicable to the
joint configuration and application.

5.1.4 The additional WPS shall be submitted to EBS / PMT for review and approval before
commencement of qualification test.

5.1.5 Upon approval of the procedure, a welding procedure qualification test shall be carried
out in the presence of EBS / PMT& TPI representative.

5.1.6 PQR test coupon shall be visually inspected before and after welding and nondestructive
tested in accordance with required specification. The acceptable test piece shall be sent for
mechanical testing by an independent third party approved by EBS. EBS shall be informed at
least two (2) days before the testing and reserve the right to witness the testing.

5.1.7 A complete documentation of the Welding Procedure Qualification Records, NDT

reports, material mill certificates, welding consumable certificates, welding procedure chart and
mechanical test results shall be compiled together with WPS and submitted to EBS / PMT for
endorsement.

5.2 WELDER QUALIFICATION

5.2.1 Prior to fabrication, ALMUTAA must perform the welder qualification tests according to
approved WPS, before implement any welding activities.

5.2.2 For the qualified welders or operator that have expired certification in order to renew the
expired certificates should perform NDT for the latest welded joints before the expired date and
submit to COMPANY QA/QC department for renew and approval.

5.2.3 ALMUTAA shall inform EBS at least 24 hours prior to any welder qualification test.
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ALMUTAA welding inspector shall monitor the welders during the qualification and check the
welding parameters used by the welders form time to time.

5.2.4 The performance test may be terminated at any stage of the qualification test, when the
welder or welding operator does not have the required skill to produce satisfactorily results.

5.2.5 The qualification of welders or welding operators shall be conducted in the presence of a
EBS representative.

5.2.6 The final acceptance of the welders or welding operator’s qualification test shall be
approved by EBS / PMT.

5.3 WELDER PERFORMANCE

The welder is asked to weld a test coupon in accordance with the qualified welding procedure
specification (WPS), then visual inspection are carried out as per the approved procedure.
Thereafter the final welded test coupon is sent for the Radiography test – RT. After a
satisfactory test report, the welder may be employed for the production welding (or fabrication
welding).

5.4 MATERIAL INSPECTION

- All materials received for fabrication and erection shall be inspected in accordance with
Materials Control System of this Plan utilizing QC Receiving Inspection Report forms.

- Issuance of materials shall be in accordance with material control requirements.

-Welding materials will be stored to type, grade batch number and specification in a
secure controlled area welding material shall be stored in dedicated shelf, stack far from
the ground and wall and humidity, the temperature shall be not lower than 5 C relative

- Special electrode shall be stored and specified storage room or area according to
manufacturer requirement.
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5.5 FABRICATION AND PREPRATION

a. All fabrication work shall be in accordance with specifications and procedures.

b. All welding procedures for pipe supports pre-fabrication shall be in accordance

with project specification and international standards.

c. All welders shall be qualified for perform piping and structural welding,

d. . All spools shall be checked for dimensional accuracy at the tack weld stage.

e. All welds shall carry welder‘s identification.

f. All completed spools shall be marked with identity number.

g. Visual inspection shall be performed during and after welding and prior to any
non- destructive testing.

h. For carbon steel and stainless steel, the level of production butt welds to be radio
graphically examined shall be as per approved procedure and design recommendation

i. Raw materials (plates, pipes, etc.) shall be cut as per drawing. All the cut edges
shall be grinding or machined to bright metal (a minimum of 1.6mm depth) and
shall be visually examined for cracks.

j. When pipe pieces and fittings are assembled into one piece, a foreman shall compare the
material grade and heat number type marked on each component with pipe isometric
drawing which shows material grade and type and shall record the heat number on a pipe
Isometric drawing by hand.

The surfaces to be welded shall be uniform and free from lamination, tears,
scale, slag, grease paint, or other deleterious material that might adversely
affect the welding. The joint design and spacing between the abutting ends shall
be in accordance with the procedure specification.
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5.6 PREPRATION PRIOR WELDING

5.6.1

Fit-up pre & post welding inspection all weld joint will be inspected and documented by the
Contractor Welding inspector at the fit-up stage and prior to welding of the root pass. All welds
joints are to be 100% visually inspected by Contractor QC Inspector. This is process
examination shall include the following:

a) Welder qualified

b) Joint preparation, root face, bevel angle, dimensional checking prior to welding etc.

c) fit-up, root gap, joint clearance and internal alignment (for piping)

D) Filler metal according to approved WPS

e) Interposes condition at cleaning.

F) Appearance of finished joint

g) Welder stamp / Marking

h) Weld joint number

I) NDT performed.

j) Dimensional check. The root pass shall be welded immediately after visual inspection of the
fit-up is approved by the Welding Inspector (company or contractor), the Contractor inspector
shall verify that the welders are qualified.

5.6.2 The joint bevels shall be prepared in accordance with the approval WPS and PQR.
Internal and external surfaces to be welded shall be clean and free from paint, oil, rust and
scale.
Pipe ends shall be beveled by machining or grinding. Preparation of weld edges by gas cutting
shall, wherever practical, be done with a mechanically guided torch. Edges shall be left free of
slag and cut surface shall be ground to a smooth uniform surface by removing approximately
0.5mm of metal.
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5.6.3 Position of seams shall be convenient for welding, heat treatment and inspection. Distance
between 2 continuous welds shall be at least 2 times of nominal pipe and for pipes diameter
equal and less than 4”, this distance shall be 2inch.
Distance between circumferential weld up to supports shall be more than 150mm. When
assembling elements of pipes with the same wall thickness, the inner wall shall be even.
Unfitness of butt joint cannot exceed the following values: 10% of wall thickness and not larger
than 1.6 mm. The alignment of the butting ends shall be set so as to minimize the offset
between surfaces. If the offset exceeds 1.6mm, provided it is caused by dimensional variations
within the specified tolerance, the pipe with the smaller diameter shall be trimmed to a taper not
steeper than 1 in 4.
Trimming length: L≥4 (δ1-δ2)
Before assembly of weld joints, inner and exterior faces of it shall be removed with manual or
mechanical method. There shall be no paint, burr, rusty stain, scale and other sundries in 2 inch
range at two sides of grooves that can impact welding.
Machining mode and dimension of grooves shall be checked. There shall be no crack or
interlayer on the surface. Do not assemble weld joints with force.

5.6.4 Argon backing gas shield shall be used for all passes and for tack welds as per WPS if
required. The backing gas shall remain on until the weld is below red heat.
Tack weld shall be the same with welding process of formal welding. Length of seam may be
10mm~15mm and thickness may be 2mm~4mm and not larger than 2/3 of wall thickness.
There shall be no crack and other defects on the seam.
After assembly and tack welding, the process welding shall be applied in time.

5.6.5 If following situations happen in construction site for welding of pipe and no protective
measure are taken, welding operation shall be stopped.

1) For arc welding of electrode, wind speed is≥8 m/s;

2) For gas shielded welding, wind speed is≥2 m/s;
3) Relative humidity is㸼90%;
4) It is raining or snowing.

Carbon steel welding, when ambient temperatures are lower than 0℃, the surface from welding
point to 100mm away of steel shall be preheated to over 15℃.
Austenitic stainless steel welding, when ambient temperatures are less than -5℃, measures for
increase of temperature shall be taken.
Cerium tungsten rod may be used for argon tungsten-arc welding. Purity of argon shall be over
99.99%
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5.7 WELDING PROCESSES

5.7.1 The following processes shall be used in production welding:

1. Gas Tungsten Arc Welding (GTAW)

2. 2. Shielded Metal Arc Welding (SMAW)

5.7.1.1 1 Gas Tungsten Arc Welding (GTAW)

1. Electrodes shall be 2% throated Tungsten (EWTH-2) or ceric Tungsten.

2. An inert gas purge is mandatory for alloy steels with greater than 2% chrome and austenitic
stainless steels.

3. The inert gas flow rate shall not be less than 10 liters/minute.

4. When back purging is required, the underside of the weld shall be blanked off and all air
expelled before welding is commenced. This shall be done by introducing purging gas to the
back space equal at least to 6 x volume of air displaced, followed by a flow rate of 2.5 to 7
liters/minute.

5. A “gas lens” should be used to improve gas shielding of the weld pool.

6. For NPS 2” and less (butt weld) shall welded by full GTAW welding.

5.7.1.2 Shielded Metal Arc Welding (SMAW):

1- . For root runs made by SMAW process, the electrodes shall be 2.5 mm or 3.2 mm only.

2- SMAW process may be used for butt weld filling and cup 2.5’’ diameter carbon steel
pipes provided that the root pass is made using 2.5 mm electrodes. The subsequent
passes may be made using the SMAW process provided the electrode size does not
exceed 3.2 mm.
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5.7.2 General Requirements

1- Welding shall not be stopped before the second pass is completed and the components
being welded shall not be moved or lifted until at least 50% of the final weld depth has been
deposited.

2- Tack welds shall be performed by qualified welders using the same parameters as specified
for the root pass in the approved WPS.

3- Temporary attachments to the surface of the pipe, storage tank, storage sphere etc. shall be
removed by grinding and the surface nondestructively examined by visual or magnetic
particle or liquid penetrant methods. Thickness checks shall be made to ensure that the
remaining wall thickness is not less than the design minimum.

4- Backing rings shall not be used for the welding of any piping butt welds.

5- Socket welds shall be performed with at least two passes.

6- For socket weld fittings or valves, the pipe face shall be spaced approximately 1.6 mm clear
from the root face of the socket to avoid weld stresses.

5.7.3 Welding Sequence

- Preheating shall be applied as required in accordance with the approved WPS using
propane gas heating or other approved method prior to tacking and welding. The
minimum pre-heating temperature shall be uniformly established over a minimum
area of 3” (76mm) on both sides of the weld groove. It shall be through thickness.

- Strong backs shall be utilized to maintain alignment during the welding process and
shall be removed after the weld is completed. Strong back weld marks shall be
ground smooth, after removal and shall be tested by visual or MPI if require.

- Temperature control, Welding supervisors and welders shall be equipped with thermo
sticks for constantly checking the minimum preheating temperature and inner pass
temperature prior to and during the welding operations until completion.
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- Welding sequence shall be posted or displayed at side and shall be referred to ensure all
necessary preparation, precaution, equipment act... have been satisfied to avoid possible
reworks. Welding of structural part/component shall be started from member(s) with high
degree of shrinkage towards member(s) with lesser shrinkage. Sequence shall include
member and location of welders at each stage of assembly, sketches and other information
as necessary. The welding progression on a member shall be from pints where the parts are
relatively fixed in position with respect to each other toward points having a degree relative
freedom of movement.

5.7.4 Weld Clearing

1- After each welding pass, the weld shall be cleaned of all flux and slag by power wire
brush, grinding or hand tools. Only stain-less steel wire brushes shall be used on
stainless steel materials. Wire brushes used for stainless steels materials shall only be
subsequently used on the same materials.

2- Each welding pass shall be visually inspected by the contractor welding inspector to
ensure freedom from slag, cracks, and porosity before the start of the next pass. Any
defects shall be removed or repaired prior to the start of the next pass.

3- On completion of the weld, the adjacent surfaces shall be cleaned of all spatter, slag,
flux and carbonaceous material.

5.7.5 Preheat Temperature

1- The minimum preheat temperature for welding shall be as specified in ASMEB31.3 Table
330.1.1-Recommended Preheat Temperatures, or other applicable code.

2- Where welding procedure specification specifies a higher preheat temperature, it shall be

used for production welding.

3- Application of pre-heat may be by electrical resistance methods or oxy-fuel torches. Direct

flame impingement by incorrectly set or adjusted burners shall be avoided and under no
circumstances shall the use of cutting torches be allowed.

4- Preheat shall be supplied in a gradual and uniform manner and shall be maintained
throughout the welding operation.
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5- The minimum preheat temperature shall be established on both sides of the joint
preparation for a minimum distance of 75 mm or three times the material thickness,
whichever is greater. If possible, the preheat temperature shall be measured on the
opposite face to that being heated. Where access to only one face is possible, the heat
source shall be removed to allow for temperature equalization (1 minute for each
25mm of material thickness) before measuring the preheat temperature.

6- The preheat temperature shall be held for at least five minutes before welding is
commenced and shall be checked before welding by temperature indicating crayons or
contact pyrometers. The allowable variation minimum preheat temperature is +50℃-
0℃ of that required by the Welding Procedure Specification.

5.7.6 Inter-pass Temperature

1- The maximum inter-pass temperature shall not exceed the maximum specified inter-
pass temperature on the Welding Procedure Specification. Maximum limits for inter-
pass temperatures shall be as follows:

™ Ferritic and low alloy steels:250℃

™ Duplex and austenitic stainless steel: 150℃ In the case of dissimilar metal joints the
lower inter-pass temperature shall apply.

2- The minimum inter-pass temperature shall be the preheat for the material.

3- Measurement of inter-pass temperatures shall be by temperature indicating crayons,

contact pyrometer or any other owner approved method of temperature measurement.
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5.7.7 Heat Input

1- For High strength steels the heat input shall be restricted in conjunction with the
maximum preheat and inter-pass temperatures required. The following parameters
shall be carefully monitored:

™ Preheat temperature.
™ Minimum and maximum inter-pass temperatures.
™ Welding speed.
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2- Suitable equipment to measure these important variables (e.g. contact pyrometer) shall
be available at the work site. Accuracy of parameters readings: temperature ±10℃,
amperage and voltage ±5%.Alternative processes which exceed the above heat input
requirements shall not be used without prior written approval from owner.

5.8 INSPECTION

The inspection activities to be performed during production welding shall also include
Non-Destructive Examination (NDE) and Post Weld Heat Treatment (PWHT if need)
of welds.

These include:

1- Prerequisite tasks to be completed prior to the start of inspection activities.

2- In process inspection while work operations and activities are in progress.

3- Inspection reports to be completed after completion of inspections.

5.8.1 Prerequisites

1- Welding Engineer shall verity that welding and other related inspection criteria meet
the requirements of following codes and/or standards as applicable:

™ ASME Boiler and Pressure Vessel Code, Section II Part C, Section V, Section Ⅷ
Div.1and Div.2, Section Ⅸ.

™ ASME/ANSI B31.3, Process Piping Code.

™ Other codes as specified.

2- The Welding Engineer shall verify that the following procedures have been approved
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by EBS/PMT prior to use:

™ Welding Procedures Specifications (WPS’s).

™ Welding Procedure Qualification Records (PQR’s).

™ Post Weld Heat Treatment (PWHT) Procedure.

™ Non-Destructive Examination (NDE) Procedure.

5.8.2 Welding Inspection

1- Inspection shall be carried out before, during, and after fabrication or installation in
accordance with ASME/ANSI Code B31.3, ASME Section Ⅷ Div.1and Div.2, API
650, API 1104, AWS D1.1 and approved specifications.

2- Prior to pipe, storage tank, storage sphere, etc. alignment, each pipe/plate or fitting
shall be inspected to ensure that the outside and inside surface and bevels are free from
foreign matter

3- Relative positions of piping components, alignment and spacing shall be checked by

the QC Inspector prior to the commencement of welding.

4- Inspection by the QC Inspector during fabrication or installation shall include the

following:

™ Verification that the welder is qualified.

™ Weld joint preparation and cleanliness.

™ Preheating and purge as required.

™ Fit-up, joint clearance and internal alignment prior to welding.

™ Verification that the welder is following the variables specified in the WPS, such as
base material, filler material, inter-pass temperature, position, electrode size, etc.

™ Profile of root pass after cleaning, both external and internal (when accessible).

™ Slag removal and weld profile between passes.

™ Completed weld profile.

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™ All completed welds shall be visually examined. Additionally, NDE shall be taken in
accordance with design drawing and applicable codes.

™ Final weld inspection shall be carried out after the removal of slag, mill scale, dirt,
weld spatter, paint, oil or other foreign matter has been achieved.

™ Prior to notifying EBS/PMT inspector of any inspection, the A QC shall inspect and
accept that item.

5.8.3 Non-Destructive Examination (NDE)

All NDE shall be performed in accordance with EBS/PMT approved NDE procedures.
Special attention shall be given to the following criteria:

1- Pre-process
™ Procedure and personnel qualification records.
™ Location, area and extent of the required examination.
™ Equipment, material and technique to be used.
™ Calibration standards and acceptance criteria.
™ Sequence and timing of examination relative to welding and PWHT.
™ Preparation and cleaning of examination surface.

2- In-Process
™ Radiography

- Type of radiation source, effective focal spot or source size.

Film type and number of films.
Type and thickness of intensifying screens specified.
Blocking or masking technique and minimum source to film distance and film to object
distance.
- Type, number and location of penetrometers Use of location markers and film processing.
Traceability to the work piece.
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™ Ultrasonic

Calibration, couplant, frequency and beam angle.

Distance-amplitude correction, coverage, sensitivity level, reference level and scanning
area.
Recording functions and evaluations of indications.

™ Magnetic Particle

Method, sequence of operations, and examination medium.

Magnetization current, pole spacing, direction of magnetization and lifting power.
Examination coverage and evaluation of indications.

™ Liquid Penetrant

Penetrant materials.
Surface cleaning, penetrant application, and penetrant dwell time, temperature, penetrant
removal and drying, Developer application, developer time, and evaluation of indications.

3- NDE Reports

™ Identification of radiographic film (Both film and film jackets), and evaluation of film
quality and indication of weld defects with results recorded.
™ Recording of magnetic particle, liquid penetrant and ultrasonic examination results on
the inspection reports included in the respective NDE procedures.
™ All NDE reports shall be traceable to the material/weld being examined and the
examiner and shall also include the results of the examination.
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6- RESPONSBILITIES OF QA/QC ENGINEER & QC INSPECTOR

Welding Engineer shall be responsible for:

1) Prepare Welding Procedure Specification (WPS).

2) Conduct Welding Procedure Qualification Test (WPQT) Welder Qualification Test
(WQT).
3) Prepare Procedure Qualification Record (PQR) Welder Qualification Record (WQR).
4) Identify weld filler material types, grades and quantities required for his sub-project work.
5) Resolve welding problems during the production welding.
6) Direct production welding process and stop welder’s activities whose does not conform to
WPS.
7) Complete all welding reports or forms.

QC Inspector shall be responsible for:

1) Monitor WPQT WQT process.

2) Identify PQR WQR.
3) Monitor the maintenance, storage and issue of welding consumables.
4) Monitor welding parameters to meet the requirements of WPS during welding.
5) Prepare and maintenance of inspection records.

7- FILLER WIRE & ELECTRODES CONTROL

™ Refer to Welding Consumable Control Procedure. .

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8- DOCUMENTATION, RECORD & REPORTING

Reports should be submitted to PMT/EBS by DCC department the inspection report should
include as minimum :
- Client name /symbol
- Date
- Job no.
- Item no.
- Drawing no.
- Status e.g. (as received, before welding, after welding, .etc.)
- Name and signature
- Observation
- Deposition... Accept /reject
- Remark