13.welding generel

Customer Job No.

Plant Location Document Number

Project of 17 Rev.

JOBTITLE:

WELDING (GENERAL)

D SAUDI ARAMCO comments incorporatedA.McClelland V.Seewöster Y.Pakel 19.

May 2001

C Issued for Review by SAUDI ARAMCOA.McClelland V.Seewöster Y.Pakel 24.

Mar. 2001

Rev. Description Prepared Checked Certified Date

This document is property of TECHNIP who will safeguard its rights according to civil and penal provisions of the law

Data File: document.doc

TPSA - Contractor

Contract No. (SA)44476 / 00

Job No. (TPGY)06041S

Document Number

QCP – CC - 13

of 17 Rev. D

TABLE OF CONTENTS

1.0 GENERAL2.0 WELDING CONSUMABLES

2.1 PURCHASE

2.2 STORAGE AND HANDLING OF ELECTRODES / FILLER WIRE

3.0 WELDING PROCEDURE INSPECTION

4.0 JOINT PREPARATION (FIT-UP) INSPECTION

5.0 WELD NUMBERING SYSTEM

6.0 WELDING INSPECTION

7.0 PRECAUTIONS DURING WELDING OF FBE COATED PIPES

8.0 VISUAL INSPECTION

9.0 NON DESTRUCTIVE TESTING PROCEDURE

10.0 RECORDS

11.0 WELD REPAIR

12.0 WELDER / WELDING OPERATOR QUALIFICATION

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. DAppendices

Appendix 1 ITP 2.1 Welding ( On Plot )

Appendix 2 ITP 2.2 Welding ( Off Plot )

Appendix 3 General Inspection Report GIR – 04

Appendix 4 Daily Welding Report PF - 19

Appendix 5 Survey Report for Welding Equipment and Consumables PF – 21

Appendix 6 Acceptance Sheet for prefabricated Spools MFS – 01

Appendix 7 Piping Welding MFS – 02

Appendix 8 Weld Tracking Log – Station Work MFS – 03

Appendix 9 Piping Installation

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D1.0 GENERAL

All work shall comply with the Scope of Work and the requirements of SAES-L-050, SAES-L-051, SAES-W011, SAES-W-012,.and other applicable SAUDI ARAMCO Standards & Specification, ANSI B 31.3 and ANSI B31.8, as applicable, and approved fabrication and construction drawings.

Welding procedure required for the project shall be selected from the existing procedures, by the QA/QC Manager, in consultation with the Construction Manager. If an existing procedure is not available, a new welding procedure shall be prepared in accordance with the standards and project requirement.

Prior to start any welding operation, the welding procedure shall be qualified by an SAUDI ARAMCO approved third party inspection agency, submitted to the SAPMT Project Engineer, and approved by SAUDI ARAMCO, in accordance with SAES-W-011/12. All submittals of welding procedures shall include a weld map.

SAUDI ARAMCO shall supply TPSA, a copy of all the latest standards and revisions, so the Welding Supervisor can review the welding procedures to verify that they are in compliance with the latest governing Codes and Standards.

All field and shop welding shall be carried out in accordance with SAES-W-011, SAES-W-012, API 1104 and ASME IX as applicable. Welders and welding operators shall be qualified and accepted in accordance with API-1104, ASME IX, and the SAUDI ARAMCO Engineering Standards. SAES-W-011/12. No welding will be performed prior to issuing of job clearance cards by SAUDI ARAMCO. Copy of their qualification cards shall be available at the field office and the original shall be with the welder / welding operator. Highly qualified Welding Supervisor will be constantly monitoring the proficiency of the welder / welding operators and the QA/QC Engineer shall assure the quality (Ref Appendix , Form MFS-03 / 04 / 05 & PF-18 / 19 / 20 / 21 / 22).

Every welded pipeline joint shall bear the welder / welding operators unique symbols and shall be progressively numbered to enable its identification and location at any time. Different symbols and numbers shall be used for Line Welding, Tie-in Welds, Road Crossing Welds and Piping Prefabrication Welds.

The position of the weld shall be marked on drawings for station piping and recorded for identification purposes by the weld inspector. For mainline welds records shall be maintained which are showing for each weld the location of the weld in the line and the symbols of all welders working on the weld shall be entered on this record along with pertinent information on any repair (for detail information refer. to section 5.0 and 9.0).

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D2.0 WELDING CONSUMABLES

2.1 PURCHASE

Welding electrodes and filler wires to be used for this project shall be purchased, only after consulting the QA/QC Engineer. The QA/QC Engineer will signify his approval by sign the requisition. Welding Electrodes and filler wires shall conform to the requirements of the ASME Boiler and Pressure vessel code, section II, part C, and shall be purchased only from the authorized distributors. Each electrode box shall contain:

* Name of manufacturer * Specification confirming to AWS class* Diameter* Batch no:* Quantity

All electrode shall meet the marking requirements of the electrode manufacturer and ASME Code Section II.

Shielding gases shall be purchased from a reliable manufacturer, with certification stating the quality of the gas. The shielding gas shall conform to the level of purity required as per the WPS. Shielding gases shall conform to the following specifications:

Argon Gas Compressed Gas Association specification G-l 1.1, Grade A

Compressed Gas Association specification G-6.2, Type F or Federal Specification BC-C-IOI Type B.

2.2 STORAGE AND HANDLING OF ELECTRODES / FILLER WIRE

Welding consumable shall be stored and kept in dry condition in accordance with the requirements of AWS AS.I and AS.S or ASME SFA 5.1 and SFA 5.5. & SAES-W-012 table –1 & 2. Electrodes shall be stored in sealed containers. Any electrodes that have become moist or wet shall not be used and shall be discarded. Non Low Hydrogen electrodes such as those with cellulosic coating, will not be stored in ovens, rather kept in a dry place.

Special care shall be taken in storage and handling of low hydrogen electrodes as stated following :

Drying: Prior to use all low hydrogen electrodes conforming to ANSI/AWS A5.1 shall be dried at 260 - 430°C (500 - 800°F) for two hours minimum. Low hydrogen electrodes conforming to ANSI/AWS A5.5 shall be dried at least one hour at temperatures between 700°F (370°C) and 800°F (430°C) before being used. The drying step may be deleted if the electrodes are supplied in dried condition in a hermetically sealed container with a positive indication of seal integrity.

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. DStorage: After drying, the electrodes shall be stored continuously in oven at 120°C (250°F) minimum. A temperature gauge and a thermostat shall be provided on the oven to measure and control the temperature. Temperature monitoring devices shall be calibrated at regular intervals and calibration records shall be available upon request by Saudi Aramco or their nominated representative.

Exposure: Upon removal from the drying or storage oven the electrode may not be exposed to the atmosphere for more than four hours. The exposure may extended to eight hours if the electrodes are continuously stored in a portable electrode oven heated to 65°C (150°F) minimum. Welders will be supplied with electrodes, which can be used within 4 hours or 8 hours, depending on the availability of portable electrode ovens.

Re-conditioning: Electrodes exposed to the atmosphere for periods less than permitted may be returned to a holding oven maintained at 120°C (250 F) minimum. After a minimum holding period of four hours at 120°C (250°F) minimum the electrodes may be re-issued. After any exposure in excess of the permitted time period, the electrodes must be re-dried in the drying-oven at the warehouse. Electrodes may be re-dried only once after atmospheric exposure.

Filler wires for GTAW / GMAW: All wires shall be stored in sealed containers in a dry environment. Any wires that have visible rusting or contamination shall not be used and shall be discarded.

Within the warehouse the Welding Engineer, with assistance form the store-keeper, shall be responsible that the drying and storage requirements will be strictly fulfilled. Furthermore he is responsible that an Electrode-Log-Book will be maintained which shows the date, time, type and quantity of electrodes which have been dried and when they have been transferred to the storage-oven. Also the date, time, type and quantity handed over to the welding foreman shall be recorded. For re-draying, if required, a separate oven (or as a minimum a separate area within the drying oven) is required and the same recording requirements as stated above shall be valid.

To avoid that electrodes are re-dried more than one time, the welding foreman shall be responsible to ensure that this electrodes will be used first every day.

At the job site, the welding foreman will be responsible for the issuance of electrodes to the welders. He will restrict the supply of low-hydrogen electrodes to the minimum quantity required, which can be used within 4 hours or 8 hours if portable oven’s heated to min. 65 C are used. Preferably the issuance of electrodes shall be spread to minimum three times over the day, from a portable storage oven (min.120C) on the welding truck. At the end of the day, all electrodes that have been not used shall be returned to this storage oven and after arriving in the camp, they shall be stored in the storage-oven at the warehouse.

The storage and welding equipment conditions shall be checked on a regular bases and reported (formsheet No. PF-21, attached to this procedure and available from the site QA/QC department).

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D3.0 WELDING PROCEDURE INSPECTION

The following points shall be checked by the Welding QC Inspector prior to start of welding and during welding to ensure concurrence with welding procedures, processes and specifications.

Confirmation of welder / welding operator qualifications, and possession of Job Clearance Cards.

Check if a valid and approved WPS is with the welding foreman

Are the welding position and welding process as per WPS

Base material, pipe diameter and wall thickness within the range of the WPS

Filler Material as per WPS

Storage of electrodes in accordance with para. 2.2 of this QCP

Is Pre-heating required as per WPS

Are the welding equipment and machine in good condition

Is post weld heat treatment required as per WPS

All welding procedures will be reviewed on a regular basis, by the QA/QC Engineer, to ensure that they are updated as governing standards are changed.

4.0 PIPING PROCEDURE INSPECTION JOINT PREPARATION (FIT-UP) INSPECTION

Before production welding, inspection shall be made on the following:

Edge and Joint preparation in accordance to the WPS

Groove angle should be provided following the WPS requirement and allowable deviation shall be plus 5, minus 0 Degree. The groove size and angle shall be measured with a groove weld gauge.

The groove welds should be provided with a maximum weld gap in accordance to the WPS.

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

Inspection of temporary welding and tack welding. Tack welds shall be examined and checked for defects occurrence such as cracks, inadequate penetration and other discontinuities. Tack welds and welds of temporary attachments shall be made only by qualified welders.

Weld line up clamps shall be used where required to remove any out of roundness in the pipe. Internal line-up clamp shall be used if the pipe diameter is 16" or larger, except for tie-in welds. Special shoes must be used to protect internal coating, if any. For pipes less than 16" diameter, either internal or external line-up clamp may be used.

The maximum misalignment at the inside surface of the pipe for circumferential joints should be lesser than 1/4 t or 15 mm, where it is the wall thickness of the thinner section of the joint misalignment can be checked by the use of templates.

Alignment of piping can be checked using spirit level water hose or dumpy level.

Fittings that are re-cut or re-beveled shall have the cut surface examined for laminations before welding. The NDE shall be dye penetrant test or magnetic Particle Inspection, as determined by SAUDI ARAMCO Inspection.

Ground clamps shall be designed and constructed to avoid sparking. It shall be a spring loaded clamp or fabricated from thick plates, which shall be compatible with the material being welded. At no time shall reinforcement bar be used for this purpose. It shall remain in place, while welding is in progress. The contact point shall be kept clean of grease, oil or paint which prevent proper metal to metal contact.

Deviations to the above stated requirements shall be corrected as per QC Welding Inspector’s instructions. If, for technical reasons, a deviation can not be evoided, this shall be reported on a General Inspection Report (GIR-04, attached to this QCP and available from the site QA/QC department).

5.0 WELD NUMBERING SYSTEM

Each weld shall be identifiable by an individual weld number. The weld numbering shall be as following:

5.1 Numbering System for Pipeline welding:

The front end welding crew shall start with the weld no. 1 (e.g. W 0001) and continue in

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

construction direction, without skip any weld number, up to the end of the relevant pipeline. Tie-In welds (TW) shall be numbered with the last front end weld number and the tie-in number 1, 2, 3, etc. with a hyphen in between, also in construction direction (e.g. if the last front end weld no. was W 0195, the tie-in numbers should be TW 0195-1, TW 0195-2, etc.)

Weld repairs shall be identified with the weld number and the identification R1 for the first repair, R2 for the second repair, etc. (e.g. if a front end weld have been repaired, the weld no. could be W 0195-R1, for a tie-in weld the weld number could be TW 0195-2-R1).If a weld was a cut out and has been re-welded, the weld shall get the same weld no. with the identification N1. N2 shall be used if a weld has been re-welded twice (e.g. if weld no. W 0195 was a cut out, the new weld number should be W 0195-N1).

5.2 Numbering System for Shop welding:

On each Isometric or Drawing the welds shall be numbered in flow direction starting from 1, with the identification SW (for Shop Welds) or FW (for Field Welds), until all welds on the relevant Isometric or Drawing are numbered. Any additional weld may be required during construction shall be mark up on the Isometric or Drawing and numbered with the weld no. of the last weld in front of the additional weld, then a hyphen and a 1 for the first additional weld, 2 for the second additional weld, etc. For identification of repairs and new welds after cut outs, reference is made to paragraph 5.1. A final weld number sequence for one Isometric or Drawing could be as following: FW 1, SW 2, SW 3-R1, SW 4, FW 4-1, FW 5-N1, SW 6, SW 7-R2, FW 8, SW 9, SW 10-N1, SW 11, FW 11-1, FW 12, etc.

6.0 WELDING INSPECTION

During the progress execution of actual welding, the following items shall be inspected by the Welding QC Inspector:

Cleanliness of grooves - area to be welded should be free from oil, rust, scale and other loose foreign materials at least 50 mm from the weld area to assure sound welds

All pre-heat requirements shall confirm to applicable welding procedure and SAES-W-012

To ensure post weld heat treatment is carried out if specified as per applicable welding procedure

The removal of slag with respect of each weld layer

The condition of the penetration

Proper identification of welder / welding operators and weld numbers. Welders code should be marked and placed on the side of weld work done .

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

It shall be the responsibility of the weld inspector to perform the foregoing inspections. The results of such inspections shall be clearly recorded in the inspectors “Weld Inspection Log”. A format for the Weld Inspection Log shall be available from the QA/QC department. For station welding are also various inspection reports attached to this QCP. The Weld Inspection Log shall be submitted to and reviewed by the QA/QC Site Engineer on a daily basis.

Welding shall not be performed when the wind is strong enough to affect arc stability or shielding gas coverage. Wind shields or tents shall be required when the wind or blowing sand is sufficient to adversely affect weld quality. The Wind velocity in the weld area for GTAW shall not exceed 8 Km/hr (2.2 m/s).

Welding shall not be done when surfaces are wet or damp or exposed to rain or snow or when the welder / welding operators are exposed to inclement conditions. Any wet or damp surfaces must be dried by heating and shall be warm to the hand before welding.

Contamination from the environment such as wind blown sand shall be prevented by the use of adequate shielding. All appropriate safety precautions shall be taken for each inspection method.

7.0 PRECAUTIONS DURING WELDING OF FBE COATED PIPES

Ensure suitable fabric blanket is wrapped round the weld covering the FBE coated area, from the edge of coating cutback on either side of weld groove

Ensure blanket is held firmly against the FBE coating area, by means of a suitable fastener, like rubber string, so that FBE coating is not damage by spatters etc. during welding.

Monitor temperature using contact pyrometer at coating cut-back area 2" on either side of the weld, to ensure temperature does not exceed 450 degrees F (232C) during welding. Temperature monitoring devices shall be calibrated at regular intervals andcalibration records shall be available upon request by Saudi Aramco or their nominated representative.

Any FBE coated pipe laying in vicinity of weld joints shall also be protected from spatters during welding using blanket.

It shall be the responsibility of the weld inspector to perform the foregoing inspections. The results of such inspections shall be clearly recorded in the inspectors “Weld Inspection Log”. A format for the Weld Inspection Log shall be available from the QA/QC department. For station welding are also various inspection reports attached to this QCP. The Weld Inspection Log shall be reported and reviewed by the QA/QC Site Engineer on a daily basis.

8.0 VISUAL INSPECTION

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

After completion of welding, visual inspection shall be applied to the following :

All butt weld joints shall be marked for identification by a weld number and welder / welding operator symbol

Groove welds shall preferably be made with slight or minimum face reinforcement (cap) except as may be otherwise provided. In the case of buttweld, the face reinforcement shall not exceed 1/8" (3 mm) in height and have gradual transition to the plane of the base metal surface, free from undercut. They shall be free of the discontinuities.

Welds shall be free from overlap

Arc strikes outside the area of permanent welds should be avoided on any base metal. Cracks or blemishes caused by arc strike shall be ground to a smooth contour and check to ensure soundness with dye penetrant method.

Slag shall be removed from all completed welds and the weld and adjacent base metal shall be cleaned by brushing or other suitable means.

The faces of fillet welds may be slightly convex, flat or slightly concave as shown in figure 3.4 (A & B) and with none of the unacceptable profiles shown in figure 3.4(C).

No skip or stitch welds are permitted.

The leg size of fillet welds shall be as per the construction drawing.

9.0 NON DESTRUCTIVE TESTING PROCEDURE

NDE shall be carried out by TPSA sub contractor, refer to SAES-W-011, SAES-W-012, GI - 448.010.

NDE procedures will be submitted to the SAPMT for approval.

Radiography crews shall consist of at least two acceptably qualified radiographers.

All NDE personnel shall be ASNT - CP - 189, level II or approved equivalent for the particular method to be used. NDE procedure and Qualifications of NDE sub-contractor personnel shall be submitted to Project Inspection for review and approval. All NDE related procedures and qualification records shall be submitted to SAPMT who will then ensure that they are forwarded to the supervisor, NDE unit, Inspection Department, for review and approval. All correspondence relating to the transmittal, review and approval of these

procedures, shall be copied to the Supervisor, Haradh Pipelines Projects Inspection Unit, Haradh Projects Inspection Section.

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. DA minimum of 10% of the welds made each day, on line shall be radiographed. An increased percentage is required if a higher percentage of coverage is established by either of the following method listed below (the higher percentage rate shall govern):

LINEAR BASIS

% RAD = (318 x L)/(N x D)

where:

% RAD is the percent NDE coverage to be applied to the production the following day.

L Total length of repairs, mm N Total number of weld joints radiographed in one dayD Pipe diameter, mm

The amount of RAD shall be rounded to the nearest amount divisible by 10. Any value ending in five (5) shall be rounded up.

JOINT BASIS

The following repair rates are calculated on a joint basis, i.e. the number of joints requiring repairs divided by the total number of joints radiographed that day.

An increase to 50% RAD is required when the repair rate exceeds 30%. This increase shall be required for both the same day's (i.e. additional joints must be radiographed to increase the RAD for that day to 50%) and the next day's production.

An increase to 100% RAD required when the repair rate exceeds 50%. This increase shall be required for both the same day's (i.e. all other joints for that day must be radiographed) and the next day's production.

100% radiography is required for the following welds:

Repaired welds

One preceding and one succeeding a repaired weld, if not previously radiographed.

The ten preceding and ten succeeding welds of a cracked weld, if not previously radiographed

Welds within 60m (200 ft) of road

Welds in class 3 or 4 location (as defined in SAES -B-064)

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

Welds that can not be hydrostatic tested

Hook Up or tie-in welds

Expansion loop fitting welds

All welds of the first day's production for a particular job or a minimum of the first forty(40) production joints whichever is greater

Tie-in welds of in-situ cement lined pipe

It shall be the responsibility of the NDE inspector to ensure the foregoing requirements are satisfied. The results of such inspections shall be clearly recorded in the inspectors “NDE Inspection Log”. A format for the NDE Inspection Log shall be available from the QA/QC department. The NDE Inspection Log shall be submitted to and reviewed by the QA/QC Site Engineer and/or the QA/QC Manager on a daily basis.

Tie-in welds that are not to be pressure tested shall be made in the presence of SAUDI ARAMCO representative and will be 100% radiographed.

NDE shall be performed after PWHT. Additional NDE may be performed prior to PWHT to ensure that rejectable indications have been removed.

Surface irregularities including cap welds, inhibiting accurate interpretation of the specified method of NDE shall be ground smooth.

Inspection of all welds shall include a band of base metal at least one inch wide on each side of the weld.

Tungsten inclusions in GTAW shall be evaluated as individual roundness indications. Clustered or aligned tungsten inclusions shall be repaired.

The radiographic interpretation shall be to the latest edition of API-1104. UT examination of the automatic welds shall be in accordance with the approved mechanized UT testing procedure. The acceptance criteria’s of defects as per API-1104 are also valid for this UT inspection.

Wire penetrameters in accordance with ASTM E747 may be used for all radiographic applications.

All radiographs shall be handed over to SAPMT at the completion of job.

Should welding quality deteriorate resulting in more than 10% of rejected welds, proper actions shall be initiated so as to detect and isolate the cause of such deterioration. Should

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

this be attributable to welder / welding operator performance then the same shall be prevented from welding until such time as a retest proves he is again able to produce acceptance welds. In this regard an individual '' welder / welding operators" performance chart shall be maintained throughout the project which includes:

Total linear inches of weld made

Total linear inches of weld reject

Reason for the reject

Percentage of reject

The “welder / welding operators” chart shall be up dated on a daily base and maintained at the QA/QC site office. The last up date will be available, on request, for ARAMCO at any time.

The QC Welding Inspector shall be responsible that each weld will be mark with the welder symbol of all welder / welding operators who have welded the joint. The symbols shall be marked on the upper half of the same side of the pipe (e.g. on both sides of the pipe), where the welder / welding operator has welded. The identifying marks shall be placed on the coating near to the weld, but clear of the area which will be covered by field joint coating. A weather-proof crayon or other suitable material which shall not harm the pipe coating shall be used for the markings.

E.g.: RP HP FP CP

REF TIJ TDE RML

WHERE: RP ROOT PASSHP HOT PASSFP FILL PASSCP CAP PASS

This will identify each welder / welding operator with the portion of the weld he has done.

Should it be found that the fault is not attributable to poor workmanship, further tests on welding rods / filler metal, parent metals and field conditions shall be carried out, to determine the cause of weld faults.

Note: If it is required to store the gamma ray isotope on site, a isotope pit as per SAUDI ARAMCO requirements and standard drawings will be installed and subject to SAUDI ARAMCO approval before any isotope shall be stored there.

10.0 RECORDS

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

A daily welding report will be provided to SAUDI ARAMCO’s Representative on a daily basis. It will identify pipe diameter, wall thickness, pipe length, bend degree, pipe number or double joint number, weld number and welding date, welder symbol, process & WPS, visual inspection acceptance date and NDT acceptance date (if any).

11.0 WELD REPAIR

All unacceptable defects such as pinholes, slag, incomplete penetration or fusion and other deleterious defects detected by the non destructive examinations specified per API 1104 Section 6.0 shall be removed, repaired and rewelded.

Repair welding shall be performed using a properly qualified and approved procedure. In process repairs (i.e. repairs performed prior to completion of the joints using the same welding procedure as for the original fabrication) during production do not require a separate repair procedure.

The procedure shall be as follows:

Grind to the depth of the defect

Conduct visual inspection

Reweld and recheck by visual and NDT.

All repaired welds shall, as a minimum, be inspected using the original testing method. Additional test method may be required if deemed necessary by the authorized SAUDI ARAMCO Inspector.

Any weld not meeting the acceptance criteria of the applicable code or standard shall be repaired or cut-out.Welds may be repaired twice only. Third repair will be carried out only by SAUDI ARAMCO Inspection approval.

Welds containing one or more cracks are not allowed to be repaired. A cylinder of the pipe containing the weld shall be removed and a new spool not less than 1/2 diameter in length shall be inserted.

12.0 WELDER / WELDING OPERATOR QUALIFICATION

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

All welder / welding operators shall be tested in accordance with International Standards, API 1104, ASME-SEC.IX, AWS-D 1.1, SAUDI ARAMCO Engineering Standards SAES-W- 011 and 012 as appropriate and prescribed for the project.

All welder / welding operators shall undergo preliminary training and testing by TPSA prior to testing by third party inspection agency. The list of welder / welding operators and the procedures they are to be tested shall be prepared. The testing procedure shall be as following:

Prepare the test piece and fix it in the required position, on a stable support

Set the welding machine to the electrical characteristics as per the approved welding procedure

The third party inspector shall check and confirm the test piece assembly, the electrical characteristics and the electrodes to be used to match with the approved welding procedure

The joint shall be pre-heated, if the procedure calls for, and the temperature shall be monitored by temperature sticks or pyrometers. Temperature monitoring devices shall be calibrated at regular intervals and calibration records shall be available upon request by SAUDI ARAMCO or their nominated representative.

The welder / welding operator shall commence welding only after the approval of the Inspector

Each operation of the test shall be witnessed by the Inspector

At the end of the test, the test piece shall be inspected by the inspector and if accepted, it shall be put for radiography

If the test piece is rejected, the welder / welding operator shall be given one more chance to prove his ability

If the radiography result is acceptable as per the specified code, the third party inspection agency shall issue a welder / welding operator qualification card and certificate indicating all the test parameters, signed and stamped by the inspection authority

The test result shall be monitored and logged by the TPSA QA/QC Engineer or his Representative, in a welder / welding operator qualification test chart indicating all the test parameters.

Each welder / welding operator shall be identified by a welder symbol. The QA/QC Engineer shall ensure that each welder / welding operator has a unique symbol.

TPSA - Contractor



Document Number

QCP – CC - 13

of 17 Rev. D

All welder / welding operators qualifications will be reviewed by the QA/QC Engineer, on a regular basis, to ensure that the chart is kept current.

No welding work will be carried out on any project, without first obtaining Job Clearance Cards from SAUDI ARAMCO Projects Inspection.

The qualification test records for all welder / welding operators will be maintained at the job location at all times for review, on request, by SAUDI ARAMCO Projects Inspection.

APPENDIX :

1. ITP 2.1 Welding ( On Plot )

2. ITP 2.2 Welding ( Off Plot )

3. General Inspection Report GIR – 04

4. Daily Welding Report PF - 19

5. Survey Report for Welding Equipment and Consumables PF – 21

6. Acceptance Sheet for prefabricated Spools MFS – 01

7. Piping Welding MFS – 02

8. Weld Tracking Log – Station Work MFS – 03

9. Piping Installation MFS - 06

13.welding generel

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