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Welding Control Procedure PDF
Welding Control Procedure PDF
Welding Control Procedure PDF
PLATFORM SERVICE
Document Number
Document Title
USP-NC-WCP-008
Page
1 of 9
Rev
Date
21 MAR 2010
Project
KINOA 4307
Company
Contractor
Document no
USP-NC-WCP-008
Document revision
status
Rev
For Submission
Date
Description
QA
Project
Manager
ABS
Client
Prepared
Reviewed
Reviewed
Approved
Document Number
Document Title
USP-NC-WCP-008
TABLE OF CONTENT
1. SCOPE
2. PURPOSE
3. REFERENCE STANDARD
4. DEFINITION
4.1. WELDING PROCEDURE SPECIFICATION (WPS)
4.2. PROCEDURE QUALIFICATION RECORD (PQR)
4.3. WELDER QUALIFICATION TEST (WQT)
4.4. WELD MAP
4.5. WELDING PROCEDURE REGISTER
4.6. WELDER REGISTER
4.7. NDE PLAN
5. RESPONSIBILITY
5.1
QA/QC MANAGER
5.2
WELDING ENGINEER
5.3
WELDING SUPERVISOR
5.4
WELDING OPERATOR/WELDER
5.5
WELDING INSPECTOR
5.6
PRODUCTION ENGINEERING
6. PROCEDURE
6.1. WPS/PQR
6.2. WELDING OPERATOR/WELDER QUALIFICATION TEST
6.3. WELDING CONSUMABLE
6.4. PRODUCTION WELDING
6.5. PERFORMANCE MONITORING
Page
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Rev
Date
21 MAR 2010
Document Number
Document Title
USP-NC-WCP-008
Page
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Rev
Date
21 MAR 2010
1. SCOPE
This procedure covers all the welding related activities which involve welder, welding
operator, foreman, supervisor, and QC welding inspector
2. PURPOSE
To prescribe a control method of welding activities during fabrication and erection of steel
construction, process piping to achieve desired welding quality.
3. REFERENCE STANDARD.
CLIENT SPECIFICATION
ABS RULE PART. 2
AWS D 1.1
ASME IX
ASME B 31.3
4. DEFINITON
4.1
A written document giving all necessary parameters and directions to make production
welds are meet specified requirement. WPS includes a reference to the Procedure
Qualification Record (PQR).
4.2
A written demonstration record that welds made by a specific welding procedure can meet
specific requirements. PQR contains actual record of the performance of all variable factors
in the WPS as well as the results of all mechanical, volumetric, and surface tests.
4.3
A test performed to verify ability of a welder or a welding operator to deposit sound weld.
This test required by each welder before being allowed to perform actual production
welds. Welder Performance Qualification:
Document Number
Document Title
USP-NC-WCP-008
4.4
Page
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Rev
Date
21 MAR 2010
Weld Map
Document that defines weld joint numbering and the WPS to be used.
4.5
A summarized list of all applicable WPS contains detail of all joint configurations,
supporting PQR and other essential variable.
4.6
Welder Register
NDE Plan
Document that defines the type of NDE method to be applied and the extent one.
5. Responsibility
5.1
QA/QC Manager
Review related codes and specification and client requirement, responsible for
welding and quality procedures related to the specification.
Audit NDE company and verify their certification, procedures, and human resource
Assess, monitor and improve the working relationship between production site, QC
personnel and client representative.
Document Number
Document Title
USP-NC-WCP-008
5.2
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21 MAR 2010
Welding Engineer
Prepare selected welder list, qualify them and monitor their expiry
5.3
Welding Supervisor
Responsible for maintaining good handling and storage specially for unused
electrode after working hours to be stored properly
5.4
Welder/Welding Operator
Prior to welding, ensure welding consumable are preserved and handled as per
approved handling procedure
Document Number
Document Title
USP-NC-WCP-008
Page
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Rev
Date
21 MAR 2010
Ensure proper welding equipment and welding parameter are suitable including
safe working practice prior to start working
5.5
QC Welding Inspector
Ensure fit up and joint preparation are accepted and surface is clean and free from
contaminant prior to welding
Ensure correct WPS is used by the welder and monitor the compliance of specific
parameter
5.6
Production Engineering
Responsible for issuing Joint detail, Welding schedule, Weld map and NDE Plan
6. Procedure
6.1
WPS/PQR
He/she shall then conduct the Procedure Qualification Test by welding test coupon
and conduct NDE and Mechanical test. Upon achieving and acceptable result of the
PQR, the WPS can be developed indicating the welding variable qualified ranges
6.2
All Welder/welding operator shall be tested and qualified under witness of QA/QC
Inspector and a Authorized Personnel/Class Surveyor for their proficiency before
being assigned for production welding. Supervisor shall select welder from welder
list for various type of production welding.
Document Number
Document Title
USP-NC-WCP-008
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Rev
Date
21 MAR 2010
For the qualification test, the approved WPS and the following rules shall be
applied or as required in the contract specification & Class Requirements.
Test specimen for qualification test shall be prepared in accordance with WPS
and Rules or Codes
Inspection and Test, the visual inspection, Radiographic Examination (NDE examination) or Mechanical Test shall be carried out according to Rules or Codes
( AWS D1.1, ASME IX and Class Regulation ). NDE and other tests may be required if applicable.
If the test joint doesnt meet the requirements, the welder or welding operator
shall perform welding for a new test joint of the same type as the rejected one.
A welder or welding operator, who failed, is permitted to retest after a minimum of 3(three) days training.
QA/QC Department shall issue an Identification Card to each qualified welder
or welding operator.
Re-qualification is required whenever a welder or a welding operator has not
used the qualified welding process for period more than as stipulated in the applicable codes or whenever there is a reason to question of his welding performance.
The Card shall be carried at all the times and presented upon request.
All welders or welding operators who qualified already by authorized 3rd party
agency or ABS and having the evidence of performing work within at least 6
months satisfying the requirements of the relevant codes will be allowed on job
without further qualification tests subject to Companys approval.
6.3
Welding Consumable
Electrode is then issued to welder and kept in heated quiver to maintain dryness
Document Number
Document Title
USP-NC-WCP-008
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Date
21 MAR 2010
Welding Supervisor shall ensure balance electrode at the end of work shall be
returned to storage holding oven and apply color coding. Before re-use, the
electrode shall be baked again to restore dryness
Un-fused flux (SAW Process) collected during welding shall be filtered to remove
contaminant, kept in holding oven to avoid moisture prior to mix with new flux
before use
6.4
Production welding
The relevant approved WPS shall be displayed nearby the welding area for easy
reference and inspection
Welding Supervisor shall ensure electrode butts are placed back into placed bin
and maintain butts for SMAW Process shall not limited to 2 dimension due to
saving company cost
After welding complete, welder shall ensure surface to be free of visible defect.
Supervisor/Foreman shall first check and conform it before issuing Request for
Inspection
Document Number
Document Title
USP-NC-WCP-008
Page
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Rev
Date
21 MAR 2010
In case of repair due to visual inspection and NDE result, Welding Foreman shall
organize to carry out weld repair
6.5
QC shall monitor daily and weekly NDE backlog to ensure NDE clearance
Performance monitoring
A target maximum rejection rate is set for production welding, recorded as per
weld joint and per weld length
A target maximum rejection rate is set for welder performance and monitored
For poor welder performing who constantly producing high rejection rate welding
shall be stopped from making production weld, and return to be re-trained
If the welder keeps performing badly after re-training, then shall be refrained from
any production welding work
Welding Engineer shall monitor and propose corrective and preventive action in
case constant welding problem arise.