Weld Surveillance

CONSTRUCTION OPERATIONS
WELD SURVEILLANCE
(PROCEDURES AND WELDER QUALIFICATIONS)
WELD SURVEILLANCE
CONTENTS
1. OBJECTIVE
2. WELD PROCEDURE QUALIFICATION PROPOSAL
3. WELD PROCEDURE TESTING
4. WELD PROCEDURE SURVEILLANCE
5. WELD PROCEDURE QUALIFICATION AND DOCUMENTATION
6. WELDER QUALIFICATION TEST PROPOSAL
7. WELDER QUALIFICATION TESTING
8. WELDER QUALIFICATION SURVEILLANCE
9. WELDER QUALIFICATION APPROVAL AND DOCUMENTATION
10. SURVEILLANCE REPORTING
11. PREVIOUSLY ESTABLISHED WELDING PROCEDURES AND

WELDER QUALIFICATIONS
APPENDICES
1. SURVEILLANCE CHECK LISTS 1 THROUGH 16
REV 1 CONVERTED TO WORDPERFECT AUGUST 1992

FORMAT AND GENERAL AMENDMENT
PREPARED BY: CONSTRUCTION DEPARTMENT
APPROVED BY: .......................

C. STANHOPE,
GENERAL MANAGER CONSTRUCTION
AUTHORISED BY: .......................

C.C. READ,
DIRECTOR OF OPERATIONS
WELD SURVEILLANCE
1. OBJECTIVE
The purpose and scope of this method is to establish a

framework of responsibilities and surveillance:-
- To ensure that the direct works Contractor is

conforming to his contractually agreed "Quality
Programme" relating to Weld Procedures and Welder
Qualification.
- To ensure that Weld Procedures and Welder

Qualifications are in accordance with the Job
Specification and all Codes and Specifications
references therein.
- To ensure that Weld Procedures and Welder

Qualifications cover all materials, thicknesses and
joint configurations necessary within the range of
joints to be welded.
- To ensure that all Weld Procedures and Welder

Qualifications are fully documented and have the
approvals required by the Quality Plan.
To ensure that all Weld Procedures and Welder

Qualifications are indexed so that their status is
continuously available for review and record.
This framework shall be adapted to the job specific

requirements called for under the contract and its
related Quality Plan. Guideline checklists indicating
activities subject to Company and/or other approving
bodies surveillance are appended to this document under
Appendix 1.
2. WELD PROCEDURE QUALIFICATION PROPOSAL SUBMISSION
a) The direct works Contactor shall prepare Welding

and Weld Repair Procedures covering all materials,
thicknesses and joint configurations required by
the Job Specification for all techniques and
welding consumables he proposes to use.
b) The direct works Contractor shall submit written

details of his proposed Weld/Repair Procedure for
approval in accordance with Contract Procedures and
shall not proceed with the test until such approval
has been obtained.
c) The details included in the Proposal shall conform

to the Job Specification and all Codes and
Specifications referenced therein and should
include the following:-
- A unique designation ascribed to the
Procedure.
- The Issue or Revision status of the
Procedure together with its effective date.
DM2010.WP5 UNCONTROLLED COPY. DOCUMENT VIEWED ON THE NETWORK TAKES PRECEDENCE.

WELD SURVEILLANCE
- The welding process or combination of

processes.
- Material type, grade/specification and
thickness.
- Sketch(es) of joint showing plate edge
preparation, joint fit up and tolerances,
run number and deposition sequence.
- Size, type, manufacturer's designation and
classification of all consumables
including, as appropriate, submerged arc
fluxes and shielding gases.
- Details of any non-consumable electrode
used.
- Treatment of welding consumables, e.g.
baking temperature and time.
- Welding position and progression
- For each run, the current type, polarity,
arc current and voltage, welding speed and
electrode run out length.
- Tack welding procedure.
- Pre-heat and interpass temperatures
together with the method of their
measurement.
- Inter-run cleaning method
- Back gouging/grinding method, if
applicable, and treatment to second side.
- Any restraint to be applied.
- The qualification range of the Procedure.
- Post weld heat treatment, if applicable.
- NDT
- Signature of a responsible member of the
Contractor's Organisation.
d) Where required the Weld/Repair Procedure Proposal

submission shall be accompanied by a Test/Mill
Certificate for the parent material(s).
3. WELD PROCEDURE TESTING
a) Having obtained approval of his proposed

Weld/Repair Procedure, the direct works Contractor
shall proceed with the test weldment as follows:-
b) He shall prepare test material of form appropriate

to the test and of sufficient size to permit
subsequent removal of all the test specimens and
possible re-test specimens required by the Job
Specification.
3. Contd.
c) The test material will be hard stamped by

designated Company Welding Inspector for
identification purposes and by other approving
bodies as required by the Quality Plan.

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d) The direct works Contractor shall set up the test

weldment in accordance with the tolerances defined
in the Job Specification, tack welding or otherwise
securing the fit up in accordance with his approved
Procedure.
e) He shall apply pre-heat (if applicable) and weld

out the test piece according to the parameters
detailed in his approved Procedure, ensuring that
the completed weld cools slowly to ambient
temperature.
f) Welding shall be essentially a continuous process

and pre-heat (if applicable)shall be continuously
maintained until the weld joint is at least half
filled. Before continuation of welding after an
interruption, the weld shall be visually examined
and, if required by the designated Company Welding
Inspector, examined by magnetic Particle or Dye
Penetrant Test.
g) The direct works Contractor shall subject the

completed test weldment to Post Weld Heat
Treatment, if required, in accordance with the job
approved method.
h) NDT shall be carried out at the stage and using the

methods detailed in the Job Specification, using
job approved procedures.
(Note: Check if there is a requirement that NDT

shall not be carried out until a period of time has
elapsed from completion of welding).
i) The direct works Contractor shall mark out on the

test weldment, all the test specimens in the
locations required by the Job Specification.
j) Each test specimen will be hard stamped by the

identification purposes and by other approving

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Should such hard stamps be removed or obliterated

during subsequent machining operations, the direct
works Contractor shall arrange for the Company
Inspector and others, if applicable, to transfer
their identification marks.
k) Sectioning for test pieces shall be undertaken

allowing a lapse of time if so specified.
l) Mechanical Test Pieces shall be machined to the

form and dimensions detailed in the Job
Specification.
m) Mechanical Testing shall be carried out in an

approved Test Facility, in accordance with the
Codes and Specifications referenced within the Job
Specification, and all tests shall be witnessed by
the designated Company Welding Inspector and other
approving bodies.
n) Test acceptance criteria shall be as detailed in

the Job Specification.
o) Should a procedure test weld fail any of the

required tests or the permitted re-tests, the cause
of the failure shall be established by the
Contractor to the satisfaction of the Company and
other approving bodies and the complete procedure
test repeated.
4. WELD PROCEDURE SURVEILLANCE
a) All stages of weld procedure submission and

testing, including those detailed in the foregoing,
will be subject to surveillance by Company
personnel and other approving bodies.
Responsible Company personnel have been indicated

within this document but shall be specifically
designated within the Quality Plan.
b) Guideline checklists indicating activities subject

to Company Surveillance are appended to this
document (Reference Appendix 1)
c) At all stages during Weld Procedure Testing the

Company will ensure that other approving bodies are
given notice of tests and are kept aware of
progress.

WELD SURVEILLANCE
5. WELD PROCEDURE QUALIFICATION AND DOCUMENTATION
a) The Company Chief Field Engineer (in close liaison

with the responsible Field Engineer/Inspector) will
expedite, record receipt, and co-ordinate approval
of the direct works Contractors proposed
weld/Repair Procedures in accordance with the
Quality Plan. he will additionally ensure
recording of progress and approval of the
subsequent test welds on the Weld Procedure Status
Log (Standard Form SF 0014).
b) The direct works Contractor shall prepare a
permanent record of the following:-
- All parameters of the Procedure Test Weld.

- The Post Weld Heat Treatment applied to
approved method.
- The NDT carried out to approved method.
- The results of all Mechanical Tests carried
to approved method.
c) These records shall be submitted via the Chief

Field Engineer for approval in accordance with Job
Procedures.
d) Such approval must be received by the direct works

Contractor before any Weld/Repair Procedure may be
implemented.
Note:- If no production tests have been carried out

on welds produced to a given Weld Procedure within
a defined period of its qualification date,
requalification may be required.
e) The direct works Contractor shall establish and

maintain an index of Approved Weld Procedures and
shall provide copies thereof to Company at
specified intervals. Distribution of this index to
other parties will be via the Chief Field Engineer.
f) This index shall include, as a minimum, for each

procedure, the following information:-
- The procedure designation.

- Details of the materials used in the test
(e.g. type, grade, thickness).
- The welding position and process(es).
- Details of the consumables used (e.g. type,
size, name classification).
- Post Weld Heat Treatment applied.
- Range of materials, consumables etc.,
approved by the procedure.
- Approval date.
g) The Company may independently of the Contractor,
establish and maintain an Approved Weld Procedure
Register with the facility for signature by the

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direct works Contractor and all approving bodies.
6. WELDER QUALIFICATION TEST PROPOSAL
a) The Contractor shall qualify welders, as required

by the Job Specification to weld all materials,
thicknesses and joint configurations within the
contract scope.
b) Welders' qualification tests shall be carried out

in conformance with and within the essential
variables of a a Welding Procedure approved by
Company and other approving bodies.
c) The direct works Contractor shall submit written

details of his proposed Welder Qualification Tests
for approval by Company and other approving bodies
and shall not proceed with any tests until such
approval has been obtained.
d) The details included in the proposal shall conform

to the Job Specification and all Codes and
Specification referenced therein and shall include
the following:-
- The designation of the Procedure to which

the Qualification Test is being conducted.
- The issue or revision status of the
Qualification Test proposal together with
its effective date.
- The welding process or combination of
processes.
- Material type, grade/specification and
thickness (or alternate material type as
may be approved).
- Sketch(es) of test joint showing plate edge
preparation, joint fit up and tolerances,
run number and deposition sequence.
- Size, type, manufacturer's designation and
classification of all consumables,
including, as appropriate, submerged arc
fluxes and shielding gases.
- Details of any non-consumable used.
- Treatment of welding consumables, e.g.
baking temperature and time.
- Welding position and progression.
- For each run, the current type, polarity,
arc current and voltage, welding speed and
electrode run out length.
- Tack welding procedure
- Pre-heat and interpass temperatures
together with the method of their
measurement.
- Inter-run cleaning method.
- The scope of the qualification.
- Post Weld Heat Treatment, if applicable.
- NDT

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- Signature of a responsible member of the

Contractor's Organisation.
7. WELDER QUALIFICATION TESTING
a) Having obtained approval of his proposed Welder

Qualification Test, the direct works Contractor
shall proceed with the test weldment, as follows:-
b) He shall prepared test material of the form

detailed in the Job Specification and of sufficient
size to permit removal of all the test specimens
required.
c) As is required, the test material shall be the same

as that approved in the Welder Qualification Test
Proposal.
d) The test material will be hard stamped by the

identification purposes, and by other approving
e) The direct works Contractor shall set up the test

weldment in accordance with his approved Weld
Procedure.
f) He shall apply pre-heat, if applicable, and weld

out the test piece according to the parameters
detailed in his approved Weld Procedure and Weld
Qualification test proposal, ensuring that the
completed weld cools slowly to ambient temperature.
g) Welding shall be essentially a continuous process

and if applicable pre-heat shall be continuously
maintained until the weld joint is at least half
filled. Before continuation of welding after an
interruption, the weld shall be visually examined
and, if required by the designated Company Welding
Inspector, examined by Magnetic Particle or Dye
Penetrant test.
h) The direct works Contractor shall subject the

completed test weldment to Post Weld Heat
Treatment, if required, in accordance with the Job
approved method.
7. Contd.
i) NDT shall be carried out using the methods detailed

in the Job Specification using job approved
procedures.
Note:- Check if there is a requirement that NDT
shall not be carried out until a period of time has
elapsed from welding completion.

WELD SURVEILLANCE
j) The direct works Contractor shall mark out on the

test weldment, all the specimens in the locations
required by the Job Specification.
k) Each test specimen shall be hard stamped by the

identification purposes, and other approving bodies
as required by the Quality Plan.
l) Should such hard stamps be removed or obliterated

during subsequent machining operations, the direct
works Contractor shall arrange for Company
Inspector and other, if applicable, to transfer
their identification marks.
m) Sectioning for test pieces shall be undertaken

allowing a lapse of time if so specified.
n) Mechanical test pieces shall be machines to the

form and dimensions detailed in the Job
Specification.
o) Mechanical Testing shall be carried out in an

approved Test Facility, in accordance with the
Codes and Specifications referenced within the Job
Specification, and all tests shall be witnessed by
the designated Welding Inspector and other
approving bodies.
p) Test acceptance criteria shall be in accordance

with the Codes and Specifications referenced within
the Job Specification.
q) Should a test joint fail to meeting the test

criteria, the welder may carry out two new test
joints of the same type as the rejected one. If
both of these test joints meet specification
requirements, the test shall be considered
satisfactory. If either or both of the new tests
joints fail to meet specification requirements, the
test shall be considered to have failed. A welder
so failed will not be permitted to re-test until he
has satisfactorily completed a period of retraining
documented by the direct works Contractor. The
duration of this period shall be to the
satisfaction of the Company but shall be not less
than one week.
8. WELDER QUALIFICATION SURVEILLANCE
a) All stages of welder qualification proposal

submission and testing, including those detailed in
the foregoing, will be subject to surveillance by
Company personnel and other approving bodies.
Responsible Company personnel shall be designated

WELD SURVEILLANCE
within the Quality Plan.
b) Guideline checklists indicating activities subject

to Company Surveillance are included in Appendix 1.
c) At all stages during Welder Qualification Company

will ensure that other approving bodies are given
notice of tests and are kept aware of progress.
9. WELDER QUALIFICATION APPROVAL AND DOCUMENTATION
a) The Company Chief Field Engineer (in close liaison

with the responsible Field Engineer/Inspector) will
expedite, record receipt, and co-ordinate approval
of the direct works Contractors proposed Welder
Qualification Procedure in accordance with the
Quality Plan. He will additionally ensure
recording of progress and approval of the
subsequent tests on the Welder qualification Status
Log (Standard Form SF 0015)
b) The direct works Contractor shall prepare a

permanent record of the following for each Welder
Qualification Test:-
- All parameters of the Welder Qualification

Test Weld.
- The Post Weld Heat Treatment applied to
approved method.
- The NDT carried out to the approved method.
- The results of all mechanical Tests carried
out to approved method.
- The approved Weld Procedure to which the
test was carried out.
- The welder's name.
- The welder's identification, uniquely
ascribed to him.
c) The records shall be submitted via the Chief Field

Engineer for approval by Company and other
approving bodies in accordance with Job Procedures.
d) Such approval must be received by the direct works

Contractor before the welder is permitted to work.
e) A welder's qualification will require renewal

whenever the welder has not used the appropriate
welding process for a defined period or whenever
there is reason, on the part of the Company or
other approving bodies, to question the welder's
performance.
f) A welder's qualification is maintained valid only

when acceptable welding performance is documented
by regular NDT during fabrication.
g) If a pre-qualification test is required by expiry

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of the time limit, by questionable performance, or

for any other reason, the re-test will be carried
out as for the initial qualification.
h) The direct works Contractor shall establish and

maintain a register of Qualified Welders and shall
provide copies thereof to Company at specified
intervals. Distribution of the register to other
parties will be via the Chief Field Engineer.
i) This index shall include, as a minimum, for each

welder, the following information:-
- The welder's name and identification mark.

- The relevant approved Welding Procedure.
- The scope of the qualification in terms of
material, type, grade and dimensions,
welding consumables, welding positions,
welding processes, etc.
- The date of approval of the Qualification.
- The date of expiry of the Qualification
unless maintained valid.
j) Company may independently of the Contractor,

establish and maintain a Qualified Welder Register
with the facility for signature by the direct works
Contractor and all approving bodies.
10. SURVEILLANCE REPORTING
a) At the end of each day or shift during which he has

been engaged in surveillance of Weld Procedure or
Welder Qualification activities, Company Welding
Inspector will complete Weld Procedure and Welder
Qualification Surveillance Reports (Standard Form
SF 0013).
b) Separate Reports will be completed for each test

weldment on which surveillance has been carried out
and copies of the completed Reports will be issued
in accordance with Job Instructions.
11. PREVIOUSLY ESTABLISHED WELDING PROCEDURES AND WELDER

QUALIFICATIONS
Direct works Contractors previously established Welding

Procedures and Welder Qualifications may be acceptable
to Company. If satisfying the Job Specifications, and
this method they may be submitted for approval complete
with records of results and complete witnessing
certification. In such cases the following sections of
this method shall essentially apply:-
a) Welding Procedures
2a, 2b (including certified results) 2d
Where approval for the previously established

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procedure is granted then further sections 51, 5d,

5e, 5f, 5g will apply. Where approval for the
previously established procedure is not granted the
whole of sections 2 through 5 and 10 will apply.
b) Welder Qualifications
6a, 6b, 6c, 6d (including certified results).

Where approval for the previously established test
is granted then further sections 9a, 9b, 9c, 9d,
9e, 9f, 9g, 9h, 9i, 9j will apply. where approval
for the previously established test is not granted
the whole of sections 6 through 10 will apply.

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APPENDIX 1
SURVEILLANCE CHECK LISTS

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A1. SURVEILLANCE CHECK LISTS
A1.1 APPLICATION
Users should note the attached checklists are intended

to highlight work, facility or methods that could impact
satisfactory acceptance. The Job Specifications,
Procedures, and related codes must be referenced for job
specific requirements and the additional detail
necessary to use these documents as an effective
surveillance tool.
The extent of Company stage and Final surveillance and

the responsibility for its performance is to be clearly
identified in the Quality Plan as is the extent of
surveillance to be carried out by other approving
bodies.
A1.2 WELD PROCEDURES
The following lists are applicable to Weld Procedures:-

List 1, 3, 5, 6, 8, 9, 10, 11, 12, 13, 14, 16.
A1.3 WELDER QUALIFICATION
The following lists are applicable to Welder

Qualifications:-
List 2, 4, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16.

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LIST 1 - WELD PROCEDURE PROPOSAL DOCUMENT
The following data shall be entered in the Proposal

Document and shall conform, where applicable, to the Job
referenced therein:-
1. Designation: Each Welding Procedure shall be

assigned a unique designation.
2. Revision/Issue: The revision/issue status of each

Welding Procedure shall be clearly indicated,
together with its effective date.
3. Welding Process: The welding process, or

combination of processes to be qualified.
4. Test Material
N.B. The Weld Procedure Proposal may be required to
be accompanied by a Mill Certificate for the Test
Material.
5. Material Dimensions.
6. Edge Preparation.
7. Consumables.
8. Non-Consumable Electrodes: The type and size of any

non-consumable electrodes used (e.g. in TIG or
GTAW) shall be quoted.
9. Deposition Augmentation: Any proposed deposition

augmentation system (e.g. auxiliary wire feed)
shall be detailed.
10. Pre-treatment of Consumables.
11. Welding Position, Progression and Technique.
12. Electrical Parameters.
13. Tack Welding Technique.
14. Welding Speed: For each run, the welding speed and
electrode run out length shall be specified.
15. Pre-Heat: The pre-heat temperature, the method of

pre-heating, and method of temperature measurement
shall be specified.
16. Interpass Temperature.
17. Inter-run Cleaning: The proposed method of inter-

run cleaning shall be detailed.
18. Back Gouging

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19. Weld Preparation Sketch: The Procedure Proposal

shall include a dimensioned sketch of the weld
preparation.
20. Run Sequence and Weld Profile: the proposed run

deposition sequence and final profile shall be
detailed in the form of a sketch or sketches.
21. Restraint: Any proposed method of restraint shall

be specified. N.B. All plate procedures for COD
testing shall be restrained using strong backs.
22. Range Qualified: The range of material types,

sizes and grades/specifications, of welding process
welding consumables and techniques, it is proposed
to qualify by the Welding Procedure, shall be
detailed.
23. Post Weld Heat Treatment: The details of any

necessary Post Weld Heat Treatment shall be entered
on the Procedure Proposal.
24. NDT: The proposed NDT operations shall be detailed

on the Procedure Proposal.
25. Signature: The Weld Procedure Proposal shall be

signed by a responsible member of the Contractor's
organisation.

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LIST 2 - WELDER QUALIFICATION PROPOSAL DOCUMENT
The following data shall be entered in the Proposal

Document and shall conform to the appropriate approved
Weld Procedure and the Job Specification and all Codes
and Specifications referenced therein:-
1. Weld Procedure Designation: The designation of the

approved Weld Procedure to which the Qualification
Test is to be conducted.
2. Welding Process
3. Test material
4. Material Dimensions
5. Consumables
6. Non-Consumable Electrodes
7. Deposition Augmentation: Any proposed deposition

augmentation system (e.g. auxiliary wire feed)
shall be quoted and shall be that used in the
approved Weld Procedure.
8. Pre-treatment of Consumables
9. Welding Position, Progression and Technique
10. Electrical Parameters
11. Tack Welding Technique
12. Welding Speed

13. Pre-Heat
14. Interpass Temperature
15. Inter-run Cleaning
16. Weld Preparation Sketch

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17. Run Sequence
18. Range Qualified
19. Post Weld Heat Treatment
20. NDT
21. Signature: The Proposal shall be signed by a

responsible member of the Contractor's
Organisation.

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LIST 3 - WELD PROCEDURE - PRE-WELDING
The following aspects shall be in accordance with the

approved Weld Procedure proposal, the Job Specification
and all Codes and Specifications referenced therein,
manufacturer's recommendations, or Company requirements,
as applicable:-
1. Parent (Base) Materials:
2. Weld Preparation
Dimensional tolerances shall be according to Job
Specification.
The weld preparation shall be clean, free from slag

and shall be ground to a smooth, uniform finish.
Inspection of the weld preparation, assessment and

treatment of any defects detected.
3. Fit-Up: The centre line of the abutting parent

materials shall be aligned such that, after
welding, they are within the tolerances stated in
Job Specification.
4. Tack Welds
5. Restraint
6. Welding Consumables
7. Earth Connections
8. Pre-heat: The pre-heat temperature and its method

of application shall be as detailed in the approved
Weld Procedure proposal.
9. Hard Stamps
10. The above operations shall be carried out under

adequate supervision and should be subject to
supervisory monitoring by Contractor's QC
personnel.

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LIST 4 - WELDER QUALIFICATION - PRE-WELDING

approved Weld Procedure, Welder Qualification Proposal,
Job Specification and all Codes and Specifications
referenced therein, or Company Welding Inspector's
requirements, as applicable:-
1. Parent (Base) Materials
2. Hard Stamps
3. Weld Preparation
4. Fit-up
5. Tack Welds
6. Welding Consumables
7. Earth Connections
8. Pre-heat

personnel.

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LIST 5 - WELD PROCEDURE & WELDER QUALIFICATION - PRE-

WELDING

referenced therein, manufacturer's recommendations or
Company requirements, as applicable:-
1. Welding and Ancillary Equipment: Sufficient

equipment, etc., shall be at the job site and shall
be of adequate capacity and maintained in good
working order. This should include welding power
source, cables, tongs, earthing connections,
cleaning tools, tempilsticks, etc., manipulators,
rotators, supports, etc.
2. Consumable Holding Ovens/Quivers etc.: Adequate

facilities should be available at the job site, or
sufficiently nearby to ensure that welding
consumables are maintained at temperatures
required.
3. Ambient Conditions: The job site shall be

adequately protected by means of suitable shelters
or screens from adverse weather conditions.
4. Weld Procedure/Instruction to Welder: A copy of

the approved Weld Procedure proposal or other
adequate instructions for the welder shall be at
the job site. Such instructions shall detail all
parameters necessary for the completion of the
weldment.
5. the above operations shall be carried out under

personnel.

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LIST 6 - WELD PROCEDURE - IN PROGRESS WELDING
The following parameters shall conform strictly to the

approval Weld Procedure Proposal and related Job
Specifications:
1. The Welding Position
2. The Welding Process
3. Arc Striking.
5. Weld Progression.
6. Welding Speed.
7. Weaving.
8. Shielding Gas Flow, if applicable.
9. Flux Feed, if applicable.
10. Run Sequence.
11. Interpass temperature.
12. Inter-run cleaning.
13. Back Gouging/Grinding, if applicable.
14. Second Side Welding.
15. Completed Weld Profile.

16. Care and Return of Consumables.

supervisory monitoring by the Contractor's QC
personnel.

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LIST 7 - WELDER QUALIFICATION - IN PROGRESS WELDING
The following parameters shall conform strictly to the

approved Weld Procedure of Welder Qualification
Proposal, and related Job Specifications:-
1. The Welding Position.
2. The Welding Process.
3. Arc Striking.
5. Weld Progression.
6. Welding Speed.
7. Weaving.
8. Shielding Gas Flow, if applicable.
9. Flux Feed, if applicable.
10. Run Sequence.
11. Interpass Temperature.
12. Inter-run Cleaning.
13. Completed Weld Profile.
14. Care and Return of Consumables.

personnel.

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LIST 8 - WELD PROCEDURE & WELDER QUALIFICATION

BEFORE POST WELD HEAT TREATMENT

approved Post Weld Heat Treatment Procedure, the Job
referenced therein, or Company requirements, as
applicable:-
1. Equipment.
2. Thermocouples.
3. Heating Elements.
4. Insulation.
5. Ambient Conditions.

personnel.

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- IN PROGRESS POST WELD HEAT TREATMENT

approved Post Weld Heat Treatment Procedure.
1. Heating Rate.
2. Soaking Time and Temperature.
3. Cooling Rate.
4. Temperature Variations during 1, 2 and 3 above.
5. Production of a Permanent Temperature Recording

from all Thermocouples.

supervisory monitoring by Contractors QC Personnel.

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FOLLOWING POSTWELD HEAT TREATMENT

approved Post Weld Heat Treatment Procedure, the Job
applicable:-
1. Post Weld heat Treatment Report dated, signed by

responsible person and precisely identified to the
weldment/item.
2. Post Weld Heat Treatment Report dated, signed by

responsible person and precisely identified to the
weldment/item.
3. The data contained in the Post Weld Heat Treatment

Report and Temperature Recordings to conform to the
criteria of 'In Progress Post Weld Heat Treatment'.

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MARKING OFF TEST PLATE

applicable:-
1. Number, Type and Location of Test Pieces.
2. Test Piece Identification: Each test specimen

shall be clearly and permanently identified by the
Contractor, such that they are precisely
identifiable to the particular Weld Procedure Test.
3. Hard Stamping: Test specimen shall be hard

stamped.
4. Elapsed Time: If applicable the test weldment

shall not be sectioned until a period of time has
elapsed following completion of welding.

personnel.

WELD SURVEILLANCE

MECHANICAL TEST PIECES

Job Specification, Codes and Specifications referenced
therein, or Company requirements, as applicable:-
1. Number and Type of Test Pieces.
2. Test Piece Dimensions.
3. Test Piece Identification: The Contractor's

identification marks shall have been preserved,
wherever possible, throughout machining operations.
4. Other Bodies Identification: These identification

marks shall have been preserved, wherever possible,
throughout machining operations.

personnel.

WELD SURVEILLANCE

PRE-MECHANICAL TESTING

therein, or Company Inspector's and other bodies
approval requirements, as applicable:-
1. Test Facility Approval: The Test Facility should

hold a formal approval awarded by a recognised
Authority (e.g. Lloyds, Ministry of Defence,
N.A.M.A.S approval).
2. Testing of Equipment.
3. Ambient Conditions.
Adequate safety precautions should be applied to

the Tensile and Impact Testing Machines.
4. Personnel Competency.

personnel.

WELD SURVEILLANCE
LIST 14 - WELD PROCEDURE - MECHANICAL TESTING

therein, or the requirements of Company, as applicable:-
1. Tensile Tests.
2. Bend Tests.
3. Macrosections.
4. Hardness Tests.
5. Charpy Impact Tests.
6. COD Tests.
7. Acceptance Criteria.

personnel.

WELD SURVEILLANCE
LIST 15 - WELDER QUALIFICATION - MECHANICAL TESTING

therein, or the requirements of Company, as applicable:-
1. Fillet Welds.
2. Plate Butt Welds, Tubular Butt Welds and Tubular

Brace/Barrel Welds.
3. Acceptance Criteria.
4. Retests.

personnel.

WELD SURVEILLANCE

CONSUMABLE STORAGE AND PRE-TREATMENT

referenced therein, consumable manufacturer's
recommendations, or Company's requirements, as
applicable:-
1. The Store: The store should be weatherproof,

lockfast with restricted admittance and ventilated
to permit escape of any fumes. It should be kept
clean and should not contain any materials (e.g.
grease, lubricants) which could cause contamination
of welding consumables.
2. Ambient Conditions: The store should be maintained

at a minimum temperature of 20C and a maximum
relative humidity of 40%. It follows that a
thermometer and a humidity gauge should be
appropriately located within the store.
3. Storage of Consumables: All consumables shall be

stored, as a minimum requirement, in accordance
with manufacturer's recommendations. Any
consumables unmarked or showing evidence of damage
or deterioration shall not be used.
4. Baking Ovens: There should be sufficient ovens of

sufficient capacity, and they should be in good,
working condition. They should be fitted with a
temperature recording instrument and there should
be adequate means of identifying their contents and
the length of time within the oven.
5. Pre-Treatment of Consumables.
6. Return and Re-cycling of Consumables.
7. Consumables Issue.

personnel.

Weld Surveillance

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Weld Surveillance

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CONSTRUCTION OPERATIONS

2. WELD PROCEDURE QUALIFICATION PROPOSAL

3. WELD PROCEDURE TESTING

4. WELD PROCEDURE SURVEILLANCE

5. WELD PROCEDURE QUALIFICATION AND DOCUMENTATION

6. WELDER QUALIFICATION TEST PROPOSAL

7. WELDER QUALIFICATION TESTING

8. WELDER QUALIFICATION SURVEILLANCE

9. WELDER QUALIFICATION APPROVAL AND DOCUMENTATION

10. SURVEILLANCE REPORTING

11. PREVIOUSLY ESTABLISHED WELDING PROCEDURES AND

1. SURVEILLANCE CHECK LISTS 1 THROUGH 16

REV 1 CONVERTED TO WORDPERFECT AUGUST 1992

PREPARED BY: CONSTRUCTION DEPARTMENT

APPROVED BY: .......................

AUTHORISED BY: .......................

The purpose and scope of this method is to establish a

- To ensure that the direct works Contractor is

- To ensure that Weld Procedures and Welder

- To ensure that Weld Procedures and Welder

- To ensure that all Weld Procedures and Welder

To ensure that all Weld Procedures and Welder

This framework shall be adapted to the job specific

a) The direct works Contactor shall prepare Welding

b) The direct works Contractor shall submit written

c) The details included in the Proposal shall conform

DM2010.WP5 UNCONTROLLED COPY. DOCUMENT VIEWED ON THE NETWORK TAKES PRECEDENCE.

- The welding process or combination of

d) Where required the Weld/Repair Procedure Proposal

3. WELD PROCEDURE TESTING

a) Having obtained approval of his proposed

b) He shall prepare test material of form appropriate

c) The test material will be hard stamped by

DM2010.WP5 UNCONTROLLED COPY. DOCUMENT VIEWED ON THE NETWORK TAKES PRECEDENCE.

d) The direct works Contractor shall set up the test

e) He shall apply pre-heat (if applicable) and weld

f) Welding shall be essentially a continuous process

g) The direct works Contractor shall subject the

h) NDT shall be carried out at the stage and using the

(Note: Check if there is a requirement that NDT

i) The direct works Contractor shall mark out on the

j) Each test specimen will be hard stamped by the

DM2010.WP5 UNCONTROLLED COPY. DOCUMENT VIEWED ON THE NETWORK TAKES PRECEDENCE.

Should such hard stamps be removed or obliterated

k) Sectioning for test pieces shall be undertaken

l) Mechanical Test Pieces shall be machined to the

m) Mechanical Testing shall be carried out in an

n) Test acceptance criteria shall be as detailed in

o) Should a procedure test weld fail any of the

4. WELD PROCEDURE SURVEILLANCE

a) All stages of weld procedure submission and

Responsible Company personnel have been indicated

b) Guideline checklists indicating activities subject

c) At all stages during Weld Procedure Testing the

DM2010.WP5 UNCONTROLLED COPY. DOCUMENT VIEWED ON THE NETWORK TAKES PRECEDENCE.

5. WELD PROCEDURE QUALIFICATION AND DOCUMENTATION

a) The Company Chief Field Engineer (in close liaison

- All parameters of the Procedure Test Weld.

c) These records shall be submitted via the Chief

d) Such approval must be received by the direct works

Note:- If no production tests have been carried out

e) The direct works Contractor shall establish and