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TRANSMmAL # lOO75-T-NE-DG-CN-1899 Contract No:MD-502-8000-CN-PS-CON-OOOl
DOCUMENT TRANSMITTAL SHEET
From: MR: Hisham AR. Noureddine To: MR Eduardo Cabanas
Project Manager Site Manager
NESMA & PARTNERS Co., Ltd. DRAGADOS GULF
P.O. Box 1498 P.O/Box No: 3140
AJ·Khobar 31952 AI-Khobar 31952
K.S.A. K.S.A.
We enclose the following documents for:
0 Construction o Cordination
[2] Action I Approval D EstimatelPrice
0 Information o Others
SIN Submittal I Doc. No. Rev. No. of Document Title I Subject
Copies
1 1 0075·CN·8000·ME-QCP·1 004 03 01 Quality Control Procedure for Weld Control.
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issUed, · '/J;; · Receipt Confirmation:
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R. HISHAM A.R.~ OUREDDINE
PROJECT MANAGER
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DC/DAP

QUALITY CONTROL PROCEDURE FOR

WELD CONTROL

(QCP I ME I 008)

1 0075-CN -8000- ME-QCP-l 004

ISSUE DATE ISSUE STATUS REVISION STATUS
ISSUED FOR APPROVAL Rev. 03
October 06, 2009 October 06, 2009 PREPARED BY:

ROGELIO L. DE GUZMAN QAlQC Welding Inspector

CHECKED BY:

CESAR P. BACOLORES QAlQC Supervisor

SAFETY REVIEWED BY:

APPROVED BY:

SATISH NAGWADE Site Manager

JACY PILLAI Safety Manager

NeslTla & Partners

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INDEX
1. SCOPE
2. PURPOSE
3. REFERENCES
4. DEFINITIONS
5. SAFETY
6. WELDING METHODOLOGY
7. INSPECTION
8. POST WELD HEAT TREATMENT
9. ORIFICE PLATE INSPECTION esrneJ & Partners

1. SCOPE

The scope of this procedure is to provide the required methodology for the fabrication, erection and inspection of welded on-plot structures as detailed in the appropriate isometric drawings.

2. PURPOSE

To define the documentation and responsibilities for controlling the welding activities involved in Piping.

3. REFERENCES

3.1 ASMEIX Welding and Brazing Qualifications
3.2 ASME II Part C ASME B & PV Code for Welding Consumables
3.3 ASME B31.3 Process Piping
3.4 ASME B31.1 Power Piping
(*) 3.5 QCP/ME/OO9 Welding Consumables Control
(*) 3.6 QCPIME/OO4 Pre-Fabrication and Installation of Aboveground Piping
3.7 ASME B16.11 Forged Steel Fittings, Socket-Welding and Threaded
3.8 ASME B16.25 Butt Welding Ends
3.9 BS 7570 Code of Practice for Validation of Arc Welding Equipment
3.10 APIRP 582 Welding Guidelines for the Chemical, Oil and Gas Industries
3.11 ASMESEC. V Non Destructive Examination 3.12 MD-I01-0000-QD-GE-PRO-OOOl 3.13 MD-500-1000-EG-PI-SPC-OOOl

Positive Material Identification

Piping Materials classes Specification

(*) Required Approval by DRAGADOS

esrna & Partners

4. DEFINITIONS
4.1 WPS Welding Procedure Specification
4.2 PQR Procedure Qualification Record
4.3 WPQ Welding Performance Qualification Status I
Register
4.4 NOT Non Destructive Testing
4.5 QCD Quality Control Department
4.6 NDT Coordinator Person (s) in the QC Department responsible to
co-ordinate NDT activities
4.7 WQT Welding Qualification Table
4.8 PWHT Coordinator Person (s) in the QC Department responsible to
co-ordinate PWHT activities SAFETY

5.1 All P.P.E must be worn at all times in accordance with MA 'ADEN Safety Standard

5.2 All welding operators will use integrated helmets & shields.

5.3 All welding will be in accordance with MA'ADEN Safety Standard

6. WELDING METHODOLOGY

6.1 Welding Fabrication - Shop & Field Erection

The Welding fabrication will be based on the requirements as provided by Ma'aden Standard and International Codes as applicable and the ENGINEER'S detailed isometric drawings. Welding consumables as per A WS classification shall be used for the purposes of this project.

Weld joint preparation shall be performed as per good shop practices and the requirements as per References item nos. 3.4,3.7,3.8,3.12,3.13 and the approved applicable WPS.

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Selection of welding consumables shall be performed on the basis of metallurgical compatibility with the parent material and the requirements as per Reference item no.3.2 and the approved applicable WPS.

In order to facilitate the control of the various types of welds following coding system shall be used throughout the controlling documentation as well as in the Talisman System. The same code convention shall also be used in the Daily Welding Report Form.

A three (3) character code shall be used to identify the weld type as follows:

• First Character

First character signifies to whether the welding takes place in shop or in field. For the shop case the symbol used is the "S" (Shop) whereas for the second case is "F" (Field).

• Second Character

This character signifies the type of the weld configuration as follows.

B = Butt Weld

F = Fillet Weld

0= DIet Weld

S = Socket Weld

P = Pipe Support Weld

L = Sleeve Weld

C = Butt Branch Connection

R = Fillet Branch Connection

• Third Character

The third character signifies the scope of the work as follows :-

W = Nesma's Original Scope

C = Cut out because ofNesma responsibility, rework

v = Vendor Changes

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D = Design Changes

The following provides a comprehensive list of all possible Weld Type combinations as well as the responsible department of implementing the above.

(Engineering - Drawing Office Responsibility)

SG : Shop Butt Weld (N esma Scope)
FG : Field Butt Weld (Nesma Scope)
SF : Shop Fillet Weld (Nesma Scope)
FF : Field Fillet Weld (Nesma Scope)
SPW : Shop Pipe Support Weld (Nesma Scope)
FPW : Field Pipe Support Weld (Nesma Scope)
SLW : Shop Sleeve Weld (Nesma Scope)
FLW : Field Sleeve Weld (Nesma Scope)
SBO : Shop Butt Weld (Design Modification)
FBD :. Field Butt Weld (Design Modification)
SFO : Shop Fillet Weld (Design Modification)
FFD : Field Fillet Weld (Design Modification)
SOD : Shop Qlet Weld (Design Modification)
FaD : Field DIet Weld (Design Modification)
SSD : Shop Socket Weld (Design Modification)
FSD : Field Socket Weld (Design Modification)
SPD : Shop Pipe Support Weld (Design Modification) ~
FPD : Field Pipe Support Weld (Design Modification)
SLO : Shop Sleeve Weld (Design Modification)
FLO : Field Sleeve Weld (Design Modification)
SCD : Shop Butt Branch Weld (Design Modification)
FCD : Field Butt Branch Weld (Design Modification)
SRD : Shop Fillet Branch Weld (Design Modification)
FRD : Field Fillet Branch Weld (Design Modification)
SBV : Shop Butt Weld (Vendor Modification)
FBY .: Field Butt Weld (Vendor Modification)
SFV : Shop Fillet Weld (Vendor Modification)
FFV : Field Fillet Weld (Vendor Modification)
SOV : Shop Olet Weld (Vendor Modification)
FOV : Field Fillet Weld (Vendor Modification)
SSV : Shop Socket Weld (Vendor Modification)
FSV . : Field Socket Weld (Vendor Modification)
SPV : Shop Pipe Support Weld (Vendor Modification)
FPV : Field Pipe Support Weld (Vendor Modification)
SLV : Shop Sleeve Weld (Vendor Modification)
FLV : Field Sleeve Weld (Vendor Modification)
SCV : Shop Butt Branch Weld (Vendor Modification)
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rev : Field Butt Branch Weld (Vendor Modification) SRV : Shop Fillet Branch Weld (Vendor Modification) FRV : Field Fillet Branch Weld (Vendor Modification) FXW : Shop tack Weld, Field to Complete

CQ.C. Responsibility)

SO : Shop Butt Weld (cut out work, rework)

FO : Field Butt Weld (cut out work, rework)

SF : Shop Fillet Weld (cut out work, rework)

FF : Field Fillet Weld (cut out work, rework)

SPC : Shop Pipe Support Weld (cut out work, rework) FPC : Field Pipe Support Weld (cut out work, rework) SLC : Shop Sleeve Weld (cut out work, rework)

FLC : Field Sleeve Weld (cut out work, rework)

6.2 Welding Processes

Acceptable Welding processes are :

• Shielded metal Arc Welding (SMA W)

• Gas Tungsten Arc Welding (GTAW)

• Submerged Arc W elding (SAW)

6.3 Welding Procedures

WPS shall be prepared by the Welding Engineer, considering the scope of work, ASME IX & 3.4. The welding procedures used for the project (production welds & repairs) shall be qualified as per ASME IX as well as ASME 31.3 and shall be followed during fabrication and erection. Pre-qualified welding procedures can be used providing that they are DRAGADOS approved. The welding procedures shall cover the entire scope of welding work, as appropriate and shall be in place as much as possible prior to works commencement. Additionally, they shall be approved by DRAGADOS prior to commencement of welding. A weld map in accordance with Project specification in the form of Isometric Drawings / Spool Drawings shall also be produced showing the applicable WPS(s) with regards to the various line classes, type of material, thickness, joint configuration etc ....

Welding Engineer shall co-ordinate all activities pertaining to WPS, PQR & WPQ with DRAGADOS and construction.

Welding shall be a minimum 2 layers. Start point of each layer shall be staggered.

essrns» & Partners

In order to provide a standardization in the numbering system of WPS(s) the following alphanumeric format is suggested.

XXX

L, Number (Numeric)

XXXX

xxx

Alloy Identifier 1-- (Alphabetic)

Index (Numeric)

For example:

• For this project, for example the Project number is AGAP.

• Alloy Identifier as follows:

CS = Carbon Steel

SS > = Stainless Steel

LA = Chrome-Moly Alloys

MON = Monel Alloys

DIS = Dissimilar Metal Joints

LT = Low Temperature c.s.

• Index : 001,002,003 etc.

Examples: WPS AGAP CS 001 is the first C.S. W.P.S.

WPS AGAP SS 001 is the first S.S. W.P.S.

WPS AGAP DIS 001 (CS/SS) is the first dissimilar metals W.P.S. between CS & SS.

It is also suggested that the corresponding PQR, qualified on site, to follow, as much as practically possible, the same alphanumeric as the WPS. E.g. the PQR corresponding to WPS AGAP CUNIOOl will be PQR AGAP CUNIOOI (this might not apply for the case of

multiple supporting PQR or PQRs pre-qualified in another project).

.eerns» 8, Partners

NOTE:

For purposes of internal reporting only, the (WPS-AGAP) may be omitted.

6.4 Welders - Welding Operators

The Welders I Welding operators shall be qualified as per ASME IX as well as ASME 31.3 requirements. No individual shall be allowed to weld (tack welding included) if he does not meet the above mentioned conditions. Welders can be qualified for one or more welding processes and material types as per the applicable WPS(s).

The Welders I Welding operators progressive examination shall be as per ASME B31.3 paragraph 341.3.4.

A Welders Qualification Status Register showing the Welder's name against the WPS qualified shall be used facilitating, in this way. the proper welder selection.

Additionally welders shall be provided with job clearance cards showing the WPS(s) for which they are qualified with, material type and range e.t.c. While at work place, they must always carry these cards with them.

6.5 Welding Consumables

Welding consumables shall be stored and treated as per manufacturer's recommendations as well as per Ref. 3.2 and 3.3. The welding consumables used during manufacturing shall always comply, in specification and size, with the consumables specified in the DRAGADOS approved vendor's list and approved WPS.

6.6 Welding I Cutting

Before welding Foreman I Charge hands will instruct welding operators on the requirements of the applicable WPS such as bevel tolerances, cleaning, preheating (if required), welding consumable type and size, electrical characteristics (amps, volts), welding speed, inter-pass temperature, welding size, welding sequence, as well as PWHT (if required). Cleanliness shall be maintained during fabrication-repair welding as per good shop practice as well as requirements of Ref. 3.6.

Instruction Cards will be formulated from the WPS' s showing the relevant information for materials to be welded & issued to the Foreman I Charge hands & Welders.

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For the case of galvanized pipes removing of galvanization as well as touch up after welding, shan be performed.

Cutting of pipes shall be in accordance with Ref. 3.6, 3.12 and 3.13. Materials requiring preheating for welding shall be preheated at the same temperature for thermal cutting.

Quality Control Inspectors (QCI's) on a surveillance mode shall also monitor the welding I cutting activity in addition to the welding supervisors and make sure that personnel complies with all project specific welding I cutting requirements. Each, weld shall be identified by marking a welder's identification number. This shall be marked permanently on the pipe near the welded seam at 2 spots 1800 apart, unless otherwise specified elsewhere. Low stress stamp or permanent marker is required for CS & Low Alloyed steels. For all Stainless steel material, only approved marker shall be used. For joints welded by multiple welders, each section is allocated to the relevant welder, who will mark his section with his unique ID No.

6.7 Welding Environment

Welding shall not be performed when the wind is strong enough to affect the arc stability, or shielding gas coverage. Wind shields or tents, shall be used when deemed necessary by NESMA - QCD. Gas-Shielded FCAW, GMA W shall not be used for field fabrication unless adequate windshields are used.

Contamination from the environment, such as blown sand, shall be prevented by the use of adequate shielding.

The wind velocity in the weld area for GTAW, SAW, GMAW or gas shielded FCAW shall not exceed 8 kph (2.2m/s). Welding shall not be performed when surfaces are wet or damp or exposed to rain. Any wet or damp surfaces must be dried by means of propane heating torch and shall be hand warm before welding.

6.8 Welding Machines, Quivers

Welding Machines shall be in good working, reliable, condition and shall be maintained as per

Ref. 3.9, and 3.10 as well as manufacturer's recommendations. Records of maintenance shall be kept.

Calibration of welding machines as per NESMA approved procedure. All machines to have calibration sticker attached.

7. INSPECTION

7.1 Welding inspectors - Visual

Welding Inspectors shall be properly qualified. They will be responsible for inspection

of Fit-ups, in-process and Visual Inspection of completed welds.

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Their task consists of monitoring welding activities and verifying adherence to appropriate drawings, WPS(s) and all other elements pertinent to welding.

Welding progressive examination shall be performed by methods outlined in this paragraph also paragraph No. 6.2 and in accordance with ASME B31.3 para. 341.4.

7.2 NDT

NOT coordinator shall be responsible for liaison of NDT related activities & documentation with NOT Sub-contractor Construction & QCI. Upon finalizing the welding work, weldments shall be checked as per specification indicated NDT methodes). All final NOT, shall be performed after PWHT, for P3 & above materials. For P-l group of materials it maybe performed before P.W.H.T.

NOT shall be performed by properly qualified technicians qualified to minimum ASNT Level II per discipline. These technicians shall follow Project approved NDT procedures and shall record the results.

Control ofNDT inspection shall be attained as per Ref 3.11

Weekly report shall be prepared by Welding Engineer with regards to welder's performance based on rejection Percentage of his welds during NDT.

8. POST WELD HEAT TREATMENT (PWHT)

When PWHT is required as per pertinent WPS and I or project specification (RefJ.IO and 3.13 ) this shall be performed as per 3.6. A hardness survey is to be carried out as per Ref 3.6.

All appropriate techniques and good shop practices shall be complied with to the full extent in carrying put PWHT.

No Welding, Hammering or Bending is allowed after PWHT.

9. ORIFICE PLATE INSPECTION

QCI's shall verify that, the orifice plates are installed and the internal welding has been ground smooth. No sharp comers or burr is left behind and shall be recorded.