NORTH FIELD SOUTH (NFS) PROJECT

OFFSHORE
Engineering, Procurement, Construction, and Installation (EPCI)
for Jackets Facilities for the North Field South (NFS) Offshore Project
COMPANY AGREEMENT No.: LTC/C/NFS/5030-A/20 CONTRACTOR Project No.: D7482

Asset : NFS Jackets

Document Title : Weld Repair Procedure

Document Number : NFSO-MCD-QM-PRC-00007

Discipline : Quality Management

Document Type : Procedure

Document Class : 1

00 8-Mar-2023 Approved for Construction PD PS TS GK JV

C 25-Jan-2023 Issue for Approval PD PS TS GK JV
B 25-Aug-2022 Issued for Review TS GK GK JP GG
DISCIPLINE QA PEM / PD
PREPARED REVIEWED
REV. DATE REVISION STATUS
BY BY
APPROVED BY

McDermott www.mcdermott.com
McDermott Middle East Inc.
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REVISION HISTORY

Revision Date Revision Description

A1 14-July-2022 Issued for Single disciplinary Check

B 25-Aug-2022 Issued for Review

C 25-Jan-2023 Issue for Approval

00 8-Mar-2023 Approved for Construction

HOLDS LIST

Hold. No. Page No. Hold Description

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CONTENTS
1. PROJECT OVERVIEW .........................................................................................................4
2. DEFINITIONS AND ABBREVIATIONS .................................................................................5
2.1 Definitions
2.2 Abbreviations
3. PURPOSE ............................................................................................................................7
4. PROCESS FLOW CHART ....................................................................................................8
4.1.1 Repair welding operations ..................................................................................8
4.1.2 Cut out Repair procedure ...................................................................................9
4.1.3 Crack Repair procedure ...................................................................................10
5. PROCEDURE FOR REPAIR WELDING .............................................................................12
6. PROCEDURE FOR CUT OUT REPAIR .............................................................................14
7. PROCEDURE FOR CRACK REPAIR .................................................................................15
8. DOCUMENTATION ............................................................................................................17
9. REFERENCES ...................................................................................................................18
10. ATTACHMENT -1 RIS form ................................................................................................19

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1. PROJECT OVERVIEW
The North Field Expansion Project (NFXP) comprises of two (2) development phases,
North Field East (NFE) and North Field South (NFS) to significantly increase the State of
Qatar LNG Production capacity from 77 MTPA to 110 MTPA and from 110 MTPA to 126
MTPA respectively.
The North Field South (NFS) project development will add new offshore wells and
infrastructure including wellhead platforms, pipelines and onshore facilities to boost LNG
production for export. The new development will add fifty (50) wells on five (5) offshore
platforms (WHPs) located approximately 20 – 30 km from Ras Laffan with a water depth
variation of 18 to 24 meters in the North Field.
The five (5) WHPs shall feed two (2) LNG mega trains, one pair of WHPs shall support one
LNG mega train. Each pair of WHPs are connected through an intrafield pipeline tying into
a trunk line.
COMPANY has awarded some NFS development work to CONTRACTOR comprising
detailed engineering, procurement, fabrication, construction, installation, hook-up and
commissioning for five (5) wellhead jackets (NFQ22, NFQ23, NFQ24, NFQ25 and NFQ26).

Figure 1.1 General Field Layout North Field South (NFS)

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2. DEFINITIONS AND ABBREVIATIONS

2.1 Definitions

COMPANY : QatarEnergy represented by its agent Qatargas Operating

Company Limited
CONTRACTOR : McDermott Middle East Inc.
SUBCONTRACTOR : Any APPROVED organisation, or group that, through
contractual agreement, performs studies for CONTRACTOR
or engineering, verification activities, manufacturing,
fabrication, construction, installation for CONTRACTOR.
PROJECT : Engineering, Procurement, Construction, and Installation
(EPCI) for Jackets Facilities for the North Field South (NFS)
Offshore Project, in the State of Qatar under contract no:
LTC/C/NFS/5030-A/20.
PARTIAL THICKNESS : Excavation and rewelding of fill/cap or cap pass only
REPAIR
FULL THICKNESS : Excavation and rewelding of the whole weld i.e.: removal of
REPAIR root pass up to capping passes.
HEAT-AFFECTED : The band of parent material immediately adjacent to the
ZONE HAZ fusion boundaries of the weld, directly affected by the heat
of the welding process to the extent that the metallurgical
structure has undergone a physical change
BUTT-JOINT : For the purpose of this procedure a 'butt-joint' shall refer to
any joints connecting plates, beams, tubes or piping to form
a weldment in a plane from 180° to a maximum mitre of
130°
T, Y OR K : For the purposes of this procedure such a connection shall
CONFIGURATION refer to any joint which form a T, Y or K configuration in a
CONNECTION plane from 30° to 180° diehedral angle
STRESS CRACK : An external or internal crack in weld metal, commonly in root
passes and aligned longitudinally with axis caused by
excessive stress, thermal contraction or fabrication
sequence
CHEVRON CRACK : Another form of Hydrogen Cracking that occurs in the weld
metal and aligned transversely with axis of heavy wall
members caused by induced stress and hydrogen in weld
metal
TRANSVERSE : A crack transverse to weld axis located in weld, HAZ or
CRACK Parent Material caused by longitudinal shrinkage strain
acting on excessively brittle weld metal
MAJOR & MINOR : As defined in below table-1
DEFECT
BUTTERING : Repair of added weld metal to correct excessive gaps

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2.2 Abbreviations
BIS Buttering Information Sheet
EPCI Engineering, Procurement, Construction & Commissioning and Installation
LNG Liquefied Natural Gas
MTPA Million Metric Tons Per Annum
NFE North Field East
NFQ North Field Qatar
NFS North Field South
NFXP North Field Expansion Project
RIS Repair Information Sheet
WHP Wellhead Platform

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3. PURPOSE
This procedure defines the correction processes to remove the defects from weld and
parents’ metal, subsequent reweld and testing for structural weldment of North Field South
(NFS) Project Offshore – Jackets in accordance with project specifications and applicable
standards. This procedure may be referred at McDermott Jebel Ali, Batam, QFAB Yard and
offshore Installation and commissioning activities .
This procedure is cover following methods: -
1. Spot Repair Welding
2. Complete Cut Out Repair
3. Crack Repair

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4. PROCESS FLOW CHART

4.1.1 Repair welding operations

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4.1.2 Cut out Repair procedure

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4.1.3 Crack Repair procedure

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4.2 TABLE -1 CATEGORIZATION OF REPAIR

Categorization of repair (Base metal repairs are specified in Buttering/Build-up

procedure NFSO-MCD-QM-PRC-00032)
1. Major Weld Repairs

1.1. Crack, except crater cracks to be immediately removed

1.2. Repair Cavity > 25 cm2 (3.88 in.2)

1.3. Any Second type repair on primary and special members

1.4. Lack of Fusion & Lack of Penetration in primary member

1.5. Repair Depth > 50% Thickness

1.6. If the repair length > 20% of weld length, or 300 mm whichever is higher

1.7. Repair on lifting lug or pad eyes

2. Minor Repairs

2.1. Porosity, slag inclusions, and repair cavities smaller than above

2.2 Crater cracks

2.3 Undercut

2.4. Arc strike if not resulted in crack

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5. PROCEDURE FOR REPAIR WELDING

5.1 Repair shall be performed as per approved RIS (Repair Information Sheet) and applicable
repair WPS. RIS shall be approved by Welding Engineer and CPY for major repairs and
only by Welding Engineer for Minor repairs. Preheat shall be as per approved Repair
Welding Procedure (WPS) and shall be maintained during welding.

5.2 Removal of Defect(s)

5.2.1 Refer to NDT (UT or RT) for the location and size of defect. Location of defective areas
shall be clearly marked on the joint.

5.2.2 Apply preheat prior to any excavation and rewelding of the defective areas. Preheat
temperature shall be 30° C higher than minimum required for original weld. Preheat /
Inter-pass temperature shall be maintained throughout the rewelding operation.

5.2.3 Excavation shall extend at least 25 mm beyond the extremities of the defect and in the
case of partial thickness repair, the depth of excavation shall extend at least 3 mm
beyond the reported depth. Thus, for single side welds, any defect located within 5mm
from the internal surface shall require through thickness repair. Any suspected crack
like indication shall be immediately reported to the Welding Engineer, Sr. QC
Inspector, and NDT Coordinator prior to performing repairs.

5.2.4 Excavation of the repair area may be done by grinding or air carbon arc gouging to
remove the defect. When air carbon arc gouging is used, it shall be followed by
grinding to remove the residual carbon prior to welding. The excavated cavity shall
have a groove preparation as required by the applicable WPS.

5.2.5 The excavated area shall be visually examined, and the extent of defect shall be
ascertained by MPI or DPT, based on accessibility.

5.2.6 When full thickness repair is to be made for single side welds, it shall be performed in
the same manner as describe above except that the gouging depth shall be at through
thickness. The last 4mm of the weldment shall be removed by grinding only. For a
double-sided joint repair, the second side shall be excavated and rewelding first prior
to repairing side one.

5.2.7 Repair Information Sheet (Form attached) shall be issued for all major weld repairs by
QA/QC or Welding Engineer. Repair Information Sheet

5.2.8 The maximum number of repairs allowed at the same location shall be as specified in
applicable repair WPS.

5.2.9 Minor repair welding shall be performed by qualified Welders using a COMPANY
approved WPS. Major and Minor repairs are defined in table 1.

5.2.10 Major Repairs in weldments etc., as defined in Table 1, shall be repaired notifying
Company as per ITP. For Major repairs – COMPANY approval is required,

5.2.11 Any repair made to weldment using a deferent welding process or consumable
requires a specific approved repair WPS.

5.2.12 The maximum repair length without cutting out girth or TKY welds shall be based on
approved RIS.

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5.2.13 All activities during the repair operation shall be monitored by QC Inspector and
welding supervisor. Ensure that the COMPANY is fully notified of the activities.

5.2.14 All repairs shall be Re-inspected (Area repaired + 25 mm on either side) by Original
NDE method applicable to the Weld / category as per NDE Spec

5.2.15 UT check for transverse cracking shall be performed based on approved Repair
Information Sheet (RIS).

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6. PROCEDURE FOR CUT OUT REPAIR

6.1 Evaluation/Assessment of cut out weldment

6.1.1 Cut out is considered major repair and shall be subject to Welding Engineer approval.
6.1.2 The Welding Engineer upon receipt of 'cut out' shall evaluate cause for rejection.
6.1.3 The Welding Engineer may prescribe further Non-Destructive Testing to assess type and
location of defect.
6.1.4 The Welding Engineer may deem necessary that destructive testing is required to
determine either the cause of rejection or physical/chemical properties of the 'cut out'
weldment.

6.2 The Welding Engineer shall advise the department concerned of his findings.

6.3 The cut lines shall be laid out parallel to the axis of the weld, at the weld by the Production
Supervisor and as witnessed by the QC Inspector.

6.4 Remove the weldment by either gas cutting or grinding as per lay out lines. Should the
adjoining member be in tension, other forms of restraint should be applied prior to
commencement of cutting. Perform MPI of the new bevel.

6.5 Upon completion of the cutting, the weldment shall be properly identified by
a. Drawing No.
b. Weld No. with suffix “X”
c. WPS & Welder(s) No.

6.6 All cut out remnants shall be forwarded to the Welding Engineer for his
evaluation/assessment.

6.7 The QC Inspector shall advise the Production Engineer of the cut-out condition and
location.

6.8 The joint shall be checked as per the AFC Drawing & verified by QC inspector, in case of
single side welds internal surface shall be free of cutting debris & bevel edge is clean.
The joint shall undergo the same inspection as the cut-out weldment (original joint).

6.9 The addition of splices requires the approval of the Engineering department and shall
undergo the same inspection prescribed for similar weld joints.

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7. PROCEDURE FOR CRACK REPAIR

7.1 No cracks shall be removed or repaired by CONTRACTOR without prior approval of

specific crack repair method statement (each case). COMPANY shall be notified of all
cracking issues. All cracks shall be repaired in accordance with an approved specific
crack repair method statement.

7.2 Evaluation and Assessment - The QC Inspector shall advise the Sr. QC Inspector, NDT
Supervisor, Welding Engineer and COMPANY representative of any crack-like indication.

7.3 The Welding Engineer shall define the type of crack and cause thereof. i.e; Stress Crack,
Shrinkage Crack, Hot Crack, Under Bead Crack, Chevron Crack etc.

7.4 The reason for cracking, with preventive actions shall be investigated and identified by
CONTRACTOR and informed to COMPANY for review prior to repair. Additional NDE
might be necessary to be performed.

7.5 Upon COMPANY acceptance, a method of resolution shall be prescribed as such:

7.5.1 Removal and repair of localized area in accordance with a " specific crack repair
method statement ".

7.5.2 Complete removal of weldment encompassing a portion of the regional members (i.e;
Weld Metal, HAZ and Parent Material) in accordance with specific crack repair method
statement.

7.6 Removal/Repair of the localized crack area; shall require a specific crack repair method
statement for each case. At a minimum the method statement shall determine the
following requirements.

7.7 The full extent of the crack shall be defined with regard to length, cross sectional
dimension and depth.

7.8 To fully ascertain the type and extent of the crack all practical means of non-destructive
tests shall be conducted.

7.9 The Welding Engineer/NDT coordinator shall specify in the method statement the
following essential items:

7.9.1 The crack repair shall be excavated 50mm beyond the defined limits.
7.9.2 The use of NDT to assure complete removal of crack.
7.9.3 The use of other NDT methods to ascertain complete removal of crack prior to
welding the cavity.
7.9.4 Method of excavation (grinding or carbon arc gouging + followed by grinding).
7.9.5 Preheat requirements prior to gouging and repair welding activity.
7.9.6 Welding parameters, consumables, technique, precautions, etc.
7.9.7 Post heat time & temperature, if applicable.
7.9.8 Method of NDT & re-inspection of weld.

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7.10 The specific crack repair method statement shall be submitted to the client for review and
approval.

7.11 Re-inspection of the repair weld joint / base metal portion

7.12 Visual examination shall be performed by the QC Inspector.

7.13 The NDT shall be carried on the entire joint regardless of length repaired.

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8. DOCUMENTATION

8.1 For repair welding

8.1.1 All repair welds and subsequent NDT test are documented in the same like manner
as that of the original weld.
8.1.2 All repair welds shall be signified by the letter 'R' located as a suffix to the weld I.D. on
all QC & NDT reports. First Time Repairs shall be indicated as R1, Second Time
Repairs as R2

8.2 For cut out repair

8.2.1 All new materials and weld joints shall be identified on the As- Built Record.
8.2.2 The replacement weld shall retain its original identification with a suffix ' X ' immediately
after original number on the As-Built Record.

8.3 For Crack repair

8.3.1 All QC and NDT documents shall be retained as part of the As- Built Record.
8.3.2 The RIS shall be retained as part of the Project Data Book.

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9. REFERENCES
REF.
DOCUMENT TITLE DOCUMENT No.
No.
1 Project Instructions EXHIBIT 5
2 Description of Work EXHIBIT 6

3 Specification for Material Traceability and Documentation 102-21-QM-SPC-00006

4 Specification for Project Quality Assurance 102-21-QM-SPC-00007

5 Specification for NDE 102-21-QM-SPC-00009

6 Specification for Structural Material 102-21-ST-SPC-00001

7 Specification for Welding and Inspection 102-21-ST-SPC-00005

Recommended Practice for Planning, Designing and
8 Constructing Fixed Offshore Platforms - Working Stress API RP 2A-WSD
Design
9 Specification for the Fabrication of Structural Steel Pipe API SPEC 2B

10 Structural Welding Code - Steel AWS D1.1/D1.1M

Note that the latest edition of recognized International Codes and Standards shall be used
throughout the course of the project unless specifically identified otherwise.

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10. ATTACHMENT -1 RIS FORM

REPAIR INFORMATION SHEET NO: RIS-NFS-0XX

Member ID : Dwg No. : Joint No. :

Toughness
Material Grade : : Thickness :
Class
General Notes : Repair Location Repair
Use qualified Root/Hot Pass First Repair
welders:
Use approved WPS: Filler Pass Second Repair
Cap Third Repair

Description of Repair Plan

Prepare By Review by Approve By

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