NG22 282 CST PSL 100020 - Revc0

OML58 Upgrade Phase 1 Project
TRANSMITTAL SHEET
FROM : CPY ~~ Company Contract n° : TO : SPD ~ SAIPEM PONTICELLI DESICON
Name : Transmittal N° : TNO-CPY-SPD-000033 Attn :
Address : Total E&P Nigeria Limited Issue Date : 2-Sep-10 Address : 1/7 Avenue San Fernando
Plein Jour, 12 bis rue Jean Jaurès Montigny le Bretonneux
PUTEAUX 92800 Remarks : 78 884 SAINT QUENTIN EN YVELINES Cedex
Tél. : 01 47 44 84 17 Tél. : 01 61 37 69 36
CD Acknowledgement of receipt :
E-mail Date :
Courier Signature : 03/09/2010
DMZ X
We are pleased to deliver to your Company the following documents. For CPY ~ Company
Prior to be sent, these documents have been checked as per contract requirements.
Information included in this transmittal for each document is in accordance with the document itself.
Name & signature
Approval Class
CONTRACTOR
Return Code
Remarks
DocNber
Document Number Rev Stat. Rev. Date Title Disc. Type
NG22-282-CST-PSL-100017 C0 IFR 9-Jul-10 PROCEDURE FOR VISUAL EXAMINATINO AND WELDING/ NDT CST PRC 2 2
NG22-282-CST-PSL-100018 C0 IFR 13-May-10 WPS / PQR QUALIFICATION PROCEDURE FOR OBITE TC STORAGE TANK CST PRC 2
NG22-282-CST-PSL-100020 C0 IFR 10-Jul-10 PROCEDURE FOR MANAGEMENT OF WELDING CONSUMABLES FOR CST PRC 2 2
NG22-282-CST-PSL-100019 C0 IFR 12-Aug-10 Procedure For Welder Qualification For Obite TC Storage Tanks Erection CST PRC 2 2
NG22-282-CST-PSL-100011 C0 IFR 29-Jun-10 WELDING BOOK FOR OBITE TC TANK ERECTION CST BOK 2
NG22-282-CST-PSL-100014 C0 IFR 7/72010 INSPECTION AND TEST PLAN FOR BASE MATERIAL RECEIVING FOR CST PLN 2 2
NG22-282-CST-PSL-100033 C0 IFR 12-Aug-10 Mobilization Plan For Obite TC Storage Tanks Erection CST PRC 2 2
NG22-282-CST-PSL-100007 C0 IFR 12-Aug-10 Project Quality Plan For Obite TC Storage Tanks Erection QUA PLN 2 2
Comments Summary for document
NG22-282-CST-PSL-100020 Rev. C0
Date of comments : Aug. 20 2010
Comments performed / validated by: QC Head
Return Code is 2 ~ Proceed with comments
There are 56 annotations following

OML 58 Upgrade Phase 1 Document Number :
PROCEDURE FOR MANAGEMENT OF WELDING CONSUMABLE NG22-282-CST-PSL-100020
FOR OBITE TC STORAGE TANK ERECTION Revision : C0 Status : IFR Approval Class : 2
Document Type : PRC System / Subsystem : Zone : Rev. Date : 10-May-2010
Page 1 of 25
RC326229
PETRA SERVICES LIMITED
PROCEDURE FOR MANAGEMENT OF WELDING
CONSUMEABLES FOR OBITE TC STORAGE TANK
ERECTION
Rev. Status Rev. Date Revision Memo Issued by Checked by Approved by
C0 IFR 10-July-2010 Issued for review O. IYO L. OBOH N. AZIKE
This document has been generated by an Electronic Document System. When printed it is considered as a for information only copy. The” controlled copy” is the
screen version and it is the holder’s responsibility that he/she holds the latest valid version.
“This document is the property of TEP NG. It must not be reproduced or transmitted to others without written authorization from the Company”.
G22-282-CST-PSL-100020_C0
Page 3 of 25
INDEX
REVISION DESCRIPTION ........................................................................................................................................ 2
INDEX ......................................................................................................................................................................... 3
1. SCOPE AND PURPOSE..................................................................................................................................... 4
2. REFERENCE DOCUMENTS ............................................................................................................................ 5
3. DEFINITIONS .................................................................................................................................................... 6
4. RESPONSIBILITIES.......................................................................................................................................... 8
5. EQUIPMENT ...................................................................................................................................................... 9
5.1. EQUIPMENT REQUIREMENTS .......................................................................................................................... 9
6. CONSUMABLE ................................................................................................................................................ 10
6.1. FILLER METALS........................................................................................................................................... 10
6.2. GRINDING AND CUTTING DISC ..................................................................................................................... 10
7. INSTRUMENT ................................................................................................................................................. 11
8. FILLER METAL HANDLING SEQUENCE................................................................................................... 11

8.1. RECEIVING / INSPECTION / STORAGE ............................................................................................................. 11
8.2. ISSUE OF CONSUMABLE FOR PRODUCTION/RETURNING UN-USED .................................................................... 11
8.3. BAKING OF THE ELECTRODE ......................................................................................................................... 12
8.4. OVENS / QUIVERS MANAGEMENT................................................................................................................. 13
9. MATERIAL CERTIFCATES .......................................................................................................................... 14
10. BAKE COLOR APPLICATION .................................................................................................................. 14
11. ANNEX ......................................................................................................................................................... 15

11.1. ANNEX1: HANDLING OF ELECTRODE WITH BAKING/ HOLDING OVEN ............................................................. 16
11.2. ANNEX 2: HANDLING OF ELECTRODE WITH QUIVER ...................................................................................... 17
11.3. ANNEX 3: BAKING COLOR CODE .................................................................................................................. 18
11.4. ANNEX 4: SMAW ELECTRODE HANDLING FLOW CHART .............................................................................. 19
11.5. ANNEX 5: ELECTRODE STORE TEMPERATURE / HUMIDITY LOG ..................................................................... 20
11.6. ANNEX 6: RECEIVING INSPECTION REPORT OF WELDING ............................................................................... 21
11.7. ANNEX 7: WELDING CONSUMABLE LOG ....................................................................................................... 22
11.8. ANNEX 8: ISSUED WELDING CONSUMABLE LOG ........................................................................................... 23
11.9. ANNEX 9: REQUEST FOR WELDING CONSUMABLE......................................................................................... 24
END OF DOCUMENT .............................................................................................................................................. 25
G22-282-CST-PSL-100020_C0
Page 5 of 25
2. REFERENCE DOCUMENTS
Doc n° Designation
Origin
GS PVV 611 Welding of Pressure Containing Piping and Equipment GS
GS PVV 312 Welding of Low Pressure Metallic Storage Tanks GS

NG22-280-CST-SPD- Carbon Steel Piping Welding Book for OBITE TC and
SPD
004501 OGBUGU CLUSTER
NG22-280-CST-SPD- Carbon Steel Structure Welding Book for OBITE TC
SPD
004502 and OGBOGU CLUSTER
NG22-282-CST-PSL-
Welding Book for Obite TC Storage Tank Erection PSL
100011
Specification for Carbon Steel Electrodes for Shielded
AWS A 5.1 AWS
Metal Arc Welding
G22-282-CST-PSL-100020_C0
Page 6 of 25
3. DEFINITIONS
COMPANY: TOTAL E & P Nigeria Ltd.
CPY: Company
CONTRACTOR: The Consortium of SAIPON snc, SCNL, PNL & DESICOM
SUB-CONTRACTOR: Company performing major part of the WORK (in agreement with the
Execution Scheme).i.e Petra Services Limited
APPROVAL: Authorization in Writing by the COMPANY to CONTRACTOR to proceed to use

the Documents to Perform the Work (Within the Limit and Variable of same Approved
Document)
WPS: Welding Procedure Specification
SMAW: Shielded Metal Arc Welding
GTAW: Gas Tungsten Arc Welding
FCAW: Flux Core Arc Welding (This to be approved by CPY)
SHIELDING GAS: ARGON the Gas Used to Shield the weld pool (With GTAW or FCAW)
PURGING GAS: ARGON the gas used to maintain a controlled atmosphere at the back of
the root, the aim is to have an O2 level of 500ppm or less .( With GTAW )
P.O.: Purchase Order, the list of ordered material with the respective Quantity, Size, Brand,
Brand name, AWS Specification, AWS Classification
Consumable Log: The List of all consumable received within the project with full traceability
related to AWS Spec- AWS Class – Diameter - Batch/Lot No – material certificate
Vacuum pack: This keeps the electrode dry and in the original condition until opened. After
the pack is opened, the electrode shall be handled as per manufacturer recommendation
Sealed Pack: This keeps the electrode dry and in the original condition until opened. After the
pack is opened, the electrode shall be handled as per manufacturer recommendation
First Baking: the electrode baked first time (after first baking the electrode shall be put in the
holding oven, and can be issued for production and if not used can be re-backed 2 more
times)
Second Baking: the electrode baked second time (after second baking the electrode shall be
put in the holding oven, and can be issued for production, and if not used can be re-backed 1
more times)
G22-282-CST-PSL-100020_C0
Page 7 of 25
Third Baking: the electrode baked third time (after third baking the electrode can be put in the
holding oven, and issued for production, and if not used MUST BE SCRAPPED)
Baking Oven: an oven where the covered electrodes are inserted in order to eliminate the
moisture picked up for being exposed outside their own vacuum pack, or after being exposed
because the same vacuum pack is damaged. The baking time and temperature shall be in
accordance with the consumable manufacturer recommendation, (the temperature range is
from 150 °C to 450 °C)
Remark: an electrode can be baked max 3 times, at each baking time the electrode back tip
shall be color coded painted in order to have full traceability of how many baking sequence it
has passed through .
Holding Oven: an oven where the covered electrodes are inserted after being baked in the
baking oven. The temperature shall be in accordance with the consumable manufacturer
recommendation, the electrode can stay in holding oven as much time until next use, provided
the oven is maintained at the approved temperature, (the temperature range is from 100 °C to
150 °C)
Quiver: a portable oven which is heated by a resistance, it may contain small quantity of
electrode, (the temperature range is from 70 °C to 150 °C)
Left-Over Electrode: The electrode issued to the welder and that are not used, at the end of
the day are taken back to the Store to under go the control Process.
G22-282-CST-PSL-100020_C0
Page 9 of 25
5. EQUIPMENT
 Electrode Baking/Holding Oven with temp. range of up to 300 °C - 400 °C for baking
and 120 °C - 150 °C for Holding, provided with proper calibration certificate
 Electrode Holding Oven with temp. range of up to 120 °C - 150 °C, provided with
proper calibration certificate
 Electrode Quiver with Temp. Range of up to 70 °C - 150 °C, provided with proper
calibration certificate. Each quiver shall be assigned to a single welder, the welder
shall be responsible to check that the quiver is functioning properly. At the end of
each shift, the welder will take the quiver to the quiver store.
 Carbon Steel Electrode Store with proper shelter, controlled atmosphere, with
thermo-hygrometer installed provided with proper calibration certificate
5.1. Equipment Requirements
 Electrode baking/Holding Oven:

 To have the temperature range up to (300°C - 400 °C for Baking , 120°C – 150 °C
for Holding ).
 To have calibration sticker.
 To be provided with Calibration Certificate, be positioned in a dry place well
repaired from atmospheric conditions
 Electrode Quiver:
 The quiver shall have the temperature range 70 °C / 150 °C.
 To be calibrated.
 To have valid calibration sticker.
 To be stored (when not used inside a proper store, in dry condition).
 To be clean inside (from dust, damaged coating pieces, moist )
 Electrode Store:
 With proper shelter, controlled atmosphere.
 Inside temperature shall be between 20 °C and 28 °C.
 Inside Relative humidity shall not be above 60% (the Temp. and Humidity Condition
shall be Monitored and Recorded on Daily.)
G22-282-CST-PSL-100020_C0
Page 10 of 25
6. CONSUMABLE
6.1. Filler Metals
FILLER METAL MATRIX

AWS Filler Metal Welding Material
S/N AWS Class Remarks
Specification Size ( mm ) Process certificate
F No A No
A 5.1 E 6010 2,5 SMAW
A 5.1 E 6010 3,2 SMAW 4 1
A 5.1 E 6010 4,0 SMAW 4 1
A 5.1 E 7018 2,5 SMAW 4 1
A 5.1 E 7018 3,2 SMAW 4 1
A 5.1 E 7018 4,0 SMAW 4 1
6.2. Grinding and Cutting Disc
 Grinding and cutting disk shall be ordered detailing the use ( for CS or SS )
 Grinding and Cutting Disc shall be provided in original containers and in good
condition to conform to the use for carbon Steel
 Grinding and Cutting Disc shall be stored separately and properly
G22-282-CST-PSL-100020_C0
Page 11 of 25
7. INSTRUMENT
 Thermometer installed on each baking/holding oven, must be calibrated
8. FILLER METAL HANDLING SEQUENCE
8.1. Receiving / inspection / storage

 The material coordinator receives information from procurement that the material is
about to arrive
 The material coordinator advises the QC Supervisor
 The material coordinator advises the project manager to arrange proper
personnel/equipment to handle the material at arrival
 The QC supervisor provides the material P.O. (received copy from the material
coordinator), prepares all the forms ready to inspect the material , provides copy of
all specification required to inspect the material ( see the Filler material matrix ),
prepares the log to be updated, and advises the QC material inspector
 The material is inspected against the P.O. requirement: Brand/Brand
Name/size/AWS Spec/AWS Class/Quantity/Material Certificate Available/damage/
 The Material Inspector records all the information on the Receiving Inspection
Report of Welding Consumable and on the Welding Consumable Log
 The Material shall be rejected if not conforming to P.O. or if damaged, or if the
material certificate is not available (the material certificate must be in accordance to
EN 10204 type 3.1 for both Chemistry and Mechanical properties)
 The Accepted materials are stored in the Electrode store
 The material certificates are archived in a file, which shall be traceable from the
Welding Consumable Log.
 The electrode shall be stored separate, divide by class and by batch, so the use is
always done by batch.
8.2. Issue of consumable for production/returning un-used

consumable to the store.
 The welding supervisor/welding Foreman issues the Request for Welding
Consumable in accordance to the actual WPS (quantity shall be minimized in order
to minimize the quantity of electrode to re-bake to as low as possible), the request is
given to the welder
 The welder takes the Request to the store keeper
G22-282-CST-PSL-100020_C0
Page 12 of 25
 The store keeper issues the consumable to the welder

 The Store Keeper updates the Issued Welding Consumable Log
 The welder insert the electrode into the quiver (the quiver must be dry inside) see
also the instructions on how to insert the electrode inside the quiver
 The welder will use the electrode at the weld station, and if a quantity is left-over,
the same shall be returned to the Store keeper.
 The quiver is understood to be used just for SMAW electrodes
 If a Quantity is returned back, the store keeper, shall update the last section of the
Issued Welding Consumable Log.
 Every day the Material Coordinator/Store Keeper updates the consumable log, in
order to have a continuous status of the consumable quantity left in the store, he
inform the QC supervisor about the balance quantity at the store
 The issuance of electrode from the store shall be done by batch, when a batch is
finished , then another batch shall be issued
 The Batch first arrived shall be the one first issued ( so to have fresh material in the
store )
8.3. Baking of the electrode
 AS the SMAW electrodes are purchased in sealed metal can pack, it is necessary
to bake the electrodes at 350°C – 370°C for at least 4 hours. It is then held in the
holding oven at temperatures between 120°C and 150°C.
 When the welder returns back the left-over electrode quantity, the store keeper
verifies the Issued Consumable Log; verify the color code painted on the back tip
side.
 Based on the above the store keeper shall decide if re-baking the electrode or
scrapping is required : if the back tip is already painted RED the electrode is for
scrap (see the annex 3 for Baking color code, see Annex 4 for Baking /Holding
Sequence)
G22-282-CST-PSL-100020_C0
Page 13 of 25
Filler Metal Handling Matrix

Handling after opening the packages
AWS Unopene
AWS Type of
S/N Specific d Pack Baking Baking Quiver Quiver max Re-baking Re-baking Max Re- Holding
Class Packaging
ation storage Temp Time temp. Time Temp Time baking Temp.
(°C) (Hours) (°C) (Hours ) (°C) (Hours) time (°C)
1 A 5.1 E 6010 Sealed Can Filler Store N/A N/A N/A N/A N/A N/A N/A N/A
2 A 5.1 E 7018 Sealed Can Filler Store 350 – 370 4 70 – 150 8 350 – 370 1 3 90 – 150
Remarks: Color code for baked electrode shall be as follow

1) After first Bake = Green
2) After second Bake = Yellow
3) After third Bake = Red ( if not used after been issued it must be scraped or used for
other works different from OML 58 )
8.4. Ovens / Quivers Management

 The Welding Supervisor and Quality Supervisor are responsible for the Ovens and
Quiver management. ( Proper functioning, cleaning, drying, baking and holding )
 The QC Supervisor is responsible for the proper calibration.
G22-282-CST-PSL-100020_C0
Page 14 of 25
9. MATERIAL CERTIFCATES
 The material certificate shall be available for every batch of electrode supplied for
the project.
 Material certificates shall have batch test certificates
10. BAKE COLOR APPLICATION
 The proper color must be applied after the baking step has been completed
 The temperature of the Electrode must be down to 120 °C ( this will avoid the color
change because of the high temperature )
 The Color shall be applied on the rear tip of the electrode
 The Color shall be applied by the means of a round sponge
G22-282-CST-PSL-100020_C0
Page 15 of 25
11. ANNEX
1: Handling of electrode with Baking/ Holding Oven
2: Handling of electrode with Quiver
3: Baking Color Code
4: SMAW Electrode Handling Flow Chart
5: Electrode Store Temperature / Humidity Log
6: Receiving Inspection Report of Welding Consumable
7: Welding Consumable Log
8: Issued Welding Consumable Log
9: Request for Welding Consumable
G22-282-CST-PSL-100020_C0
Page 18 of 25
11.3. Annex 3: Baking Color Code
Side to apply the Color Code
NONE The electrode is new, taken directly from Sealed

Pack
GREEN The electrode has been baked 1 time
YELLOW The electrode has been baked 2 times
RED The electrode has been baked 3 times (if returned

to store, it must be scrapped)
G22-282-CST-PSL-100020_C0
COMPANY JOB UNIT
PLANT LOCATION REPORT No

QC CODE PROGRESS No
RC326229 PROJECT TITLE
PETRA SERVICES LIMITED ITP REF.
RECEIVING INSPECTION REPORT OF WELDING CONSUMABLE

TAG/ITEM CODE/SPECIFICATION
Page of
INSPECTION
Packing Type Dimension Quantity Mat. Cert. Mat.
P.O. Item NCR / Damage
S/N P.O. No Brand Brand Type AWS Class Lot / Batch No Available ( Mat. Cert. No Accepted Remarks
No Vacuum Sealed Carton Diam Length Report No
Pack Kg yes/no) (yes/no)
Pack Pack Pack (mm) (mm)
INSPECTION NOTIFICATION REFERENCE

NOTES:
RFI No
PREPARED BY: ISSUE DATE
QC SUBCONTRACTOR QC CO-ORD SUBCONTRACTOR QC SCNL COMPANY

NAME NAME NAME NAME
SIGNATURE SIGNATURE SIGNATURE SIGNATURE
Date Date Date Date
Form code : MDT.WL.CDQ.0137 Sh. 01 / Rev.00.07
"This document is the property of TEP NG / It must not be reproduced or transmitted to others without written authorization from the Company "
COMPANY Job No
PLANT LOCATION
RC326229
PROJECT TITLE
WELDING CONSUMABLE LOG
Consu Mat.Cert. Mat. Receiving

P.O. Item Lot / Batch Packing Kg Mat. Cert. Achived in NCR/Damage
S/N Date Imput P.O. No Brand Type mable AWS Class Size Kg Balance Available Accepted Inspection
No No Type Received No File No Report No
ID ( yes / No ) (Yes/No) Report No
COMPANY Job No
PLANT LOCATION
RC326229
PROJECT TITLE Location / Yard
ISSUED WELDING CONSUMABLE LOG
To be filled at Consumable Store at receiving

To Be Filled at Consumable Store at issue of Consumable to the Welder or to the Foreman Back of Consumable from Welder
To Go for Backing
Welder ID / Diam Returned
S/N Date Brand Type AWS Class Batch / Lot No KG New 1 Backing 2 Backing 3 Backing Remarks Sequence ( 1 or 2 or 3 ) / to
Foreman (mm) Quantity KG be Scrap
COMPANY
PLANT LOCATION Date:

RC326229
PETRA SERVICES LIMITED PROJECT TITLE
REQUEST of WELDING CONSUMABLE
To Be Filled by the WELD SUPERVISOR / WELD FOREMAN To be Filled By the Store keeper
Consumable
Supervisor / Issued :
Supervisor / Brand Consumable Diam. To be Given to Store Keeper
S/N Date Batch No
AWS Class KG Welder ID
Foreman New / 1backing KG
SIGNATURE
Foreman Type (mm) SIGNATURE / 2Backing/
3Backing
Remarks By Supervisor / Foreman :
Remarks By Store Keeper :

NG22 282 CST PSL 100020 - Revc0

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OML58 Upgrade Phase 1 Project

FROM : CPY ~~ Company Contract n° : TO : SPD ~ SAIPEM PONTICELLI DESICON

Name : Transmittal N° : TNO-CPY-SPD-000033 Attn :

Name & signature

There are 56 annotations following

PROCEDURE FOR MANAGEMENT OF WELDING

CONSUMEABLES FOR OBITE TC STORAGE TANK

Rev. Status Rev. Date Revision Memo Issued by Checked by Approved by

C0 IFR 10-July-2010 Issued for review O. IYO L. OBOH N. AZIKE

1. SCOPE AND PURPOSE..................................................................................................................................... 4

2. REFERENCE DOCUMENTS ............................................................................................................................ 5

8. FILLER METAL HANDLING SEQUENCE................................................................................................... 11

10. BAKE COLOR APPLICATION .................................................................................................................. 14

11. ANNEX ......................................................................................................................................................... 15

GS PVV 312 Welding of Low Pressure Metallic Storage Tanks GS

COMPANY: TOTAL E & P Nigeria Ltd.

CONTRACTOR: The Consortium of SAIPON snc, SCNL, PNL & DESICOM

APPROVAL: Authorization in Writing by the COMPANY to CONTRACTOR to proceed to use

WPS: Welding Procedure Specification

SMAW: Shielded Metal Arc Welding

GTAW: Gas Tungsten Arc Welding

FCAW: Flux Core Arc Welding (This to be approved by CPY)

5.1. Equipment Requirements

 Electrode baking/Holding Oven:

6.1. Filler Metals

FILLER METAL MATRIX

A 5.1 E 6010 2,5 SMAW

A 5.1 E 6010 3,2 SMAW 4 1

A 5.1 E 6010 4,0 SMAW 4 1

A 5.1 E 7018 2,5 SMAW 4 1

A 5.1 E 7018 3,2 SMAW 4 1

A 5.1 E 7018 4,0 SMAW 4 1

6.2. Grinding and Cutting Disc

 Thermometer installed on each baking/holding oven, must be calibrated

8. FILLER METAL HANDLING SEQUENCE

8.1. Receiving / inspection / storage

8.2. Issue of consumable for production/returning un-used

 The store keeper issues the consumable to the welder

8.3. Baking of the electrode

Filler Metal Handling Matrix

Remarks: Color code for baked electrode shall be as follow

8.4. Ovens / Quivers Management

 The QC Supervisor is responsible for the proper calibration.

10. BAKE COLOR APPLICATION

2: Handling of electrode with Quiver

3: Baking Color Code

4: SMAW Electrode Handling Flow Chart

5: Electrode Store Temperature / Humidity Log

6: Receiving Inspection Report of Welding Consumable

7: Welding Consumable Log

8: Issued Welding Consumable Log

9: Request for Welding Consumable

11.3. Annex 3: Baking Color Code

Side to apply the Color Code

NONE The electrode is new, taken directly from Sealed

GREEN The electrode has been baked 1 time

YELLOW The electrode has been baked 2 times

RED The electrode has been baked 3 times (if returned

PLANT LOCATION REPORT No

RECEIVING INSPECTION REPORT OF WELDING CONSUMABLE

INSPECTION NOTIFICATION REFERENCE

PREPARED BY: ISSUE DATE

QC SUBCONTRACTOR QC CO-ORD SUBCONTRACTOR QC SCNL COMPANY