OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 1 OF 9
001
PETRODAR OPERATING COMPANY
WELDER/WELDER OPERATOR
PROCEDURE
CONTRACT NO.: PDOC/31/03-123A
B RE-ISSUE FOR APPROVAL 21.09.2004 SM AA
A ISSUED FOR APPROVAL 24.08.2004 SM AA
PREPARED APPROVE PDOC
REV DESCRIPTION DATE BY DBY REVIEW
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 2 OF 9
001
TABLE OF CONTENTS
1.0 PURPOSE...............................................................................................................................................3
2.0 REFERENCES.......................................................................................................................................3
3.0 SCOPE....................................................................................................................................................3
4.0 DEFINITION.........................................................................................................................................3
5.0 PROCEDURE........................................................................................................................................3
6.0 SPECIAL REQUIREMENTS..............................................................................................................8
7.0 RECORDS..............................................................................................................................................8
8.0 APPENDICES.........................................................................................................................................8
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 3 OF 9
001
1.0 PURPOSE
To provide guidelines for conducting welder/welder operator qualification test to verify their
capability to deposit welds at acceptable quality.
2.0 REFERENCES
PDOC-SP-PIP-005 - Specification for Pipe Welding
PDOC-SP-PPL-009 - Specification for Pipeline Welding
ASME SECTION IX - Welding & Brazing Qualification
API 1104 - Welding of Pipeline and Related facilities
AWS D1.1 - Structural Welding Codes - Steel
3.0 SCOPE
This procedure covers the qualification of welders to be engaged in the welding of process
pipe, pipeline, equipment and structural works. This shall be conducted based on the
approved welding procedure specification.
4.0 DEFINITION
WPS - Welding Procedure Specification
WQT - Welders Qualification Test
RP - Ranhill Petroneeds
OWNER - Petrodar Operating Company Ltd. and it’s Representatives
NDT - Non-Destructive Test
5.0 PROCEDURE
Welder qualification shall be classified in two categories:
a. Pre-qualified welders.
b. Welders for qualification.
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 4 OF 9
001
5.1 PRE-QUALIFIED WELDERS
5.1.1 The proposed pre-qualified welders welding operators shall meet the following
minimum criteria:
[Link] Pre-qualified welders shall have valid welders qualification test records
from their previous work conducted by RP our RP’s sub-contractor.
[Link] All test records including their previous performance record shall be
submitted to OWNER for review and approval.
[Link] The welder shall have performed similar welding process within the last
six (6) months for structural and three (3) months for piping, pipeline and
equipment.
[Link] Both item [Link] and [Link] are subject to production test and approved
by Owners.
5.2 WELDERS FOR QUALIFICATION
5.2.1 Preparation
[Link] RP is responsible to organize the Welder Qualification Test for non-
qualified welders.
[Link] Welder's qualification test schedule shall be prepared and submitted to
the Owner for review.
[Link] RP shall submit the welder names inclusive of Identification Certificate
(IC) or passport number in the request report.
[Link] RP shall ensure proper supervision and inspection during testing. WQT
shall be limited to 5 welders (conducted simultaneously) per inspector at
any one time.
[Link] RP shall provide sufficient training to all welders prior to the WQT.
[Link] Owner shall be notified 24 hours before the test by using the Inspection
Request Form (IRF) as per Appendix I
5.2.2 Tools and Equipment
[Link] Calibrated Voltmeter and Ammeter (Clamp Meter)
[Link] Tempilstick/Calibrated Digital Thermometer
[Link] Flash Light
[Link] Inspection Mirror
[Link] Welding Gauge
[Link] Taper Gauge
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 5 OF 9
001
[Link] Measuring Tape
[Link] Steel Ruler
5.2.3 Prior to commencement of WQT
[Link] RP’s inspector shall brief the welders the following:
[Link].1 Owner and RP’s requirements for WQT including safety and
quality.
[Link].2 Welding parameters as per approved WPS and performed in
simulated production conditions.
[Link].3 Pre, During and Post Welding Requirements
[Link] RP shall perform and verify the following:
[Link].1 A welding test detail of the approved WPS shall be displayed
during the test booth for welder's reference.
[Link].2 The correct test material, joint detail (fit-up and test position)
including consumable size to be used for the WQT.
[Link].3 The welding machines including auxiliary equipment and
electrode quiver are in good working condition and with included
calibration and safety tag.
[Link].4 Ensure the current, voltage, polarity and other welding
parameters specified in the WPS are followed.
[Link].5 Safety provisions shall be made available at the test site. The
test site shall be protected from draught and adequate lighting
shall be provided.
[Link].6 Ventilation for welding fumes and smoke is adequate.
[Link].7 Welders are using appropriate personnel protective equipment
like eye/face shield for welding, grinding or chipping.
[Link].8 Welding ground cables shall be firmly attached to the work
bench or stand.
[Link].9 Prepare the welder qualification test report (Appendix II). The
report shall be filled and signed by the RP and OWNER
Representative upon completion of the test.
5.2.4 Commencement of WQT
[Link] The test piece shall be clean and pre-heated (if applicable) to remove oil,
dust and moisture and commence welding only upon approval from
OWNER’s Representative.
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 6 OF 9
001
[Link] Duration of test for welders will depends on the test coupon length and
thickness.
[Link] Welders will be stopped and considers failed if not meeting the
requirement of travel speed range of the WPS, however the welder shall
be allowed a reasonable time to adjust the welding equipment and
cleaning/grinding of weldments.
[Link] The following shall be verified during welding:
[Link].1 Correct welding current/voltage.
[Link].2 Travel speed.
[Link].3 Inter-pass temperature.
[Link].4 Direction of travel progression for vertical welds.
[Link].5 Ensure correct welding consumable for each layer of weld being
deposited, shielding gas being used at specified flow rate,
welding wire 'stick out', cup size etc. if applicable.
[Link].6 Use of correct techniques in depositing weld, i.e. string, weave
and split layer.
[Link] No personnel shall be allowed at the test booth except the welder to be
qualified, OWNER and the RP Representative.
[Link] The test may be terminated at any stage, whenever it becomes apparent
to the welding inspector that the welder does not have the required skill to
produce satisfactory result.
5.2.5 Inspection and Test
[Link] Visual inspection of the root pass shall be conducted before depositing
the succeeding passes. Failure on visual inspection at the root warrants
an outright rejection.
[Link] After completion of welding, the visual inspection shall be conducted to
determined the following:
[Link].1 Weld Size.
[Link].2 Weld profile (height of reinforcement).
[Link].3 Convexity/concavity of sufficient throat for fillets.
[Link].4 Undercut (internal/external for tubular).
[Link].5 Surface pinholes, craters, crater cracks.
[Link].6 Root penetration.
[Link].7 Start/stop area defects.
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 7 OF 9
001
[Link].8 Arc strike outside the welding groove.
[Link] Damage due to incorrect removal of temporary attachments.
[Link] The visual acceptance criteria of the completed test piece shall meet the
‘minimum’ requirements of OWNER’s specification and the relevant
Codes and Standard (ASME IX, AWS D1.1, API 1104, etc).
[Link] The visual accepted test piece shall be subjected to the following
inspection and tests:
[Link].1 100% Radiographic Testing.
[Link].2 100% Ultrasonic Testing (For 6GR structural welder as per AWS
D1.1).
[Link].3 Bend Test and Nick Break Test (where applicable).
[Link] The NDT and Destructive Test acceptance criteria for WQT shall be in
accordance with OWNER’s specification and international Codes and
Standard (AWS D1.1, ASME IX/ANSI B31.3, API 1104, etc) whichever is
applicable.
[Link] The NDT result shall be verified by OWNER’s representative prior to
bend/tensile test.
[Link] RP shall proceed in preparing and illustrating the locations and
dimensions of the test specimens to be removed from the test piece for
the required bend test. Removal of test specimens shall be as per AWS
D1.1 or ASME IX or other codes whichever is applicable.
[Link] The bend test shall be witnessed by the RP and OWNER’s
Representative.
[Link] The test results shall be recorded in the Welder’s Qualification Test
Record (Appendix III) and submitted together with the welder's
photograph for OWNER’s review and approval.
5.2.6 Retest
[Link] The welder or test piece which does not comply to either requirements of
the governing WPS, visual inspection, NDT or bend test shall be
considered failed.
[Link] At the discretion of OWNER’s Representative, immediate retest may be
allowed by carrying out two (2) new test coupons for the position and type
which he has failed.
[Link] Subsequent retest shall only be considered upon completion of adequate
training.
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 8 OF 9
001
5.3 IDENTIFICATION SYSTEMS
The welder identification system is intended to identify the welder’s qualification and
limitations when they are assigned to perform production welding.
5.3.1 The system established shall include a numbering and identification card index
agreed by Owner. Welders number assigned to the qualified welders shall be
unique and ascending running number e.g. 001, 002, 003, etc. with ‘NO’
duplication of welder's number.
5.3.2 Welder shall be identifiable by identification card as shown in Appendix lV.
5.3.3 Welder identification number should ‘NOT’ be transferred or used by another
welder employed on the project.
5.3.4 Welders shall wear their badges at all time while performing their duties or
otherwise shall be warned and reprimanded. Repetition of such acts shall result
in the disqualification of the welder.
5.4 PERIOD OF EFFECTIVENESS
5.4.1 The welder's qualification is considered valid when the acceptable welder's
performance is documented by the NDT results during the project.
5.4.2 Re-qualification test is required when the welder does not use the appropriate
welding process of which the welder is qualified for a period exceeding 6 months
(structural) or 3 months (piping), or when there are reasons to question the
welder’s ability or performance during production welding
6.0 SPECIAL REQUIREMENTS
6.1 Welder's performance record shall be kept up-to-date in order to maintain the validity of
the record. (Appendix V).
6.2 A welder or welding operator shall required to re-qualify if the accumulative length of
repair weld over a period of one (1) month exceeds 5% of the total weld length deposited
i.e. linear repair rate.
6.3 RP shall ensure that only qualified welders are employed during fabrication.
7.0 RECORDS
OWNER : PMC : EPC CONTRACTOR :
MELUT BASIN OIL CONSULTANT:
DEVELOPMENT
PROJECT
DOCUMENT NO: PDOC-123A(COM)-PR-QC- REV. : B PAGE 9 OF 9
001
7.1 Records shall be kept by the QA/QC Engineer and made available to the authorized
personnel for verification and reference.
8.0 APPENDICES
APPENDIX I - Inspection Request Form
APPENDIX II - Welder and Welding Operator Qualification Test Report
APPENDIX III - Welder and Welding Operator Qualification Test Record
APPENDIX IV - Welder and Welding Operator Identification Pass
APPENDIX V - Welder and Welding Operator Performance Record.
