GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
DOCUMENT TITLE: WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) DOCUMENT NO.: PR-W-1102.21-4012-004 REVISION: A REVIEW STAMP COMMENTS E. Work may proceed. F. Work may proceed. Submit for Construction Documents. G. Revise and Resubmit. Work may proceed Subject to incorporation of changes indicated. H. Revise and Resubmit. Work may not proceed. I. Review not required. Work may proceed. Acceptance in any of these categories shall be in no way relieve the Contractor/Supplier of its responsibility for the due and proper performance of the Work in accordance with the Contract/Purchase Order. Name: Sign: Date:
A 25/03/13 Issued for Approval WS JR NP Rev. Date Description Prepared By Checked By Approved By CONTRACTOR: SIAM RAJATHANEE JOINT VENTURE CONSULTANT: UNITY ENGINEERING AND CONSULTANCY SERVICES CO.,LTD.
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 2 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
DOCUMENT CHANGE RECORD
Rev Date Prepared/ Revised By Reviewed By Approved By Description A 25/03/13 WS JR NP Issued for Approval
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 3 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 4 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
1. PURPOSE
This Procedure is for the Welding of Gas Pipeline and Gas Metering and Regulating Station Project. The Material of Pipe used is under standard of ASTM A36, ASTM A53 for Structural Steel. The applied Welding Procedure are SMAW for Steel Structure in accordance with AWS D1.1
2. SCOPE For Steel Structure welding SMAW process (manual) can be selected. The Steel Structure welders shall be qualified based on the approved Welding Procedures Specifications and Procedure Qualification Records. 3. DEFINITION
Owner means Ratchaburi World Cogeneration Company Limited. Advisor means PTT Public Company Limited. Project means Gas Pipeline and Gas Metering and Regulating Station Project. Consultant means Unity Engineering and Consultancy Services Co., Ltd Contractor means Siam Rajathanee Joint Venture Co., Ltd. HSS&E means Health, Safety, Security and Environment JSEA means Job Safety and Environment Analysis WPS means Welding Procedure Specification WPQ means Welder Performance Qualification PQR means Procedure Qualification Record WPR means Welding Procedure Record PCN means Personnel Certification for NDT. CSWIP means Certification Scheme for Welding Inspection Personnel ASNT means American Society of Non Destructive Testing AWS means American Welding Society QA means Quality Assurance QC means Quality Control NDT means Non Destructive Testing PT means Penetrant Test RT means Radiographic Testing QC Manager means Quality Control Manager Welding Supervisor means Controls and Coordinates all of the site welding activities Welding Forman means Controls the specific day to day welding activities for one or more welding location Welding Inspector means Inspects the activities related to welding Quality Control Engineer means Writes, Runs and approves the welding procedures and WPS for the Contractor Subcontractor means The party to which Contractor has sub-contracted a portion of the Work under the Contract
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 5 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
4. RESPONSIBILITY 4.1 Quality Control Manager The QC Manager shall report to the Project Manager, and his duties include, but are not limited to: Implementation of the Contractors Quality Specifications and Procedures relevant to pipeline inspections. Complete inspection, witness monitoring verification activities in accordance with the Contractors Inspection and Test Plan and Procedures. Ensure inspection personnel are issued with approved Procedures and adequate inspection equipment Review and complete (where applicable) all required documentation and obtain all necessary approvals and signatures. Review destructive and non-destructive examination reports including interpretation of weld radiographs. Prepare all Quality Control documentation, i.e. Procedure Qualifications for Welding, NDT and Coating etc. for acceptance. Prepare all pre-construction documentation with respect to Control of Welding, NDT and Coating. Liaise with the Owner/Consultant Inspectors during pipeline fabrication and installation to resolve any Quality related problems. Co-ordinate Welding, NDT Coating and Installation Inspection personnel, including: Welding Inspectors Erection QC Inspectors 4.2 Welding Supervisor The Welding Supervisor shall report to the Construction Manager, and his duties include, but are not limited to: Coordinating welding activities Ensure that the welding foreman is fully conversant with the welding techniques and procedures. Ensures that the welding consumables are available and complied with approved Procedure Qualification Records. Liaise with the Contractors Welding Inspector on a daily basis to resolve any related problems. Ensure non-destructive examination requests are progressed. 4.3 Welding Foreman The Welding Foreman shall report to the Welding Supervisor, and his duties include, but are not limited to: Ensure welding plant equipment is maintained in good order.
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 6 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
Implementing the approved weld procedures; supervise all welding personnel and ensure their competence. Ensure that all welders are approved for the welds they have to perform. Ensure that all welders are issued with the correct consumables and equipment, and are familiar with, and understand, all welding parameters. Ensure that welding is carried out under the correct conditions and suitable weather protection is available. Liaise with the Contractors Welding Inspector on a daily basis to resolve any related problems. Ensure non-destructive examination requests are progressed. Ensure the WSP parameters I.E. voltage, travel speed, current are correct
4.4 Welding Inspector The QC Inspector / welding inspector reports to the QC Manager and is shall be responsible to ensure all inspection and testing activities are conducted, reported and recorded in accordance with the relevant procedures.
4.5 Quality Control Engineer The Quality Engineer shall be responsible for assisting Quality Control Manager to prepare the proposed WPS, running the procedure qualification tests, arranging and witnessing the mechanical testing, preparing the weld procedure qualification records and final WPS.
5. RECORDING WELDING PARAMETERS DURING WPQR
The procedure to be employed for recording welding parameters and calculating heat input shall be as follows: One recorder shall record each half of a weld joint Amperage and voltage shall be set within the range specified in the WPS Travel speed shall be measured by a stop watch using the stop / start method i.e. the stop watch shall be started at the start of an arc and shall stop whenever the arc is broken. As soon as the welder restarts welding the stop watch shall also restart. The total time recorded shall be reflective of actual arc time The voltage and amperage readings taken shall be averaged out The travel speed and heat input shall be calculated
The welding supervisor shall give guidance to the welders in his team based on the information generated during monitoring and recording. The method for management and control of travel speed and hence heat input is further illustrated below (See figure 1)
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 7 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
5. QUALIFICATION OF WELDING
Preparation and welding of test pieces are to be carried out in accordance with the WPS and under the general condition of production welding which it represents.
Welding of the test assemblies and testing of test specimens are to be witness by third party
If tack welds and/or starts and stops points are conditions of the weld process they are to be fused into the joint and are to be included in the test assemblies.
Butt weld Assembly of test pieces The test assembly is to be of a size sufficient to ensure a reasonable heat distribution and according with the minimum dimensions: Plate - Width = 3xt, min 150 mm. - Length = 6xt, min 350mm. - Position 3G+4G Pipe - OD. = 2 in, Thickness 3.91 mm. - OD. = 6 in, Thickness 9.53 mm. - Position 6G
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 8 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
Examination and tests Test assemblies are to be examined non-destructively - Visual testing 100% - Radiographic 100% 7. WELDING CONSUMABLE CONTROL Welding consumables (electrodes), shall be controlled by the following measures : Centralized controlled dry storage area Issuance of electrodes shall be controlled by the welding supervisor, and the minimum amount of electrodes, shall be in use at all times Electrode containers shall only be opened sufficiently to extract electrodes and to prevent as far as practical the ingress of water and contaminants Electrodes shall be kept dry and clean at all times during use Open, partially used electrode containers shall be returned to the central store every evening Electrodes that become contaminated, shall not be used and shall be removed and discarded 8. WELDER IDENTIFICATION Welders shall be identified by issuance of identification cards stating: Welders name, photograph and signature Welder I/D no. Welding procedures and positions qualified Date of WQT Card issue number All welder I/D cards shall be approved, and signed by welding supervisor, reviewed and initialed by QA / QC manager prior to issuance to the welders. The I/D cards shall be controlled by issue number and shall be traceable to the register of steel structure welders. Recommended pass sequence Refer to PR-W-1102.21-4012-002 - Welding Procedure Specification For Steel Structure (WPS). 13. ACCEPTANCE CRITERIA
All welds shall be subject to 100% visual and Radiographic Test in accordance with AWS D1.1. Any welder whose welds have passed visual and Radiographic Test will be certified as qualified welder.
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 9 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
14. RANGE QUALIFIED Position
AWS D1.1 Table 4.9 Welder Qualification Production Welding Positions Qualified by Plate, Pipe and Box Tube Tests (See 4.18.1.1)
Qualification Test Production Plate Welding Qualified Weld Type Positions 1 Groove CJP Groove PJP Fillet PLATE Groove2 1G 2G 3G 4G 3G+4G F F, H F, H, V F, OH All F F, H F, H, V F, OH All F F, H F, H, V F, H, OH All (Note 8) TUBULAR Groove2 (Pipe or Box) 1G Rotated 2G 5G 6G 2G + 5G (Note 9) F F, H F, V, OH All All
F F, H F, V, OH All All
F F, H F, V, OH All All (Note 8) 6GR (Fig. 4.27) All All All (Note 8) 6GR (Fig. 4.27 & 4.28) All All All (Note 8)
Notes (notes shown at the bottom of a column box apply to all entries): 1. 6ee digures e.., e.e, e.r and e.S 2. Groove weld qualification shall also qualify plug and slot welds for the test positions indicated. 3. Only qualified for pipe over 24 in. [600 mm] in diameter with backing, back gouging, or both. 4. Not qualified for joints welded from one side without backing, or welded from two sides without back gouging. 5. Not qualified for welds having groove angles less than 30 (see 4.12.4.2) 6. Qualification using box tubing (Figure 4.27) also qualifies welding pipe over 24 in [600 mm] in diameter. 7. Pipe or box tubing is required for the 6GR qualification (Figure 4.27). If box tubing is used per Figure 4.27, the macro etch test may be performed on the corners of the test specimen (similar to Figure 4.28) 8. See 4.25 and 4.28 for dihedral angle restrictions for plate joints and tubular T-, Y-, K- connections. 9. Qualification for welding production joints without backing or back gouging shall require using the Figure 4.24 joint detail. dor oelding production joints
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 10 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
Thickness and Diameter
AWS D1.1 Table 4.10 Welder and Welding Operator Qualification Number and Type of Specimens and Range of Thickness and Diameter Qualified (Dimensions in Inches)(see 4.18.2.1)
(1) Test on Plate Qualified Dimensions Production Groove or Plug Welds Nominal Plate, Pipe or Tube Thickness Qualified, in. Type of Test Weld (Applicable Figures) Nominal Thickness of Test Plate (T) in. Min Max Groove (Fig. 4.30 or 4.31) 3/8 1/8 3/4 max 4
Groove (Fig. 4.21, 4.22 or 4.29) 3/8<T<1 1/8 2T max 4
Groove (Fig. 4.21, 4.22 or 4.29) 1 or Over 1/8 Unlimited 4
Note:
1. All welds shall be visually inspected (see 4.30.1). One test pipe, plate or tubing shall be required for each position tested, unless otherwise note. 2. Radiographic examination of the test plate, pipe or tubing may be made in lieu of the bend tests (see 4.19.1.1) 3. For 3/8 in. plate or wall thickness, a side-bend test may be substituted for each of the required face- and root- bend tests. 4. Also qualifies for welding any fillet or PJP weld size on any thickness of plate, pipe or tubing. (2) Tests on Pope or Tubing 6
Nominal Pipe or Tube Size Qualified, in. Nominal Plate, Pipe or Tube Wall Thickness 4 Qualified, in. Production CJP Groove Butt Joints Type of Test Weld Nominal Size of Test Pipe, in. Nominal Test Thickness, in. Min Max Min Max Groove 4 Unlimited 3/4 4 1/8 3/4 Groove > 4 3/8 (Note 5) Unlimited 1/8 3/4 Groove > 4 > 3/8 (Note 5) Unlimited 3/16 Unlimited Production T-, Y-, or K-Connection CJP Groove Welds Nominal Pipe or Tube Size Qualified, in. Nominal Wall or Plate Thickness 3
Qualified, in. Type of Test Weld Nominal Size of Test Pipe, in. Nominal Test Thickness, in. Min Max Min Max Pipe Groove 6 O.D. 1/2 4 Unlimited 3/16 Unlimited
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 11 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
5. The minimum pipe size qualified shall be the test diameter or 4in., whichever is greater. 6. See Table 4.9 for appropriate groove details. 7. Two plates required, each subject to the test specimen requirements described. One plate shall be welded in the 3F position and the other in the 4F position. 8. For dihedral angles < 30, see 4.26.1.
Tack Welders (1) To a process not qualified (GMAW-S is considered a separate process X X X (2) To an SMAW electrode with an F-number (see Table 4.12) higher than the WPQR electrode F-number X X (3) To a position not qualified X X X (4) To a diameter or thickness not qualified X X (5) To a vertical welding progression not qualified (uphill or downhill) X (6) The omission of backing (if used in the WPQR test) X X (7) To multiple electrodes (if a single electrode was used in the WPQR test but not vice versa X 1
General Notes: An x indicates applicability for the welding for the welding personnel; a shaded area indicates nonapplicability. WPQR = Welding Performance Qualification Record. See Table 4.9 for positions qualified by welder WPQR
Note: 1. Not for ESW or EGW. 2. Welders qualified for SAW, GMAW, FCAW or GTAW shall be considered as qualified welding operators in the same process(es) and subject to the welder essential variable limitations. 3. A groove weld qualifies a slot weld for the WPQR position and the thickness ranges as shown in Table 4.10.
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 12 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
15. REFERENCE DOCUMENT(S) ASTM A36 - Standard Specification for Carbon Structural Steel ASTM A35 - Specification for Pipe, Steel, Black and Hot-Dipped Zinc Coated Welding and Seamless Pipe AWS D1.1 - Structural Welding Code SP-S-1102.21-010-001 - Specification for Line Pipe SP-S-1102.21-010-002 - Standard for Welding of Pipelines and Related Facilities PL-A-1102.21-4012-002 - Project Execution Plan PR-W-1102.21-4012-002 - Welding Procedure Specification For Steel Structure (WPS)
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 13 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
ATTACHMENT 1 VISUAL INSPECTION REPORT
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 14 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 15 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
ATTACHMENT 2 WELDER IDENTITY
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 16 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 17 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))
\
ATTACHMENT 3 WELDERS QUALIFICATION REGISTER
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT) GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT Document No. PR-W-1102.21-4012-004 Rev. A Page 18 of 18
PR-W-1102.21-4012-004 Rev.A (WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))