QCP - Hot Tapping, Welding & Testing

0

1 August 2011

Rev

Date

Issued for Company Approval Description

CLIENT

VJ

SA

GM

Prepared

Checked

Approved

EPC CONTRACTOR

ABU DHABI GAS INDUSTRIES LTD. (GASCO)

CONSOLIDATED CONTRACTORS COMPANY (CCC)

PROJECT

HABSHAN FLARE GAS RECOVERY PROJECT GASCO AGREEMENT NO.13524502 TITLE

QUALITY CONTROL PROCEDURE HOT TAPPING,WELDING & TESTING Contractor Document Number: QCP-5245-07-***

DOCUMENT CLASS: 1 COMPANY DOCUMENT INFORMATION: Project No. 5245

Document Number

Sheet No.

Rev. No.

QCP- 5245-07- ***

1 OF 11

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

2 OF 12

INDEX 1.0

Scope

2.0

Purpose

3.0

References

4.0

Definitions

5.0

Responsibilities

6.0

Procedure

7.0

Attachments

Rev. No.

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

3 OF 12

1.0

Rev. No.

0

SCOPE The scope of this procedure is to describe the control of welding of piping and structural steel fabrication for Habshan Flare Gas Recovery Project.

2.0

PURPOSE To define the documentation and responsibilities for controlling the welding activity.

3.0

REFERENCES 3.1

CODES AND STANDARDS:

3.1.1

ASME Sect IX

:

Welding and Brazing Qualifications

3.1.2

ASME B31.3

:

Chemical Plant and Petroleum Refinery Piping

3.1.3

ASME Section II -Part C

:

Welding Rods , Electrodes and Filler Metals

3.1.4

ASME Section V

:

Non Destructive Examination

3.1.5

AWS D1.1

:

Structural Steel Welding

3.1.6

ASNT-TC-1A

:

Recommended Practice for Non destructive Testing Personnel Qualification and Certification

3.1.7

ASTM-A833

:

Indentation Hardness of Metallic Materials by Comparison Hardness Testers

3.1.8

ASTM -E10

:

Test Method for Brinell Hardness of Metallic Materials

3.1.9

ASTM -E 92

:

Test Method for Vickers Hardness of Metallic Materials

3.1.10

ASTM E 110

:

Standard test Method for Indentation hardness of Metallic materials by portable Hardness Testers.

3.1.11

ASTM E 140

:

Standard Hardness Conversion Tables for Metals.

3.1.12

AWS A2.4

:

Standard Symbols for Welding Brazing and Non Destructive Examination

3.1.13

AWS A 3. 0

:

Standard Welding Terms and Definitions

3.1.14

ANSI / AWS A 5. 01

:

Filler Metal Procurement Guidelines

PROJECT SPECIFICATIONS: 3.1.15 3.1.16 3.1.17 3.1.18 3.1.19

DGS-0000-002 and ADD-0000-001 DGS-6300-001 and ADD-6300-001 DGS-1883-001 and ADD-1883-001 DGS-1300-175 and ADD-1300-175 DGS-1884-001 and ADD-1884-001

:

Specification for Carbon Steel Piping and Equipment in sour wet H2S Service and its Addendum

:

Specification for Welding and NDE of Piping System and its Addendum

:

Specification for Structural Steel Fabrication and its Addendum

:

Specification for Galvanizing and its Addendum

:

Specification for Structural Steel Erection and its Addendum

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

4 OF 12

3.2

4.0

5.0

Rev. No.

QCP's:

3.2.1

QCP-5245-07-003

:

Welding Consumables Control

3.2.2

QCP-5245-07-004

:

Radiographic Inspection

3.2.3

QCP-5245-07-005

:

Magnetic particle Inspection

3.2.4

QCP-5245-07-006

:

Dye Penetrant Inspection

3.2.5

QCP-5245-07-007

:

Ultrasonic Inspection

3.2.6

QCP-5245-07-008

:

NDT Control

3.2.7

QCP-5245-07-018

:

Hardness Testing

DEFINITIONS: 4.1

WPS

:

Welding Procedure Specification

4.2

PQR

:

Procedure Qualification Record

4.3

WPQT

:

Welding Procedure Qualification Test

4.4

NDT

:

Non Destructive Testing

4.5

QCD

:

Quality Control Department

4.6

DWR

:

Daily Welding Report

4.7

WQT

:

Welder Qualification Test

4.8

QCI

:

Quality Control Inspector

4.9

COMPANY

:

Abu Dhabi Gas Industries, Ltd (GASCO)

4.10

CONTRACTOR

:

Consolidated Contractors Company(CCC)

RESPONSIBILITIES: 5.1

CONTRACTOR WELDING SUPERVISOR / FOREMAN 5.1.1

Ensure that all welding activities are controlled within the requirements of relevant WPS/QCP’s

5.1.2

Requisition of welding consumables & ensuring proper storage / handling/ baking of welding electrodes as required and as specified by manufacturer

5.1.3

Assign and supervise welders in his area.

5.1.4

Instruct welders with respect to welding procedures and consumable requirements.

5.1.5

Verify weld fit-up as per WPS, cleanliness etc.

5.1.6

Liaise with QCI to expedite required inspection and testing.

5.1.7

Follow up repair instructions to be done in a timely manner.

5.1.8

Ensure correct materials being fabricated as per isometric drawing

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

5 OF 12

5.1.9

Rev. No.

Mark the weld number and ISO number on the spool/pipe, using approved marking materials, according to the marked-up isometric drawing.

5.1.10 Mark the Heat No’s on isometrics of materials requiring traceability. 5.1.11 Ensure cleanliness of bevels and adjacent area. 5.1.12 Ensure weld spacing as per specification. 5.1.13 Monitor Welder Performance and repair level. 5.2

PROJECT QUALITY CONTROL MANAGER 5.2.1

5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

To ensure the preparation, compilation and review of construction quality control procedures / Inspection test plan for all disciplines review of sub-contractors’ quality construction procedures / ITP’s implementation / monitoring of ISO 9001 system on Habshan Flare Gas Recovery project construction area and review of PWPS / WPS Co-ordination with COMPANY representative for welding procedure qualification. Co-ordination with construction department for welding procedure qualification / welder qualification Review the performance of welders and feed back to CONTRACTOR construction manager & COMPANY. Maintaining welding register for procedure qualification / welder qualification & final dossier preparation Monitoring computer software operations for daily / weekly / completion of the project / like; pipe book, weld history sheet, and test packs

5.2.7

Review NDT / PWHT / Hydrostatic construction procedures & ITP’s

5.2.8

Control of incoming material inspection

5.2.9

Welder performance statistics

5.2.10 Co-ordination with third party laboratory for mechanical testing 5.2.11 Review CV’s & selection of QC personnel 5.2.12 Maintaining all quality documents 5.3

CONTRACTOR QC INSPECTOR (WELDING /MECHANICAL) 5.3.1 5.3.2

Witness Welding procedure Qualification & Testing & recording of parameters during welding procedure qualification. Witness welder performance qualification & testing and recording

5.3.3

Prepare PQR & Welder Qualification Records / Certificates & welder Identification cards

5.3.4

Inspect weld fit-up and completed weld.

5.3.6

Carry out inspection and tests as required by relevant ITP’s.

5.3.8

Carry out regular Reviews & Inspections of field/shop welding operations to ensure WPS parameters are followed.

5.3.9

Coordinate all site Sub-Contractor NDT activities for pipe work/ Structural Steel Fabrication & Ensure that all require NDT is completed as per the relevant specifications & QCP.

5.3.10 Review the NDT reports of Sub contractor 5.3.11 Coordinate with NDT sub contractor & CONTRACTOR Fabrication Foreman for Identifying weld repairs and completion of repairs and subsequent NDT required.

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

6 OF 12

Rev. No.

5.3.12 Monitor welder performance, repair rate etc, and ensure their compliance within the acceptable scope of relevant Project Specifications / Codes and Standards and COMPANY requirements. 5.3.13 Report to PQCM for any Nonconformance to Specifications / code / standard for action 5.3.14 Ensure maintenance of Traceability of Fabricated Piping spools/ assemblies and fabricated structures, using proper metallic tags / Permanent metal markers. 5.3.15 Prepare the Daily Welding Report (DWR) in the format FM-5245-07-0017, giving clearly ISO Dwg. reference No/ Spool No/ Joint No size etc. 5.3.16

Properly identify shop weld /field weld etc, as per sect 6.1.2.1 of this document in the daily welding reports (DWR)

5.3.17 Identify the post weld heat treatment requirements, segregate the spools/ weld joints requiring PWHT and prepare request for PWHT. 5.3.18 Follow the flow diagram (FM-5245-07-1062) and issue “Requisitions" in format FM-5245-1061 for all NDT/ PWHT of Piping. 6.0

PROCEDURE 6.1

REQUIREMENTS FOR WELDED FABRICATION 6.1.1

Fabrication Welding/Erection

The welding and fabrications will be based on the information provided by ASME B31.3, AWS D1.1, COMPANY Specification referred in section 3 of this document and the detailed Isometric engineering drawings. AWS welding consumables being used for this project shall be from the supplier approved for piping / structural welding for this project. Weld joint preparation shall be performed as per appropriate specifications/drawings and COMPANY approved WPS for this project. Selection of welding consumables shall be on the basis of metallurgical compatibility with the parent material, as well as project specifications. 6.1.2

Identification of Welds

In order to facilitate control of the various types of welds the following coding system shall be used throughout the controlling documentation as well as the Talisman Computerized Database System. The same code convention shall also be used in the Daily Welding Report form (Attachment 7.7) as appropriate. • First Character First character signifies whether the welding takes place in shop or 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

P = Pipe Support Weld

F = Fillet Weld

L = Longitudinal Weld (Jacketed Piping)

S = Socket Weld

C = Branch Connection

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

7 OF 12

Rev. No.

The following provides a comprehensive list of all possible Weld Type combinations: SB: FB: SF: FF: SS: FS: SO:

Shop Butt Weld Field Butt Weld Shop Fillet Weld Field Fillet Weld Shop Socket Weld Field Socket Weld Shop O-let Weld

FO: SP: FP: SC: FC: XXX: SL:

Field O-let Weld Shop Pipe Support Weld Field Pipe Support Weld Shop Branch Weld Field Branch Weld Dummy Weld Shop Longitudinal Weld Piping)

(Jacketed

6.1.3Welding Processes Acceptable Welding processes to be used for piping / structural welding are: • •

Shielded metal Arc Welding (SMAW) Gas Tungsten Arc Welding (GTAW)

6.1.4Welding Procedure Specification. CONTRACTOR Sr. QC Inspector (welding) will prepare welding procedure for different Project piping material, Test Qualify as per ASME sect. IX and as per sect.7/ sect11.2 of the project specification DGS-6300-001. The qualified welding procedure shall be reported in the format FM 5245-07-0011 and COMPANY approval shall be obtained. Pre-qualified welding procedures can be used provided that they are COMPANY approved for only general structural fabrication and Pipe supports except not directly welded to the pressure retaining pipes, which are classified under sour service. Welding procedure for pipe supports which are being welded directly to pipe work shall be qualified by the CONTRACTOR and approved by the COMPANY. For sour service all procedures require qualification. The welding procedures shall cover the entire scope of welding work as appropriate and shall be in place. 6.1.5

Welders-Welding Operators Qualification:

The welders/welding operators shall be qualified to ASME IX or AWS D1.1 and as per the specification requirement stated in section 3 of this document. No individual shall be allowed to weld (tack welding included) unless he is properly qualified. Welders can be qualified for one or more welding processes and material type as per the applicable WPS. General Structural & Pipe support welders, except for welders, welding of supports directly to the pressure retaining piping under sour service, shall be pre-qualified or qualified & approved by COMPANY prior to start the Production welding. Initially the welders/welding operators are identified according to their badge number. Once he is qualified, a welder number shall be assigned starting with PP/01. A Welder’s Qualification list showing the welder’s name, welder Identification No against the WPS qualified shall be maintained. The welders shall be provided with Laminated ID cards (Attachment 7.9) showing the Badge No, Welder No and WPS for which they are qualified with, material type, range etc. During work they must always carry these cards with them.

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

8 OF 12

6.1.6

Rev. No.

0

Weld Map:

Detailed Weld Map / WPS Register (Refer section 7.2 of Project Spec DGS-6300-001) shall be prepared and submitted by CONTRACTOR to COMPANY for the commencement of piping welding activities. 6.1.7 Welding Consumables Welding consumables shall be stored and treated as per manufacturer’s recommendations as well as project requirements and QCP-5245-07-003 Welding Consumable Control. The welding consumables used during manufacturing shall always comply, in specification and size, with the consumables specified in the relevant CONTRACTOR and COMPANY approved WPS. Welding Electrodes and filler wires shall conform to the requirements of the ASME Boiler and Pressure Vessel Code, Section II, Part C, and shall be purchased only from the authorized distributors. Each electrode box shall contain: 

6.1.8

Name of manufacturer 

Specification confirming to AWS class



Diameter



Batch No.



Quantity Fit-Up for Welding

The Fabrication Foreman will indicate the joint number beside the joint on two locations 180° apart. The QC Inspector will check the joint fit-up and materials are correct as per the relevant specification and drawing. After checking the weld fit-up and the joint number the QC Inspector will sign beside the joint and state that “Fit-Up OK”. Each electrode shall have the electrode class, stamped clearly, 2 inches from the bottom of the electrode. Shielding gasses shall be purchased from a reliable manufacturer, with certification stating the quantity of the gas. The shielding gas shall conform to the level of purity required as per the WPS. Shielding gases shall conform to the following specifications: Cleanliness of grooves- Area to be welded should be free from oil, rust, scale and other loose foreign materials at least 50 mm from the weld area to assure sound welds. All weld groove surfaces prior to welding shall be sandblasted internally and externally.

 To ensure post weld heat treatment is carried out if specified as per applicable welding procedure.

 The occurrence of unacceptable defects such as pin holes, blow holes, cracks etc. with respect to each weld layer.

 The removal of slag with respect to each other weld layer.  The condition of the penetration.

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

9 OF 12



Rev. No.

Proper identification of welder / welding operators and weld numbers. Welder’s code should be marked and placed on the side of weld work done.

Welding shall not be performed when the wind is strong enough to affect arc stability or shielding gas coverage. Wind shields or tents shall be required when the wind or blowing sand is sufficient to adversely affect weld quality. Welding shall not be done when surfaces are wet or damp or exposed to rain or snow or when the welder / welding operators are exposed to inclement conditions. Any wet or damp surfaces must be dried by heating and shall be warm to the hand before welding. Contamination from the environment such as windblown sand shall be prevented by the use of adequate shielding. All appropriate safety precautions shall be taken for each inspection method. 6.1.9

Welding/Cutting & Joint Preparation:

During welding, all the relevant welding information mentioned in the applicable WPS such as bevel tolerances, cleaning, preheating (if required), welding consumable type and size, electrical characteristics (amps, volts) welding speed, interpass temperature, welding size, welding sequence, as well as PWHT (if required) shall be followed by the qualified welder and his supervisor. Cleanliness shall be maintained during fabrication-repair welding as per good shop practice as well as requirements specified in Project Specification. Cutting of pipes shall be in accordance with sect 11.5.1 of Project Spec DGS-6300-001. Materials requiring preheating in welding shall be preheated at the same temperature prior to thermal cutting. Pre-heating requirements as per the WPS. Thermal cut surfaces / edges shall be mechanically ground by removing 2 mm metal to expose sound metal prior to welding Quality Control Inspector(s) on a surveillance basis shall also monitor the welding/cutting activity in addition to the welding supervisors and make sure that personnel comply with all project specific welding/cutting requirements. Welding inspection check and NDT release is per isometric basis. After welding the welder shall mark his Welder No. against the joints with an approved marker. 6.1.10 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 CONTRACTOR QC Inspector /welding or COMPANY representative. The wind velocity in the weld area for GTAW 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 heating and shall be hand warm before preheating and welding. 6.1.11 Welding Machines Welding Machines shall be in good working, reliable, condition and shall be maintained as per manufacturer's recommendations. Calibration of welding machines shall be as per Project Procedure, Inspection Measuring and Test Equipment. Calibration and maintenance records shall be kept in QC Department. 6.1.12 Marking of welder Identification: The Welding Foreman is to ensure that the welder identification number is marked (with approved marker) beside the weld joint. If more than one welder welded the joint then a clear identification should state each and every welder’s pass (i.e. Root, Hot Pass, Fill and Cap). 6.1.13 Daily Weld Report

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

10 OF 12

Rev. No.

Details of daily welding works for Piping Fabrication / Welding shall be reported on the Daily Welding Report (DWR) Form No. FM-5245-07-0017.The DWR for all welding activities will be completed by the responsible QCI. The details of structural fabrication welding shall be reported in format FM-5245-07-1431. 6.2

INSPECTION 6.2.1

Visual Inspection:

Welding Inspectors shall be qualified as per Project Specification. Their task consists of monitoring welding activities and verifying adherence of the work to the appropriate drawings and WPS in accordance with Project requirements. Welding progressive visual examination shall be performed by methods outlined in the project specification and in accordance with ASME B31.3 Para 341.4 as well as any additional requirements specified in project specification DGS-6300-001. For structural steel fabrication reference shall be made to sect 12. 3.9 to 12.3.13 and 12.3.19 of project spec DGS-1883-001 All Visual Inspection results shall be recorded in the DWR Format FM-5245-07-0017 (for Piping) and in Form FM- 5245-07-1431 for Structural Fabrication. 6.2.2

NDT

Upon completion of the welding, weldments shall be checked by NDT methods as specified in project spec (sect.3). The minimum extent of NDE shall be as per Appendix 3 of Project spec. DGS- 6300-001.NDT shall be performed by properly qualified technicians having minimum qualification ASNT Level II per discipline. These technicians shall follow NDT procedures, approved by CONTRACTOR and COMPANY and shall record the results. They shall carry out the examination to the frequency and acceptance-rejection criteria according to, ASME B31.3 and AWS D1.1 specification as well as the Project Specification DGS-6300-001 for Piping welding and section 12.3.14 to 12.3.18 of Project Specification DGS-1883-001 for structural steel fabrication. Control of NDT inspection shall be attained as per QCP-5245–07-008 for all the welding activities in this Project. All NDT requests shall be issued through Form FM – 5245-07-1061. Safety requirements as per Project specific Safety manual shall be strictly followed. 6.3

POST WELD HEAT TREATMENT (PWHT) When PWHT is required as per pertinent WPS and/ Appendix -1 of Project Specification DGS-6300-001. Welding Inspector shall identify whether a particular joint requires PWHT or not and record in the Daily Welding Report at the appropriate column as Y/ N.

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

11 OF 12

6.4

Rev. No.

REPAIRS Unacceptable weld discontinuities shall be completely removed by chipping, gouging, grinding, or other methods (suitable for the type of material being repaired) to clean, sound metal and the excavated area shall be examined by Magnetic Particle Inspection (preferred for ferrous materials) or Liquid Penetrant or suitable NDT method to assure complete removal of defects. Repairs to correct weld defects shall be made using the same WPS or other previously approved WPS by a qualified welder. The repaired areas shall be re-examined by same NDT method which the defect was originally detected. Two repair attempts will be allowed for Piping Welds, on any one defective area. No further attempts to repair shall be carried out without the authorization of the COMPANY.

7.0

ATTACHMENTS: 7.1

FM-5245-07-0011

:

Welding Procedure Specification sheet

7.2

FM-5245-07-0012

:

Procedure Qualification Record

7.3

FM-5245-07-0013

:

As Run Sheet

7.4

FM-5245-07-0014

:

Welding Procedure Qualification Register for Piping

7.5

FM-5245-07-0015

:

Welders Qualification List

7.6

FM-5245-07-0016

:

Welder Qualification Test Record

7.7

FM-5245-07-0017

:

Daily Welding Report

7.8

FM-5245-07-0018

:

Isometric Control sheet

7.9

N/A

:

Welder ID Card

7.10

FM-5245-07-1431

:

Structural Fabrication Including Pipe Supports Inspection Report

7.11

FM-5245-07-1061

:

NDT Request for Piping

7.12

Appendix 1 of DOC. DGS-6300-001 ( 1 sheet)

7.13

Appendix 3 of DOC. DGS-6300-001 ( 1 sheet)

NOTES:

1. While filling forms do not leave any blanks. If something is not applicable in the case denote as N/A.

2. Use of Blanco, TIpp-ex (Correction Pen) is forbidden

0

ABU DHABI GAS INDUSTRIES LTD.(GASCO) HABSHAN FLARE GAS RECOVERY PROJECT GASCO PROJECT no.5245 Quality Control Procedure Welding Control for Piping & Structural Issued Date

Project No.

Document Number

Sheet. No.

1 August 2011

5245

QCP- 5245-07-***

12 OF 12

Rev. No.

0