Welding Consumable Control Procedure 3380 Saip 4 2.1 6072_2.(01.01).2863

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GLNG GAS TRANSMISSION PIPELINE

Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

WELDING CONSUMABLE CONTROL PROCEDURE

2

Approved for Construction (AFC)

N. Santos

L. Roselli

V. Renzoni

01/05/2013

1

Approved for Construction (AFC)

N. Santos

L. Roselli

V. Renzoni

23/02/2013

0

Approved for Construction (AFC)

Pellegrini

Roselli

Rapiti

26/09/2012

B

Issued For Review (IFR)

Pellegrini

Roselli

Rapiti

26/08/2012

A

Issued For Review (IFR)

Pellegrini

Roselli

Rapiti

10/07/2012

Revision

Reason for Issue

Prepared

Checked

Approved

Date

This document contains confidential information and is not to be disclosed to any third parties without prior written permission from the CEO GLNG Operations Pty. Ltd.

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

This document contains confidential information and is not to be disclosed to any third parties without prior written permission from Saipem Australia Pty Ltd.

COMPANY REVIEW CODE Code

Description

1

No comment. Proceed to AFC.

2

Revise as noted and re-submit.

3

Revise as directed and re-submit. Works may NOT proceed.

4

Information Only. Re-submission not required.

5

Approved for Construction (AFC)

Signed:

Tick

Dated:

Contractor remains responsible for the due and proper performance in accordance with the Contract. Comments do not limit or relieve Contractor of any obligation or liability under the Contract or give rise to any claim.

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

CONTENTS 1 

2 

GENERAL

5 

1.1 

Project Overview

5 

1.2 

Purpose

6 

1.3 

Scope

6 

REFERENCE DOCUMENTS

6 

2.1 

Standards

6 

2.2 

Company Documents

6 

2.3 

Contractor Documents

6 

3 

TERMS, DEFINITIONS AND ABBREVIATIONS

7 

4 

ROLES AND RESPONSIBILITIES

8 

4.1 

Welding Engineer

8 

4.2 

Welding Supervisor

9 

4.3 

QC Inspector

9 

4.4 

Material Controller/Store Keeper

9 

4.5 

Welders

5 

WORK PROCESS 5.1 

10 

Selection Identification and Traceability of Consumables

10 

5.2 

Purchase of Consumables

10 

5.3 

Receipt of Consumables

11 

5.4 

Storage of Welding Consumables.

11 

5.5 

Welding Consumable Issue Control

12 

5.6 

Storage Oven General Requirements

14 

5.7 

Segregation of Non-Conforming/Uncertified Consumables

14 

Baking Procedure

14 

5.8  6 

10 

APPENDIX

16 

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

6.1  

Appendix A. Approved Consumable Batch Numbers Register

16 

6.2  

Appendix B. Consumable Issue Control Register

16 

6.3  

Appendix C. Electrode Baking Log

17 

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Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

1

GENERAL

1.1

Project Overview GLNG Operations Pty Ltd is planning the development of a liquefied natural gas (LNG) processing facility on Curtis Island near Gladstone. A gas transmission pipeline (GTP) called the GLNG Pipeline of approximately 420km length will transport coal seam gas (CSG) to the LNG plant from existing and future fields in the Roma, Fairview and Arcadia Valley area (see Figure 1). A Fibre Optic Cable (FOC) will be laid in the same trench as the GTP. The FOC will be connected to a dedicated Pipeline SCADA monitoring system. The Scope of Work (SoW) includes all buried and surface facility requirements for the mainline pipeline including a HDD/micro-tunnelled pipeline crossing from the mainland to Curtis Island (beneath the marine crossing near the “Narrows”). Approximately 85 kilometres of the onshore pipeline are constrained within the Callide Infrastructure Corridor (CIC) State Development Area (SDA) which is subject to coordination and access limitations imposed by the shared use of this corridor with existing and new pipelines being built by other LNG proponents. The Company is planning a large scale development to extract CSG from existing and future fields in the Roma, Fairview and Arcadia Valley area (Upstream) and to supply that gas for commercial sale and/or conversion to LNG.

Fig. 1 – Project area

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

1.2

Purpose The purpose of this procedure is to detail the welding consumable controls required as the type and condition of welding consumables can seriously affect the integrity of welded joint. Incorrect selection or deterioration may result in joint failure with severe consequences. All welding consumables shall be stored and conditioned in accordance with this procedure. Special care and attention is required for hydrogen controlled electrodes.

1.3

Scope The scope of this procedure covers selection, purchasing , receiving, identification, storage, handling, request and issuing of consumables to site for all welding works on the GLNG Gas Transmission Pipeline Program.

2

REFERENCE DOCUMENTS

2.1

Standards     

2.2

American Petroleum Institute (API) 5L Specification for Line Pipe AS 2885.1 Pipelines – Gas and Liquid Petroleum (Part 1: Design and Control) AS 2885.2 Pipelines – Gas and Liquid Petroleum (Part 2: Welding) AS 1553.1 Covered Electrodes for Welding Low Carbon Steel AS 2717.1 Gas Metal Arc Welding of Ferritic Steel Electrodes

Company Documents  Pipeline EPC Contract No. 897315  3380-GHD-3-3 3-0260 Scope of Work for GLNG Pipeline  Schedule 21 – QA/QC Requirements

2.3

Contractor Documents  3380-SAIP-4-3.3-6014  3380-SAIP-4-2.1-6017   3381-SAIP-4-3.3-5051  3381-SAIP-4-3.3-5041  3380-SAIP-4-1.2-1884

CAD Welding Procedure Pipeline Welding Procedure Project Specification for Pipeline Welding and NDE Piping Installation – Welding Procedures Qualification Program Material Handling and Storage Procedures

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

3

TERMS, DEFINITIONS AND ABBREVIATIONS Company

GLNG Operations Pty Ltd

Contractor

Saipem Australia Pty Ltd

Project

Gas Transmission Pipeline (GTP) Project

TPI

Works

Third Party Inspection: Any organisation, authority, person or persons, to which Company/Contractor has subcontracted the execution of inspection and or laboratory testing, related activities Means the facilities, constituting the Project, including all the construction services, materials and equipment to be provided by Company/Contractor to satisfy its obligations pursuant to the Contract undertaken with the Company

QMS

Quality Management System: part of the organisation’s management system that focuses on achievement of results, in relation to the quality objectives, to satisfy the needs, expectations and requirements of Saipem/Company and of any other interested parties, as appropriate.

QAS

Quality Assurance Specification: Contract document 3380SAIP-4-6.6-1259 & 3380-SAIP-4-6.6-1260 specifying the minimum requirements related to Contractor’s QMS and QA/QC Manual specific for the Works

QCS

Quality Control Standard: Contractor Standard for quality control requirements

QCP

Quality Control Plan: Contractor plan containing all quality control requirements. This plan complements and compiles all applicable ITP(s). Inspection and Test Plan: Contractor plan of inspection and tests specified in ITP(s) and/or required by engineering and vendors documents or elsewhere specified. ITP(s) shall provide references to applicable procedures, acceptance criteria, documentation, quality records and inspection attendance to be performed, in chronological order, from initial inspection, throughout final inspections and mechanical completion. ITP(s) and relevant forms shall be issued as QCP enclosures.

ITP

MDT

Inspection report form, attached to the ITP. They shall be used during checks and inspections /tests and signed by the

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

involved parties, as per relevant QC code. RFI

Request for Inspection: Written notification to be issued by Contractor in order to allow all parties involved to perform their inspection and test witness as planned in the applicable ITP

QA

Quality Assurance: Part of quality management focused on providing confidence that quality requirements will be fulfilled

QC

Quality Control: Part of quality management focused on fulfilling quality requirements

NCR

Non Conformity Report: Document recording a non-fulfilment of a requirement

Non Conformity

The non-fulfilment of specified requirements

Special Process

A process, the results of which are highly dependent on the control of the process or the skill of the operator and in which the specified quality cannot be readily determined by inspection or test on the product

Calibration

Comparison of a measurement and test equipment with a reference standard or with another one provided with better tolerance in order to detect or to measure possible inaccuracies and to document or eliminate them

WPS

Welding Procedure Specification

MTC

Material Test Certificate

Any other terms related to quality and not listed above shall conform to section 3 “Term and Definition” of ISO 9000:2005 “Quality Management System – Fundamentals and vocabulary”.

4

ROLES AND RESPONSIBILITIES

4.1

Welding Engineer The Welding Engineer shall determine consumable requirements and requisition all welding consumables. He shall purchase only filler metal consumables listed in Table 2.2.1 of AS 2885.2 which have been qualified during procedure qualification and approved by the Company. He shall maintain a list of all approved consumables and batch numbers. (See sample Appendix A.)

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

4.2

Welding Supervisor The Welding Supervisor shall be responsible for:    

4.3

Implementing this procedure within the scope of work and ensure that the procedures are effectively followed; Oversee the work place to make sure that it is kept clean and tidy and that all surplus consumables and stubs are removed from each welding location to prevent inadvertent use; Ensuring adequate stocks of welding consumables are available at all times during the construction/installation phase; Ensure that welders are using the correct welding procedure and correct consumables

Acquire appropriate electrodes from consumable store and confirm receipt by initial on Appendix B.QC Inspector The QC Inspector shall ensure that the requirements of this procedure are adhered to at the work site, and that consumables used in production are approved and traceable. The QC Inspector shall be responsible for inspections as per the approved inspection and test plan and routine checking of baking and issue of consumables as per this procedure. He shall ensure that consumable traceability is maintained throughout the pipeline construction process.

4.4

Material Controller/Store Keeper The consumables controller/storekeeper will be responsible to maintain proper receiving, identification, storage, handling, preservation and issuing of consumables including any related safety procedures. He shall:   

Check consumables received and ensure that they are stored in accordance with this procedure; Notify the QC Inspector of the arrival of a new consumable batch; Notify the QC Inspector when a change of consumable batch numbers are to be issued.

An inventory/register of all welding consumables held within the consumable store shall be maintained and shall comprise the following minimum information:  

Consumable Brand name (i.e. Full name shall be specified); Consumable size;

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

   4.5

Consumable batch identification number; Unique number; Quantity held in store.

Welders The welders and welders helpers shall be responsible to ensure they are using the correct consumables as defined by the relevant WPS. They shall also ensure that electrode stubs are removed from the work area and unused electrodes are dealt with as per this procedure.

5

WORK PROCESS

5.1

Selection Identification and Traceability of Consumables All consumables shall conform to Section 2 of AS 2885.2 and will be procured in sealed containers. No atmospheric air entrapment is permitted. Welding consumables to be used on the Project shall conform to the requirements of applicable specifications/classifications as per the approved WPS. Batch certificate shall be verified/accepted by a QC Inspector. Inspection reports and certificates shall be made available to the Company for review upon request. Unique numbering of welding consumables enables positive tracking and matching to certification. Unique numbering is the preferred method of identifying and tracking consumables where full traceability is a contract requirement. A consumable traceability register will be used to record welding consumable details. (Refer to appendix A). When a batch change is occurring ie. (the end of one batch number and the start of a new batch number for the same type and size of consumable) then all consumables of the previous batch number shall be withdrawn and the new batch made available for issue. Where practical this change would occur at the end of a shift or during a break in production. All consumables of the obsolete batch shall be removed from production.

5.2

Purchase of Consumables

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

The welding engineer shall purchase only filler metal consumables listed in Table 2.2.1 of AS 2885.2 which have been qualified during procedure qualification and approved by the Company. Welding consumables shall only be purchased from approved suppliers. A list of all approved consumables and batch numbers shall be maintained. (See sample document: Appendix A.) 5.3

Receipt of Consumables Material Controller/Store Keeper assigned shall check that the received consumables match up with the delivery note, purchase order and batch test certificates. The Material Controller/Store Keeper shall notify the QC Inspector for the required inspection as per the approved QCP. Welding consumable certification shall be registered in a file held in the QC department, head office. The welding consumable test certificate shall be submitted for review upon request from the Company. Welding consumables shall be received and checked by the Material Controller/Store Keeper and QC Inspector, against the following:      

Identification: Manufacturer, grade and batch number; Approved list of welding consumables; Correlation with batch test certificates; Transit damage to containers/contents; Recommended storage conditions; Conformance of batch test results to relevant welding consumable.

Where a discrepancy is identified, the items shall be quarantined, a NonConformance Report (NCR) shall be raised .

5.4

Storage of Welding Consumables. The welding consumables shall be stored in their original packing in a dry place adequately protected from the effects of weather and in accordance with the manufacture’s recommendation.

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Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

Consumables shall be held in manufacturers packaging until required for use. All stored consumables shall be segregated (by type size and batch number) with the batch number and allocated unique number clearly displayed. They shall be stored on pallets as supplied by the distributor in a single layer only. They shall be stored carefully so as to avoid damage. Consumables which show signs of dirt, deterioration or lack of identification shall be removed from service and quarantined. Non-conforming materials shall be stored separately in the quarantine area with identification and acted upon as per the contractor’s management of nonconformance. Consumables which become wet, contaminated or damaged shall be removed from service and quarantined. All quarantined or destroyed consumables shall be notified to the Welding Engineer so that shortfalls may be identified. 5.5

Welding Consumable Issue Control Consumables will only be issued by the store person upon the completion/initialed “Consumable Issue Control Register”.(See sample Appendix B). This form shall be completed and signed by the Welding Supervisor, crew foreman or authorized person. This process is necessary to ensure the correct consumables are requested and issued as per the relevant WPS. Only sufficient amount of welding consumables will be issued on a daily basis to suit each production day. A daily issuing log shall be maintained by the authorisation person. (See sample Appendix B). For all welding consumables, the usage principle valid is: First-In/First-Out. 

Cellulosic electrodes: Cellulosic Electrodes shall be used directly from the manufacturer’s packages (Manufacturer’s recommendation) and shall not be subjected to any baking or heating process.

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Once the hermetically sealed containers have been opened, humidity below 50% and temperatures above 55 C should be avoided. Cellulosic electrode should be stored in cool, dry location and should not be exposed to direct sunlight. Cellulosic electrodes shall not be reconditionied. 

Kryo 1P/Kryo 1 Low hydrogen electrodes supplied in vacuum packs: Kryo 1P/Kryo 1 electrodes may be used directly from the packet at the work site. The date and time of issue shall be written on each packet (the welders and welders helpers will be responsible for the writing of the date and time as they open the packs). The maximum cumulative exposure is to be a maximum of 8 hours after which any remaining electrodes are to be re-baked or discarded. Kryo 1P/Kryo 1 electrodes may also be transferred directly from a freshly opened pack into a heated quiver set at a minimum of 125⁰C. These electrodes may remain in the quiver indefinitely provided they are not allowed to cool. If allowed to cool these electrodes shall be subjected to the rebaking procedure as outline in this specification.



Esab OK 53.70 Low hydrogen electrodes supplied in vacuum packs: Esab OK 53.70 Low hydrogen electrodes may be used directly from the packet at the work site. The date and time of issue shall be written on each packet (the welders and welders helpers will be responsible for the writing date and time as they open the packs). The maximum cumulative exposure is to be a maximum of8 12 hours after which any remaining electrodes are to be re-backed or discarded as per manufacturer recommendatjion. Esab OK 53.70 Low hydrogen electrodes may also be transferred directly from a freshly opened pack into a heated quiver set at a minimum of 125⁰C. These electrodes may remain in the quiver indefinitely provided they are not allowed to cool. If allowed to cool these electrodes shall be subjected to the rebaking procedure as outline in this specification.



GMAW wires shall be issued and used directly from the manufacturers packaging.



Gas shall be procured with certificates of conformity. Welding Supervisors and the welding operator shall be responsible for correct supply and installation to the welding stations.

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

5.6

Storage Oven General Requirements Each baking and holding oven shall have an information tag or label placed on the door identifying the electrodes stored in each section of the oven. A welder may be required to use low hydrogen electrodes from a portable oven. The portable oven shall be used to transport the baked electrodes to the work front. Calibration Certificates of the Baking Oven, Holding Oven, Portable Ovens (Quivers) shall be verified by a QC Inspector. Each oven shall display a calibration tag and the certificates shall be held in the main QC office. Certificates shall be available to the Company for review upon request.

5.7

Segregation of Non-Conforming/Uncertified Consumables The consumable Controller/Store Keeper will segregate all non-conforming and/or uncertified material in an established area, designated as the quarantined area, pending receipt of the certification or a destination order. He will contact the QC Inspector for the issuance of the related non-conformance, according to the Contractor’s management of non-conformity.

5.8

Baking Procedure Rebaking will be carried out on the ESAB OK 53.70, Lincoln Kryo 1 7018 and Lincoln Kryo 1P 8018 electrodes. Rebaking of these electrodes shall be carried out when sufficient numbers of electrodes have accrued. They will be placed in the baking oven for a period of 2 hours at 350°C. All rebaked electrodes shall be color coded YELLOW. Electrodes shall be subjected to this baking procedure only once. Once baked these electrodes will be transferred to a holding oven set at 120-180⁰C. Electrodes may be issued from the holding oven in heated quivers set at 125⁰C min. Any color coded electrodes issued in a quiver and allowed to cool shall be discarded. A log (See example Appendix C) shall be maintained to demonstrate conformity to requirements and this shall be displayed near the oven. Only the required amount of consumables for the day’s welding activities shall be transferred to quivers.

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Contract No. 897315

Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

Baking ovens, holding ovens and portable hot boxes shall have valid calibration certificates and identification tag displaying the calibration date. Different types/makes or sizes of electrodes must be kept separated and identified while in ovens. Damaged and contaminated consumables shall be removed and quarantined.

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Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

6

APPENDIX

6.1

Appendix A. Approved Consumable Batch Numbers Register APPROVED CONSUMABLE BATCH NUMBERS REGISTER

MANUFACT.

6.2

TRADE NAME

AWS CLASSIF.

LOT / BATCH No.

SIZE (mm)

UNIQUE NUMBER

BATCH BATCH COMMENCE CLOSING ISSUE DATE ISSUE DATE

CERTIFICATE No.

QUANTITY RECEIVED Kg

REMARKS

Appendix B. Consumable Issue Control Register

CONSUMABLE ISSUE CONTROL REGISTER Date

Cons. Type

Size Ø (mm)

Unique QTY. WPS No. ISSUED number

welding Received crew id by

Initials

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Company Doc. No. 3380-SAIP-4-2.1-6072 Document Title: WELDING CONSUMABLE CONTROL PROCEDURE

6.3

Appendix C. Electrode Baking Log

ELECTRODE BAKING LOG Date

Electrode Size Ø Type (mm)

Unique Oven Quantity Time In Number No.

Time Out

Name Initials