CARIGALI STANDARD PROCEDURE NO. : CSP-I4 CARIGALI | PROCEDURE [eee eee ee eee | JACKET / TOPSIDES REVISION. 0 WELDING CONTROL PROCEDURE FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR In the event of any ambiguity, inconsistency or conflict between this procedure and the Contract Document and / or the Petronas Technical Standards (PTS), the Contract Document and / or PTS shall take precedence over this procedure. CARIGALI's interpretation shall be final REV. | DaTE| PREPARED BY REVIEWED BY APPROVED BY No | NAME] SIGNATURE | DATE || NAME aafelaelerc | A) [paleiad| mam £ be lage ATURE | DATE [NAME | sicyrunE | DATE O |23/%Ap Aad.PROCEDURE NO. : CSP-I4 poe WELDING CONTROL CARIGALI PROCEDURE REVISION. - 0 JACKET / TOPSIDES PAGE ELT OF LE TABLE OF CONTENTS SECTION sia DESCRIPTION PAGE 1.0 PURPOSE 2 20 SCOPE 2 3.0 REFERENCES 2 4.0 DEFINITIONS 2 5.0 PROCEDURE 2 5.1 Welding Procedure Qualification 2 2 Welder Qualification 3 3 Welder Performance 4 4 Welding Machine Maintenance 4 53 Material Inspection 3 56 3 5.7 1g Sequence 7 58 Preparation prior welding 8 39 Inspection during welding 9 5.10 Inspection after welding lo 6.0 SPECIAL REQUIREMENTS I 7.0 RECORD u2.0 3.0 4.0 ae WELDING CONTROL PROCEDURE NO. : CSP-14 CARIGALI PROCEDURE REVISION. - 0 JACKET / TOPSIDES PAGE 2 OF 12 10 PURPOSE This procedure describes the general requirements for control of welding activities to ensure all production welds are of good quality, meeting CARIGALI specifications SCOPE This procedure covers all stages of work before welding, which include selection of WPS, welder qualification, welding machine maintenance, material identification, visual inspection, welding sequence and inspection during and after welding. REFERENCES PTS 20 104 (SES 11 | REV. 4) PTS 20.074 (SES 11.6 REV. 1) PTS 20.112 (SES 38.2 Rev.3) ANSIB313 (1993) Construction of Structural Steel Works Structural Steel Materials Welding of Pipeworks ‘Chemical Plant and Petroleum Refinery Piping ASMEIX (1993) - Welding and Brazing Qualification AWSDIL1 (1994) - Structural Welding Code DEFINITIONS RT - Radiograhic Testing UT - Ultrasonic Testing WPS - Welding Procedure Specification MPI - fagnetic Particle Inspection NDE - — NonDestructive Examination NDT - —— NonDestructive Testing QA = Quality Assurance QC = Quality Contro! AFC Approved For Constructionperaomas CARIGALI WELDING CONTROL PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 3 OF 12 PROCEDURE NO. : CSP-I4 5.0 PROCEDURE 51 WELDING PROCEDURE SPECIFICATIONS SAL Prior to fabrication, CONTRACTOR shall identify from the pre-accepted Welding Procedure Specifications, (FSP-XXX-17), the applicable WPS for the work. The list of the applicable WPS shall be submitted to CARIGALI for review and approval If additional WPS is required, the WPS shall be qualified in accordance with AWS D.1.1. for structural, ASME Section IX for piping and CARIGALI specifications It is the duty of the Welding Engineer to formulate welding procedures applicable to the joint configuration and application. The additional Welding Procedures shall be submitted to CARIGALI for review and approval before commencement of qualification test. Upon approval of the procedure, a welding procedure qualification test shall be carried out in the presence of CARIGALI's representative, CARIGALI shall be informed at least two (2) days before the testing The test piece shall be visually inspected and nondestructive tested in accordance with CARIGALI specification. The acceptable test piece shall be sent for mechanical testing by an independent third party approved by CARIGALI CARIGALI shall be informed at least two (2) days before the testing and reserve the right to witness the testing, A complete documentation of the welding qualification records, NDT reports and mechanical test results shall be compiled together with WPS and submitted to CARIGALL for endorsement,peraonas CARIGALI WELDING CONTROL, PROCEDURE NO. > CSP-14 PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 4 OF 12 5.1.8 The Welding Engineer shall issue an updated register of all the approved WPSs applicable to the work to the relevant departments ie, QW/QC, Production, Engineering, etc, for information WELDER QUALIFICATION Prior to fabrication, CONTRACTOR may submit names of welders who were previously qualified on CARIGALI's projects or from other projects together with their perfomance records to CARIGALI for consideration on acceptance without qualification test Those welders that need to be qualified shall undergo qualification test as per AWS D1.1. or ASME Section IX requirements for structural and piping respectively. $23 CONTRACTOR shall inform CARIGALI at least 48 hours prior to any welder qualification test. CONTACTOR's welding inspector shall monitor the welders during the qualification and check the welding parameters used by the welders from time to time The final acceptance of the welders and welding operators qualification shall be by CARIGALL WELDER PERFORMANCE 53.1 CONTRACTOR's Welding Engineer shall compile a register of all qualified welders / welding operators and their qualification. 53.2 The Welding Engineer shall develop and maintain a record of welder performance and submit to CARIGALI on weekly basis. 5.3.3 Welders who are unable to maintain a good standard of workmanship or who have accumulated repair rate more than 3% per total weld length for piping and 4% per total weld length for structural shall be warned and counseled. If after the warning and counseling their performance have notPROCEDURE NO. : CSP-I4 PETROMAS WELDING CONTROL carical |___Procepvne | revision JACKET / TOPSIDES PAGE 3 OF 12 improved, they shall be demoted or removed from the project at the discretion of CARIGALI “Each qualified welder shall be given a welder identification number, The welder shall mark his LD number on his welds by means of indelible crayon or metal marker adjacent to the weld. 54 WELDING MACHINE MAINTENANCE 54.1 Prior to all fabrication work the welding machine and ancillary equipment shall be checked and made good and safe for its purpose 3.4.2 Periodical checking and maintenance work are essential to the safety, reliability and accuracy of the machines. 3.4.3 Calibration of all welding machines for the project shall be conducted before the start of fabrication work and to be witnessed by CARIGALI Representative 3 MATERIAL INSPECTION 5.5.1 All material shall be inspected in accordance with latest approved AFC/shop drawing, mill certificate and cutting plan 0 ensure correct material specification, dimension, cutting profile and piece mark and free from any surface defects, 5.5.2. CONTRACTOR shall ensure that transfering of heat number of material is done prior to cutting 5.5.3 Inspection and acceptance by QC Inspector and CARIGALI representative are required prior to cutting of any materials, 5.6 FIT-UP 5.6.1 All fit-up inspections shall be conducted by QC Inspectors and when required shall be witnessed by CARIGALI RepresentativeperaoMas CARIGALI Getic conten PROCEDURE NO. : CSP-14 PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 6 OF 12 All joints shall be checked in conformance to the shop drawings and welding procedure specifications. Preparation of weld edges shall be by thermal cutting or machining, Wherever practicable, thermal cutting shall be done with a mechanically guided torch. For thermal cutting, the cut surfaces shall be ground to a smooth uniform surface. The edge preparations shall be visually checked for any lamination and defect at the cut and ground edges. Any lamination or defect observed shall be removed by grinding and counter check MPL. The main member weld area shall be UT prior to fit up to ensure they are free from lamination. Design and tolerances of a weld groove shall be in accordance with the approved WPS . However, in general, the groove shall be bevelled to give an included angle of not less than 60 degrees for single and double Vee and not less than 30 degrees for single and double bevel. The root opening shall not be less than 2 mm and not greater than $ mm and the root face shall not be greater than 2 mm. If the root opening is larger than maximum specified, buttering of the joint is required. Procedure for butitering shall be submitted for CARIGALI approval on case by case basis. In any case, the thickness of the buttering shall not be more than two times of the thinner section or 19mm, whichever smaller. Tacking work shall be done by qualified welders and be perfomed with the same qualified welding procedure as that will be used for fabrication welds. Consumables used for tacking shall be the same as per the qualified WPS Tack welds for structural joints shall be a minimum of 50 mm long, Tack welds shall be sufficient and equally spaced to prevent the tack weld from cracking. These tack welds shall be cleaned by grinding before actual welding commences. For fit up of piping or tubular connection, the internal and external transition shall be in accordance to the AFC Drawing and CARIGALI specifications,pernonas CARIGALI WELDING CONTROL PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 7 OF 12 PROCEDURE NO. : CSP-14 5.6.8 The alignment and dimension of the material to be welded shall be checked during fit up inspection. The offset at structural butt joints shall not exceed 1/10 (where T is the thickness of the thinner material) or 6 mm, whichever is less. The offset of the longitudinal seams shall not exceed T/10 or 3 mm , whichever is less, The offset or misalignment of the abutting pipe ends of a same nominal thickness shall not exceed 1.5 mm, For joints of unequal pipe ends thickness, the external offet shall not exceed 3 mm and internal offset shall not exceed 1,5 mm.All offsets or misalignments greater than 2 mm shall be machined or ground to a 1: 4 tapered transition 5.69 Surfaces to be welded shall be cleaned and free from oil, grease, water, loose scales, paint or any foreign materials 5.6.10 All temporary attachments shall be cut from a good condition plates and shall match the adjoining members in term of weldability. All temporary attachments shall be removed by thermal cutting to a minimum of 6mm from the surface of the ‘material and subsequently ground flush with the surface. Aer grinding, the area shall be checked by MPI 5.6.11 Temporary attachment shall not be removed by breaking, knocking or other means which will cause damage to the surface of the structure WELDING SEQUENCE 5.7.1 Where shrinkage and distortion is likely to affect the adequacy of the member or structure, welding sequences shall be developed to control distortion, warping, creeping and the build-up of excessive internal stresses in the structure and shall be submitted to CARIGALI for approval before the welding activity commence. 5.7.2 The approved welding sequence shall be briefed to the welders and displayed prominently at the working area, 5.73 Welding engineer or supervisor shall supervise the welding of the assembly to ensure the planned sequences are followedWELDING CONTROL PROCEDURE NO. : CSP-14 pertonas CARIGALI PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 8 OF 12 5.7.4 Welding sequence shall include i WPS to be applied oii Sequence of joints to be welded ii. Number and location of welders at each stage of assembly iv. Tack welds, temporary attachments and spacers used in the assembly of components v. Preheating of joint to be welded vi PWHT (if required) Whenever practical, two welders are required to weld a joint trom both sides simultaneously. For welding of pipes or tubulars with diameter greater than 20 inch, two or more welders are required to weld simultaneously. 5.7.6 Avoid welding component at both ends simultaneously because this will cause a high stress in the component due to weld metal shrinkage when cooling. The high stress can cause distortion of component or crack in the weld joint 5.7.7 Special attention is required when welding a large panel of tubulars, beams or plates to minimise distortion. Welding of the panel shall start from the centre and out to the perimeter, 5.8 PREPARATION PRIOR WELDING 58.1 All approved WPS shall be posted at site for welding supervisor and welder's reference. Welders shall adhere to the parameters as specified in the related WPS. The welding supervisor shall ensure that the welders follow the parameters in the WES. Welding consumables to be used for welding shall be checked for the correct classification, type, and size as per approved WPS. It must be dry and free from foreign material such as grease, oil, water and paint.permomas CARIGALI WELDING CONTROL See eee reece PROCEDURE, REVISION. : 0 JACKET / TOPSIDES aaGettatton tia 58.6 5.8.7 3.9.1 Preheating temperature shall be carried out by electrical resistance or with gas burner (not exceed 250°C) for carbon steel and shall be checked by means of thermocouple or “tempilstick. The preheating temperature shall be established to a distance of at least 75 mm from the joint groove and through the wall thickness prior to welding. Heating torches MUST NOT be lighted by striking an arc on the steel surface Welder qualification shall be checked and his identification number shall be written with permanent marker adjacent to the joints, The welding supervisor must select good welders for welding of critical joints The welder(s) shall be briefed on the applicable WPS requirements i.e. amperage, voltage, travel speed, type and size of consumables, preheating, etc. Weldi reference, sequences shall be available at work area for All pieces or structures to be welded shall be earthed. If welding is done on fabrication table, the work piece shall be earthed individually. Shelter and wind breaker shall be provided at all times to give protection to the weld areas from wind, rain and moisture, INSPECTION DURING WELDING Interpass temperatures and welding parameters shall be controlled during welding and in accordance with the approved WPS, Welding supervisor and QC Inspector shall check on the interpass temperature and welding parameters. All arcing or re-arcing of electrodes must be done in the weld groove and not on the area adjacent to the weld. The maximum weave width for SMAW shall not exceed 2.5 x electrode diameter or 12mm which ever is lesser. For SAW, the width beads shall not exceed 6x electrode diameter or 16mm whichever is lesser.pemoxas WELDING CONTROL PROCEDURE NO. : CSP-14 CARIGALI PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE ot one: 5.9.4 Weld start and stop should be staggered within 50 mm of each weld pass for each weld layer. This is essential in order to avoid unnecessary defects and poor weld profiles which may require dressing and re-welding Weld progression in vertical or near vertical position shall be by uphill method 5.9.6 Prior to any gouging, the QC inspector shall check and ensure that the compressed air is completely dry. all gouged area shall be MPI to check for surface crack, porosity ete. 5.9.7 Fillets weld shall be completed in three or more runs. Seal welds shail be done in one mun. 5.98 Care must be taken when laying down welding tongs to ensure that the electrode end do not come in contact with the plate surface. Any arc sirikes shall be subjected to repair or rejection at the discretion of CARIGALI 5.9.9 As far as possible welding of each joint shall be a continuous operation, In the case that welding must be discontinued, at least half of the final weld thickness shall be achieved. This partly welded joint must be completed as soon as possible but in no case more than two days, Before continuation of welding, the partly welded joint shall be thoroughly cleaned by power brushed and inspected visually and MPI. The maximum number of heat cycles allowed for production weld shall be two 5.9.10 Rapid or abrupt cooling of weld shall be avoided. The completed welds shall be covered with asbestos blankets or any other method. If it is raining during welding, the welding activities must be immediately stopped and the incomplete weld shall be covered with asbestos blankets with water resistant material 5.9.11 Electrodes shall be kept in a heated quiver at all times.PROCEDURE NO. : CSP-14 61 62 5.10.1 PETROMAS WELDING CONTROL CARIGALI PROCEDURE REVISION, : 0 JACKET / TOPSIDES PAGE 11 OF 12 5.10 INSPECTION AFTER WELDING The following inspection shall be carried out after a welded ™ component is completed 5} Weld size and reinforcement ii) Completeness of all welds iii) Appearances of welds (such as weld profile, spatter, etc.) iv) Geometrical and surface defects on weld such as underfilling, undercuts, overlaps, cracks, craters, etc. ¥) Identification of weld and welder numbers vi) Distortion of component vii) Are strikes on parent metal vill) Dimension check ix) Straightness check x) NDE Inspection For effective inspection, it is essential that the weld and adjacent surface is cleaned from slag, spatters, mill scales and oxides. 6.0 SPECIAL REQUIREMENTS All material with thickness of 25 mm and above shall be checked for lamination prior to welding, A split-layer technique shall be used for GMAW or FCAW in making all multipass welds when the width of the layer exceeds 16 mm.WELDING CONTROL PROCEDURE NO, : CSP-I4 CARIGALI PROCEDURE REVISION. - 0 JACKET / TOPSIDES PAGE 12 OF 12 7.0 RECORD The following inspection reports shall be produced by CONTRACTOR. a) Fit up report b) NDE reports i.e MPI, DPI, RT, UT (whichever applicable) ©) Weld visual report 4) Lamination report (if required) 2) Dimensional report All reports shall verified by CARIGALI representative and must be kept by CONTRACTOR for Final Documentation