EPC OF LAWE-LAWE FACILITIES RDMP

RU-V BALIKPAPAN

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ENGINEERING, PROCUREMENT AND CONSTRUCTION (EPC)

OF LAWE-LAWE FACILITIES RDMP RU-V
BALIKPAPAN

WELDING CONTROL PROCEDURE

006 02-Nov-22 Re-Issued for Construction Irham Tanjung M. Falhan Cui Guojun
005 31-Aug-22 Re-Issued for Construction Irham Tanjung M. Falhan Cui Guojun
004 21 July-22 Re-Issued for Construction Irham Tanjung M. Yousrizal Cui Guojun
003 7-June-22 Issued For Construction Irham Tanjung M. Yousrizal Cui Guojun
002 10-Des-21 Issued For Construction Victor N M. Yousrizal Cui Guojun
001 30-Mar-21 Issued For Construction Victor N A Rashid Saip Cui Guojun
000 25-Feb-21 Issued For Construction Victor N A Rashid Saip Cui Guojun
00B 2-Sep-20 Issued For Review Victor N A Rashid Saip Cui Guojun
00A 18-Aug-20 Issued For Review Victor N A Rashid Saip Cui Guojun
Rev. Date Description Prepared By Review By Approved By
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REVISION HISTORY

Rev. No. Page / Section Revision Detail

00A All Issued for Review

00B All Page Changed OWNER logo to KPB logo

Page 3 / TOC Revised Table of Content by including Section 7.0 Attachment

Page 4 / 1.0 Paragraph 2: Detail out procedure scope

Page 4 /3.0 Deleted AUT

Page 5 /
Add AWS A5.1
Section 4.0
• Add “CONTRACTOR” to title
Page 6 /
• Add another bullet point about Weld Log, NDE and Welder
Section 5.1
compliance
Page 6 /
Replaced “control” with “execute the quality of”
Section 5.2
• Add EN10204 3.1 certification requirement
• Add Note about same brand electrode
• Add reference to Attachment 1
• Add storage condition
Page 7-8 /
• Revise Table 6.1
Section 6.2
• Add reference to Attachment 2
• Add different color for differentiation purposes
• Add Note for handling return of second issuance electrode
• Add reference to Attachment 3
• Revise first paragraph by including the Weld Log recording
Page 9 /
• Add reference to Attachment 4
Section 6.3
• Change “are” to “is” and “reached” to “reaching
• Add “calibrated and”
Page 9-10 /
• Change “an” to “all”
Section 6.4
• Add Note about maximum two repair allowed.
• Add 7.0 ATTACHMENT
Page 10-14 /
• List all the attachment
Section 7.0
• Add all the attachment
Added:
Page 6-7 / • 26076-110-GPP-GCQ-00001 Control of IMTE Procedure
000
Section 4.0 • “Latest edition” after code
• Five new codes as suggested by IPMT
Page 7 / Included IPMT comment on Subcontractor’s overall, fitter
Section 5.3 and welder responsibilities.
Page 8-9 / Included IPMT comment on consumable control – storage,
Section 6.2 heating & baking requirement, and issuance & return.
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Rev. No. Page / Section Revision Detail

Page 8-9 / Added Stainless electrode in Welding Consumable Control
Att. 1 Flowchart.
001 Page 4 / TOC Listed three attachments as commented by IPMT
Page 6-7 / Include the revision/edition of the Code and added two more
Section 4.0 Codes as commented as IPMT
Page 7 /
Section 5.1 & Added additional responsibilities as commented by IPMT
5.3
Page 8 /
Added “and welder list”
Section 6.1
Added the repair rate calculation method for double
Page 11 /
processes joints and specific training requirement prior to
Section 6.3
requalification.
Page 12 /
Listed three attachments as commented by IPMT
Section 7
Page 17-19 /
Added three attachments as commented by IPMT
Att. 5-7
Page 9 / section
002 Added document for receiving according as commented IPMT
6.2
Page 11 / Section Added Welding material shall be clearly identified with
6.2 manufacturer’s according as commented IPMT
Page 9 / section Added “Distribution of all electrode to welder shall be controlled by Store
003
6.2 man for traceability record purpose”
Page 10 / section
Added “Quivers should in good condition and ready for used.”
6.2
Page 11 / section
Added “More than one should be scraped/ dispose.”
6.2
Page 12 / section
Added “The Rejection Rate shall be controlled by film & length for pipeline
6.3
Page 12 / section Added “Periodically check should use control check sheet and should be
6.4 clarified by Welding Inspector.”
Page 13 / section
Added “The Rejection Rate shall be controlled by film & length for pipeline.”
6.4
004 Page 7 / section 1 Added “electrode, wire/rod, flux & shielding gas”

Page 7 / section 1 Added “Weld Map, Welding Sequences, Welding Identification/Numbering”

Separate table of Project Specification, Contractor Procedure and
Page 8 / section 4
International Standard
Page 8 / section 4.1 Update table of Project Specification

Page 9 / section 4.3 Update table of International Standard

Page 9 / section 5.1 Added “and compliance with spec and code (ASME Section II, Part C)”

Page 9 / section 5.1 Added “Project Specification, & NDE Procedure”

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Rev. No. Page / Section Revision Detail

Added “Construction department responsible to erected and installing,
performing production welding for all welding joint to be welded using approved
WPS, using operable and calibrated equipment and performed by qualified
Page 9 / section 5.2
welders in accordance with project specification, procedure and code/standard,
so that generating acceptable weld joint as per acceptance criteria of quality of
weld”
Added “Fit-up shall be inspected by QC Inspector, status inspection shall be
Page 10/section 5.3
mention on welding matrix box (accepted / or not)”
Page 10/section 5.3 Revised to be " Approved & Qualified Welder"
Revised to be " If the fit-up is not accepted or the welder is not satisfied with
Page 10/section 5.3 his/her work conditions, weather, position etc. he/she shall not perform the
weld. "
Page 10/section 6.1 Added “also welder/welding operators”

Page 11/section 6.1 Added “Approved”

Page 11/section 6.1 Added “prior to start production welding.”

Added “in accordance with specification ASME Section II, Part
Page 11/section 6.2
C.”
Page 11/section 6.2 Added “SFA No, F No, A No, Batch No/ Lot No., Brand Name/ Trade Name.”

Page 11/section 6.2 Added “PQR”

Page 11/section 6.2 Added “ASME Section II Part C”

Added “shall be reviewed and approved by QC/Welding Engineer whether
compliance with specification and standard or not prior to be used including
Page 11/section 6.2
shielding gas certificates shall be in accordance with ASME Section II, Part C, SFA
A5.32 (Purity, Dew Point Temperature and Moisture Content)”
Added “Humidity measuring devices and temperature measuring devices shall
Page 11/section 6.2
be available and calibrated in store.”
Added “Damage/scrapped welding electrode shall be identified and separated in
Page 12/section 6.2
scrapped bin”
Added “Baking oven, holding oven for electrode and flux shall be calibrated and
Page 12/section 6.2
valid condition”
Page 12/section 6.2 Revised to be “80°C”

Page 13/section 6.2 Revised Table 6-1: Storage, Baking, and Holding Condition

Page 14/section 6.2 Added “and recorded on Baking Log form”

Page 14/section 6.2 Revised to be “80°C”
Page 14/section 6.2 Added “Return electrode shall be separated with new electrode during re-
baking and prioritized to issuance return electrode first before new electrode”
Page 14/section 6.2 Added “(Refer to Attachment 10)”
Page 14/section 6.2 Added “Mixing of colour identification is prohibited.”

Page 15/section 6.3 Added “Project Specification”

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Rev. No. Page / Section Revision Detail

Page 15/section 6.3 Added “Piping /Tank/ Pressure Vessel welders in accordance with ASME Section
IX, Structural Welders in accordance with AWS D1.1, Pipeline welders in
accordance with API 1104”
Page 15/section 6.3 Added “Only approved and qualified welder who can perform welding work for
any welding.”
Page 15/section 6.3 Added “Welder Stamp ID /”
Added “Welders who reaching 3% reject rate can perform welding again after
Page 16/section 6.3
his requalification test are passed.”
Added “Calibration sticker/tag and expiration calibration date shall be attached
Page 16/section 6.4 on the machines for evidence. Only operable and calibrated welding machines
which are allow to be used for production welding.”
Page 16/section 6.4 Added “Wire Feeder of welding machines, baking oven, holding oven, clamp
meter/tang ampere, infrared temperature/ temperature gun, other measuring
devices shall be calibrated, calibration sticker/tag evidence shall be attached on
the equipment/tools/measuring devices”
Page 16/section 6.4 Revised to be “Outside welding work using arc welding process and shielding
gas shall be protected using welding habitat/shelter to protect arc and molten
metal during welding from outside weather atmosphere (wind, rain, moisture).”
Page 16/section 6.4 Revised statement on Preheat and Inter-pass Temperature Control
Added “Welding parameter shall be recorded and available”
Page 17/section 6.4 Added “Random Selection of NDT”

Page 18/section 6.4 Added “at same”

Page 19/att.1 Revised Attachment 1: Welding Consumables Control Flow Chart

005 Page 11/6.1 Replaced to be “Owner”

Page 19/Att.1 Replaced to be “Accepted”

006 Page 8 /3 Removed DEPNAKER/DIMET

Page 9/5.1 Replaced to be “Owner”

Modified “All welding consumables shall accordance with
Page 11/6.2
specification ASME Section II, Part C.”
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Table of Contents
1.0 PURPOSE.................................................................................................................................................7
2.0 DEFINITIONS ...........................................................................................................................................7
3.0 ACRONYMS .............................................................................................................................................7
4.0 REFERENCES ...........................................................................................................................................8
4.1 PROJECT SPECIFICATION ..........................................................................................................................8
4.2 CONTRACTOR PROCEDURE ......................................................................................................................8
4.3 INTERNATIONAL STANDARD ....................................................................................................................9
5.0 RESPONSIBILITY ......................................................................................................................................9
5.1 CONTRACTOR QA/QC Department.........................................................................................................9
5.2 Construction Department.......................................................................................................................9
5.3 Subcontractors .....................................................................................................................................10
6.0 PROCEDURE ..........................................................................................................................................10
6.1 Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) ..........................10
6.2 Consumable Control ..............................................................................................................................11
6.3 Welder Control .......................................................................................................................................14
6.4 Welding Control .....................................................................................................................................15
7.0 ATTACHMENT .............................................................................................................................................17
Attachment 1: Welding Consumables Control Flow Chart ..........................................................................18
Attachment 2: Sample Electrode Baking and Holding Register ...................................................................19
Attachment 3: Sample Electrode Issuance Register.....................................................................................20
Attachment 4: Sample Welder List Format ..................................................................................................21
Attachment 5: Sample Inspection, Measuring and Test Equipment (IMTE) Control Log ............................22
Attachment 6: Sample Welding Summary Report .......................................................................................23
Attachment 7: Sample WPS Summary .........................................................................................................24
Attachment 8: Welding Material Issue Slip ..................................................................................................25
Attachment 9: Baking Log ............................................................................................................................26
Attachment 10: Table Welding Consumables Colour Code .........................................................................27

LIST OF TABLE
Table 6-1. - Storage, Baking, and Holding Condition
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1.0 PURPOSE
The purpose of this procedure is to establish and outline the process to control the welding activities
to achieve a sound weldment for the fabrication and erection of pipeline, piping, storage tank and
steel structure for EPC LAWE-LAWE Project.
The scope of this procedure shall apply from the receiving of welding consumables until the
acceptance of the weldment as follow:
• WPS Qualification
• Welding consumable control (electrode, wire/rod, flux & shielding gas)
• Welder control including welder and welding repair rate
• Welding control including Weld Log
• Weld Map, Welding Sequences, Welding Identification/Numbering

2.0 DEFINITIONS
The following constitutes a list of terms, which have been used in this procedure:

CONTRACTOR Organization to which PERTAMINA awards the EPC Scope of Work for
the PROJECT i.e., Joint Operations of China Petroleum Pipeline
Engineering and PT. HUTAMA KARYA (JO-CPPHK)
OWNER PT. KILANG PERTAMINA BALIKPAPAN
IPMT Integrated Project Management Team consists of OWNER personnel
and PMC. Communication between OWNER and CONTRACTOR to be
executed through IPMT as representative of OWNER. The PMC is
represented by Worley.
PROJECT Engineering, Procurement and Construction (EPC) for the scope of
work for the Lawe – Lawe storage terminal defined within and in
referenced document and drawings
SPECIFICATION Technical requirement which has not been included in Standards
STANDARDS Industry codes, standards, and recommended practices referenced
for this Project. These technical documents shall govern the products,
services, and Works to be performed by CONTRACTOR.
SUBCONTRACTOR Person or persons, firm, partnership, corporation, or combination
thereof engaged by the CONTRACTOR, (not being the employee of
CONTRACTOR) for supplying services to CONTRACTOR

3.0 ACRONYMS
The following constitutes a list of acronyms, which have been used in this procedure:
IPMT Integrated Project Management Team consists of a combination of
OWNER personnel and PMC. Communication between OWNER and
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CONTRACTOR to be executed through IPMT as representative of

OWNER. The PMC is represented by Worley.
AWS American Welding Society
GTAW Gas Tungsten Arc Welding
LNG Liquefied Natural Gas
MIGAS Representatives from the Indonesian Government who are
responsible for issuing licenses and permits for oil and gas Facilities
DEPNAKER Representatives from the Indonesian Government who are
responsible for issuing licenses and permits for Boiler or out of oil and
gas Facilities.
DIMET Representatives from the Indonesian Government who are
responsible for calibration tools, equipment, and measuring devices
NDE Non-Destructive Examination
PQR Procedure Qualification Record
RT Radiographic Test
RWPS Repair Welding Procedure Specification
WPS Welding Procedure Specification
PI “Perusahaan Inspeksi” - Certifying Authorities authorized Inspection
Agency

4.0 REFERENCES
This procedure refers to the following document:
4.1 PROJECT SPECIFICATION
26076-110-3PS-NWPO-L0016 Specification for Pipeline Welding (Amendment)
26076-110-3PS-MMT0-L0017 Specification for Pipeline Weld Radiography / NDE (Amendment)
26076-110-3PS-NW00-L1005 Specification of Welding, Shop and/or Field Fabricated Piping
LaweLawe Terminal
26070-100-3SS-NWP0-J0003 Engineering Specification for General Welding and NDE
Requirements for Vendor - Fabricated Piping and Piping Field
Welds
26070-100-3SS-NW00-J0004 Engineering Specification for General Welding Requirements for
Tanks
26070-100-3SS-NW00-J0005 Engineering Specification for General Welding Requirements
Structural Steel
4.2 CONTRACTOR PROCEDURE
26076-110-GPP-GCQ-00001 Control of IMTE Procedure

26076-110-GPP-GCQ-00002 Inspection and Testing Procedure

26076-110-GPP-GCQ-00009 Weld Repair Procedure
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26076-110-GPP-GCQ-00010 Welder Qualification Procedure

4.3 INTERNATIONAL STANDARD
ASME IX, 2019 Welding & Brazing Qualification
API 1104, 2021 Welding of Pipelines and Related Facilities
AWS A5.1, 2012 Specification for Carbon Steel Electrode for Shielded Metal Arc
Welding
AWS A5.01, 2008 Procurement Guidelines for Consumables — Welding and Allied
Processes — Flux and Gas Shielded Electrical Welding Processes
AWS D1.1, 2020 Structural Welding - Steel
API 650, 2020 Welded Tank for Oil Storage
API RP 582, 2016 Welding Guidelines for the Chemical, Oil, and Gas Industries
ASME II Part C, 2019 Specification for Welding Rod, Electrode and Filler Metals
ASME II Part A, 2019 Ferrous Material Specification
ASME V, 2019 Non-Destructive Examination
ASME B31.3, 2020 Process Piping
ASME B31.1, 2020 Power Piping

5.0 RESPONSIBILITY
It shall be the responsibility of the following personnel to successfully implement this procedure as
describe in the section 6.0:
5.1 CONTRACTOR QA/QC Department
QA/QC Department is responsible for overall execution of this procedure and specifically responsible
for ensuring the soundness of every weldment produce in the project. In doing this,
QA/QC Department shall be responsible for assuring the following:
• MIGAS endorsed WPS/PQR shall be approved by Owner prior to the start of any welding.
• Consumables used for welding all joint must be following approved WPS/PQR, and compliance
with spec and code (ASME Section II, Part C) and shall be control as detailed in Section 6.2
• Specified welding joint shall be non-destructively tested in accordance with respective
• Code, Project Specification & NDE Procedure
• Creating and updating a Weld Log for each discipline/subcontractor for NDT and welder
compliance assurance.
• Responsible to manage Subcontractors QA/QC activities

5.2 Construction Department

Construction department responsible to erected and installing, performing production welding for
all welding joint to be welded using approved WPS, using operable and calibrated equipment and
performed by qualified welders in accordance with project specification, procedure, and
code/standard, so that generating acceptable weld joint as per acceptance criteria of quality of
weld.
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Construction department shall be responsible to execute the quality of each weldment produced
from consumables control to the acceptance of the weldment.

5.3 Subcontractors
Responsible to provide quality tools and conditions for the FITTER and WELDER to produce a sound
weldment in executing their scope of work.
Fitter: Is responsible for the weld fit-up and preparation to match the WPS, Fit-up shall be inspected
by QC Inspector, status inspection shall be mentioned on welding matrix box (accepted / or not)
Approved & Qualified Welder: The welder is single handily responsible for the quality of the weld
itself. If the fit-up is not accepted or the welder is not satisfied with his/her work conditions,
weather, position etc. he/she shall not perform the weld.
Warehouse Supervisor: Is responsible for receiving the incoming welding consumables and will
verify consumable specification test requirements certificate along with correct quantities. He is
responsible for supplying the welding consumables to the welders and welding operators in
accordance with Request Sheet welding foreman. He is also responsible and good knowledge for
examining and rejecting damaged welding consumables after inspected from packaging. He will
maintain all consumable issue requests, baking / re-baking records and shall follow / implement
the requirements of this procedure
Welding Foreman: Is responsible for issuing to the welder a consumable Request Sheet which is
submitted to the Store men. The Store men will keep it for traceability records.

6.0 PROCEDURE
6.1 Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR)
All welding shall be made in accordance with the Owner approved WPS/PQR. Prior to the approval
of Owner, each of the WPS shall be reviewed and endorsed by MIGAS Certified Inspector. WPS
qualification shall be done by the following:

• Pre-Qualified WPS: Applicable to where the changes of the production welding requirement
do not include welding essential variables. The WPS still need to be
revised to capture the changes and supported by the existing PQR.

Note: Not applicable to Pipeline WPS.

• Qualified WPS: Applicable to where there are no existing WPS/PQR, or the changes of the
production welding requirement include the essential variables.

WPS and Pipeline’s repair WPS also welder/welding operators shall be qualified in accordance with
the following Codes:

• Pipeline : API 1104, 2021 edition1

• Piping : ASME Section IX, 2019 edition1

• Tank : ASME Section IX, 2019 edition1

• Structure : AWS D1.1, 2020 edition1

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All Approved WPS and welder list shall be posted in the Notice Board and relevant approved WPS
shall be posted to the welding station for welders’ reference, prior to start production welding.

Foot note 1:
Latest edition means for proposed new PWPS or WPS.
For WPS that already perform PQR, review approved OWNER, with or without acknowledge by PI
and approved by MIGAS will follow edition year code that statement in pWPS and PQR. OWNER could
notification about latest edition in WPS/PQR that has been approved if need it.

6.2 Consumable Control

General

Welding consumables shall be purchased from manufacturers who are acknowledged by bodies
which independently test consumables.

All welding consumables shall accordance with specification ASME Section II, Part C.

All consumables shall be shown on the WPS by their AWS classification, SFA No, F No, A No, Batch
No/ Lot No., Brand Name/ Trade Name.

All filler material shall be supplied with a minimum of EN10204 3.1 certification of Manufacturer’s
test certificate, which shall be available at Site for verification purposes.

Note: The consumable brand shall be the same as the used to qualify the WPS/PQR.

Detail of the welding consumable control as per Attachment 1: Welding Consumable Control
Flowchart.

Receiving inspection of welding material shall be performed by QC Inspector (or QC Engineer), and
to check the following items.

a. Visual condition of welding material

b. Welding electrode compliance with applicable codes and standards (ASME Section II Part C)
c. Certificate of welding material shall be reviewed and approved by QC/Welding Engineer whether
compliance with specification and standard or not prior to be used including shielding gas
certificates shall be in accordance with ASME Section II, Part C, SFA A5.32 (Purity, Dew Point
Temperature and Moisture Content)
d. Marking, damage, quantities etc.
e. Identification of color code
f. PMI or Ferrite check, if required

Storage

Welding consumables shall be stored with care in accordance with manufacturers’ instructions in
their original unopened packing with clean, dry conditions where a temperature of 20°C and humidity
of less than 40% are maintained. It shall be stored indoor and not directly contact with the floor.
Humidity measuring devices and temperature measuring devices shall be available and calibrated in
store. Each type, size and batch of welding consumable shall be properly identified and segregated
up to time of usage.
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No electrodes shall be left lying at the site or in the workshops and shall be removed or scrapped.
Damage/scrapped welding electrode shall be identified and separated in scrapped bin. Any
consumables packages, which are unidentified and showing signs of damage, deterioration, or
dampness, shall be returned to warehouse store for disposal.

Note: The record should be done by daily basis and the measuring devices & instrument required

for control of the consumable storage area shall require calibration as outlined in 26076-110-
GPPGCQ-00001 Control of IMTE Procedure.

Heating and Baking Requirement

Storage and baking of welding consumables shall be carried out in different ovens. Baking oven,
holding oven for electrode and flux shall be calibrated and valid condition. Ovens shall be heated by
electrical means and shall have automatic heat controls and visible temperature indication.
Distribution of all electrodes to welder shall be controlled by Store man for traceability record
purpose. The storage, baking, issue and return of welding consumables shall be controlled as per
procedures with records.

Basic low-hydrogen electrodes and fluxes shall be baked in accordance with the manufacturers'
instructions and shall give a weld metal deposit with a diffusible hydrogen content which shall not
exceed 10 ml/100 g weld metal.

All low hydrogen electrodes shall be baked as per manufacturer’s recommendation or at 270°C to
330°C for one (1) hour prior to use.

All oven for baking, holding and drying welding electrode shall be calibrated periodically, only
calibrated oven shall be used for drying welding consumables electrode.

On completion of baking, the electrodes shall be transferred to a holding oven at 120°C to 150°C.
When removed from the holding oven for use, the electrodes shall be transferred to heated quivers
or containers capable of maintaining a temperature of at least 80°C and used within 8 hours. Quivers
should in good condition and ready for used.
Electrodes not used within 8 hours or for some reason exposed to adverse atmospheric conditions
shall be re-baked and then transferred to the holding oven for later use.

Welding Consumables Storage Condition

Drying Condition
Air Holding Oven (Baking/Re-
Conditioned (Temperature Baking)
Type AWS Class
before open after open the
the packing Packing)

Cellulose 20°C to 45°C

Welding EXX10, EXX11 Not recommended Not recommended
Electrode 50% Max RH
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Welding Consumables Storage Condition

Drying Condition
Air Holding Oven (Baking/Re-
Conditioned (Temperature Baking)
Type AWS Class
before open after open the
the packing Packing)

10°C to 20°C above One Hour at 120°C

Rutile 20°C to 45°C to 150°C or
Welding EXX12; EXX13 ambient
50% Max RH Manufacturer’s
Electrode
temperature Recommendation

Low One Hour at 270°C

Hydrogen EXX15; EXX16; 20°C to 45°C to 330°C or
120°C to 150°C
Welding EXX18 50% Max RH Manufacturer’s
Electrode Recommendation

Stainless 5°C to 50°C

Steel Welding 120°C to 150°C Manufacturer’s
60% (±10%)
Electrode EXX15; EXX16 Recommendation
RH

E81T1-Ni1M; 20°C to 45°C

Flux Core Manufacturer’s
E81T1-M21A8; Not recommended
Wire 50% Max RH Recommendation
E71T1-C1A0

1,5-2 Hours at
Agglomerated 20°C to 45°C
F7XX; F6XX Not recommended 300°C-350°C or
Flux of SAW 50% Max RH Manufacturer’s
Recommendation

2 Hours at 350°C-
Agglomerated 20°C to 45°C
F55A6 Not recommended 400°C or
Flux of EGW 50% Max RH Manufacturer’s
Recommendation
Table 6-1: Storage, Baking, and Holding Condition

Refer to Attachment 2 for sample Electrode Baking and Holding Register

Issuance and Return

Baking and holding ovens temperatures shall be checked and recorded on Baking Log form daily by
the Welding Inspector.

The electrodes shall be taken out from the holding oven and issued to welders by transferring into
their heated quivers at minimum 80°C.
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The issuance and return of electrodes to/from the respective welders shall be recorded by Welding
Consumables Supervisor/Controller.
Limited but enough electrodes shall be issued to individual welders for use within eight (8) hours
period or as per manufacture recommendation.
The welders are required to carry along empty cans for electrode’s butt disposal to maintain good
housekeeping at site.
The return welding consumables shall be as follow:

• Welder shall return unused electrodes within eight (8) hours from issuance to the consumable
store
• The Welding Consumables Supervisor/Controller shall identify these electrodes by paint marking
at the end grip of electrodes and re-bake together with fresh electrodes before re-issue. Return
electrode shall be separated with new electrode during re-baking and prioritized to issuance
return electrode first before new electrode
Note: Should there are more than one welding consumables being baked in the same oven a
different paint colour shall be used for differentiation purposes.
• Welding material shall be clearly identified with manufacturer’s identification marking and it
shall be readable during site welding. SMAW welding electrode and GTAW welding rod shall be
color-coded additionally at the end of welding electrode or rod by Subcontractor Welding
Material Controller prior to issue it to welder as per welding material COLOR CODE TABLE (Refer
to Attachment 10)
Note: Should there are more than one welding consumables being baked in the same oven, a
different paint colour shall be used for differentiation purposes. Mixing of colour identification
is prohibited.
• The re-baked electrode shall be issued first before issuing the new electrodes
• The welder shall make it a priority to use electrodes identified with paint marking first
• The re-baking of electrodes shall be limited to one time only. More than one should be scraped/
dispose
• The temperature and time for the second baking shall be the same with the first time and the
distribution process should also be the same with the normal electrode distribution.
Note: Returned of the unused second baked electrode shall be recorded, painted, and disposed
accordingly.

Refer to Attachment 3 for sample Electrode Issuance Register.

6.3 Welder Control

Qualification

All welders shall be qualified in accordance with the Project Specification, approved WPS and
respective Codes as follows:

- Piping /Tank/ Pressure Vessel welders in accordance with ASME Section IX,
- Structural Welders in accordance with AWS D1.1
- Pipeline welders in accordance with API 1104
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Please refer to 26076-110-GPP-GCQ-00010 Welder Qualification Procedure for detail welder

qualification process. Only approved and qualified welder who can perform welding work for any
welding.
Welder Performance
Welder Stamp ID / Welder’s Tag No shall be recorded on the material being welded and verified
against the Welder List for their qualification confirmation. The same welder’s Tag No shall be
recoded in Visual Inspection Report and Weld Log.
Refer to Attachment 4 for sample Welder List Format.
Welder’s performance shall be measured on weekly basis for the weekly and cumulative evaluation.
The measurement shall be based on linear length as follow:

for those intended above, both steel structure, piping, pipeline, and Tank calculation defects
according to the above formula. the NDE method (RT, UT, PAUT or AUT). The Rejection Rate shall
be controlled by film & length for pipeline.

Note: For double processes joint, the owner of the defect shall be determined by its defect location
and measured as per the above formula.

The maximum rejection rate for each welder is 3%. Any welder reaching the maximum 3%, their
qualification shall be revoked, and requalification is needed before being allowed to continue
welding. Welders who reaching 3% reject rate can perform welding again after his requalification test
are passed.

Note: Specific training based on welder's individual type of defect shall be performed prior to their
requalification.

Please refer to 26076-110-GPP-GCQ-00010 Welder Qualification Procedure for detail welder

requalification process.

6.4 Welding Control

Welding Equipment

All welding machines shall be calibrated and periodically checked for their feature which control the
welding variables stated in relevant WPS. Calibration sticker/tag and expiration calibration date shall
be attached on the machines for evidence. Only operable and calibrated welding machines which are
allowed to be used for production welding. Periodically check should use control check sheet and
should be clarified by Welding Inspector. Such feature is as follow:

• Condition of amperage and voltage used for the operation of welding machine
• Condition of control system in mechanized and/or automatic welding equipment and its
accessories such as cable.
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• Wire Feeder of welding machines, baking oven, holding oven, clamp meter/tang ampere,
infrared temperature/ temperature gun, other measuring devices shall be calibrated,
calibration sticker/tag evidence shall be attached on the equipment/tools/measuring
devices

Weather Protection

Outside welding work using arc welding process and shielding gas shall be protected using welding
habitat/shelter to protect arc and molten metal during welding from outside weather atmosphere
(wind, rain, moisture).

Preheat and Inter-pass Temperature Control

Minimum Preheat shall be done as required by Approved WPS and shall be done using propane gas
torch or ceramic electric resistance heating pads. When Oxy fuel used for preheating appropriate
torch tip (rose bud tip) shall be used, using cutting/welding tip is prohibited. Preheating gas shall be
either ethylene gas, propane gas, acetylene gas or LNG. Preheating temperature measuring shall be
taken 75 mm from bevel edge, and interpass temperature shall be taken on the edge of weldment.

Maximum inter pass temperatures shall not exceed the limit established by the Approved WPS.

Temperature control can be carried out with temperature sensitive crayons, digital pyrometers,
contact thermometers or calibrated thermocouples. Temperature indicating crayons shall not be
marked on weld bevels, weld beads or surfaces to be welded. Temperature indicating crayon for
stainless steel materials shall not contain low-melting temperature elements (sulphur and halogen).
Temperature measurement device shall be available on site for welding which require preheating
and restricted interpass temperature. Application of Preheating for material P No. 1, also apply for
thermal gouging and cutting, and tack welding. Excluding P No.1, weldment which are required
preheating shall be completed with no intermediate cooling.

Non-Destructive Test

Visual inspection shall be conducted at the minimum during fit up and after welding. This will be
recorded in the respective quality records. Welding parameter shall be recorded and available during
daily surveillance and focus should be given to the critical line and concern welder.

Based on the project requirement, all NDE shall be conducted after the acceptance of visual
inspection. The Rejection Rate shall be controlled by film & length for pipeline. This shall be
recorded in the respective NDE Record and the result will be evaluated weekly for the weekly and
cumulative production repair rate as follow:

• Radiographic Testing shall be measured by film at 3% maximum repair rate

• Ultrasonic Testing shall be measured by joint at 3% maximum repair rate.
For fabrication and installation of Process Piping, random NDT selection shall follow ASME B31.3, as
follow:

• Normal Fluid Service: 5 % by RT

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• Severe Cyclic Conditions: 100% by RT

• Category D Fluid Service: 100% by VT
• Category M Fluid Service: 5% by RT, except mention in ASME B31.3, paragraph M341.4.b
• High Pressure: 100% by RT

Determination of piping service category shall follow Supplement A-Piping Welding Data Sheet
26076-110-3PS-NW00-L1005-001 Specification of Welding, Shop and or Field Fabricated Piping Lawe-
Lawe Terminal (AMENDMENT)

Weld Repair
NDE rejected weldment shall be repaired and retest as per the original NDE method
Weld repair shall be done based on the WPS as follow:

• Pipeline : Based on the Repair Welding Procedure Specification (rWPS)

• Structure: Based on the original WPS

• Piping : Based on the original WPS

• Tank : Based on the original WPS

Note: Only two repair attempts are allowed on any defective at same area. Additional attempt shall
require OWNER’s approval.

Refer to 26076-110-GPP-GCQ-00009 Weld Repair Procedure for weld repair process

7.0 ATTACHMENT

Attachment 1 : Welding Consumable Control Flowchart

Attachment 2 : Sample Electrode Baking and Holding Register

Attachment 3 : Sample Electrode Issuance Register

Attachment 4 : Sample Welder List Format

Attachment 5 : Sample Inspection, Measuring and Test Equipment (IMTE) Control Log

Attachment 6 : Sample Welding Summary Report

Attachment 7 : Sample WPS Summary

Attachment 8 : Welding Material Issue Slip

Attachment 9 : Baking Log

Attachment 10 : Table Welding Consumables Colour Code

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Attachment 1: Welding Consumables Control Flow Chart

START

Consumables Received with

Supporting Documents

Receiveing Inspection

NO
Check Return to Supplier

Accepted

Rutile Low Hydrogen Cellullose Stainless Steel Flux Core Wire

Agglomerated Flux for SAW Agglomerated Flux for EGW
Open Pack at 20-45° C; 50% Open Pack at 20-45° C; 50% Open Pack at 20-45° C; 50% Open Pack at 20-45° C; 50% Open Pack at 20-45° C; 50%
Open Pack at 20-45° C; 50% Max RH Open Pack at 20-45° C; 50% Max RH
Max RH Max RH Max RH Max RH Max RH

Apply Color Coding at end Apply Color Coding at end Apply Color Coding at end Apply Color Coding at end
grip grip grip grip

Dry (Bake) for 1 Hour at Dry (Bake) for 1 Hour at Dry (Bake) at for 1,5-2 Hours Dry (Bake) at for 1,5-2 Hours
120°C-150°C or 270°C-330°C or Dry (Bake) at Manufacturer Dry (Bake) at Manufacturer Dry (Bake) at Manufacturer at 300°C-350°C or at 300°C-350°C or
Manufacturer Manufacturer Recomendation Recomendation Recomendation Manufacturer Manufacturer
Recomendation Recomendation Recomendation Recomendation

Apply White Color at end Apply White Color at end Apply White Color at end Apply White Color at end Mixed with the new flux with Mixed with the new flux with
grip for return electrode Holding Oven at 10°C-20°C grip for return electrode grip for return electrode grip for return electrode ratio 1:4 ratio 1:4
Holding Oven at 120°C-150°C Holding Oven at 120°C-150°C
above ambient temp

Issuance Issuance Issuance Issuance Issuance Issuance Issuance

Welding Process (quiver Welding Process (quiver Welding Process (quiver Welding Process (quiver
Welding Process Welding Process Welding Process
temp is 80°C) temp is 80°C) temp is 80°C) temp is 80°C)

Remaining electrode/wire Remaining electrode/wire Remaining electrode/wire Remaining electrode/wire Remaining electrode/wire
after 8 hours exposure time after 8 hours exposure time after 8 hours exposure time after 8 hours exposure time after 8 hours exposure time

OK OK OK OK OK OK OK
Check Remaining Check Remaining Check Remaining Check Remaining Check Remaining
Check Remaining Flux Check Remaining Flux
Electrode Electrode Electrode Electrode Electrode

NO NO NO NO NO NO NO

Scrapped Scrapped Scrapped Scrapped Scrapped Scrapped Scrapped

END END END END END END END

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Attachment 2: Sample Electrode Baking and Holding Register

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Attachment 3: Sample Electrode Issuance Register

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Attachment 4: Sample Welder List Format

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Attachment 5: Sample Inspection, Measuring and Test Equipment (IMTE) Control Log
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Attachment 6: Sample Welding Summary Report

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Attachment 7: Sample WPS Summary

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Attachment 8: Welding Material Issue Slip

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Attachment 9: Baking Log

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Attachment 10: Table Welding Consumables Colour Code