Doc. No.

: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 1 of 15

LPG Train-4 Project

at
MAA Refinery

Contract CA/CSPD/0009

WELDER AND WELDING OPERATOR

QUALIFICATION PROCEDURE
(LPG4-CGP-053)

0 02-Jul-11 For Construction J.H. SONG J.H. SEO HS.EOM SK.KIM

Revised as per Company

B 18-Jan-11 comments via PMC-DICS- KR.PARK HS.HAN HS.EOM SK.KIM
LPG$- X - 301

A 13-Nov-10 For Aprroval KR.PARK HS.HAN HS.EOM SK.KIM

ORIGINAL/
CHECKED CHECKED APPROVED
REV. DATE DESCRIPTION REVISED
BY BY BY
BY

LPG Train-4 Project at MAA Refinery

Contract CA/CSPD/0009
 Doc. No.: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 2 of 15

REVISION LOG

Rev. NO. Rev Date Revised Page Revision Description

2 Insert revision log
Clause 10.0 Revised as per Company
B 18 Jan‘11 9
Comments
10 Clause 11.3 added Company Comments
Issuance of Rev “0” of previous Company
0 02 Jul‘11 approved construction documents with
A1 status
 Doc. No.: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 3 of 15

TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCE CODES, SPECIFICATIONS AND PROCUDURES

3.0 RESPONSIBILITIES

4.0 GENERAL

5.0 TEST COUPON

6.0 POSITION

7.0 QUALIFICATION TEST

8.0 ACCEPTANCE CRITERIA

9.0 RETEST

10.0 RENEWAL OF QUALIFICATION

11.0 EXPENSE

12.0 DOCUMENTATION

13.0 ATTACHMENTS
 Doc. No.: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 4 of 15

1.0 SCOPE

1.1 This procedure is to provide the method of qualification of welder and welding operator
to the requirements of ASME sec. IX, ANSI B 31.3 and AWS D 1.1 which shall be
prepared and executed at the site for LPG Train-4 Project at MAA Refinery.

1.2 Welder qualification tests shall be performed in accordance with welding procedure
specification (WPS) based on ASME section IX and this procedure.

1.3 One of the following process will be applied or combination.

a) Shielding metal arc welding (SMAW)

b) Gas tungsten arc welding (GTAW)
c) Submerged arc welding (SAW)
d) Flux cored arc welding (FCAW)
e) Gas Metal Arc Welding (GMAW)

2.0 REFERENCE CODES, SPECIFICATIONS AND PROCEDURES

2.1 Reference Codes

ASME Sec. IX - Qualification Standard for Welding And Brazing Procedure,

Welders, Brazers, And Welding And Brazing Operators.

ASME Sec. II Part C - Specifications For Welding Rods, Electrodes, and Filler Metals.

ASME B 31.3 - Process Piping

ANSI B 16.25 - Buttwelding Ends

ASME Sec.V - Nondestructive Examination

SNTTC-1A - Qualification and Certification of Nondestructive Test Personnel.

2.2 Project Specification

 Doc. No.: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 5 of 15

KNPC Engineering Standard 50D11 - PIPING WELDING

KNPC Engineering Standard 50D12 - WELDING SPEC CARBON STEEL.

KNPC Engineering Standard 50D13 - WELDING SPEC CARBON-MOLY STEEL.

KNPC Engineering Standard 50D14 - WELDING SPEC STAINLESS STEEL.

KNPC Engineering Standard 52C1 - SHOP AND FIELD FABRICATION PIPING.

KNPC Engineering Standard 52C2 - PIPING REINFORCEMENT.

KNPC Engineering Standard 52C4 - SHORT ARC WELDING RESTRICTIONS.

KNPC Engineering Standard 52C6 - CEMENT LINED PIPING FABRICATION.

KNPC Engineering Standard 53C1 - PIPING ERECTION.

2.3 Project Procedures

LPG4-CGP-051 : General Welding Procedure.

LPG4-CGP-053: Welder and Welding Operator Qualification Procedure.

LPG4-CGP-052: Welding Material Control Procedure.

LPG4-CGP-059: Welding Repair Procedure.

LPG4-CGP-058: Positive Material Identification Procedure.

3.0 RESPONSIBILITIES

3.1 Contractor QC Engineer and Company shall be responsible for assuring that testing is
done in accordance with code requirements and welding procedure specifications
(WPS).

3.2 The Welding Qualification Test (WQT) shall be reviewed I witnessed and certified by the
Contractor QC Engineer and Company

3.3 Contractor QC Engineer and Company shall be responsible for interpreting radiographic
film of welder qualification test in accordance with the acceptance criteria of ASME Sec.
 Doc. No.: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 6 of 15

IX, QW191.2.

3.4 Contractor QC Engineer and Company may require re-qualification of welder or welding
operator if their ability to produce sound welds is questionable.

3.5 Vendor / Contractor is responsible for the welding performed by his welder who shall
conduct the required qualification test. Qualification for vendor fabrication is may
acceptable provided copy of the welder and welding operator qualification test records
are available for Contractor QC and/or Company for request.

4.0 GENERAL

4.1 All welders and welding operators shall be tested to qualify the performance of welder in
accordance with qualified procedure specification.

4.2 Only welders that are experienced in the specific welding technique shall be presented
for testing.

4.3 A welder shall be re-qualified if change is made in one or more of the essential variables
listed for each welding process as per ASME Sec.IX.

4.4 Any welder certified by other organizations shall be required to re-qualify as per the
requirement of this procedure.

4.5 For weld tests conducted on pipe in the 6G position, the pipe bottom shall be fixed rigidly
at 450mm above ground level at an angle of 45° ± 5°

4.6 The test plates or pipes must not be moved from their initial position until all welding is
completed and the completed weld shall be thoroughly brushed and cleaned.

4.7 No backing strips or rings are allowed.

4.8 No back gouging or grinding for root pass is allowed.

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OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 7 of 15

4.9 No inter-pass grinding is allowed, in general. However, spot inter-pass grinding may be
done, if required, with the approval of Contractor QC Engineer or Comapny

4.10 During qualification test, Welder will not be allowed to take help of any support during
welding.

4.11 Contractor QC Engineer or Company Inspection Engineer may stop the test and fail the
welder at any time during the test, if the welder shows insufficient skill or welding
knowledge.

5.0 TEST COUPON

5.1 Test coupon materials for welder qualification will be made from the same P-number
materials or substituted in accordance with ASME Sec IX, QW-423 .1.

5.2 Test coupon shall be flame cut I machined and beveled as shown on joint detail of
welding procedure specification (WPS) and the minimum length shall be 4 inches.

5.3 Generally, the size of test coupon will be used as follows unless otherwise specified.;

Item Test Coupon Qualified Range

& Diameter Thickness Outside Thickness Remark
Position
Position (NPS-INCH) (mm) Diameter (mm)

Sch80 1"
2” Up to 11.0t All
(5.5t) and Over
Pipe (6G)
Sch120 2⅞"
6” Unlimited All
(14.2t) and Over Groove
&
24" Fillet
Plate 6.0t Up to 12.0t All
and Over
Plate
(2G/3G/4G)
24"
Plate 13.0t(½”) Unlimited All
and Over

Plate 2⅞(73mm)" Fillet

Plate 6.4t Unlimited All
(3F/4F) and Over Only

Pipe (5F) 2”(Pipe) Sch40(3.91t) 1" Unlimited All

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WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 8 of 15

Plate 6.4t and Over

Note) 1. 2⅞”(73mm) O.D is the equivalent of NPS 2½"

2. Welder qualified with 2G & 3G(Plate) Position may be applied for shop welding

6.0 POSITION

6.1 Welder and welding operator will be tested in a position that can cover all welding
process as long as possible.
Example)
For pipe welder: 6G position
For plate welder: 2G, 3G & 4G position.
For fillet welder: 3F & 4F position.

6.2 In special cases, welding operators may be qualified by production welding when
welding conditions shall be restricted as few quantity or special reasons. In case, No
welding is able to start without conforming with Company.

6.3 Special attention shall be taken for qualification of small bore and/or thin wall thickness
pipe (Sch10 and less) and owing to job conditions, welder qualification test for small
bore pipe may be performed in accordance with ASME Sec IX, QW452.1, QW 452.3
and QW 452.4.

7.0 QUALIFICATION TEST

7.1 The test pieces shall be prepared, cleaned, fitted and tacked as required on welding
procedure specification (WPS).

7.2 After welding, test piece identification No and position shall be marked on the top of test
piece for identification before the radiographic test or other mechanical test.

7.3 QC Engineer shall inform the results of qualification test and witness all qualification
tests to evaluate welder's ability.

7.4 The identification card of welder or welding operator may be terminated at any stage by
QC engineer, whenever it become apparently that welder or welding operator does not
have the required skill to produce satisfactory results.

7.5 After test coupon are welded completely, the test coupon shall be visually inspected by
welding inspector or QC engineer and Company. (at its discretion) prior to radiographic
test or mechanical tests.

7.6 Combination Process

a) Where a combination welding processes are used on a single test coupon, the limits
of thickness for which the welder is qualified dependent upon the thickness of the
deposited weld metal with each welding process.
b) Failure of any portion of a combination test in a single test coupon shall constitute
failure of the entire combination.
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WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
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7.7 All mechanical tests shall be met with the requirements of prescribed in ASME Sec IX,
QW-160 or QW-180 or Radiographic Test shall be met with the requirements of
prescribed in ASME Sec IX, QW-302.2.

7.8 Radiographic Test may be substituted for mechanical tests in groove weld performance.

8.0 ACCEPTANCE CRITERIA

8.1 Guided bend test shall meet the acceptance criteria of ASME Sec IX, QW-163.

8.2 Fillet weld test shall meet the acceptance criteria of ASME Sec IX, QW-180.

8.3 The Radiographic technique and acceptance criteria shall be in accordance with ASME
Sec IX, QW-191.

9.0 RETEST

If a welder fails to qualify for given class, he may not retake that qualification test until a
minimum of one month practice. Under special circumstances immediate retest may be
conducted, provided double the number of test coupons are prepared and tested.

10.0 RENEWAL OF QUALIFICATION

The welder / welding operator's qualification test shall be effected under the following
conditions;

 Certification will be issued for one year duration and shall be renewable every year,
on the basis of satisfactory performance of the welder.

 When he has not welded with a process during a period of 6 months or more, his
qualification for that process shall be expired even another process continues
welding. Welder validity can’t be extended for one process based on the continuity
of another process as per Section QW-322 of ASME Sec IX.

 When there is a suspicious that the welder would not shows his skills to the welding
requirement, his qualification may be expired at the discretion of Contractor QC
Engineer / Company and required of re-qualification test.

11.0 EXPENSE.

11.1 All Contractor’s welders must have valid Company welding certificates. For conducting
the welder qualification test, the Company shall charge the Contractor KD.25/-per welder
per test as per the contract.

11.2 For conducting the welder qualification test, Contractor shall provide test coupon.
 Doc. No.: LPG4-CGP-053
WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 10 of 15

11.3 Contractor QC Engineer will prepare the new identification card (Project ID number) for
assigning new personnel provided he has qualified in Company's previous project under
Company's staff signed ID card. In case, subcontractor (welder) submit copy of
qualification record with original stamp and original welder identification card for
verification by Contractor QC Engineer and Company's staff. Issue of new ID card shall
be subjected to the performance verification of concerned welders.

12.0 DOCUMENTATION

12.1 Welding inspector or sub-contractor shall notify to the Contractor QC Engineer the date /
time / location for welder qualification test. And Contractor QC Engineer shall submit the
notification to Company. The notification contains copy of identification card in English to
verify the welder such as passport and any other supporting document that verifies his
experience.

12.2 All qualification test shall be performed under the witness of QC Engineer and/or
Welding Inspector and Company (at its discretion).

12.3 The test piece identification number shall be assigned by Contractor QC Engineer and
the identification number is consisted of a series of number in sequence. For example,
the number should be begun from TC-0001, TC-0002 and so on regardless of process,
kinds of code etc.

12.4 After qualification test are accepted, Contractor QC Engineer will assign permanent
welder identification number for LPG Train-4 project such as WD-001.WD-002 and so on
regardless of process, kinds of code etc.

12.5 The welder identification number shall not be duplicated in our project.

12.6 Welder identification card and Welding performance qualification certificate for each
qualified welder shall be prepared and submitted to Contractor QC department. Original
certificate shall be maintained by Company. Original welder card and copy of welder
qualification record may to be issued to subcontractor.
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WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
PROCEDURE Rev. 0 Page 11 of 15

12.7 Welder identification card shall be issued to each qualified welder by Company.

12.8 The contractor shall maintain an active welder register / log in the attached form PRJ
QMS 91-97-5136. This form shall be updated and revised whenever there is an addition
or deletion of welders. The updated welder register / log shall be submitted in the final
QC dossier.

13.0 ATTACHMENTS

13.1 Notification for Qualification Test of Welder I Welding Operator.

13.2 Welding Performance Qualification(WPQ) Certificate - QMS FORMAT

13.3 Welder Identification Card.- QMS FORMAT

13.4 Welder Register - Log - QMS FORMAT.

 Doc. No.: LPG4-CGP-053
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OPERATOR QUALIFICATION Job No.: 090768
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Attachment 13.1

Notification for Qualification Test of Welder I Welding Operator

New Ethane Recovery Plant Project at MAA Refinery

You are kindly be notified that our welder I welding operator qualification test are scheduled as described in
following. We would be much appreciated for your timely witness

A. Applicants (*) Test piece 10 No will be assigned by Contractor QC Department

Discipline Subcontractor Notification No.

Test piece Specimen Used Remark

No Name WPS No Process Position
ID No. C*) Spec O.D Thk. electrode (Appli. Code)

B. The test will be performed at (Place). (Time) On (Date)

Prepared (WE/Sub-con) by

Received (Contractor QCE) by

Received (Company) by

Signature Date

Form no. : 608-E-01

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OPERATOR QUALIFICATION Job No.: 090768
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Attachment #13.2
WELDER PERFORMANCE
QUALIFICATION (WPQ) CERTIFICATE
Qualification: Codes/Standards

Manufacturer's Name WPQ Certificate No.

Address Date

Welder Name

Welder Identification No. Weld Test No.

WPS’'No. Rev. No. Welder Signature

Validity of this Certificate Expires on Place of Test/Shop or Site Date of Test

MATERIAL(S) AND WELDING DETAILS

Materials Specification, Type & Group Filler Type and Designation
Materials Specification, Type & Group Shielding and Purging Gases
Type of Joint (Sketch-with WELD TEST DETAILS RANGE OF
dimensions) APPROVAL
WELDING PROCESS
PLATE OR PIPE (FD.'EDIROTATED)
JOINT TYPE
TEST PIECE THICKNESS (mm)
WELDING POSITION
GOUGING BACKING
WELDED-0NElBOTH SIDES
OTHER

TEST RESULTS STATE "SATISFACTORY", "UNSATISFACTORY" OR "NOT APPLICABLE"

NON-DESTRUCTIVE EXAMINATIONS DESTRUCTIVE TESTS
VISUAL MACRO EXAMINATION
MAGNETIC PARTICLE ROOT BEND
LIQUID PENETRANT FACE BEND
RADIOGRAPHIC SIDE BEND
ULTRASONIC FILLET \VELD FRACTURE
OTHER OTHER

We Certify that the above statements are correct and that the test pieces were prepared, welded
and tested in accordance with the specified Codes or Standards
Approved by: Date

PRJ-QMS 91-97-5135 Rev. 0

Form no. : 608-E-02

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WELDER AND WELDING
OPERATOR QUALIFICATION Job No.: 090768
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ATIACHMENT #13.3

KUWAIT NATIONAL PETBOLEUM COMPINY

PROJECTS DEPARTMENT
INSPECTION &. SAFETY DIVSION
WB.lBlII8mRCII1I1 CU.

NAME:

IDENTIFICATION NO. :

CONTRACTOR:

PROJECT REF:

APPROVED BY: WITNESSED I RENEWED BY DATE

SUPDT. INSP. & SAFETY-PD INSP. ENGR.
PRJ.QMS·91·97·51~· REV. 1 (SIDE 1)

WELDER CIVIL 10 NO: _

WELDER QUALIFIED ON
PIPE: □ PLATE: □
TEST POSITION:
MATERIAL SIZE & THICKNESS :
MATERIAL: P. No. :
FILLER MATERIAL: F. No. :
TECHNIQUE:
DATE OF TEST: VALIDITY:
DATE OF RENEWAL : VALIDITY:

This card may be revoked on the job if, in the opinion of the Inspection
Engineer, weld quality Is not satisfactory.

PRJ.QMS·91-97·5134· REV. 1 (SIDE 2)

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Attachment 13.4