PTT PUBLIC COMPANY LIMITED RATCHABURI WORLD COGENERATION COMPANY LIMITED GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT DOCUMENT TITLE: WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT) DOCUMENT NO.: PR-W-1102.21-4012-003 REVISION: 0 REVIEW STAMP COMMENTS E. Work may proceed. F. Work may proceed. Submit “for Construction” Documents. G. Revise and Resubmit. Work may proceed Subject to incorporation of changes indicated. H. Revise and Resubmit. Work may not proceed. I. Review not required. Work may proceed. Acceptance in any of these categories shall be in no way relieve the Contractor/Supplier of its responsibility for the due and proper performance of the Work in accordance with the Contract/Purchase Order. Name: Sign: Date: 0 02/04/13 Issued for Construction WS JR NP A 29/01/13 Issued for Approval WS JR NP Rev. Date Description Prepared By Checked By Approved By CONTRACTOR: SIAM RAJATHANEE JOINT VENTURE CONSULTANT: UNITY ENGINEERING AND CONSULTANCY SERVICES CO.,LTD.
Transcript
PTT PUBLIC COMPANY LIMITED RATCHABURI WORLD COGENERATION COMPANY LIMITED
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
DOCUMENT TITLE: WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT)
DOCUMENT NO.: PR-W-1102.21-4012-003 REVISION: 0
REVIEW STAMP COMMENTS
E. Work may proceed.
F. Work may proceed. Submit “for Construction”
Documents.
G. Revise and Resubmit. Work may proceed Subject to incorporation of changes indicated.
H. Revise and Resubmit. Work may not proceed.
I. Review not required. Work may proceed.
Acceptance in any of these categories shall be in no way relieve the Contractor/Supplier of its responsibility for the due and proper performance of the Work in accordance with the Contract/Purchase Order.
Name:
Sign:
Date:
0 02/04/13 Issued for Construction WS JR NP
A 29/01/13 Issued for Approval WS JR NP
Rev. Date DescriptionPrepared
ByChecked
ByApproved
By
CONTRACTOR:
SIAM RAJATHANEE JOINT VENTURE
CONSULTANT:
UNITY ENGINEERING AND CONSULTANCY
SERVICES CO.,LTD.
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 2 of 19
DOCUMENT CHANGE RECORD
Rev Date Prepared/
Revised
By
Reviewed By
Approved By
Description
A 29/01/13 WS JR NP Issued for Approval
0 02/04/13 WS JR NP Issued for Construction
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 4 of 19
1. PURPOSEThe procedure sets an outline for qualification test welders of the Gas Pipeline and Gas Metering and Regulating Station Project in accordance with ASME Section IX, API 1104.
2. SCOPE
For pipe welding GTAW (manual) process and GTAW+SMAW (manual) can be selected. The pipeline/piping welders shall be qualified based on the approved Welding Procedures Specifications (main line welding, tie-in welding and welding repairs) and Procedure Qualification Records.
3. DEFINITION
Owner means Ratchaburi World Cogeneration Company Limited.Advisor means PTT Public Company Limited.Project means Gas Pipeline and Gas Metering and Regulating Station Project.Consultant means Unity Engineering and Consultancy Services Co., Ltd Contractor means Siam Rajathanee Joint Venture Co., Ltd.HSS&E means Health, Safety, Security and EnvironmentJSEA means Job Safety and Environment AnalysisWPS means Welding Procedure SpecificationWPQ means Welder Performance QualificationPQR means Procedure Qualification RecordWPR means Welding Procedure RecordPCN means Personnel Certification for NDT.CSWIP means Certification Scheme for Welding Inspection PersonnelASNT means American Society of Non Destructive TestingAWS means American Welding SocietyQA means Quality AssuranceQC means Quality ControlNDT means Non Destructive TestingPT means Penetrant TestRT means Radiographic TestingQC Manager means Quality Control Manager Welding Supervisor means Controls and Coordinates all of the site welding activitiesWelding Forman means Controls the specific day to day welding activities for one or
more welding locationWelding Inspector means Inspects the activities related to weldingQuality Control Engineer means Writes, Runs and approves the welding procedures and
WPS for the ContractorSubcontractor means The party to which Contractor has sub-contracted a portion
of the Work under the Contract
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 5 of 19
4. RESPONSIBILITY
4.1 Quality Control Manager
The QC Manager shall report to the Project Manager, and his duties include, but are not limited to:
Implementation of the Contractors Quality Specifications and Procedures relevant to pipeline inspections.
Complete inspection, witness monitoring verification activities in accordance with the
Contractors Inspection and Test Plan and Procedures.
Ensure inspection personnel are issued with approved Procedures and adequate inspection equipment
Review and complete (where applicable) all required documentation and obtain all necessary approvals and signatures.
Review destructive and non-destructive examination reports including interpretation of weld radiographs.
Prepare all Quality Control documentation, i.e. Procedure Qualifications for Welding, NDT and Coating etc. for acceptance.
Prepare all pre-construction documentation with respect to Control of Welding, NDT and Coating.
Liaise with the Owner/Consultant Inspectors during pipeline fabrication and installation to resolve any Quality related problems.
Co-ordinate Welding, NDT Coating and Installation Inspection personnel, including:
Welding Inspectors
Erection QC Inspectors 4.2 Welding Supervisor
The Welding Supervisor shall report to the Construction Manager, and his duties include, but are not limited to:
Coordinating welding activities
Ensure that the welding foreman is fully conversant with the welding techniques and procedures.
Ensures that the welding consumables are available and complied with approved Procedure Qualification Record’s.
Liaise with the Contractor’s Welding Inspector on a daily basis to resolve any related problems.
Ensure non-destructive examination requests are progressed.
4.3 Welding Foreman
The Welding Foreman shall report to the Welding Supervisor, and his duties include, but are not limited to:
Ensure welding plant equipment is maintained in good order.
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 6 of 19
Implementing the approved weld procedures; supervise all welding personnel and ensure their competence. Ensure that all welders are approved for the welds they have to perform.
Ensure that all welders are issued with the correct consumables and equipment, and are familiar with, and understand, all welding parameters.
Ensure that welding is carried out under the correct conditions and suitable weather protection is available.
Liaise with the Contractor’s Welding Inspector on a daily basis to resolve any related problems.
Ensure non-destructive examination requests are progressed.
Ensure the WSP parameters I.E. voltage, travel speed, current are correct
4.4 Welding Inspector
The QC Inspector / welding inspector reports to the QC Manager and is shall be responsible to ensure all inspection and testing activities are conducted, reported and recorded in accordance with the relevant procedures.
4.5 Quality Control Engineer
The Quality Engineer shall be responsible for assisting Quality Control Manager to prepare the proposed WPS, running the procedure qualification tests, arranging and witnessing the mechanical testing, preparing the weld procedure qualification records and final WPS.
5. JOINT PENETRATIONDimensions and line up around the circumference of the pipe is seldom uniform. Pipe variations within the specified tolerances shall be permitted with little line up difficulties. The tolerances for pipeline shall be as follows:Uphill weldingBevel 30°, +5° -0°Root face or land 1/16” ± 1/32”Fitting - Up Joint and alignmentThe longitudinal weld seams of adjacent pipe shall be offset by the lesser of 90° or a circumferential distance of 250 mm (whichever is the least). Cold bending or heating of the pipe to force expansion or angular deflection during alignment of the weld joint is prohibited. Hammering will be held to a minimum. When aligned for welding, adjoining lengths of pipe shall be parallel and under no circumstances shall mitered pipe welds be allowed.Use of External ClampsExternal clamp is permitted for tie-in welds, fabricating pipe strings for obstacle crossings and auger bored crossings. External line up clamp shall not be removed until at least 50% of the root bead is deposited. For station welding bridge tacks shall be used for alignment of pipes. Grounding All ground clamps shall be securely attached to avoid arc burns under the clamp and no ground clamp shall be welded to the pipe or fitting being welded. When welding pre-coated pipe, ground clamps shall be attached to the un-coated area near the welds.
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 7 of 19
6. RECORDING WELDING PARAMETERS DURING WPQRThe procedure to be employed for recording welding parameters and calculating heat input shall be as follows:
One recorder shall record each half of a weld joint Amperage and voltage shall be set within the range specified in the WPS The total distance shall be measured from 12 o’clock to 6 o’clock position (or ½
circumference of the joint) and this shall be marked on the pipe prior to welding Travel speed shall be measured by a stop watch using the stop / start method i.e. the stop
watch shall be started at the start of an arc and shall stop whenever the arc is broken. As soon as the welder restarts welding the stop watch shall also restart.
The total time recorded shall be reflective of actual “arc time” Voltage and amperage readings shall be taken in the 1 o’clock, 3 o’clock, 5 o’clock 7 o’clock,
9 o’clock and 11 o’clock positions circumferentially The voltage and amperage readings taken shall be averaged out The travel speed and heat input shall be calculated This procedure shall be carried out for each welder on each pass
The formula for heat input calculation shall be as follows:Heat input = Amps x Volts x 60 ÷ Travel speed x 1000Welding parameters shall be recorded in :
the WPQR for welding procedure qualification testing. the WQTR for welder qualification testing. the production welding parameters shall be recorded for production welding
The welding supervisor shall give guidance to the welders in his team based on the information generated during monitoring and recording. The method for management and control of travel speed and hence heat input is further illustrated below (See figure 1)
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 8 of 19
7. PIPE CUTTING / BEVELLING/ CLEANINGGenerally, pipeline materials are supplied with beveled ends. However where bevels are unsuitable or are re-cut to suit field dimension, such cutting will be executed using machine cutting techniques and re-beveled by using a beveling machine.
All cut / re-cut beveled pipe ends shall be inspected using MT/UT for a distance of 100 mm from the end.
Pipe or fittings supplied with bevels that are not in accordance with the approved WPS, shall be re-beveled.
All weld bevels shall be thoroughly cleaned. Cleaning shall extend from the prepared edge on both inner and outer surfaces to the interface with the external coating / internal lining, by power wire brushing.
When the pipe is wet or moist for any reason, the ends will be dried using oxy-fuel heating torch before being placed in alignment for welding.
8. WELDING CONSUMABLE CONTROLWelding consumables (electrodes), shall be controlled by the following measures :
Centralized controlled dry storage area Issuance of electrodes shall be controlled by the welding supervisor, and the minimum
amount of electrodes, shall be in use at all times Electrode containers shall only be opened sufficiently to extract electrodes and to prevent as
far as practical the ingress of water and contaminants Electrodes shall be kept dry and clean at all times during use Open, partially used electrode containers shall be returned to the central store every evening Electrodes that become contaminated, shall not be used and shall be removed and discarded
9. WELDER IDENTIFICATIONWelders shall be identified by issuance of identification cards stating:
Welders’ name, photograph and signature Welder I/D no. Welding procedures and positions qualified Date of WQT Card issue number
All welder I/D cards shall be approved, and signed by welding supervisor, reviewed and initialed by QA / QC manager prior to issuance to the welders. The I/D cards shall be controlled by issue number and shall be traceable to the “register of pipeline welders”.
WELDING POSITION AND DIRECTION
Mainline welding and Tie-in welding
Minimum 2 welders shall perform welding for all passes. Position 6G fixed.
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 9 of 19
Direction uphill for all passes for GTAW +SMAW (manual) process as an option
Recommended pass sequence
Refer to PR-W-1102.21-4012- PTT Welding Procedure Specification for Piping and Pipeline (WPS).
10. WELDING METHODStringer bead
The WPS should be checked for proper electrode size, wall thickness and chemistry of the
pipe being welded.
After the pipe is lined up and held in position with the clamp, the two welders working on the
opposite sides of the pipe make the first and most important weld, the stringer or the root
bead.
The pipe or the external clamp shall not be moved unless the stringer bead is 50% complete.
Hot Pass
Thoroughly clean the stringer bead before starting the hot pass.
Remove slag from each bead by power wire brushing or light grinding.
Disc grinding may sometimes be necessary on the stringer bead to remove a humpy start or
to improve the bead contour before applying the hot pass.
The current as set by the “feel and touch” of the operator must be high enough to burn wagon tracks out, but not enough to cause electrode coating breakdown. Start the hot pass immediately after completion of stringer bead always within 1-6 minutes.
Filler Pass
A slight side to side weave is used when applying filler passes to completely fill the groove. Pinholes also result if the electrode is dried by exposure to the hot sun or exceptionally dry
weather. The correct current for filler and cover passes gives a clean slag free crater about 3/8″ long.
Cover Pass
The cover pass is usually 1/16″ to 1/8″ higher than the pipe wall and overlaps the groove by 1/16″ to 1/8″ on each side.
Each pass must be thoroughly cleaned before running the next bead. Don’t start a new bead at the same point where a previous bead has been started. Avoid undercutting at the edge of this bead.
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-003
Rev. 0 Page 10 of 19
11. RANGE OF WELDING VOLTAGE AND AMPERAGE
Use voltmeter and ampere meter to check voltage and current while the welder is performing welding at 1 o’clock, 3o’ clock, 5 o’clock, 7 o’clock, 9 o’clock and 11 o’clock positions and calculate the average values.
Prior to start of welding the welding current must be properly set. Uphill uses low currents and slow travel speeds.
12. RANGE OF AXIAL SPEEDS
Electrode travel speed shall be measured using stop watch as mentioned in paragraph 5. The range of upset stroke shall be recorded. Any time delay before removal of clamps shall be recorded.
13. ACCEPTANCE CRITERIA
All welds shall be subject to 100% visual and Radiographic Test in accordance with API 1104. Any welder whose welds have passed visual and Radiographic Test will be certified as qualified welder.
14. RANGE QUALIFIED
For groove welds diameter limits refer to API 1104 (6.2.2 item d and e.) Outside diameter greater than 12.750 inch welder is qualified on Nominal pipe diameter then is qualified for unlimited diameter range
Welders qualified on test specimen with base metal thickness T shall be qualified to Nominal pipe wall thickness from 0.188 inch through 0.750 inch according to API 1104 (6.2.2 ,item d and e.)
15. REFERENCE DOCUMENT(S)
ASME Section IX - Qualification for Standard Welding And Brazing Procedures
ASME B31.3 - Process Piping
ASME B31.8 - Gas Transmission and Distribution Piping Systems
API Std 5L - Specification for Line Pipe
API Std 1104 - Standard for Welding of Pipelines and Related Facilities
PL-A-1102.21-4012-002 - Project Execution Plan
PR-W-1102.21-4012-001 - PTT Welding Procedure Specification for Piping and Pipeline
(WPS)
PR-Z-1102.21-4012-001 - Non Destructive Testing Procedure
PR-W-1102.21-4012-003 Rev.0 (WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND UNDERGROUND PIPING (WQT))
WELDER QUALIFICATION TESTING FOR ABOVEGROUND PIPING AND
UNDERGROUND PIPING (WQT)
GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT
