PTT PUBLIC COMPANY LIMITED

RATCHABURI WORLD COGENERATION

COMPANY LIMITED

GAS PIPELINE AND GAS METERING AND REGULATING STATION PROJECT

DOCUMENT TITLE:
WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT)
DOCUMENT NO.: PR-W-1102.21-4012-004 REVISION: A
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:


A 25/03/13 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.

WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 2 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))


DOCUMENT CHANGE RECORD

Rev Date Prepared/
Revised
By
Reviewed
By
Approved
By
Description
A
25/03/13 WS JR NP Issued for Approval




















WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 3 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))


TABLE OF CONTENTS

ARTICLE PAGE

1. PURPOSE ...................................................................................................................................... 4
2. SCOPE ........................................................................................................................................... 4
3. DEFINITION ................................................................................................................................... 4
4. RESPONSIBILITY .......................................................................................................................... 5
5. RECORDING WELDING PARAMETERS DURING WPQR .......................................................... 6
5. QUALIFICATION OF WELDING ................................................................................................... 7
7. WELDING CONSUMABLE CONTROL ......................................................................................... 8
8. WELDER IDENTIFICATION .......................................................................................................... 8
13. ACCEPTANCE CRITERIA ............................................................................................................. 8
14. RANGE QUALIFIED ...................................................................................................................... 9
15. REFERENCE DOCUMENT(S) .................................................................................................... 12
16. ATTACHMENT ............................................................................................................................ 12



WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 4 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))

1. PURPOSE

This Procedure is for the Welding of Gas Pipeline and Gas Metering and Regulating Station Project.
The Material of Pipe used is under standard of ASTM A36, ASTM A53 for Structural Steel. The
applied Welding Procedure are SMAW for Steel Structure in accordance with AWS D1.1

2. SCOPE
For Steel Structure welding SMAW process (manual) can be selected. The Steel Structure welders
shall be qualified based on the approved Welding Procedures Specifications 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 Environment
JSEA means Job Safety and Environment Analysis
WPS means Welding Procedure Specification
WPQ means Welder Performance Qualification
PQR means Procedure Qualification Record
WPR means Welding Procedure Record
PCN means Personnel Certification for NDT.
CSWIP means Certification Scheme for Welding Inspection Personnel
ASNT means American Society of Non Destructive Testing
AWS means American Welding Society
QA means Quality Assurance
QC means Quality Control
NDT means Non Destructive Testing
PT means Penetrant Test
RT means Radiographic Testing
QC Manager means Quality Control Manager
Welding Supervisor means Controls and Coordinates all of the site welding activities
Welding Forman means Controls the specific day to day welding activities for one or
more welding location
Welding Inspector means Inspects the activities related to welding
Quality Control Engineer means Writes, Runs and approves the welding procedures and
WPS for the Contractor
Subcontractor means The party to which Contractor has sub-contracted a portion
of the Work under the Contract



WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 5 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))



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 Records.
Liaise with the Contractors 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.

WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 6 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))

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 Contractors 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. RECORDING WELDING PARAMETERS DURING WPQR

The 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
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
The voltage and amperage readings taken shall be averaged out
The travel speed and heat input shall be calculated

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)

WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 7 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))


5. QUALIFICATION OF WELDING

Preparation and welding of test pieces are to be carried out in accordance with the WPS and under
the general condition of production welding which it represents.

Welding of the test assemblies and testing of test specimens are to be witness by third party

If tack welds and/or starts and stops points are conditions of the weld process they are to be fused
into the joint and are to be included in the test assemblies.

Butt weld
Assembly of test pieces
The test assembly is to be of a size sufficient to ensure a reasonable heat distribution and according
with the minimum dimensions:
Plate
- Width = 3xt, min 150 mm.
- Length = 6xt, min 350mm.
- Position 3G+4G
Pipe
- OD. = 2 in, Thickness 3.91 mm.
- OD. = 6 in, Thickness 9.53 mm.
- Position 6G



WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 8 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))

Examination and tests
Test assemblies are to be examined non-destructively
- Visual testing 100%
- Radiographic 100%
7. WELDING CONSUMABLE CONTROL
Welding 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
8. WELDER IDENTIFICATION
Welders 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 steel structure welders.
Recommended pass sequence
Refer to PR-W-1102.21-4012-002 - Welding Procedure Specification For Steel Structure (WPS).
13. ACCEPTANCE CRITERIA

All welds shall be subject to 100% visual and Radiographic Test in accordance with AWS D1.1.
Any welder whose welds have passed visual and Radiographic Test will be certified as qualified
welder.









WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 9 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))

14. RANGE QUALIFIED
Position

AWS D1.1 Table 4.9
Welder Qualification Production Welding Positions Qualified by Plate, Pipe and Box Tube Tests
(See 4.18.1.1)


Qualification Test Production Plate Welding Qualified
Weld Type Positions
1
Groove CJP Groove PJP Fillet
PLATE Groove2
1G
2G
3G
4G
3G+4G
F
F, H
F, H, V
F, OH
All
F
F, H
F, H, V
F, OH
All
F
F, H
F, H, V
F, H, OH
All
(Note 8)
TUBULAR
Groove2
(Pipe or Box)
1G Rotated
2G
5G
6G
2G + 5G
(Note 9)
F
F, H
F, V, OH
All
All

F
F, H
F, V, OH
All
All

F
F, H
F, V, OH
All
All
(Note 8)
6GR
(Fig. 4.27)
All All
All
(Note 8)
6GR
(Fig. 4.27 &
4.28)
All All
All
(Note 8)

CJP Complete Joint Penetration; PJP Partial Joint Penetration

Notes (notes shown at the bottom of a column box apply to all entries):
1. 6ee digures e.., e.e, e.r and e.S
2. Groove weld qualification shall also qualify plug and slot welds for the test positions indicated.
3. Only qualified for pipe over 24 in. [600 mm] in diameter with backing, back gouging, or both.
4. Not qualified for joints welded from one side without backing, or welded from two sides
without back gouging.
5. Not qualified for welds having groove angles less than 30 (see 4.12.4.2)
6. Qualification using box tubing (Figure 4.27) also qualifies welding pipe over 24 in [600 mm] in
diameter.
7. Pipe or box tubing is required for the 6GR qualification (Figure 4.27). If box tubing is used per
Figure 4.27, the macro etch test may be performed on the corners of the test specimen
(similar to Figure 4.28)
8. See 4.25 and 4.28 for dihedral angle restrictions for plate joints and tubular T-, Y-, K-
connections.
9. Qualification for welding production joints without backing or back gouging shall require using
the Figure 4.24 joint detail. dor oelding production joints






WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 10 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))

Thickness and Diameter

AWS D1.1 Table 4.10
Welder and Welding Operator Qualification Number and Type of Specimens and Range of
Thickness and Diameter Qualified (Dimensions in Inches)(see 4.18.2.1)

(1) Test on Plate Qualified Dimensions
Production Groove or Plug Welds
Nominal Plate, Pipe or Tube
Thickness Qualified, in.
Type of Test Weld (Applicable Figures)
Nominal Thickness of Test
Plate (T) in.
Min Max
Groove (Fig. 4.30 or 4.31) 3/8 1/8 3/4 max
4

Groove (Fig. 4.21, 4.22 or 4.29) 3/8<T<1 1/8 2T max
4

Groove (Fig. 4.21, 4.22 or 4.29) 1 or Over 1/8 Unlimited
4



Note:

1. All welds shall be visually inspected (see 4.30.1). One test pipe, plate or tubing shall be required for each
position tested, unless otherwise note.
2. Radiographic examination of the test plate, pipe or tubing may be made in lieu of the bend tests (see 4.19.1.1)
3. For 3/8 in. plate or wall thickness, a side-bend test may be substituted for each of the required face- and root-
bend tests.
4. Also qualifies for welding any fillet or PJP weld size on any thickness of plate, pipe or tubing.
(2) Tests on Pope or Tubing
6

Nominal Pipe or Tube Size
Qualified, in.
Nominal Plate, Pipe or Tube Wall
Thickness
4
Qualified, in.
Production CJP Groove Butt Joints
Type of
Test Weld
Nominal
Size of
Test Pipe,
in.
Nominal
Test
Thickness,
in.
Min Max Min Max
Groove 4 Unlimited 3/4 4 1/8 3/4
Groove > 4 3/8 (Note 5) Unlimited 1/8 3/4
Groove > 4 > 3/8 (Note 5) Unlimited 3/16 Unlimited
Production T-, Y-, or K-Connection CJP
Groove Welds
Nominal Pipe or Tube Size
Qualified, in.
Nominal Wall or Plate Thickness
3

Qualified, in.
Type of
Test Weld
Nominal
Size of
Test Pipe,
in.
Nominal
Test
Thickness,
in.
Min Max Min Max
Pipe
Groove
6 O.D. 1/2 4 Unlimited 3/16 Unlimited

WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 11 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))

5. The minimum pipe size qualified shall be the test diameter or 4in., whichever is greater.
6. See Table 4.9 for appropriate groove details.
7. Two plates required, each subject to the test specimen requirements described. One plate shall be welded in
the 3F position and the other in the 4F position.
8. For dihedral angles < 30, see 4.26.1.

Essential Variable
AWS D1.1 Table 4.11
Welding Personnel Performance Essential Variable Changes Requiring Requalification

Essential Variable Changes to WPQR Requiring
Requalification
Welding Personnel
Welders
2

Welding
Operators
2,3

Tack
Welders
(1) To a process not qualified (GMAW-S is considered a
separate process
X X X
(2) To an SMAW electrode with an F-number (see Table
4.12) higher than the WPQR electrode F-number
X X
(3) To a position not qualified X X X
(4) To a diameter or thickness not qualified X X
(5) To a vertical welding progression not qualified (uphill or
downhill)
X
(6) The omission of backing (if used in the WPQR test) X X
(7) To multiple electrodes (if a single electrode was used in
the WPQR test but not vice versa
X
1


General Notes:
An x indicates applicability for the welding for the welding personnel; a shaded area indicates
nonapplicability.
WPQR = Welding Performance Qualification Record.
See Table 4.9 for positions qualified by welder WPQR

Note:
1. Not for ESW or EGW.
2. Welders qualified for SAW, GMAW, FCAW or GTAW shall be considered as qualified welding operators
in the same process(es) and subject to the welder essential variable limitations.
3. A groove weld qualifies a slot weld for the WPQR position and the thickness ranges as shown in Table
4.10.



WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 12 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))


15. REFERENCE DOCUMENT(S)
ASTM A36 - Standard Specification for Carbon Structural Steel
ASTM A35 - Specification for Pipe, Steel, Black and Hot-Dipped Zinc
Coated Welding and Seamless Pipe
AWS D1.1 - Structural Welding Code
SP-S-1102.21-010-001 - Specification for Line Pipe
SP-S-1102.21-010-002 - Standard for Welding of Pipelines and Related Facilities
PL-A-1102.21-4012-002 - Project Execution Plan
PR-W-1102.21-4012-002 - Welding Procedure Specification For Steel Structure (WPS)

16. ATTACHMENT
16.1 Attachment 1 Visual Inspection report
16.2 Attachment 2 Welder Identity
16.3 Attachment 3 Welders Qualification Register




















WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 13 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))








ATTACHMENT 1 VISUAL INSPECTION REPORT


































WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 14 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))



WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 15 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))




















ATTACHMENT 2 WELDER IDENTITY
































WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 16 of 18


PR-W-1102.21-4012-004 Rev.A
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WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 17 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))












\







ATTACHMENT 3 WELDERS QUALIFICATION REGISTER




































WELDER QUALIFICATION TESTING
FOR STEEL STRUCTURE (WQT)
GAS PIPELINE AND GAS METERING AND
REGULATING STATION PROJECT
Document No. PR-W-1102.21-4012-004
Rev. A Page 18 of 18


PR-W-1102.21-4012-004 Rev.A
(WELDER QUALIFICATION TESTING FOR STEEL STRUCTURE (WQT))