CARIGALI STANDARD PROCEDURE NO. : CSP-15 pemoxas SURE PROCEDURE CARIGALI REVISION. : 0 JACKET / TOPSIDES WELDING QUALIFICATION TEST PROCEDURE FOR PETRONAS CARIGALI SDN BHD. KUALA LUMPUR In the event of any ambiguity, inconsistency or conflict between this procedure and the Contract Document and / or the Petronas Technical Standards (PTS), the Contract Document and / or PTS shall take precedence over this procedure. CARIGALI's interpretation shall be final. REV. | DATE PREPARED BY REVIEWED BY ‘APPROVED BY No NAME] SIGNATURE | DATE [| NAME] SIGNATURE | DaTE || NAME siofpuReE DATE, oO pehbata| races eA Pte | 4% fa/e/ac] Morn . s/sWELDING QUALIFICATION TEST] PROCEDURE NO CSP-15 ertonas CARIGALI PROCEDURE avISION EO JACKET / TOPSIDES pice tore TABLE OF CONTENTS SECTION DESCRIPTION 1.0 PURPOSE. 2 2.0 SCOPE 2 3.0 REFERENCE 2 4.0 DEFINITIONS 2 5.0 PROCEDURE 3 1 WPS Preparation 3 2 Step in Conducting WPQT 3 33 Retest 7 6.0 SPECIAL REQUIREMENTS 8 7.0 RECORD 8 Attachments Appendix I Welding Procedure Specification Appendix II Welding Procedure Qualification Test Recordprreomas WELDING QUALIFICATION TEST] PROCEDURE NO. - CSP-15 CARIGALI PROCEDURE REVISION, : 0 JACKET / TOPSIDES PAGE 2 OF 8 1.0 PURPOSE The purpose of this procedure is to provide guidelines for qualifying WPS required in the fibrication of Jacket and Topsides structures. 2.0 SCOPE This procedure shall be applied for welding procedure qualification test on all WPS established in the fabrication of structure, process pipeworks, pressure vessels and related works 3.0 ERENCES PTS 20.104 (SES 11.4 REV. 4) Construction of Structural Steel Works: PTS 20.112 (SES 38.2 REV. 3) Welding of Pipework AWS D1. (1994) Structural Welding Code ASME IX (1995) Qualification Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators, ANSI B31.3 (1993) Chemical Plant and Petroleum Refinery Piping 4.0 DEFINITIONS wes Welding Procedure Specifications PQR Procedure Qualification Record weQ Welding Procedure Qualification Test NDT Non Destructive TestingWELDING QUALIFICATION TEST) PROCEDURE NO. « CSP-15 CARIGALI PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 3 OF 8 MPI Magnetic Particle Inspection UT Ultrasonic Testing RT Radiography Testing 5.0 PROCEDURE 51 WPS Preparation 5.11 CONTRACTOR's Welding Engineer shall identify and submit to CARIGALI the list of relevant WPS to be used for the project from the pre-accepted WPS (FSP-17 ). If additional | WPS is required, WPS shall be developed and submitted for | CARIGALI' approval before WPQT. 5.12 The Welding Engineer shall formulate the welding procedures to the joint configuration and application. The WPS shall be prepared as per AWS D1.1 for structural and ASME IX / ANSI 31.3 for piping (see Appendix I for the WPS format). 5.1.3 The proposed WPS shall contain all the essential welding parameters whichever are applicable as per Appendix I 5.14 Upon approval of the WPS, a WPQT shall be carried out in the presence of CARIGALI Representative. CARIGALI Representative shall be informed 48 hrs in advance prior to the testing, 52 Step In Conducting WPQT 52.1 Prior to commencement of WPQT the following shall be verified by CARIGALI's. Representative and CONTRACTOR's Welding Engineer a) Test material (s) used, including the heat number. b) Dimensions of the test material (s) e.g, length, diameter, thickness etc.Perens CARIGALI WELDING QUALIFICATION TEST PROCEDURE NO. : CSP-15 PROCEDURE REVISION. : 0 JACKET / TOPSIDES PAGE 4 OF 8 5.24 5.2.5 Edge preparation of the test material (s) Safety provisions are available and the test site protected from draughts Adequacy of lighting for cleaning and visual inspection Copy of the proposed WPS is displayed for welder’s reference Welding machine including auxiliary equipment for use are calibrated and in good working conditions. Setting of current type, polarity including amperage and voltage Correctness of welding consumables to be used as per proposed WPS. Upon fit-up, weld preparation and alignment shall be checked for compliance to the proposed WPS. After fit-up inspection, mark the PQR number, test position and indicate the top of joint position (if pipe is used for the test) The test piece shall be secured firmly per the required test position. Preheat the test piece properly by gas burners or other approved method to the required temperature specified in the proposed WPS. Check the preheat temperature with thermosticks or equivalent before allowing the welder to commence welding. The required preheat shall be achieved uniformly across the thickness of the test piece A trial test may be carried out on a separate specimen prior to welding on the test piece to ensure the welding parameters set out in the WPS are maintained Monitor and record the following welding parameters in the PQR form (see Appendix IT) on each pass until completion of test weld to ensure compliance within the ranges specified in the proposed WPS.WELDING QUALIFICATION Ee rernonas CARIGALI PROCEDURE EST REVISION. 0 JACKET / TOPSIDES pie etetae tte a) Welding current ie, amperage and voltage by mean of AC/DC Digital Clamp Meter (tong tester) “b) Travel speed / Wire feed speed ¢) Direction of travel for vertical welding d) Use of specified welding consumables diameter, flow rate, electrode stick out length e) Welding technique i. string, weave, split layer f) _ Interpass temperature by use of or Thermosticks Digital thermometer 8) Approximate width of weld pass h) Approximate thickness of weld layer i) Interpass cleaning method j) Sequence and Number of weld passes per layer k) Treatment to back side (backgouged, ground, backwelded, inspection etc.) 5.2.6 Upon completion of welding, visual inspection shall be carried out in accordance with AWS D1.1 or ANSI B31.3/ASME IX whichever is applicable. 5.2.7 Upon verification and acceptance of the recorded welding parameters in the PQR form followed by visual acceptance of test weld, the CONTRACTOR's Welding Engineer shall arrange for the required NDT in accordance with PTS 20.104 or PTS 20.112. No non-destructive testing (RT, UT & MPI) ‘on mild steel should be carried out less than 24 hours after welding has been completed. For high strength steel the time delay should be minimum 48 hours. 5.2.8 NDT result shall be verified by CARIGALI's Representative prior to any further testing For acceptable test weld, it shall be subjected to destructive testingpereonas CARIGALI [WELDING QUALIFICATION TEST] Sete ee DE REVISION. | 0 JACKET / TOPSIDES PAGE 6 OF 8 PROCEDURE NO. CSP-15 329 CONTRACTOR's Welding Engineer shall proceed to illustrate the locations of test specimens on the welded test piece for each type of destructive test before cutting at site or direct despatch to an approved independent testing laboratory for both cutting and machining work. The location for removal of the required specimen shall be in accordance with PTS 20.104 of PTS 20.112. The machined test specimen shall be die stamped to indicate the PQR number and the type of test required ie. 'T’ for tensile test, 'RB' for root bend. 'FB' for face bend, 'SB' for side bend, 'I' for impact test, ‘M/H' for macroetch and hardness test. The identification stamped shall remain identifiable throughout the specimen preparation and testing, All the required test carried out in the laboratory shall be witnessed by the CONTRACTOR's Representative and CARIGALI's Representative The following shall be checked during the course of mechanical testing a) Identification markings on the specimen to its related PQR number, type of test and number of specimens required. b) Dimensions of tensile, bend, impact test specimens, c) Calibration certificates of tensile test and impact test equipment are valid, dimensions of guided bend test equipment must be adequate to produce bending radius specified by test code for root, face and side bend testing 4) Impact testing is carried out at the specified temperature e) Specified numbers of hardness spots are taken on the regions of the macroetched test specimen ie, weld heat affected zone, weld area and base metalperaonas CARIGALI |WELDING QUALIFICATION TEST PROCEDURE REVISION. - 0 JACKET / TOPSIDES PAGE TTHOR LEA PROCEDURE NO. : CSP-15 13 During each test all results shall be recorded on the draft copies of test report by the laboratory tester. 14°” Upon completion, test results shall be signed off and a copy extended to the CONTRACTOR's Representative and CARIGALI's Representative for signature and evaluation against test code and specification Upon acceptance of the mechanical test results, the WPS/PQR shall be prepared by the CONTRACTOR'S Welding Engineer using the format shown in Appendix I and I. The WPS/PQR shall be submitted to CARIGALI for review and approval Retest 5.3.1 When Retest Is Not Allowed Unacceptable defects evaluated by visual, NDT and macroetch testing shall be cause for rejection, A new test weld shall be required. 5.3.2 When Retest Is Allowed When one of the following mechanical test specimens fails to meet the required acceptance criteria, two additional specimens shall be prepared for retesting. The location of the two additional specimens shall reflect the location of the failed specimen. If one or both of the retest specimens fail, then this shall be cause for rejection. A new weld shall be required a) Tensile Test b) Bend Test c) Impact Test (when applicable) d) Hardness Test Prior to retest, a study and evaluation shall be made on the failed test to established probable cause of failure.erronas CARIGALI PROCEDURE PROCEDURE NO. : CSP-15 |WELDING QUALIFICATION TEST| REVISION. : 0 JACKET / TOPSIDES PAGEL a ORE 6.0 SPECIAL REQUIREMENTS 6.1 CONTRACTOR's welding engineer shall prepare the WPSs to simulate, the actual welding conditions and materials to be used for production welding. Limitations imposed by the essential variables of the procedure qualification shall be adhered to in production welding 62 Only a skilled and experienced welders shall be assigned for WPQT to minimize rework, RECORDS All records pertaining to welding qualification test shall be kept by the CONTRACTOR's Welding Engineer All copies of the approved WPS shall be readily available for reference by the welders, Welding Engineers and CARIGALI's RepresentativeAPPENDICESAPPENDIX | Pace TOF 2 f WELDING PROCEDURE SPECIFICATION Ps No nev no FeV. OATE cove serior | | Tee BANAL SBmAuTO —_ | WELD GROOVE : SINGLE VEE DOUBLE VEE SINGLE BEVEL (DOUBLE BEVEL | SINGLE U —____ bouste u SINGLE J COUBLE J cove. acts SAGE Sarcoma’ ka must we.os shit pase wT PSS | suproarne porno. 0) te | werenacencumne” ave FH 7 j merece aoe | nov oRGUP HG | TUNGSTEN ELECTROOE : SIZE | cwetonc ves 0 oa tin | | prone tes 6 now Um i WELDING CURRENT { y: OC ac POSITIVE, NEGATIVE _ a | | ave pousnry ‘ ye DT a postive carve ; oe < es necaTve Re FEED SPEED RANGE cM aw roaw ‘owe | | soe Fac nen ro cian See RS ora — | [SRE oRMuCTRE ys WSN wee SAUTER ] | pass USING STRING ( 8 DM siRNe weave SUT LAYER weave oR SPLIT LAYER ( a weave smuruwen | WELD WIDTH MAXIMUM waNuaL M_ SEMI AUTO. ‘MM MACHINE | vernicaL pRosression: = ioe fue crac em an i ‘ es cons | posmcnor sacovcTioN WetD SHA aan aa ora aw | nowoes or anes ec. GE TAA onecTON eR To Teves RECTION | Root WELD sxc NO ves SRCIS WAT. 7 sTeK-oUT LENGTH ae eared Sp sae | ax no omer ovetes ” Two Ma. The BETWEEN PEAT VEE Tone (TREATMENT oF aacxSicE OF a morte nove ano couse snus omen | revenrresss rower" At vowm o CEng cua ee \eT-00 oF arexeaTING METHOD OF TEP OOK | Pos eo esr arses ves PROCEDURE REGURED Saar PACT TESTA REQUIRED x ve PROCEDURE REQUIRED [ueesiaceaes = a faa we AuWeio METAL TEST REQURED 0 ves REPORT ATTACHED TO Po hncaoeron & m0TS 0 ves RePORT ATTACKED 70 Pa FERRITE DETERMINATION NO ves REPORT ATTACHED TO POR _ | RSGe oF wate eT ERE [3 Rance GF SASENETAL CNIS WEN BROOUETON : a wrx | wea noren touemness | “ yn wax | ean sorrean ‘ yy we am a | ance oF Now ape BANETERS \ | ve wax wax ax Ssesseseeseeseeee eee laname: CSP-15ASAMospas APPENDIX! PAGE 20F 2 WPS NO. WELDING PROCEDURE SPECIFICATION SPECIFIED PRODUCTION WELDING PARAMETERS 9 930 “dWaL SSvauSINI BAYT Las anvam onnus Wwiry 3ONv AndNi 13H NIN BONE agus Tava Bony, 3OVLION aonve sovuaany Ainiviod any SdAL INNO wa NIT Nouvorissv19 awiaW waTId ‘sg300ud ‘ONIGTIM 4180430 aan N JOINT PREPARATI APPROVED BY DATE CONTRACTOR oaTe CARIGALL Aloname CSP-158 SAMcsp. APPENDIX PAGE 1 OF is " 3 PROCEDURE QUALIFICATION RECORD _ lear no CONTRACTORS REP gE ‘TEST OATE WELDING CODE 3 | 2 |weLone Processes. SuAW saw aw craw Faw 1 2 3. equipment TPE - MANUAL “eewatro NE 7 4. |TYPE OF TEST JOINT eis |sueronrwe Wes Nos. (1) @ @ i 7 MATERIAL SPECIFICATION USED FOR TESTING 75 | fa | METAL SPECIFICATION : : 1 ( ) MFG / BRAND 3! eee ve aRano [8 is METAL cLassificarion [2 ! eects ane eno |#2/ ra a0 Fs gB oe Te Etec. conmiaTion ! | BS 5 |weromortux evassicarion © wes: arena | lad is £cTRODE OIA ree ar once SE | ¥ > swetans oas rrPe (5) vax Flow | |e feunce cas ree (8) wes Flow [7 F TWELOING CURRENT ano POLARITY é | ( ) ce ac Pos. NEG - ! ( i oe ac Pos. Neo | @ | 5. wine FEED SPEED RANGE, CM/MIN SAW Faw Gwaw | fete OR MULTIPLE ( ) s M STRING WEAVE, SI LAYER IPASS USING STRING ( ) SM ___ STRING WEAVE ‘SPLIT LAYER: Fg | eave om sour LavER - ( ) SM STRING WEAVE SPUT LAYER |B 2 jwwuwum weaveworw: manual wi “SE -auro wat MACHINE va iz | 3. VERTICAL WELO PROGESSION fi y UPWARD DOWNWARD ;2 || 6) uPwaan oownano 1 E | leosmonor vesrweip: awaw am aim cal rome | | 5. NO. OF ARCS ELEC. ANGLE : TRAVEL DIRECTION NORM, TO DIRECTION OF TRAVEL 6 [Root weLo ack? YES (NO __——_«BACRING MATERIALS | | Istiek-our venera Wa. ELEGTRODE sPAcIG | 1 [TREATMENT OF BACKSIDE OF ROOT WELD NONE GRIND _-GOUGE BRUSH —~=COTHER—=Cd | gg 2 PREHEAT TewP oF TesT Piece Max INTERPASS Teme. OF TEST PIECES |B. |. jertoo oF preneat METHOD OF TEMP. CHECK |g | lessmer mpscr Tests PenronweD 7 No | 3 |e |uamoness rests conoucreo ves No ;* | 7 [au wero wera. renaue Test penronwea ves No | 6. ImacRo erow anaLvsis CONDUCTED ves No I l / | CCARIGAL REP | Note «See Bar 2 anacned ename cSP.15C SAMg-9ga"aNat ‘sSvdu1NI | sas [APPENDIX PAGE 20F 3 : | Hh aa ine No gee ee | toi anwar «lll || ava ‘onnuis DATE : ves ves ves ves ww ret nani vai BEAD SEQUENCE ves ves NUW wet | aaads 13AVEL TEST WELD DETAILS : | 3OVLION MIN, PREMEAT MAX. INTERPASS TENE HARDNESS SURVEY MACROETCH + PHOTS ALL WELD METAL TENSILE FERRITE MEASUREMENT wescr TESTS aovuaany Autuyiow ony rT y] Saat inaeuno WELDING PARAMETERS FOR WPS NO. Noiss390¥d swOUan | er? corner yaLawvio | qwiai was | Nouvousissw19 | wisn waTId JOINT DETAILS ves weave won) 88300% ‘ON ssvd | _——__H| ON eat iu JL tL L TEST MATERIAL TYPE BACKING MATERIAL PAR NO, ‘Test Posen BACKING GAS TYPE ROOT WELD BACKING - a NOM TEST PIPE DA ‘cas PURGEPAGE 30F 3 PROCEDURE QUELIFICATION - MECHANICAL ANO NON OESTRUCTE TEST RECORD ] | | PORS NO, FOR WPS NO. Rev PAGE oF | ease METAL TYPE JOINT PWHT : YES No TENSE Test [SPECIMEN |” FINISHED [FINISHED | MEASURED UNIT STRESS FAILURE on | ‘wiott | THICKNess | AREA KGIMMs Location ) | i 1 | L I L I I | | i Ee ! | a i I \ If ‘SIDE BEND I ‘SIDE BEND T FACE BEND ROOT BEND eo | 5 pee 2 2. | | Macro -2TcH | "SPECIMEN | REMOVAL FUSION 1 POROSITY-SLAG-L.OP. | \ is pocanot ‘ACCPT. RE. acct RED. NON DEsTaUCTIVE TESTS T ‘GOVERNING CODE T_TEST RESULTS REPORT ATTACHED [ur | aws | aNsi | ASME nocer. | RELVES No THER Ts 7 cone | stD SPEC. REPORT ATTACHED \“accrr. 7 Red. REQUIRED BY [esr aeRO ialeadtsssie ys Tn WE CERTIFY THAT THE STATEMENTS IN THIS RECORD ARE CORRECT AND THAT THE TEST WELDS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF WPS NO AND cueNT CLIENT REP DATE ABOVE TESTS CONDUCTED SY csp. 1s SAM COOE FOR WELOING FABRICATOR ey DATE LAa. TEST NO.