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Santos Engineering Standard

Specification 1515-120-SPC-0050-0 Rev 3


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Santos Specification

Title: Welding

Table of contents:

FOREWORD ......................................................................................................................... 2
1 SCOPE ...................................................................................................................... 3
2 STANDARDS, CODES OF PRACTICE, REFERENCES ........................................... 3
2.1 Codes ............................................................................................................. 3
2.2 Australian And International Codes................................................................. 4
2.3 Santos Standards ........................................................................................... 4
2.4 Definitions....................................................................................................... 5
2.5 Identification and Responsibilities ................................................................... 6
3 TECHNICAL CONSIDERATIONS ............................................................................. 9
3.1 Weld Procedure Specification Development ................................................. 10
3.2 Weld Procedure Qualification ....................................................................... 10
3.3 Welding Operator Qualification ..................................................................... 11
3.4 Control Of Welding Consumables ................................................................. 11
3.5 Quality Assurance Of Welding Operations .................................................... 11
4 REVISION NOTES................................................................................................... 14
5 APPENDICES.......................................................................................................... 15

Custodian: Principal Engineer - Integrity


Approved By: Chief Facilities Engineer
Date: August 2014

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


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Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 2 of 15

FOREWORD

Application of this Santos Engineering Standard shall meet requirements of the


Santos Environment Health and Safety Management System – in particular, but not limited
to:

EHSMS 02 - Legal and Other Obligations

EHSMS 06 - Training and Competency

EHSMS 09 - Hazard Identification, Risk Assessment and Control

EHSMS 10 - Contractor and Supplier Management

EHSMS 11 - Operations Integrity

EHSMS 12 - Management of Change

EHSMS - Definitions & Acronyms

HSHS 06 - Electrical Safety

Santos Engineering Standards apply to all Santos facilities and are based on
Australian Regulations and Standards. When applied outside of Australia, Local Regulations,
Codes of Practice and Environmental Regulations shall take precedence.

The Santos Engineering Standards are generated, implemented and reviewed in accordance
with the Santos Engineering Management Standards (EMS).

Compliance with Regulations, Engineering Management Standards (1520-002-STN-0002


and 1520-002-STN-0004) and Engineering Standards is compulsory in accordance with
EHSMS 02 and EHSMS 11.2. The current Santos Engineering Standards shall apply unless
specifically stated within individual standards or when directed by the Custodian of the
relevant Standard. Regulations may superimpose retroactive provisions.

Use of this Santos Engineering Standard is MANDATORY. If any part of this Standard
appears inadequate, unsuitable or not cost effective, consult with the Custodian to agree a
suitable solution. This may result in a revision to the Standard.

Deviations from Santos Engineering Standards shall be approved in writing via the Santos
Engineering Standards Waiver process. Approval of waivers is vested in the Santos Chief
Facilities Engineer or his delegate.

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


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Specification 1515-120-SPC-0050-0 Rev 3
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1 SCOPE

This Specification defines requirements for fabrication, construction and maintenance


welding systems for Santos facilities.
It covers workshop and site requirements to establish and maintain quality systems to:
 Develop welding procedures
 Qualify welding procedures
 Qualify welding operators
 Control welding consumables
 Quality Assure completed welds
for:
 Pressure Welding per AS/NZS ISO 3834.2
 Structural Welding per AS/NZS ISO 3834.3
Key areas and design codes considered are:
 Santos piping specification 1515-050-SPC-0001 including
- Plant piping to ASME B31.3
- Flowlines to AS 2885
- Hot Taps to ASME B31.3 and AS 2885
- Specialty carbon/stainless steel
- Duplex stainless steel
 Santos pressure vessel specification 1515-020-SPC-0001 including
- Vessel Repair to AS 1210
- Tank repair to API 653
 Structural Steel welding to AS 1554
Santos Welding Procedure Specifications referred to in this specification apply to off-site and
on-site welding of process piping, flowline piping systems, welding of hot taps, vessel and
tank repair work, and structural welding. Santos Welding Procedure Specifications can be
found at Technical Services - Quality Assurance, or refer to Custodian or Santos Senior
Metallurgist.
Quality Assurance:
Existing fully qualified Welding Procedure Specifications with ISO 9000 certification or
equivalent may be proposed for acceptance by the Santos Welding Coordinator.
Where a new Welding Procedure Specification is required for a given task, such welding
procedure will be registered and owned by Santos.
New or expired procedures shall be qualified by testing.
For summary of Welding Work Flow, refer diagram attached to this document.

2 STANDARDS, CODES OF PRACTICE, REFERENCES

2.1 Codes
Workmanship and materials shall conform to requirements of the latest edition of the
following codes and standards.

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2.2 Australian And International Codes

AS 1210 Pressure Vessels


AS 1554 Structural Steel Welding
AS 1674 Safety in Welding and Allied Processes
AS 1796 Certification of Welders and Welding Supervisors
AS 2214 Certification of Welding Supervisors -
Structural Steel Welding
AS 2812 Glossary of Welding Terms
AS 2885 Pipelines - Gas and Liquid Petroleum
AS 3834 Quality Requirements for Welding
AS 3920 Quality Assurance - Pressure Equipment Manufacture
AS 3992 Pressure Equipment - Welding and Brazing
AS 4041 Pressure Piping
AS 4037 Pressure Equipment Examination and Testing
AS 4343 Pressure Equipment - Hazard Levels
AS 4458 Pressure Equipment – Manufacture
ASME B31.3 Chemical Plant and Petroleum Piping
ASME IX Boiler and Pressure Vessel Code Section 9 -
Welding and Brazing Qualifications
API 582 Welding Guidelines for Oil and Gas Industries
API 653 Tank inspection, repair, alteration and reconstruction
WTIA Tech Note 7 – Health and Safety in Welding
WTIA Tech Note 20 - Repair of Steel Pipelines

2.3 Santos Standards

1515-120-SPC-0015 Specification for Fabrication of Pressure Piping


1515-120-SPC-0016 Specification for Above Ground Pipeline Systems
1515-120-SPC-0017 Specification for Buried Field Pipeline Systems
1515-020-SPC-0001 Specification for Unfired Pressure Vessels
1515-050-DSG-0001 Design Practice for Piping
1515-050-SPC-0001 Specification for Pipe and Valve Materials
1515-050-SPC-0004 Specification for High Pressure Steel Line Pipe

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2.4 Definitions
Pressure Vessel – A vessel subject to internal or external pressure, including any vessel
that falls within the definition of a boiler or pressure piping or tank described below. It
includes interconnected parts and components, valves, gauges and other fittings up to first
point of connection for external pipe work.
Piping System – A section of pipe work including piping and pipe work components such as
flanges and fittings, valves, anchors, supports, linings, insulation and protection.
Atmospheric storage tank – A container subject mainly to hydrostatic pressure.
ITP – Inspection Test Plan
FIC – Field Installation Checklist
Weld Procedure Specification (WPS) – Weld(ing) Procedure Specifications are sometimes
referred to as Weld(ing) Procedures. These terms are interchangeable, and are normally
abbreviated to WPS.
A Welding Procedure Specification is a controlled document that defines a range of
essential welding variables and other variables based on parameters qualified by test
welds or determined by applicable codes, standards and specifications. A Qualified WPS
includes reference to the Weld Procedure Qualification on which it is based.
Welding Procedure Qualification Record (WPQR) – The term Weld(ing) Procedure
Qualification Record is sometimes abbreviated as PQR.
Weld Procedure Qualification Records are quality assurance documents that record the
development, inspection and testing of a WPS.
Welding Work Pack (WWP) – Quality Management System dossier including Work Order,
Job Plan, ITP, FICs, WPS, WPQR, welder's review of work scope and welder's check that
required equipment, consumables, relevant procedures and documentation are provided at
site.
Weld Types –
BR – Branch fitting including WOL TOL BW – Butt Weld
PW – Pad Weld FW – Fillet Weld
HT – Hot Tap SW – Socket Weld

Welding Processes –
FCAW - Flux Cored Arc Welding SAW - Submerged Arc Welding
GMAW - Gas Metal Arc Welding SMAW - Shielded Metal Arc Welding
GTAW - Gas Tungsten Arc Welding OFW - Oxyfuel Gas Welding

Welding Positions – as determined by AS3992 and ASME IX

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Essential welding variables – Essential variables are those variables defined in AS/NZS
3992 Section 5, AS/NZS 3992 Section 9 and ASME IX that are included in a Welding
Procedure Specification where a change reduces the ability of a welder to make a weld with
required mechanical properties and soundness.
Essential variables include:
Parent material specification Weld joint detail
Welding consumables Welding Process
Welding Position Welding energy input
Welding direction Welding current and polarity
Range of Material thickness Preheat requirements
Range of Pipe Diameters Post Weld Heat Treatment

For qualified weld procedure specifications, variations to essential variables listed in AS/NZS
3992 Table 5.1are not permitted and qualification of a new weld procedure may be required.
Refer section 3.1
Other welding variables – Other variables are items of AS/NZS 3992 Table 4.1 which are
not classified as essential variables by AS/NZS 3992 Table 5.1. Further definition is provided
in AS/NZS 3992 Table 9.1.
Variations to other variables on qualified weld procedure specifications are permitted. These
require deviation or concession request and Santos Construction Representative’s written
approval. See section 3.1 for procedure.

2.5 Identification and Responsibilities


Each individual involved with welding is responsible to maintain quality and encourage safe
working practices. Specific actions for nominated persons are:

2.5.1 Inspecting Or Regulatory Authority


A State or Territory Authority with statutory power to control registration, inspection, repairs,
modifications and issuing of certificates of registration and inspection of pressure equipment.
Responsible for:
 Registration of pressure vessels
 Certification of vessel inspection

2.5.2 Senior Metallurgist


Principal Integrity Engineer or the Santos Senior Metallurgist in an area of responsibility.
Responsible for:
 Review of proposed Welding Work Packs
 Approval of Santos Welding Procedure Specifications

2.5.3 Santos Nominated Project Engineer


Responsible for:
 Contract review process including contract details of:
o Scope of project welding work
o Proposed Welding Procedure Specifications

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Specification 1515-120-SPC-0050-0 Rev 3
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o Welding Standards
o Welder Identification requirements
o Schedule of work.
 Review and audit of welding Quality Assurance.
 Informing Senior Metallurgist, Santos Welding Coordinator and Welding Supervisor(s)
of proposed welding activities.

2.5.4 Santos Construction Representative


Either a Santos Nominated Project Engineer, Construction Supervisor, Santos Maintenance
Supervisor or Santos Welding Coordinator.
Responsible for:
 Review and acceptance of Quality Management System dossier and Welding Work
Packs, ITP, FICs
 Management of welding activities at site
 Check and accept documentation provided by Welding Supervisor as evidence that
work complies with Weld Procedure Specifications
 Collating FIC and ITP records including on-site repairs of pressure equipment.

2.5.5 Santos Welding Coordinator


Either a Santos Nominated Construction Supervisor or Santos Maintenance Supervisor. The
Welding Coordinator is directly responsible:
 For issue to Santos Document Control of Approved Welding Procedure Specifications
 To confirm the following:
o Brief description of work to be performed
o Bar chart program of work / ITP / FICs
o Proposed/Approved WPS, WPQR
o Details of crew to be used, Welder Qualification
Location plan of work
o Proposed emergency response including evacuation routes
o Qualified Welding Supervisor's name and qualification details
o Job Hazard Analysis (JHA).
 For issue of proposed Welding Work Packs, ITP, FICs for Santos Construction
Representative acceptance prior to work commencement.
 To monitor that site work proceeds safely and efficiently once commenced.

2.5.6 Santos Operations


Santos Plant or Production Management is responsible for:
 Maintaining a safe environment throughout the operation
 Containing any live line operating conditions within the Work Pack limits
 Use of Santos Operator's Safety Checklists (attached) for preparation of the work
permit
 Issue of Work Permits for on-site work
 Permit Authority continuous monitoring of the environment surrounding the work area
throughout the operation

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 Permit Authority directing that work shall cease at any time should this be deemed
necessary.

2.5.7 Welder Or Welding Company


Responsible for quality assurance and safety responsibilities including:
 Preparation of a detailed Quality Management System dossier and Welding Work
Pack including:
o Brief description of work to be performed
o Bar chart program of work / ITP / FICs
o Proposed/Approved WPS, WPQR
o Details of crew to be used, Welder Qualification
o Location plan of work
o Proposed emergency response including evacuation routes
o Qualified Welding Supervisor's name and qualification details
o Job Safety Analysis (JSA).
Note: Inspection test plan shall include welder’s review of work scope requirements
and welder’s check that required equipment, consumables and relevant procedures
are provided at site.
 Issue of QMS and WWP dossier to Santos Construction Representative for approval
prior to commencement of work.
 Establishing that all necessary approvals and permits as described on WWP are
approved by Santos Construction Representative before welding.
 Verifying that welding is carried out using a qualified Welding Procedure Specification,
and Welder is qualified to the Weld Procedure Specification
 If site work is to be carried out, ensuring welder is competent in application of Santos
work permit procedures and safety requirements.
 Clear the ground of any flammable liquids or other combustible material within 15m of
the welding operation.
 For underground pipelines, confirm excavations are of adequate size with suitable
shoring, ladder access and secondary means of escape and with adequate ventilation
to prevent accumulation of dangerous concentrations of vapour. The Permit Authority
may require a sloped emergency exit free of obstacles.
 Provide suitable scaffolding and staging with adequate and safe means of access and
escape when work is carried out at elevated position.
 Provide suitable non-combustible protective shields where necessary to control
welding spatter.
 Provide protective clothing including face shield and gloves as necessary for use by
all persons employed in the welding operations, to protect them against burns due to
accidental leakage of flammable liquid or vapour.
 Submit all NDT certificates, documents and completed FICs and ITPs to the Santos
Construction Representative at work completion.

2.5.8 Welding Engineer


Responsible for:
 Definition of welding safety requirements.
 Establishing welding quality standards, WPS, WPQR, Welder Qualification.

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 Reviewing existing weld procedures.


 Qualifying welding procedures.
 Monitoring weld tests.

2.5.9 Qualified Welding Supervisor


Qualification: A person with a welding supervisor's certificate in accordance with AS 1796
Certificate 10 (pressure equipment) or AS 2214 (structural).
Responsible for:
 Conducting Weld Procedure qualification tests.
 Conducting Welding Operator qualification tests
 Authorisation for use of existing WPS and WPQR
 Welding Inspection
 Demonstrating that welding complies with requirements of AS 3834 and associated
standards - for both plant and field installations
 Demonstrating that NDT of completed welds show that it complies with appropriate
code requirements.

2.5.10 Welding Operator


Responsible for
 Review of WWP, welding safety.
 Ensuring that welding complies with requirements of Welding Work Pack, AS 3834
and associated standards - for both plant and field installations
 Review of NDT of completed welds for compliance with code requirements
(For summary of Welding Work Flow, refer Appendix D attached to this document.)

3 TECHNICAL CONSIDERATIONS

General.
Production welding shall not be carried out unless both Welding Procedure Specifications
and Welder Qualifications are qualified in accordance with specified codes and statutory
requirements and accepted by Santos Senior Metallurgist.
Each Welding Company is responsible for timely qualification of Weld Procedure
Specifications and welders.
Santos will automatically reject welds completed by unqualified welders or any welds not
identified and recorded to code requirements. It is the Welding Company’s responsibility to
prove that all welds conform to applicable standards. This may require 100% radiography.
For site work, welders shall complete site safety inductions and training in work permit
procedures prior to any welding. Personal protective equipment shall be worn in accordance
with Santos personal protective equipment policy.
Repair of registered pressure vessels usually requires Statutory Approval. Details of
proposed repairs including Weld Procedure Specifications shall be sent to Santos Senior
Metallurgist who will, as required, apply for and advise of Statutory Approval.
Refer 1515-020-SPC-0001 Pressure Vessels.

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3.1 Weld Procedure Specification Development


Existing fully qualified Welding Procedure Specifications with ISO 9000 certification or
equivalent may be proposed for acceptance by the Santos Welding Coordinator.
For qualified weld procedure specifications:
 Variations to essential variables are not permitted. A new qualified weld procedure
specification may be required for a given task.
 Variations to other variables are permitted only with the Santos Construction
Representative’s written approval.
 New or expired Weld Procedure Specifications shall be qualified by testing.
 A Weld Procedure Specification may be established from multiple WPQRs.
Otherwise, where a new Welding Procedure Specification is required for a given task, such
welding procedure shall be developed and qualified, and will be registered and owned by
Santos.
Where a Welding Engineer is of an opinion that a Weld Procedure Specification requirement
cannot be met, a written deviation or concession request complete with all supporting
information shall be forwarded to the Santos Construction Representative.
Work in accordance with a deviation or concession request shall not be carried out without
the Santos Construction Representative’s written approval.

3.1.1 Welding Procedure Specification Identification


Welding Procedure Specifications are controlled documents and shall be identified and
registered per Appendix. Quality Assurance requirements on welding documents include
identification signatures and dates of Preparer, Reviewer and Approver.

3.1.2 Draft Welding Procedure Specification


Draft Welding Procedure Specifications shall be developed in accordance with applicable
codes, standards and specifications, and shall instruct a welding operator on all test welds
required. A format similar to a Welding Procedure Specification may be used, clearly marked
as ‘draft’.
Review of welding proposals shall verify that each configuration likely to be encountered on a
project is addressed. Testing requirements shall include NDT and mechanical properties,
with any time lapse required prior to testing, and any other tests additional to code
requirements.
Following review, qualification (if required) and approval, the draft shall be registered and
become a controlled document.

3.2 Weld Procedure Qualification


Weld Procedure Specifications shall be qualified in accordance with AS 3992, ASME IX, or
AS 2885 or AS 1554, including all reference documents.
On receipt of test results, a Weld Procedure Qualification Record (WPQR) package is
compiled into a single document, comprising of:
 Front sheet (WPQR).
 Material certification.
 Consumable batch certification.
 NDT reports.
 Mechanical test reports.

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 Calibration reports for test equipment.


 Other information relevant to the test weld.
Documentation indicating Santos approval shall be added to the package when approved.

3.3 Welding Operator Qualification


Welding shall not commence until appropriately qualified welding procedures are sighted and
accepted by the Santos Construction Representative.
Welders are not permitted to weld unless qualified to the procedure in use, and documentary
evidence of welder qualification is accepted by the Santos Construction Representative.

3.4 Control Of Welding Consumables


Documentation supplied with welding consumable materials shall verify that Weld Procedure
Specification requirements are met.
Welding consumables shall be managed in accordance with WTIA technical notes and
manufacturers recommendations.

3.5 Quality Assurance Of Welding Operations

3.5.1 Welding Procedures


Proposed welding procedures shall be submitted, together with a copy of the qualification
documents to the Senior Staff Metallurgist for review one week prior to welding activity.

3.5.2 Pre-Welding Preparations


Weld preparation shall be in accordance with the specified design code. Two sided welding
shall be applied wherever possible.

3.5.3 Welding Operation


Welding shall be performed in accordance with a qualified weld procedure, accepted by
Santos.
Back welding or seal welding of screwed fittings is prohibited.
Hardness of weld shall not exceed the maximum level permitted by equipment specification.
In cases where no minimum is specified, hardness shall not exceed 248Hv. Santos reserves
the right to measure hardness of a completed weld.

3.5.4 Hot Tap Welding


Refer to Santos Engineering Standards 1515-050-DSG-0006 and 1515-050-WPR-0001.

3.5.5 Pre And Post Weld Heat Treatment


Welding pre and post weld heat treatment shall be carried out in accordance with the
applicable WPS and with ASME B31.3 and AS 4458 Sections 10 and 14. Heat treatment
procedures shall be prepared and submitted for Santos Senior Metallurgist acceptance
before starting any heat treatment.
On Carbon steel welds (P1 materials) Non Destructive Testing (NDT) shall be carried out
before any required Post Weld Heat Treatment (PWHT). For other than P1 materials,
additional NDT may be required after PWHT.

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3.5.6 Site Welding Safety


The Work Permit shall cover all welding carried out at site. This includes Job Hazard
Analysis.
Any person observing an unsafe condition shall immediately halt work and notify the Permit
Authority for resolution before work is resumed.
Hazardous Considerations
General hazards of external access to equipment are associated primarily with normal
operational temperature of equipment and working at heights. Additional hazards due to
presence of toxic and corrosive substances apply to internal access.
The Welder shall inform the Permit Authority of all potential hazards arising from welding,
such as spark or heat or ergonomic hazards. The Welder shall record potential hazards
arising from inspection or equipment used on the work permit and check they form part of the
Job Hazard Analysis.
Confined Spaces
Vessel entry Permits are required for entry to all confined spaces. Vessel entry shall be in
accordance with Santos Confined Spaces Entry Procedures. Refer to the Santos work permit
procedures handbook.
Heat Stress
Heat stress awareness is vital in welding operations. Refer Moomba Safety Handbook.
Housekeeping
 Keep work environment clean and free from waste.
 Cover valves and special items to prevent entry of moisture or foreign matter.
 Avoid contamination of stainless steel materials.

3.5.7 Methods Of Inspection


Destructive tests shall be performed by a laboratory registered with the National Association
of Testing Authorities, Australia (NATA).
Applicable codes are:
AS 1171 Methods for Magnetic Particle Testing
AS 1710 NDT - Ultrasonic Testing of Carbon and Low Alloy Steel Plate
AS 2062 Methods for Non-Destructive Penetrant Testing of Products and Components
AS 2207 NDT - Ultrasonic Testing of Fusion Welded Joints in Carbon and Low Alloy
Steel
AS 2452.3 NDT - Determination of Thickness - Use of Ultrasonic Testing
AS 4037 Boiler and Pressure Vessels - Examination and Testing

Weld inspection and sentencing shall be carried out in accordance with AS 4037.
Radiographic examination (or ultrasonics under circumstances agreed by all parties) is
performed for every material thickness and material grouping and for each welding process
and procedure, progressively throughout the entire job.
Where 5% or 10% radiography is specified, at least that percentage of all welds within the
relevant line class shall be radiographed for 100% of their circumference. Similarly, the

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specified percentage of all welds made by each welder shall be examined. Acceptance
criteria for 5% or 10% radiography is the same as specified for 100% radiography.
As gamma radiography has limited sensitivity when used with heavy wall material, all welds
requiring radiography through material over 19 mm thick shall be 100% ultrasonically tested
instead. If single wall single image radiography is possible, this material thickness limit is
extended to 30 mm.
Welds that cannot be radiographed because of their location or joint type or material shall be
examined by ultrasonic, liquid penetrant or magnetic particle method. Radiography is
generally not required for welds on slip-on flanges or socket welds or seal welds.
For each weld found to be defective, two additional welds made by the same welder who
produced the defective weld are subjected to radiographic examination. These additional
examinations are made immediately after a defective weld is found and are in addition to the
minimum examination requirements for the line class as specified in drawings or
specifications. Additional examinations are progressive so that two additional welds are
examined for each tracer examination found not to comply. Weld repairs shall be re-
examined by the same method used to detect the original defect.
Illumination - Inspection shall be carried out under suitable lighting conditions. The Welder or
Qualified Welding Supervisor may request additional lighting through the Santos
Construction Representative if required.

3.5.8 Repairs
If the Santos Construction Representative considers a weld to be grossly defective, or if a
weld does not comply with a Weld Procedure Specification, it shall be cut out and the joint re-
welded. All associated costs shall be the Welding Company’s responsibility.
Repair of weld defects shall be made using an approved welding procedure.
All repairs and modifications are subject to an appropriate level of quality control consistent
with Class and Standard to which pressure equipment is designed - in accordance with
AS3920.1and AS4458. A Santos Senior Metallurgist shall review and accept all repair
procedures.

3.5.9 Field Installation Checklists


All welding history details shall be recorded on appropriate FICs and ITPs. The reports shall
detail at least the following:
 Welder and date of weld or repair, and weld number
 Description of item or repairs
 Weld Procedure Spec and/or sketches to define size and location of welding
 Referenced Codes and Standards for welding and testing
The Project Team Leader, Maintenance Supervisor and the Senior Metallurgist shall be
advised of any non-compliance with the Weld Procedure Specification criteria
The Welding Company shall be responsible for compiling and handing over all certificates,
documents, FIC’s and charts of weld heat treatments applicable to the completed work to the
Santos Construction Representative.
Records shall be retained for seven years.

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4 REVISION NOTES

This standard is next scheduled for review: June 2006

Revision 3
This standard was previously TIMS document [1515-120-S-050-0].
Revision 3 reflects the migration of Santos engineering documentation from The Technical
Information Management Systems (TIMS) to myPlant OP during 2014. No technical update
changes have been made to this standard but where possible the update has addressed:
 Compliance with the new Santos naming conventions
 Links, including Redirect documents, to Santos Intranet, Extranet and external web
sites
 Keyword replacements (eg. replace TIMS with myPlant)
 Inclusion of reference to the Santos Engineering Management Standards (EMS)
which were launched in 2014.

Prepared AF Rooney, ARQS Aug-2014


Reviewed DR Robinson, Santos Aug-2014
Approved Michael McCarthy, Chief Facilities Engineer August 2014

Revision 2
Document updated (January 2009) as part of continuous improvement. All changes are for
improved useability and no technical changes have been made since the last revision.

Revision 1
General revision, removal of procedural items

Prepared R J Schulz, Principal Mechanical Engineer May 2005


Reviewed C J Moss, Principal Integrity Engineer Aug 2005
Approved D A Craig, Manager – Facilities Engineering Governance Oct 2005

Revision 0
Initial issue, comprising input from…
 CBU (R Schulz, G Bryan, H Moss)
 SABU meeting minutes rjs27501, May 2001
 Review comments as filed by Custodian

Prepared R Schulz May 2003


Reviewed H Moss May 2003
Approved D P Young, P J Strimaitis, Engineering Managers June 2003
Issued D R Poole, Corporate Engineering June 2003

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 15 of 15

5 APPENDICES

Appendix A Welding Procedure Identification


Appendix B Welding Procedure Specification Data Sheet
Appendix C Welding Procedure Qualification Record Data Sheet
Appendix D Welding Work Flow Diagram

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 1 of 1
Appendix A Santos Welding Procedure Identification

APPENDIX A SANTOS WELDING PROCEDURE IDENTIFICATION

Number Systems
Records of Welding Procedure Specifications and Weld Procedure Qualifications shall be
identified using the following nomenclature and guidelines
Identification Format Px-SYy-Zz
Px Material Type
Material being welded is identified by P number designation from AS 3992 and
ASME Section IX.
P1 – Carbon Steel P8 – Stainless Steel
Where a joint is between two materials of a dissimilar type, two P number's
are listed separating them with a ‘/’. e.g. P1/P8.
SYy Sequential Registration
‘S’ indicates a Santos procedure. Yy is registration sequence: S01, S02...
Approved Welding Procedures are controlled documents.
Registration is responsibility of Santos Welding Coordinator.
Zz Welding Process
Each welding process is designated by a two character Alpha code.
GT - Gas Tungsten Arc Welding SM - Shielded Metal Arc Welding
GM - Gas Metal Arc Welding FC - Flux Cored Arc Welding
SA - Submerged Arc Welding OF - Oxy Fuel Gas Welding
Where different processes are used for root and fill passes, the two processes
will be listed, separating them with a ‘/’. e.g. GT/SM.
Templates of proforma welding documents use sequential number (xxx)
WWP-xxx Template for Welding Work Pack
WPS-xxx Data sheet for Welding Procedure Specification
WPQR-xxx Data sheet for Welding Procedure Qualification
ITP-xxx Template for Welding Inspection Test Plan
FIC-xxx Template for Welding Field Installation Checklist
Draft documents use alphabetic revision – e.g. Rev A, Rev B etc.
Controlled Documents and use numeric revisions – e.g. Rev 0, Rev 1 etc.
Controlled Documents require identification signatures and dates of Preparer, Reviewer and
Approver for each revision.

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 1 of 2
Appendix B Welding Procedure Specification Data Sheet

APPENDIX B WELDING PROCEDURE SPECIFICATION DATA SHEET

WELDING PROCEDURE SPECIFICATION


WPS No. REV. PROJECT
WELDING CODE AS 3992 / 4458 / ASME IX / B31.3 FORMER WPS No
WELDING PROCESS(ES) SUPPORTING WPQR No
EDGE PREP. METHOD WO / JOB No.
JOINT TYPE JOINT POSITION

JOINT DETAIL PASS SEQUENCE


MATERIAL GRADE
MIN. PREHEAT TEMP. EXTENT OF PREHEAT THICKNESS RANGE to
MAX. INTERPASS TEMP. HEATING METHOD DIAMETER RANGE to
TEMP CHECK METH’D. PWHT SMYS.RANGE

Heat Time
Flux /
Weld Pass Details Filler Metal Description Welding Parameters to next
Gas Input pass
No. Direct’n Posn. Type Size Class. Type Amps Volts Polarity Speed kJ/mm Sec.

CONSUMABLE DETAILS
TYPE DESCRIPTION SPECIFICATION & CLASS BRAND NAME
FILLER METAL -ROOT
-FILL

FLUX
SHIELDING GAS FLOW RATE L/m
PURGE GAS FLOW RATE L/m
TUNGSTEN ELECTRODE TYPE SIZE CLEANING METHOD
NOTES : reference Santos Engineering Specification 1515-120-SPC-0050

Prepared by SIGNED DATE


Welding Engineer
Reviewed by SIGNED DATE
Santos Welding Coordinator

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 2 of 2
Appendix B Welding Procedure Specification Data Sheet

Approved by SIGNED DATE


Santos Senior Metallurgist
Form WPS-001 Rev 0 Reference AS 3992 Appendix B

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 1 of 2
Appendix C Welding Procedure Qualification Record

APPENDIX C WELDING PROCEDURE QUALIFICATION RECORD

WELDING PROCEDURE QUALIFICATION RECORD


WPQR No. REV. PROJECT
WELDING CODE AS 3992 / 4458 / ASME IX / B31.3 WPS No
WELDING PROCESS(ES) WO / JOB No.
EDGE PREP. METHOD CLEANING METHOD
JOINT TYPE JOINT POSITION

JOINT DETAIL PASS SEQUENCE


MATERIAL GRADE
MIN. PREHEAT TEMP. EXTENT OF PREHEAT THICKNESS RANGE to
MAX. INTERPASS TEMP. HEATING METHOD DIAMETER RANGE to
TEMP CHECK METH’D. PWHT SMYS.RANGE

Heat Time to
Flux /
Weld Pass Details Filler Metal Description Welding Parameters next
Gas Input pass
No. Direct’n Posn. Type Size Class. Type Amps Volts Polarity Speed kJ/mm Sec.

CONSUMABLE DETAILS
TYPE DESCRIPTION SPECIFICATION & CLASS BRAND NAME
FILLER METAL -ROOT
-FILL

FLUX
SHIELDING GAS FLOW RATE L/m
PURGE GAS FLOW RATE L/m
TEST PLATE IDENTIFICATION TEST RESULTS - REPORT No.
TEST COUPON No. VISUAL TENSILE
WELDER NAME RT BEND
DATE UT IMPACT
STICKOUT MT/PT HARDNESS
TUNGSTEN SIZE OTHER MACRO
NOTES:

Witnessed and Approved by Qualified SIGNED DATE


Welding Supervisor
Reviewed and Accepted by Santos SIGNED DATE
Welding Coordinator

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 2 of 2
Appendix C Welding Procedure Qualification Record

Approved by Santos Senior SIGNED DATE


Metallurgist
Form WPQR-000 Rev 0 Reference AS 3992 Appendix B

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923
Santos Engineering Standard
Specification 1515-120-SPC-0050-0 Rev 3
Page 1 of 1
Appendix D Welding Work Flow Diagram

APPENDIX D WELDING WORK FLOW DIAGRAM

Santos Welding
Representative
Santos Project

Responsibility
Construction

Coordinator

Operations

Supervisor
Company
Engineer

Engineer

Qualified

Operator
Welding

Welding

Welding

Welding
Activity

Santos

Santos
Related Documents
DELIVERABLE
or Procedures

Contract initiation and review process


including:
Scope of project welding work
1 SCOPE Contract Scope
Proposed Welding Standards
Welder Identification requirements
Schedule of work
Review and audit of Welding Quality
2 SCOPE Contract Scope
Assurance
Informing Senior Metallurgist, Welding
3 Coordinator and Welding Supervisor of SCOPE Review Review Contract Scope
proposed welding activities
Preparation detailed QMS and Welding
Welding Work Plans, ITP, FICs
Work plan including:
Brief description of work to be performed
Test plan shall include welder's review
Bar chart program of work / ITP / FICs
4 WWP Review of work scope requirements and
Proposed/Approved WPS, WPQ
welder's check that required equipment,
Details of crew to be used, WQ
consumables and relevant procedures
Location plan of work
are provided at site
Proposed emergency response, evacua
Definition of welding safety
5 WWP Review Welding Work Plans, ITP, FICs
requirements
Establishing welding quality standards,
6 WWP Welding Work Plans, ITP, FICs
WPS, WPQ, WQ
Reviewing new and existing weld
7 WPS Welding Procedure Specifications
procedures
8 Qualifying welding procedures Review WPQ WPQ Weld Procedure Qualification
9 Monitoring weld tests Review WPQ Weld Procedure Qualification
Conducting Weld Procedure
10 WPQ Review Weld Procedure Qualification
Qualification test
Conducting Welding Operator
11 WQ Review Welder Qualification
Qualification test
WWP confirmation...
Brief description of work to be performed
Bar chart program of work / ITP / FICs
Proposed/Approved WPS, WPQ
Welding Work Plans, ITP, FICs, WPS,
12 Details of crew to be used, WQ WWP
WPQ, WQ, JSA
Location plan of work
Proposed emergency response,
evacuation routes
Qualified Welding Supervisor
Review and acceptance of Quality
13 Management System Dossier, Welding WWP Review Welding Work Plans, ITP, FICs
Work Plans, ITP, FICs
14 Management of site welding activity SCOPE Contract Scope
15 Issue of Work Permits for on-site work PERMIT Work Permit
Use of Santos Operator's Safety
16 Checklists in preparation of the work PERMIT Work Permit
permit
WWP approvals and permits are all
17 WWP Welding Work Plans, ITP, FICs
received prior to commencement of work
Permit Authority continuous monitoring
18 PERMIT Work Permit
of work area throughout the operation
Welding Inspection to WWP
19 WWP Review Welding Work Plans, ITP, FICs
requirements
Welding complies with Welding Work
20 Review WWP WWP Welding Work Plans, ITP, FICs
Plan, AS 3834 and associated standards
NDT of completed welds show that it
21 complies with appropriate code WWP Review Welding Work Plans, ITP, FICs
requirements
Submit all NDT certificates, completed
22 FICs to the Santos Representative at Review WWP Welding Work Plans, ITP, FICs
work completion
Check, accept evidence that work
23 complies with Weld Procedure WPS Welding Procedure Specifications
Specifications
Collating and document control of FIC
24 records including on-site repairs of Review SCOPE Review Contract Scope
pressure equipment.

Rev Date: Aug-2014 Issued by Facilities Engineering  Santos Ltd


Printed document may not be current issue. Check ‘SES site’ ABN 80 007 550 923