NATIONAL OIL CORPORATION
GENERAL ENGINEERING SPECIFICATION
GES W.01
WELDING PROCEDURE AND WELDER QUALIFICATIONS
Rev Date Description Checked Approved
0 1999 Issued for Implementation DL
Compiled by Teknica (UK) Ltd
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INDEX
SECTION TITLE PAGE
1.0 SCOPE OF SPECIFICATION 3
1.1 Introduction 3
1.2 Other NOC Specifications 3
1.3 Restrictions 3
2.0 DEFINITIONS 3
2.1 Technical 3
2.2 Contractual 4
3.0 DESIGN 4
3.1 Codes and Standards 4
4.0 MATERIALS 5
4.1 Base Material 5
4.2 Filler Metals and Welding Fluxes 5
4.3 Shielding and Purging Gases 6
5.0 WELDING 7
5.1 Joint Details 7
5.2 Welding Positions and Applications 7
5.3 Welding Processes 7
5.4 Welding Variables 8
5.5 Cleaning and Conditioning 9
6.0 PREHEAT AND POST-WELD HEAT TREATMENT 9
6.1 Preheat 9
6.2 Inter-pass Temperatures 9
6.3 Temperature Control 10
6.4 Post-weld Heat Treatment (PWHT) 10
7.0 INSPECTION 10
7.1 Welder Performance Qualification 10
8.0 TESTING 11
8.1 Statutory Tests 11
8.2 Welder Performance Qualifications 11
8.3 Test Certificates 11
9.0 DOCUMENTATION 11
9.1 Requirements 11
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1.0 SCOPE OF SPECIFICATION
1.1 Introduction
1.1.1 This specification defines the minimum requirements to be observed for welding procedures
and the qualification of welders for shop and field fabrication of:
(a) pressure vessels and pressure containing equipment, including welded internal and
external attachments;
(b) fired heaters and power boilers;
(c) piping and piping components;
(d) storage tanks;
(e) structural steel and non-coded items such as flare and incinerator stacks.
1.1.2 This specification applies to welding procedure and welding qualifications to be used in the
manufacture, fabrication and erection of equipment for use in refineries, onshore oil and gas
installations and processing facilities, including items either purchased directly or as part of
the plant or package.
1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification.
Any exception must be authorised in writing by the Owner.
1.1.4 In the event of any conflict between this specification and with any applicable codes and
standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification from the Owner before proceeding with the work.
1.1.5 This General Engineering Specification will form part of the Purchase Order.
1.2 Other NOC Specifications
1.2.1 Where indicated in this specification, the following additional NOC Specifications shall
apply:
GES W.06 - Storage and Control of Welding Consumables
GES W.07 - Non-destructive Testing
1.3 Restrictions
1.3.1 This specification does not cover the qualification of welding procedures and welder
qualification for oil and gas transmission pipelines. For this, refer to GES R.03.
2.0 DEFINITIONS
2.1 Technical
The technical terms as used in this specification are defined as follows:
Welding Procedure Specification (WPS)
The document, compiled in accordance with this specification, listing the parameters to be
employed in producing weldments.
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Welder Performance Qualification Test (WPQT)
The demonstration of a welder's skill in producing weldments meeting the prescribed
standards.
Procedure Qualification Record (PQR)
A listing of the approved welding procedures.
Post-weld Heat Treatment (PWHT)
Any heat treatment subsequent to welding which may be designed to provide the welded
joint with desired properties.
2.2 Contractual
The commercial terms used in this specification are defined as follows:
2.2.1 Owner
The oil or gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.
2.2.2 Vendor
The company supplying the equipment and material.
2.2.3 Contractor
The main Contractor for a defined piece of work
2.2.4 Sub-Contractor
A company awarded a contract by a Contractor to do part of the work awarded to the
Contractor.
2.2.5 Inspection Authority
The organisation representing the Owner or Vendor/Contractor that verifies that the
equipment and facilities have been designed, constructed, inspected and tested in accordance
with the requirements of this specification and the Purchase Order/Contract.
2.2.6 Inspector
A qualified individual representing the Owner, Vendor/Contractor or the assigned
Inspection Authority, who verifies that the equipment and facilities have been designed,
constructed, inspected and tested in accordance with the requirements of this specification
and the Purchase Order/Contract.
3.0 DESIGN
3.1 Codes and Standards
3.1.1 The qualification of all welders and welding procedures shall fully comply with the
requirements of this specification and with the codes and standards listed below. In cases
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where more than one code or standard applies, the more stringent shall govern. Unless
specified otherwise, the current editions of the codes and standards at the time of Purchase
Order/Contract shall be used.
3.1.2 ASME - American Society of Mechanical Engineers
B31.3 - Process Piping
ASME Boiler and Pressure Vessel Code
Section II - Material Specification, Part C, Welding Rods, Electrodes and
Filler Metals
Section V - Non-destructive Testing
Section VIII - Pressure Vessels
Division 1
Division 2, Alternative Rules
Section IX - Welding and Brazing Qualifications
3.1.3 AWS - American Welding Society
A5.1 to A5.24 - Filler Metal Specifications
AWS D1.1 - Structural Welding Code
4.0 MATERIALS
4.1 Base Material
4.1.1 This specification covers the qualification of welders and welding procedures for any of the
materials listed under QW 422 of ASME Code, Section IX.
4.1.2 Base metals not listed in QW 422 of ASME Code, Section IX, but which have equivalent
chemical and mechanical properties as listed materials may be classified in a listed P-number
and, where applicable, group number subject to the approval of the Inspector.
4.1.3 Each base metal within a given P-number or Group number having nominally different
chemical or mechanical properties (as defined in QW 422 of ASME Code, Section IX) requires:
(a) a separate Welding Procedure Specification;
(b) a separate Welding Procedure Qualification Test and Record whenever a welding related
operation satisfactory for one base metal is, in the opinion of the Inspector, unsatisfactory
for another base metal within the same P-number or Group number.
4.1.4 Backing strip material specification or its nominal chemistry shall be considered a non-
essential variable and shall be recorded in the welding procedure, or on the applicable
fabrication drawing.
4.1.5 Deletion of a backing strip in a butt joint welded from one side only shall require procedure
qualification.
4.2 Filler Metals and Welding Fluxes
4.2.1 All filler metals shall comply with ASME Code, Section II, Part C or with ANSI/AWS A5,
Sections A5.1 to A5.24, Filler Metal Specifications.
4.2.2 Each WPS shall identify filler metals by AWS grade or by make and type. However, welding
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fluxes for Submerged Arc Welding (SAW) shall be specified by manufacturer and type.
4.2.3 All welding consumables shall be stored and handled in accordance with the manufacturer's
recommendations and GES W.06. Consumable handling procedures shall form part of the
WPS and shall be subject to review by the Inspector. A system shall be employed to identify
and retain the identity of all filler metals and welding fluxes. Damaged or non-traceable
consumables shall be disposed of and shall not be used.
4.2.4 When joining similar metals, unless specified otherwise, welding consumables shall be
chosen to produce weld deposits matching the parent metal chemical composition and
mechanical properties as closely as possible.
4.2.5 Where the throat thickness of a butt-weld or fillet weld is greater than ½" (13 mm), welding
processes and filler metals producing low hydrogen weld deposits shall be selected. Because
low hydrogen SMAW electrodes do not have good penetration, cellulose coated electrodes
shall be used if the weld must be welded from one side (WOC).
4.2.6 All low hydrogen coated electrodes shall conform to the moisture content requirements of the
applicable ASME/AWS specification.
4.2.7 The WPS shall require re-qualification where:
(a) There is any change in the manufacturer or brand designation of SAW wire or flux or
both.
(b) There is any change in the electrode or wire classification, except if notch toughness
properties are not required, or if the A or F number is not changed. Under these
circumstances the WPS does not require requalification.
(c) There is a change in the filler metal from one manufacturers make and type designated
under AWS classification "G" to any other manufacturer or manufacturer's designation.
This shall apply only where the application requires specific low temperature toughness
or creep resistance.
(d) There is a change in the classification of the chemical composition of the deposited weld
metal from one A-number to any other A-number under QW-442 of ASME Code, Section
IX. However, where the difference in alloying content between A1 and A2 will not
significantly affect the room temperature, mechanical properties of the test specimen
requalification will not be required.
4.3 Shielding and Purging Gases
4.3.1 Where a shielding gas is used in the welding process, the WPS shall specify the gas
composition, its purity and the flow rate.
4.3.2 Where an internal gas purge is used to prevent root oxidation, the WPS shall specify:
(a) The gas composition and flow rate.
(b) The period of time allowed for gas flow through the weld area, prior to the start of
welding, to purge the area of oxygen.
(c) The method of venting shall be adopted to allow oxygen to escape prior to the start of
welding and to prevent excessive pressure build-up of purge gas on the root side of the
weld.
(d) The back purge shall be maintained until at least _" (10 mm) depth of weld metal has
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been deposited.
4.3.3 The WPS shall require re-qualification where the back purge is deleted.
5.0 WELDING
5.1 Joint Details
5.1.1 The WPS shall indicate the specific types of joint detail preferably by means of a sketch, and
range of thicknesses applicable to production welds.
5.1.2 All pressure containing butt-welds, including branch connection welds shall be full
penetration welds.
5.1.3 The typical run deposition sequence shall be indicated in the WPS. All SAW welds shall be
multipass, that is, shall be performed with a minimum of two passes.
5.1.4 Change in basic groove design or type of groove is a non-essential variable and therefore
does not require WPS requalification, however the change shall be agreed with the Owner.
5.2 Welding Positions and Applications
5.2.1 Vertical down welding is prohibited.
5.2.2 Whenever joint accessibility, restraint or environmental conditions are such that the
WPS/PQR are not representative of actual working conditions, additional procedure and
performance qualifications shall be undertaken which simulate local conditions.
5.2.3 Where weld overlaying or backcladding is to be undertaken, each welding position requires a
separate performance qualification. Qualifications in the horizontal (2G), vertical (3G) and
overhead (4G) positions do not qualify for welding in the flat (1G) position.
5.2.4 Only welders qualified for weld overlaying and for backcladding shall carry out these
operations.
5.2.5 Peening is prohibited on all passes except as follows:
(a) piping according to ASME B31.3, where peening is only prohibited on the root and cover
pass of welds;
(b) relief of residual stress.
5.2.6 After buttering (adding metal to a metal surface to obtain a desired dimension, e.g., to close a
root gap), the back-gouging shall remove the first layer of weld metal deposited.
5.3 Welding Processes
5.3.1 Acceptable welding processes, subject to the conditions below are:
(a) Shielded Metal Arc Welding (SMAW)
(b) Gas Tungsten Arc Welding (GTAW)
(c) Submerged Arc Welding (SAW)
5.3.2 The use of any welding process other than those specified above shall be subject to specific
agreement by the Inspector. The Vendor/Contractor shall submit his proposal, and this shall
include evidence from extensive testing and examination of test and/or production welds, to
demonstrate that the required quality will be achieved.
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5.3.3 GTAW must be used with the addition of filler metal. Autogenous GTAW shall be subject to
specific approval of the Inspector as per paragraph 5.3.2 above.
5.3.4 GTAW shall be carried out using equipment with a high frequency start unit and crater
eliminating device. The torch shall have a gas lens.
5.3.5 Welding processes using coatings or fluxes shall not be used for austenitic stainless steel,
nickel or aluminium alloy root passes, unless the slag can be removed from the underside of
the root passes and the area inspected.
5.3.6 Each combination of welding processes or procedures, or both, requires qualification as a
combination, unless specifically approved by the Inspector. Any process or procedure used
solely for the root pass in joints welded from one side only, may be eliminated without re-
qualification for double welded butt joints, or for joints welded from one side using a backing
strip.
5.3.7 For each automatic welding process, the WPS shall specify all applicable equipment settings
in order to ensure consistent performance and reproducibility of results by all welders and
welding operators.
5.3.8 The use of Gas Metal Arc Welding (GMAW) is permitted only with specific Owner approval
as per paragraph 5.3.2, and the following conditions shall apply:
(a) Additionally, this shall include the preparation and welding of test samples
representative of the work for which the GMAW process is to be used. These samples
shall be submitted for approval by the Inspector.
(b) Each welder shall demonstrate his ability in the use of GMAW by duplicating the
workmanship on the representative test samples.
(c) The representative test samples and welder test samples shall be sectioned, polished and
etched in accordance with QW-470 of ASME Code, Section IX. These specimens shall be
submitted to the Inspector for examination and shall demonstrate freedom from lack of
fusion.
(d) These examinations are supplementary to the inspection and testing requirements of
ASME Code, Section IX.
5.4 Welding Variables
5.4.1 Essential and Supplementary Essential Variables
In the ASME Code Section IX, the essential and supplementary essential variables are listed in
tables as follows:
SMAW Q-253 Page 18
Q-253.1 Page 18.1
SAW Q-254 Pages 19 and 20
Q-254.1 Page 20.1
GTAW Q-256 Pages 23 and 24
Q-256.1 Page 24.1
In addition to the requirements for procedures where impact testing is required, the WPS
shall require re-qualification if any of the following changes are made:
(a) there is an increase in the welding heat input outside the range specified in the WPS.
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(b) there is an increase in the electrode diameter to over ¼" (6.3 mm) diameter accompanied
by an increase in heat input;
(c) there is an increase in the width of weave or a change from string to weave bead
technique.
(d) where the interpass temperature is increased 100°F (56°C) above that recorded on the
PQR, the WPS must be re-qualified.
5.4.2 For weld overlay operations, the overlap of adjacent weld beads is considered an essential
variable and must be specified in the WPS.
5.5 Cleaning and Conditioning
5.5.1 The WPS shall detail the methods to be used for cleaning the weld preparation prior to
welding.
5.5.2 The WPS shall detail the method to be used for inter-pass cleaning during welding.
5.5.3 The backside of joints to be welded from both sides shall be cleaned to sound metal prior to
second side welding, and the method of cleaning shall be stated on the WPS.
5.5.4 On completion of welding, all slag shall be cleaned from the weld surface.
5.5.5 Unless it can be demonstrated that welding slag can be completely removed from the
underside of the root pass on stainless steel or nickel alloy welds, and the area inspected, a
process which does not leave a slag residue, e.g. GTAW, shall be selected.
6.0 PREHEAT AND POST-WELD HEAT TREATMENT
The WPS shall specify the minimum preheat and maximum interpass temperatures in
accordance with the following:
6.1 Preheat
6.1.1 Where the material surface is wet or the metal temperature is below 50°F (10°C), preheat shall
be employed to dry the surface.
6.1.2 Preheat shall be applied, where necessary, to avoid cracking or undesirable hardening of
weldments.
6.1.3 For carbon steels, this shall take into account joint design, heat input, presence of diffusible
hydrogen and the base metal composition including the effects of higher carbon and alloy
content. Unless specifically agreed otherwise, minimum preheats shall be in accordance with
ASME Code, Section VIII, Pages 164-170, Table UCS-56 and UCS-56.1.
6.2 Inter-pass Temperatures
6.2.1 Before each subsequent pass, the weld shall cool sufficiently to ensure the maximum inter-
pass temperature, which shall be specified on the WPS, shall not be exceeded.
6.2.2 For any weld, the inter-pass temperature shall not be allowed to fall below the specified
preheat temperature until completion of not less than 30% of final weld depth in the case of
P1 material. For other `P' numbers, the weld must not be allowed to drop below the preheat
temperature until all the hydrogen diffuses.
6.2.3 Where the inter-pass temperature falls below the specified preheat temperature, the preheat
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level shall always be restored before welding is resumed.
6.3 Temperature Control
6.3.1 The method of applying preheat and the means of checking and controlling preheat and
inter-pass temperatures shall be stated in the WPS.
6.4 Post-weld Heat Treatment (PWHT)
6.4.1 Post-weld heat treatment is considered an essential variable and the WPS shall clearly state
whether it is required.
6.4.2 All PWHT shall be performed after all welding is complete, there shall be no welding of
pressure parts after PWHT. No attachments shall be welded to pressure parts after PWHT.
6.4.3 The WPS shall include all heat treatments to which the weld shall be specially or incidentally
subjected, including for example, stress relief, tempering, hot forming, normalising, solution
heat treatment and/or thermal stabilisation. For any PWHT, the WPS shall state, or make
reference, to the following procedures:
(a) methods of heating and cooling;
(b) rates of heating and cooling;
(c) holding temperature range and soak time;
(d) extent of heating and insulation for local or partial PWHT (including sketch if
appropriate);
(e) location and number of thermocouples used to control and record the PWHT;
(f) precautions taken to prevent distortion or collapse that could be caused by thermal
expansion or loss of tensile strength.
7.0 INSPECTION
7.1 Welder Performance Qualification
7.1.1 For welder performance qualification, the requirements for visual inspection of welded joints
shall be as specified in the applicable fabrication code. As a minimum, the weld shall be of a
uniform appearance and shall be free from excessive profile defects, e.g. excessive cap height
and/or root penetration. There shall be a smooth transition between the weld metal and
parent material and the weld shall be free from undercut, pinholes or any other visible defect.
7.1.2 For welder performance qualification, radiographic inspection of butt-weld joints may be
substituted for the guided bend tests specified in QW-452 of ASME Code, Section IX. Such
radiographic examination and acceptance criteria shall be in accordance with QW-191 of the
code.
7.1.3 All welder performance qualifications and welding procedure qualification tests shall be
witnessed and certified by the Owner and/or an authorised independent Inspection
Authority.
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8.0 TESTING
8.1 Statutory Tests
8.1.1 In addition to the requirements of ASME Code, Section IX, the following welding procedure
qualification testing requirements shall apply:
(a) Each PQR shall be certified by the Owner and/or an authorised independent Inspection
Authority.
(b) Where impact tested base materials, e.g. ASTM A333 Gr 6, are specified, the welding
procedure qualification shall also include Charpy V-notch impact testing in accordance
with ASTM A370 using the type A specimen.
(c) Test welds for C and C-Mn steel weldments shall be subject to hardness testing and the
survey shall cover the weld, heat affected zone (HAZ) and base material on one sectioned
face of the weld. The survey shall be performed along a line parallel to, and within 2 mm
of, the inside (process side) and the outside surface. The maximum hardness shall not
exceed 225 Hardness Brinell micro hardness as per NACE RP 0472-87 paragraph 1.3.
(d) For vessels and steel piping containing fluids such as salt water, C12, H2 and H2S, the
maximum hardness shall not exceed 200 Hardness Brinell as per NACE RP 0472-87.
8.1.2 Procedure qualification test welds in C-Mo and Cr-Mo welds shall be subject to hardness
testing as detailed in 8.1 above. The maximum hardness shall not exceed 225, Hardness
Brinell.
8.2 Welder Performance Qualifications
8.2.1 Welder performance test samples shall be qualified in accordance with QW 302 and QW 452
of ASME Code, Section IX.
8.3 Test Certificates
During weld procedure qualification testing, all welding parameters and test results shall be
recorded on the PQR (Procedure Qualification Record). This shall be used as a basis for
producing the applicable WPS.
9.0 DOCUMENTATION
9.1 Requirements
9.1.1 Following satisfactory procedure qualification, a Welding Procedure Specification (WPS) and
weld map that identifies which WPS applies to each weld, shall be prepared setting out all of
the parameters to be observed during production welding. The WPS will be supported by
the procedure qualification record (PQR) detailing the results of all non-destructive
examinations and mechanical testing carried out. These shall be submitted to the Inspector
for approval prior to work commencing.
9.1.2 During fabrication, the WPS shall be available at the work-site for the use of the welding
supervisor, welders and Inspector. All of the parameters listed shall be observed in full.
9.1.3 Following satisfactory welder qualification, a welder qualification test report (WQTR) shall be
prepared showing the actual test results and the range of material diameters, if pipe, and
thicknesses for which the welder is qualified. This report shall also show the WPS number to
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which the welder is qualified.
9.1.4 Welder qualifications shall be revalidated on a six monthly basis to ensure that the
requirements of QW-322 of ASME Code, Section IX are met. Revalidation shall be by the
Vendor/Contractor and shall be countersigned by the Owner or an authorised independent
Inspection Authority.
9.1.5 A welder qualification index shall be prepared showing, as a minimum, the welders name,
identification number, which welding procedure specifications the welder is qualified to, the
date of qualification for each WPS and the date when revalidation of qualification is due for
each procedure.
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