GTA POWERMECH FZE

COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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PROCEDURE NO: JOB PROCEDURE FOR WELDING CONTROL
DORC/EIL/GTAPM/3007/JP-012 Page 1 of 9

JOB PROCEDURE FOR WELDING CONTROL

PROCEDURE NO: DORC/EIL/GTAPM/3007/JP-012, Rev-0

NAME OF WORK COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

OWNER M/s DANGOTE OIL REFINING COMPANY LIMITED

CONSULTANT M/s ENGINEERS INDIA LIMITED

CONTRACTOR M/s GTA POWERMECH FZE

CONTRACT NO TR__0015_3007

Prepared Checked
By GTA By GTA Reviewed Approved
Rev Date
POWERMECH POWERMECH By EIL By EIL
FZE FZE

0 27.10.2018
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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INDEX

SL NO. CONTENTS PAGE NO.

1. PURPOSE ……………………………………………………………..………....3

2. SCOPE ……………………………………………………………… …………...3

3. ABBREVIATION AND DEFINITION……..……………………………………3

4. REERENCE …………………………………………………………………..…..3

5. RESPONSIBILITIES……………………………………………………………..4

6. GENERAL ………………………………………..……………………………...3

7. PROCEDURE………………………………………………………..…….…......4

8. QUALIFICATION OF STEEL STRUCTURE WELDER………………………5

9. TESTING ……………………………………………………………………......6

10. RE-TEST …………………………………………………………………... …...7

11. CERTIFICATION/COLOUR CODING ………………………………….…….8

12. TERMINATION OF QUALIFICATION …………………………………….…9

13. INSPECTION, TESTING AND DOCUMENTATION …………………..…….9

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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1. PURPOSE

This procedure is prepared to define the requirements to be fulfilled in

welding work and to control the welding activities and welders to achieve
good quality of weld.

2. SCOPE

This procedure is to be applied by GTA Powermech FZE COMPOSITE

WORKS FOR ONSHORE & UTILITIES.

3. ABBREVIATION AND DEFINITION

WPS - WELDING PROCEDURE SPECIFICATION

QW - QUALIFICATION OF WELDING

PQR - PROCEDURE QUALIFICATION RECORD

NDT - NON-DESTRUCTIVE TESTING

RT - RADIOGRAPHY TESTING

ASME - AMERICAN SOCIETY OF MECHANICAL

ENGINEERS

4. REFERENCES

4.1 ASME BPVC Section IX : Welding and brazing Qualification Latest Edition
2017

4.2 ASME B31.3 : Process Piping Latest Edition 2016

4.3 API 650 : Storage tank

4.4 A545-000-6-77-0001Rev.0: Welding Specification for Fabrication of Piping

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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5. RESPONSIBILITIES

5.1 General manager/Engineers in charge is responsible for implementing

this procedure in their area.
5.2 Document control Department/FQA is responsible for maintaining this
procedure.
5.3 Document control/FQA Department is the custodian of this document

6. GENERAL

6.1 Qualified WPS shall be provided in accordance with the codes,

Standards and specification to carry out production welding.

6.2 Production welding shall be performed only by the qualified welders

who have demonstrated their ability and determined as satisfactory in
Accordance with the approved WPS.

7. PROCEDURE

7.1 General requirements

7.1.1 Welding shall not be carried out when the surface of the parts to be
welded are wet.
7.1.2 Welding shall not be started when the temperature of the parts to be
welded is below 100C or EIL specification.
7.1.3 Under rainy and windy weather condition, proper shielding device
shall be used to carry out welding.
7.1.4 The surface to be welded shall be free from oil, grease, rust, dirt,
paint etc. Grinding or filing shall be done, if required to make the
surface free of these materials.
7.1.5 All welders shall display their welder identity card while they are on
the job.
7.1.6 Tack weld shall have the same quality as that of finished weld.
Therefore, tack weld shall be done by qualified welder using qualified
WPS.
7.1.7 If weld preparation is made by thermal cutting, beveling surface
should be smoothened by grinding, brushing to remove oxidized
surface or scale.

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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7.2 Preheating and inter-pass temperature

7.2.1 Preheating shall be done in accordance with approved WPS and heat
treatment procedure.
7.2.2 When the base metal temperature is below 100C, the welding area shall
be preheated to the temperature required as per WPS.
7.2.3 Preheating shall be extended up to three times of the thickness of the
base metal to be welded.
7.2.4 Inter-pass temperature shall be maintained to avoid excess heat input
to the weld joint.

7.3Pipe groove weld test

7.3.1 For pipe weld, no one should check inside of the pipe visually until
root pass is completed.
7.3.2 After root pass, root weld shall be inspected to determine weld
condition.

7.3.3 If root weld indicates any unacceptable defect, the test shall be
discontinued and welder shall be rejected.
7.3.4 If root weld shows no significant defect, welding shall be continued.
7.3.5 Visual inspection shall be done after completion of welding and
further NDT shall be carried out if the result of visual inspection is
found acceptable.

7.3.6 Plate groove weld test (Storage tank)

7.3.7 Basically, welder test for plate groove welding will be performed for
double bevel groove welds.
7.3.8 Root pass of the plate shall be inspected after one side welding but
before back chipping.
7.3.9 If root weld reveals no significant root defect, welding shall be
continued till completion of cap weld.
7.3.10 Welders and welding operators who passes the required tests for
groove welds shall also be qualified to make fillet welds in all
thickness and pipe diameters of any size within the limits of the
welding variables of ASME section IX Table QW 461.9.

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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7.4 Production test

7.4.1 All the welders should be qualified through the formal welder
performance test, unless otherwise production test is approved by
EIL.
7.4.2 If production test is decided, radiographic testing of this weld shall
not be considered in random RT.
7.4.3 If production weld result does not meet the acceptance criteria, that
weld shall be repaired by a qualified welder and radiographed.

8 QUALIFICATION OF STEEL STRUCTURE WELDER

8.1 LIMITS OF QUALIFIED POSITION AND THICKNESS

The extent of approval for a welder shall be the same as that for the approved
welding procedure. The acceptance of a welder test in a particular position
will give approval for welding in the following position

8.1.1 A test in the flat (1G) position will give approval for the flat position
(1G).
8.1.2 A test in the 2G position will give approval for horizontal and flat
position (2G & 1G). A test in the vertical position (3G) will give
approval for, vertical and flat position (3G, and1G).
8.1.3 A test in the overhead position (4G) will give approval for the
overhead (4G) and flat position (1G).
8.1.4 A test in the 5G position will give approval for the 4G, 2G, and 1G
position.
8.1.5 A test in the 6G position will give approval for that position all
position.
8.1.6 A test joint inclined at 450 to the horizontal involving the overhead
position shall include approval for all welding position.
8.1.7 The approval of a welder on material of thickness t shall include
approval for thickness range will be depends on ASME Sec IX Table
QW-451.

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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8.2 TEST

8.2.1 Before test, the test coupon shall be provided with good fit up, tack weld
condition and size of the test coupon as per ASME Sec IX.
8.2.2 Welder’s shall be allotted unique identification number before test and that
number shall be marked on the specimen clearly.

9 TESTING

9.1 For piping and storage tank welders, the test coupon shall be visually
inspected after welding to conform following requirements.

9.1.1 Root run should show full penetration with complete fusion of base
metal.
9.1.2 For piping, weld should not have any of the unacceptable flaws
mentioned in ASME B 31.3 Table K341.3.2 or in EIL Specification
A545-6-44-0016 Rev.2.
9.1.3 If the test coupon is visually accepted, the test shall be
radiographically tested and should meet QW-191 standard of ASME
section IX.

9.2 For steel structure welders, exposed porosities and overlaps should
not be detected by visual inspection. Further, surface it should meet
ASME sec IX QW-191.

9.2.1 When destructive test is required, ASME sec IX QW-450 shall be

applicable to determine the number of test specimens required.
9.2.2 When non-destructive testing is required for welder qualification,
ASME Sec-IX QW-191.1.2.2 shall be applied to determine the
acceptance criteria.

9.3 The test may be terminated at any stage of the testing procedure,
whenever it becomes apparent to the supervisor conducting the test that
the welder does not have the required skill to produce satisfactory result.
Too slow progress of welding will be one of the criteria for such
termination of testing.

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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10 RE-TEST
The welder who fails the qualification test, may appear for re-test under the
following condition.

10.1 When qualification coupon has failed in visual examination, the welder may
have an immediate re-test. In such cases the welder shall make two
consecutive test coupons and both the coupons should pass visual
examination. One of the coupons shall be radiographically tested.
10.2 When qualification coupon has failed in radiographic testing, the welder will
not be allowed immediate re-test.
10.3 When the welder has had further training or practice, a new test shall be made
as per the initial test procedure after the approval of EIL.
10.4 This further training or practice means at least one month training or 7 days
full time training.

11 CERTIFICATION/ COLOUR CODING

11.1 QA/QC Manager shall prepare welder’s or welding operator’s performance

qualification record and pocket size identification card for the qualified
welders. All welders shall display their identity card while working. Identity
card of different color shall be issued to welder.

11.2 WELDER IDENTITY CARD COLOUR CODING

DESCRIPTION POSITION COLOUR

CODE
Structure / plate (3G/4G) White colour

C.S and L.T.C.S (5G/6G) Blue colour

Piping
Alloy Steel Piping (5G/6G) Pink colour

Stainless steel (5G/6G) Yellow colour

Piping

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)
 GTA POWERMECH FZE
COMPOSITE WORKS FOR –ONSHORE AND UTILITIES.

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12. TERMINATION OF QUALIFICATION

12.1 When the welder has not welded with a certain process for a period of 6
months or more, his qualification will be terminated...

12.2 When there is a specific reason to question the welder’s ability to make welds
that meet the specification, his qualification will be suspended until he passes
the renewal test.

13. INSPECTION, TESTING& DOCUMENTATION

Inspection, testing& documentation shall be carried out as per approved

ITP:-DORC/EIL/GTAPM/3007/ITP-101.

In case of any conflict in any reference code in this procedure, EIL

specification shall prevail.

PREPARED BY CHECKED BY REVIEWED BY APPROVED BY

(GTA Powermech FZE) (GTA Powermech FZE) (EIL) (EIL)