KINOA 4307 ACCOMMODATION

PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 1 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

WELDING CONTROL PROCEDURE

Project : KINOA 4307

Company : NAVTECH KELOA/KINOA INVESTMENT S.A

Contractor : PT. UNITED SINDO PERKASA

Document no : USP-NC-WCP-008

Document revision
: 0
status

0 For Submission

Project
QA ABS Client
Manager
Rev Date Description
Prepared Reviewed Reviewed Approved
 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 2 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

TABLE OF CONTENT

1. SCOPE
2. PURPOSE
3. REFERENCE STANDARD
4. DEFINITION
4.1. WELDING PROCEDURE SPECIFICATION (WPS)
4.2. PROCEDURE QUALIFICATION RECORD (PQR)
4.3. WELDER QUALIFICATION TEST (WQT)
4.4. WELD MAP
4.5. WELDING PROCEDURE REGISTER
4.6. WELDER REGISTER
4.7. NDE PLAN
5. RESPONSIBILITY
5.1 QA/QC MANAGER
5.2 WELDING ENGINEER
5.3 WELDING SUPERVISOR
5.4 WELDING OPERATOR/WELDER
5.5 WELDING INSPECTOR
5.6 PRODUCTION ENGINEERING
6. PROCEDURE
6.1. WPS/PQR
6.2. WELDING OPERATOR/WELDER QUALIFICATION TEST
6.3. WELDING CONSUMABLE
6.4. PRODUCTION WELDING
6.5. PERFORMANCE MONITORING
 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 3 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

1. SCOPE

This procedure covers all the welding related activities which involve welder, welding
operator, foreman, supervisor, and QC welding inspector

2. PURPOSE

To prescribe a control method of welding activities during fabrication and erection of steel
construction, process piping to achieve desired welding quality.

3. REFERENCE STANDARD.

• CLIENT SPECIFICATION
• ABS RULE PART. 2
• AWS D 1.1
• ASME IX
• ASME B 31.3

4. DEFINITON

4.1 Welding Procedure Specification (WPS)

A written document giving all necessary parameters and directions to make production
welds are meet specified requirement. WPS includes a reference to the Procedure
Qualification Record (PQR).

4.2 Procedure Qualification Record (PQR)

A written demonstration record that welds made by a specific welding procedure can meet
specific requirements. PQR contains actual record of the performance of all variable factors
in the WPS as well as the results of all mechanical, volumetric, and surface tests.

4.3 Welder Qualification Test (WQT)

A test performed to verify ability of a welder or a welding operator to deposit sound weld.
This test required by each welder before being allowed to perform actual production
welds. Welder Performance Qualification:

• Indicates the WPS reference during the qualification test

• Identifies the welder by name and/or ID number

 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 4 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

• List the essential parameters

• Report the results

• Specifies qualified limits and range of welding

4.4 Weld Map

Document that defines weld joint numbering and the WPS to be used.

4.5 Welding Procedure Register

A summarized list of all applicable WPS contains detail of all joint configurations,
supporting PQR and other essential variable.

4.6 Welder Register

A summarized list of all qualified welders/welding operator contains detail of qualification

range, welder stamp number and their qualification expiry date.

4.7 NDE Plan

Document that defines the type of NDE method to be applied and the extent one.

5. Responsibility

5.1 QA/QC Manager

• Review related codes and specification and client requirement, responsible for
welding and quality procedures related to the specification.

• Coordinate with other discipline in welding quality trouble shooting.

• Responsible for issuing NCR and monitoring the close-out.

• Audit NDE company and verify their certification, procedures, and human resource

• Monitor welder/welding operator training certification and performance.

• Liaise with external certifying authority.

• Assess, monitor and improve the working relationship between production site, QC
personnel and client representative.

• Improve welder performance by monitoring and reporting rejection rate.

 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 5 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

5.2 Welding Engineer

• Prepare WPS and PQR

• Prepare WPS Register

• Prepare selected welder list, qualify them and monitor their expiry

• Together with Warehouse department to ensure incoming welding consumable

complies with requirement.

• Provide information in regards to weld map development to Production

Engineering

• Set up welder/welding operator training and re-training programs and work

together with facility manager to prepare welding machine and its utility

• Provide technical assistance in regards to welding problems

• Monitor and responsible to recommend solution in improving welding rejection rate

5.3 Welding Supervisor

• Mobilize welder/welding operator, organize and ensure approved WPS are

available on site for welding reference

• Ensure welder/welding operator who is making production welding is qualified for

the job

• Responsible for the correct and appropriate welding consumable

• Responsible for maintaining good handling and storage specially for unused
electrode after working hours to be stored properly

• Submit daily welding report

• Responsible for maintaining good performance of welder/welding operator

• Responsible to carry out appropriate welding repair if any

5.4 Welder/Welding Operator

• Responsible to perform acceptable WPS

• Prior to welding, ensure welding consumable are preserved and handled as per
approved handling procedure
 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 6 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

• Ensure proper welding equipment and welding parameter are suitable including
safe working practice prior to start working

5.5 QC Welding Inspector

• Ensure fit up and joint preparation are accepted and surface is clean and free from
contaminant prior to welding

• Ensure correct WPS is used by the welder and monitor the compliance of specific
parameter

• Coordinate with Welding Supervisor to perform good quality of weld

• Perform visual inspection until accepted

• Request NDE operator to conduct NDE execution as per NDE Plan

• Ensure welder/welding operator is qualified for the weld joint

5.6 Production Engineering

• Responsible for issuing Joint detail, Welding schedule, Weld map and NDE Plan

6. Procedure

6.1 WPS/PQR

• Welding Engineer to review Client specification and reference code to establish

WPS for qualification

• He/she shall then conduct the Procedure Qualification Test by welding test coupon
and conduct NDE and Mechanical test. Upon achieving and acceptable result of the
PQR, the WPS can be developed indicating the welding variable qualified ranges

• WPS compilation consists of all welding data to be issued for construction

6.2 Welder/Welding operator Qualification Test

• All Welder/welding operator shall be tested and qualified under witness of QA/QC
Inspector and a Authorized Personnel/Class Surveyor for their proficiency before
being assigned for production welding. Supervisor shall select welder from welder
list for various type of production welding.
 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 7 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

• For the qualification test, the approved WPS and the following rules shall be
applied or as required in the contract specification & Class Requirements.

• Test specimen for qualification test shall be prepared in accordance with WPS
and Rules or Codes
• Inspection and Test, the visual inspection, Radiographic Examination (NDE ex-
amination) or Mechanical Test shall be carried out according to Rules or Codes
( AWS D1.1, ASME IX and Class Regulation ). NDE and other tests may be re-
quired if applicable.
• If the test joint doesn’t meet the requirements, the welder or welding operator
shall perform welding for a new test joint of the same type as the rejected one.
• A welder or welding operator, who failed, is permitted to retest after a minim-
um of 3(three) days training.
• QA/QC Department shall issue an Identification Card to each qualified welder
or welding operator.
• Re-qualification is required whenever a welder or a welding operator has not
used the qualified welding process for period more than as stipulated in the ap-
plicable codes or whenever there is a reason to question of his welding per-
formance.
• The Card shall be carried at all the times and presented upon request.
• All welders or welding operators who qualified already by authorized 3rd party
agency or ABS and having the evidence of performing work within at least 6
months satisfying the requirements of the relevant codes will be allowed on job
without further qualification tests subject to Company’s approval.

6.3 Welding Consumable

• All welding consumable shall be handled and storage according to establish

procedure, and manufacture recommendation

• Once electrode packing is opened, it shall be baked according to specified baking

temperature and time, thereafter transfer to holding oven for storage

• Electrode is then issued to welder and kept in heated quiver to maintain dryness

• Welding Supervisor shall ensure correct types of electrode as per WPS

 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 8 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

• Welding Supervisor shall ensure balance electrode at the end of work shall be
returned to storage holding oven and apply color coding. Before re-use, the
electrode shall be baked again to restore dryness

• Limited to 2 (two) time re-bake of electrode is allowed, otherwise the electrode

shall be discarded or shall not be used for this project material (Refer to Handling
Consumable Procedure )

• Un-fused flux (SAW Process) collected during welding shall be filtered to remove
contaminant, kept in holding oven to avoid moisture prior to mix with new flux
before use

6.4 Production welding

• Production Engineering produces approved drawings which specify welding type,

weld map joint number, and NDE Plan

• The relevant approved WPS shall be displayed nearby the welding area for easy
reference and inspection

• QC Inspector shall inspect and release fit up prior to welding

• In particular, surface preparation and pre-heating shall be produce according to

WPS

• Welding Supervisor shall prepare daily welding report to monitor progress of

welding, record type and quantity of consumables

• Welding Supervisor shall ensure electrode butts are placed back into placed bin
and maintain butts for SMAW Process shall not limited to 2” dimension due to
saving company cost

• All wet , damaged, contaminated or unidentified loose electrode shall be remove

and disposed off properly at designated area

• After welding complete, welder shall ensure surface to be free of visible defect.
Supervisor/Foreman shall first check and conform it before issuing Request for
Inspection

• QC Welding Inspector shall then verify and invite client/classification in accordance

approved ITP
 KINOA 4307 ACCOMMODATION
PLATFORM SERVICE
PT UNITED SINDO PERKASA

Document Number Document Title Page 9 of 9

Rev 0
USP-NC-WCP-008 WELDING CONTROL PROCEDURE
Date 21 MAR 2010

• In case of repair due to visual inspection and NDE result, Welding Foreman shall
organize to carry out weld repair

• QC shall monitor daily and weekly NDE backlog to ensure NDE clearance

6.5 Performance monitoring

• QC department prepares weekly report in regard to monitor rejection rate

• A target maximum rejection rate is set for production welding, recorded as per
weld joint and per weld length

• A target maximum rejection rate is set for welder performance and monitored

• For poor welder performing who constantly producing high rejection rate welding
shall be stopped from making production weld, and return to be re-trained

• If the welder keeps performing badly after re-training, then shall be refrained from
any production welding work

• Welding Engineer shall monitor and propose corrective and preventive action in
case constant welding problem arise.