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MAJOR PROJECTS
CANADIAN PIPELINE
CONSTRUCTION SERVICES
PIPELINE WELDING
INSPECTION EXECUTION PLAN
Table of Contents
1 Overview .............................................................................................................. 3
2 Primary Areas of Welding Inspection ............................................................... 3
3 Organization and Deployment of Inspection Personnel .................................. 4
4 Inspector Responsibilities ................................................................................. 4
4.1 Senior Welding Inspector ........................................................................ 5
4.2 Front-end Inspector ................................................................................. 6
4.3 Back-end Inspector .................................................................................. 6
4.4 Repairs ...................................................................................................... 7
4.5 Tie-Ins ....................................................................................................... 7
4.6 Fabrication (Field) .................................................................................... 8
4.7 Welding Inspection Reports .................................................................... 9
5 Welding Inspector Qualification Requirements ............................................... 9
6 Inspector Training Requirements .................................................................... 10
7 Welding Management ....................................................................................... 11
7.1 Contract Review ..................................................................................... 11
7.2 Welding Personnel ................................................................................. 12
7.3 Equipment .............................................................................................. 12
7.4 Maintenance ........................................................................................... 13
7.5 Production Plan...................................................................................... 13
7.6 Welding Consumables ........................................................................... 13
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1 Overview
Complete weld quality is defined through the proper implementation and execution of the various activities
associated with welding construction. The Execution Plan will provide a clear understanding of each of
these distinct areas and how they influence weld quality.
The purpose of the Pipeline Welding Inspection Execution Plan is to provide a common structure for
ensuring that the Enbridge Pipeline Specifications, appropriate Codes, Regulatory requirements and the
terms and conditions of the Contract are followed. It is considered to be a dynamic document with periodic
revisions made to enhance the purpose for which it is intended.
Compliance with Construction Standards must be achieved as part of the Contractors contractual
obligation. The responsibility of the actual performance of the work to the specified level of quality rests
solely with the Pipeline Contractor.
The Quality Control function will take precedence over the Production Control function from the standpoint
of welding inspection. The technical performance and specified standard requirements will not be sacrificed
for production expediency.
Enbridge shall approve, select and position the welding inspection personnel. To ensure that all welding
Inspectors are competent, adequately equipped and capable of monitoring the specific activities, for which
they have been assigned, all Welding Inspectors will complete a Welding Inspector Training Program. Each
Inspector will receive training on Enbridge Pipeline Specifications and upon satisfactory completion will
receive a Certificate to inspect welding activities. Training will be provided in the areas of Regulatory
requirements, specific Job Duties and methods of implementing inspections, radiographic and ultrasonic
examination, basic metallurgy, mechanized GMA welding and the prevention of hydrogen induced
cracking.
The effectiveness of the Inspection Program is maintained by reporting results of specific monitoring
activities to the appropriate responsibility areas. Written reporting on a daily basis will be used to provide a
record of compliance using Company Inspection Forms.
All Welding Inspectors will report directly to the Chief Inspector. A Senior Welding Inspector will be
assigned to each Construction Spread to coordinate the activities of welding inspection.
Each Inspector will have his own responsibilities; however, the cross communications for related and
sequential activities of the entire construction function is essential to minimize conflicts and varying opinion
between phases of construction
Welding inspections will be completed during all phases of pipeline construction involving the welding of
pipes, components and non-pressure containing attachments to pressure piping by means of arc welding.
Construction activities are defined as follows:
a) Mainline Welding
Mainline welding shall consist of all welding activities completed by the Contractor's maingang
welding crew and poorboy (or mini-gang) crew.
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b) Repair Welding
Repair welding shall consist of all welding activities completed by the Contractor's repair welding
crew.
c) Tie-In Welding
Tie-in welding shall consist of all welding activities completed by the Contractor's tie-in crew(s)
joining pipeline sections including final tie-in of hydrostatically tested pipe sections.
d) Fabrication (Field)
Fabrication welding shall consist of all welding activities completed by the Mainline Construction
Contractor's Fabrication crew(s) in the course of the fabrication of pipeline valve assemblies and
component welding.
Fabrication welding may consist of welding performed by a Sub-Contractor (Fabricator) completing
the above mentioned tasks.
4 Inspector Responsibilities
Welding Inspectors will monitor and document all aspects pertaining to pipe and component welding
activities during pipeline construction. It is the Welding Inspectors responsibility to document that the
Pipeline Contractor is following the Enbridge Pipeline Specifications, appropriate Codes and Regulatory
requirements. Additionally, the Welding Inspector will ensure the terms specific to welding in the
Construction Contract are documented. Finally the Welding Inspector will minimize construction practices
that could have a negative influence on the safety of the work site, the environment or the final technical
performance requirements of the pipeline system.
The Safety and Environmental responsibilities are important aspects for all the Welding Inspectors and are
detailed in other documents; only the primary welding inspection tasks will be outlined in this document.
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Welding Inspectors are grouped into categories defining the principal inspection areas in which they will be
performing their tasks. Welding Inspector categories are listed below:
Senior Welding Inspector
Activity Welding Inspector Front-end
Activity Welding Inspector Back-end
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g) Interaction with the ultrasonic (or radiographic) Contractor and with the Senior Welding Inspector to
identify weld defect trends or solutions.
h) Monitoring and documenting ultrasonic/radiographic crew down times.
i) Monitoring and documenting welding equipment down times.
j) Assisting the Front-End Inspector as required.
4.4 Repairs
4.5 Tie-Ins
The Tie-In Welding Inspector is responsible for:
a) Documenting welding essential variables on weld pass deposition as required.
b) Documenting that the pre- and inter-pass heat temperatures specified in the approved WPS are
achieved and maintained prior to and during all weld pass deposition.
c) Documenting that the additional requirements for cold weather welding are being performed by the
Contractor.
d) Communicating any Non-Compliance to the Chief Inspector and Senior Welding Inspector.
e) Visually inspecting all finished welds and documenting the results.
f) Ensuring that welds are completed in a stress free condition.
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g) Ensuring that the carrier pipe is properly supported, as per Contractors Specification.
h) Checking pipe transition requirements prior to fit-up and welding
i) Liaising with Non-Destructive Inspection teams to ensure the NDT of the weld is completed in the
most efficient manner possible.
j) Checking cover depths, ditch wall stability and back slopes and ensuring that shoring
requirements, as per Contractors Specifications are in place before the work commences and
remains in place until all work activities at the work site are completed.
k) Ensuring that bell holes are as dry as possible and that the Contractors pumping facilities are
sufficient to ensure that water will not encroach onto the pipe surface until the weld is completed,
cooled, inspected and coated.
l) Monitoring joint coating and holiday inspections (when required), to ensure that this operation is
performed in accordance with the specified Procedure
m) Ensuring that test leads required are installed in accordance with the Specification requirements.
n) Ensuring that full identification is available on all pipe included in the tie-in.
Note: When pre-fabricated valve assemblies are installed, the Tie-In Inspector is responsible for
verifying material traceability and suitability for joining the piping assembly to the mainline piping.
o) Ensuring that all pipe pups not used are identified properly for re-use or disposal.
p) Completing accurate As-Built tie-in sketches.
q) Monitoring backfill and cleanup activities when required
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j) Ensuring that proper handling procedures are being used and material/component damage is not
occurring.
k) Maintaining a close liaison with the Contractor and a clear understanding of fabrication schedule
and progress.
l) Ensuring that pipe heat numbers are transferred to all cut-off ends of pipe and that pipe numbers,
pipe heat numbers and location of welds / components are documented for each fabrication
assembly.
m) Evaluating and recommending remedial action on mechanical damage to pipe or components
through consultation with the Senior Welding Inspector.
n) Ensuring that proper transitions are used at changes in pipe wall thickness in accordance with
Enbridge specifications.
o) Monitoring fabrication assembly cleaning, priming, coating and holiday inspections to ensure that
this operation is performed in accordance with the specified Procedure (when directed by the Chief
Inspector).
p) Ensuring that completed fabricated assemblies are hydrostatically tested in accordance with the
specified procedures.
Each category of Welding Inspector requires completion of Enbridge supplied and approved Welding
Inspection Reports on a daily basis. The design of each Report will be specific to the principal inspection
area in which the task is performed. Attachment A provides a Table detailing Report Number, Report
Name, Responsible Inspector and Frequency of Reporting. Enbridge will supply the Inspection Service
Provider and the NDT Service Provider with electronic versions of the Reports suitable for Project use. The
Welding Inspector will be provided sufficient training and instruction that should enable completion of the
report in an accurate, detailed and acceptable manner. Review of the individual completed Inspection
Report shall be performed by the Senior Welding Inspector and Chief Welding Inspector. Any Reports that
are incomplete or inaccurate will not be accepted for signature.
The NDT Contractor is responsible for the completion of two Enbridge Welding Inspection Reports listed in
Attachment A. Enbridge may approve a Contractor formatted Report which meets the intent of the original
Report requirements for Project- specific use.
The requirements for the qualification of Field Joining Inspectors shall be the following:
a) Minimum of 10 years of relevant construction experience.
b) Note: Junior and/or intermediate Inspectors may be permitted to have fewer years experience if
directly supervised by a Senior Welding Inspector.
c) Ability to participate in a team environment for the implementation of a structured Quality Control
Program.
d) Familiarity/working knowledge of Construction Specifications and Codes and a working knowledge
of:
Enbridge Welding Specifications.
Welder and Welding Procedure Qualification requirements.
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Enbridge Pipelines Inc. is embarking on a Training Program for Pipeline Welding and Fabrication
Inspectors. This Program is intended to provide minimum training standards within the general area of
welding to enable welding inspection to address pertinent areas in a consistent manner. Training will
include the areas of general welding technology, welding processes, Enbridge Pipeline Specifications, non-
destructive testing concepts and expectations and basic principles of specialized Welding Techniques i.e.
mechanized GMA welding.
Welding technology fundamentals in the areas of safety, welding processes and equipment, weld faults
and causes, mechanical testing and inspection techniques will provide the Inspector with a technical
background for welding inspection. This portion of the training will formally certify the Inspector to verify
acceptability of materials, verify set-up and preparation for welding, confirm the correct application of
qualified Welding Procedures and techniques and the visual evaluation of completed weldments.
The definition of specific individual responsibilities will comprise another aspect of the Training Program.
Formal areas of inspection will be defined and the responsibilities within areas will be discussed. Report
forms and expectations will be outlined. The forum also presents itself well to the open discussion of
construction activities and provides an opportunity to discuss not only the details of the Specification but
also the reasons behind specific requirements. This also presents a good opportunity for participants to
provide solid input discussing items they have observed that require attention. Construction Welding
Specifications can be thoroughly reviewed and the more general philosophies can be discussed.
Consistent understanding of construction welding requirements combined with consistent areas of
responsibility and reporting formats allows for a controlled Inspection Program.
An understanding of the basic principles of the non-destructive testing techniques will be another area of
formal training. An understanding of the welding inspection techniques combined with a knowledge of the
methods of welding and construction practices brings an individual into an area of more complete
understanding of the practical requirements of the Inspectors task and methods of attaining the best
possible results.
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CHIEF INSPECTOR
LINE OF COMMUNICATION
LINE OF REPORTING
7 Welding Management
Weld mechanical properties can only be verified by destructive testing so in-process inspection is required
to verify that the welding application has been applied in the same manner that was qualified. In addition,
girth welding is a critical path activity that controls the overall Construction Schedule. To ensure that
construction progress is not interrupted by welding problems Enbridge Pipelines has developed a Welding
Management System that operates concurrently within the Welding Inspection Program.
Construction projects which use mechanized Gas Metal Arc Welding (GMAW) for girth welds will also
implement the alternative Girth Weld Acceptance Criteria provided in Annex K of CSA Z662. Use of these
Acceptance Criteria requires adherence to a closely defined set of Welding Process Parameters which
requires the adoption of a Welding Quality Management System to demonstrate to Third Parties that the
process parameters were not exceeded.
Within the Welding Quality Management System the following key elements will be addressed:
Contract Review
Welding Personnel
Equipment
Maintenance
Production Plan
Welding Consumables
A Contract review will be carried out with the pipeline Contractor to verify that sufficient resources are
available to achieve Production Schedules and that the Specifications and Procedures received from
Enbridge are clearly understood and unambiguous.
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The Pipeline Contractor will provide a list of suitable individuals who are responsible for specific welding
and welding equipment related roles to demonstrate that they have an organizational structure that will
enable key welding issues to be addressed. The duties, interrelationships and limits of responsibility of
welding personnel should be clearly defined with particular reference to:
a) Planning and coordination of welding activities.
b) Acceptance of welding procedures.
c) Training and qualification of welders.
d) Maintenance of welding equipment.
e) Storage and distribution of welding consumables.
f) Bevel preparation and fit-up.
g) Production rates and repair rates.
7.3 Equipment
To ensure that the Contractor has sufficient resources to carry out the Project, the Pipeline Contractor will
provide a list of all essential welding equipment that will be supplied to the Project such as:
a) SMA welding rigs.
b) GMA welding machines and generators.
c) Sidebooms for carrying the welding shacks.
d) Internal alignment/welding clamps.
e) External alignment clamps.
f) Pre-heating equipment.
g) Pipe facing machines.
h) Electrode holding ovens.
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7.4 Maintenance
To ensure that the Pipeline Contractor has a planned Maintenance Schedule for his welding related
equipment, Plans should be submitted covering the maintenance and replacement intervals of the relevant
equipment that is necessary to produce welds of consistently high quality. Examples of equipment to be
included are:
a) Pipe facing equipment.
b) Power sources.
c) Welding tractors.
d) Internal welding/alignment clamps.
e) Wire feeders, contact tips, etc...
The Pipeline Contractor will organize facilities and implement Procedures for the storage, handling and
distribution of welding consumables. The facility shall be such that moisture pick-up, oxidation or
shipping/storage damage does not occur.
GMAW heat numbers shall be recorded by the Contractor. GMAW heat numbers cannot be changed
without re-qualification of the Welding Procedure. Stock amounts should be monitored to ensure adequate
notice if re-qualification of a GMAW consumable heat number is required.
The Contractor shall have specific Procedures to handle low hydrogen consumables. Heated storage
facilities should be provided by the Contractor to provide protection from hydrogen pick-up.
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Attachment A
Welding Inspection Reports
RESPONSIBLE FREQUENCY OF
REPORT NUMBER REPORT NAME
INSPECTOR REPORTING
SENIOR WELDING
MPCS-FORM-WCIR-011 W-14 WELD CRACK INVESTIGATION AS REQUIRED
INSPECTOR
ASSIGNED WELDING
MPCS-FORM-ABRR-012 W-15 ARC BURN REPAIR AS REQUIRED
INSPECTOR
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