Sl-Elt-Pr-Wps1-4107-C2-S1-Welder Qualification

Engineering, Procurement, Construction and
Installation of Wellhead Platform(S1), Submarine

Cables and Pipelines Between S1 and Salman
Complex
S1-TOPSIDE WELDER QUALIFICATION PROCEDURE
AREA DISCIPL. DOC. SCOPE SEQ. REV.
Project Code: 4545 SL ELT PR WPS1 4107 C2 Page 2 of 15
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TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................ 4
2 DEFINITIONS ................................................................................................................ 4
3 Abbreviations ................................................................................................................... 5
4 REFERENCES............................................................................................................... 5
5 SCOPE OF WORK ........................................................................................................ 6
6 Responsibilities and authorities ................................................................................. 6
7 Procedure ..................................................................................................................... 6
8 WELDING POSITIONS .................................................................................................. 7
9 TEST COUPON PREPARATION ................................................................................ 10
10 QUALIFICATION OF WELDERS AND WELDING OPERATORS .............................. 10
APPENDICES
APPENDIX 1 VISUAL TEST REPORT
APPENDIX 2 WELDERS MONTHLY PERFORMANCE FORM
APPENDIX 3 WELDER CERTIFICATE FORM
APPENDIX 4 WELDER DART

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1 INTRODUCTION
This project involves work in two locations; new facilities in satellite wellhead platform, S1, over the
Salman reservoir and additions to the existing Salman Complex. The modifications to Salman Complex
facilities are intended to increase the predictability of the oil wells by increasing gas lift capabilities in S1
facilities.
Salman Oil and Gas Field is an active oil producing complex in the Persian Gulf, in Iranian waters some
144 km south of Lavan Island. This field straddles the Iran – Abu Dhabi border with approximately two-
thirds of the producing structure lying in Iranian waters.
The existing offshore facilities at the Salman oil and gas field have been producing since 1968. The
extracted crude oil is processed and exported via a subsea pipeline to onshore facilities at Lavan Island.
The project scope includes:

 A new offshore platform and facilities,S1
 Production and test lines from S1 satellite platform to existing Salman Complex
 Gas lift line from existing Salman Complex to new S1 satellite platform
 Subsea cabling between existing Salman Complex and S1 satellite platform
 Tie-ins to existing offshore facilities
 Modification of existing platform
Item No. Description Location Depth

N: 2827565.5
1 Wellhead platform - S1 23 m
E: 715569.7
N: 2826165
2 Salman Complex - FP Platform
E: 716185
N: 2826323
3 Salman Complex - PP3 Platform
E: 716272
2 DEFINITIONS
PROJECT NAME Transportation, Engineering, Procurement,
Installation of S1 Topside for Salman Field
CLIENT Iranian Off-shore Oil Company (IOOC)
EPCIC CONTRACTOR Asfalt Tous Company (ATC)
INSTALLATION SUB-CONTRACTOR Sanaye Daryafan Qeshm (SADAF)
Complex
INSTALLATION ENGINEERING SUB-CONTRACTOR Farazan Saze Darya (FARDA)

 TPA: Iranian Classification Society(I.C.S)
 MWS: Iranian Classification Society(I.C.S)
 SITE: Salman Oil Filed
3 ABBREVIATIONS
INSPECTION AND TEST PLAN
ITP:
Quality control
QC:
Visual Test
VT:
MAGNETIC TEST
MT:
ULTRASONIC TEST
UT:
PENETRATION TEST
PT:
NON DESTRUCTIVE TEST
NDT:
4 REFERENCES
The documents that are referred in this procedure are (but not limited to) as below
Standard: AWS D1.1

API RP2X
API RP2A
ASME SEC XI
Approved WPS, PQR and WPQ’s

Specification for fabrication of offshore structures (SL-EST-SP-WPS1-3104-D1)
Topside_Standard_Welding_Details (SL-EST-DR-WPS1-2030-B2-S1)
Material specification (SL-EST-DB-WPS1-2003-B3)
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5 SCOPE OF WORK
This procedure covers qualification requirements applicable to welder performance for structure installation
& sea fastening of S1 topside for SALMAN field
6 RESPONSIBILITIES AND AUTHORITIES

The responsibilities will be explained as follows:
6.2 QA\QC Manager is responsible for the preparation of the WQT report, qualification of welder and
welding operators in accordance with this procedure and standard.
6.3 Welding school supervisor and QC inspector are responsible for witnessing of welder qualification
test.
6.4 QC Engineer and QA\QC Manager are responsible for the review and approval of the documentation
required for qualifying welders and welding operators.
6.5 Inform QC inspector when fit-up and weld of test piece is completed.
6.6 Inform QC inspector when weld and NDT is finished.
7 PROCEDURE
7.1 Properly documented evidence of previous qualification of previous performance qualification of

welder to be accepted for working when submitted to company and get their approval.
7.2 The welder qualification test shall be performed in accordance with qualified WPS.
7.3 Re-qualification of welder is required when changes are made with respect to any of essential
variables and supplementary variables (if applicable) as per referenced codes and Company
specifications or the properly documented evidence of previous qualification of welding procedure
and poor performance.
7.4 Welding and welder qualification test shall be witnessed and approved by contractor, TPA and
Company representative (As per approved ITP).
7.5 All welders shall be qualified with approved WPS.
7.6 Welder qualification for TKY joints will be qualified in 6GR position.
7.7 The installation sub-contractor can use a pre-qualified welder or welding operator if they meet the
standard and WPS.
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8 WELDING POSITIONS
Because various welding position will be encountered in actual construction, each procedure qualification
shall be tested in the manner stated for each position for which it is to be qualified. Therefore, when WPQT
and Welder Test are performed, understanding of various welding position shall be very important. Welding
position for each type of weld shall be represented by the following figures and as per AWS D1.1 standards
and Company specification requirements.
8.1 Fillet and Groove weld

Complex
Figure 1. Positions of test plate for fillet welds
Figure 2. Positions of test plate for groove welds

Complex
Figure 3. Positions of test pipe or tubing for groove welds

Complex
9 TEST COUPON PREPARATION

Test coupon for testing shall be prepared as per the AWS D1.1 for structure.
10 QUALIFICATION OF WELDERS AND WELDING OPERATORS
10.1 Qualification of new welders for construction should be in accordance with flow chart for new welder
qualification flow chart.
10.1.1 Welders, welding operators and tack welders shall be qualified in accordance with AWS D1-1
for structure & Project fabrication specification.
10.1.2 If the test does not meet the requirement, the welder shall carry out a new test of same type as
the one retested in accordance with the reference code.
10.1.3 A welder is qualified when a complete WPS is carried out by the welder (all passes)
10.1.4 The certificate according to AWS D1-1 shall be prepared for each welder who passes the test
successfully. For starting the test welder I.D shall be available.
10.1.5 Re-Qualification is required whenever a welder has not used for any related welding process
for a period of more than 3 months.
10.1.6 A retest may be made, provided there is evidence that the welder or welding operator in need
of further training or practice and paragraph 10.1.8 this document.
10.1.7 QA keeps records of periods and type of work for each certified welder and welding operator.
Welder’s ID card shall be issued by the contractor for company approval.
10.1.8 High repair rate within % (2-3) the welder shall be notified and retested for more than 5% the
welder shall be disqualified and taken off from the project.
10.1.9 Repair rate shall be reported officially to company representative weekly and or any time in his
consider necessity.
Formulas of repair rate follow up to:

Σ total length of weld rejected by RTorUT
Repair rate =100 *
Total length of weld inspected by RTorUT
or UT
13.1.9 List of welders who are welding on project, should be issued and after each
Time to be updated.
10.2 WELDING OPERATOR

Complex
Welding operator using fully merchandised or fully automatic process need to pass a qualification
TEST
10.3 TEST COUPON
The dimensions of test coupon shall provide sufficient materials for test in accordance with the
reference documents. All test coupons shall be paint marked /hard line with the assigned welder I.D
number on the test coupon before welding.
Type and Position for welder qualification shall conform to the requirement of AWS D1-1 for structure.
10.4 TEST TO BE APPLIED
Each test piece shall be inspected as below:
• 100% VISUAL INSPECTION,

• 100% RT or UT
10.5 ACCEPTANCE CRITERIA FOR TEST
Structural test coupon shall conform to requirement of AWS D1-1 and project specification.
10.6 TEST METHODE

10.6.1 Each welder introduced for test must be trained and pass a preliminary test successfully.
10.6.2 The candidate will be introduced to QA for arrange the test. Training may be given by training
center &Production / welding department.
10.6.3 The test coupon should be prepared in accordance with WPS and AWS D1-1. For structure.
10.6.4 QC Engineer shall prepare the notice and records as per shown in flow chart.
10.6.5 After welding and necessary testing, the record shall be prepared and submitted to
Company for approval.
10.6.6 QA documentation shall keep the records and certificates and renewal documents and their
registration.
10.6.7 Qualified welders shall receive ID card and they shall keep it by themselves during welding.
Complex
10.6.8 In accordance with WPS, welding engineer shall determine the necessary procedure
qualification tests
APPENDIX 1: VISUAL INSPECTION REPORT
Complex
APPENDIX 2: WELDER QUALIFICATION TEST RECORD
TRANSPORTATION , ENGINEERING, PROCUREMENT,

INSTALLATION OF S1 TOPSIDE FOR SALMAN FIELD
REPORT Number:
WELDERS MONTHLY PERFORMANCE FORM DATE:
TYPE OF REPAIR
TOTAL WELDED
REPAIR (mm)
PERCENT (%)
WELDER ID
LENGTH OF
REPAIR
LENGTH
Other defect
(mm)
LOF
LOP
UC
PO
GP
RC
CP
CR
OL
EP
BT
SA
SI
Type of Imperfection:
SI: Slag Inclusion PO: Porosity GP: Gas Pore OL: Over Lapping
LOF: Lack of Fusion CR: Crack or Linear Type RC: Root Concavity
LOP: Lack of Penetration EP: Excess Penetration BT: Burn-through
CP: Crater pipe UC: Undercut SA: Stray Arc
Company
Contractor (SADAF) TPA
Inspection Rep IOOC Rep
Name Name: Name: Name:
Date: Date: Date: Date:
Sign Sign Sign Sign

Complex
APPENDIX 3: WELDER & WELDING OPERATOR CERTIFICATE FORM

Complex
APPENDIX 4: WELDER ID CARD

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Engineering, Procurement, Construction and

Installation of Wellhead Platform(S1), Submarine

AREA DISCIPL. DOC. SCOPE SEQ. REV.

Project Code: 4545 SL ELT PR WPS1 4107 C2 Page 2 of 15

TABULATION OF REVISED PAGES

AREA DISCIPL. DOC. SCOPE SEQ. REV.

Project Code: 4545 SL ELT PR WPS1 4107 C2 Page 3 of 15

APPENDIX 1 VISUAL TEST REPORT

APPENDIX 2 WELDERS MONTHLY PERFORMANCE FORM

APPENDIX 3 WELDER CERTIFICATE FORM

APPENDIX 4 WELDER DART

AREA DISCIPL. DOC. SCOPE SEQ. REV.

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The project scope includes:

Item No. Description Location Depth

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INSTALLATION ENGINEERING SUB-CONTRACTOR Farazan Saze Darya (FARDA)

Standard: AWS D1.1

Approved WPS, PQR and WPQ’s

AREA DISCIPL. DOC. SCOPE SEQ. REV.

Project Code: 4545 SL ELT PR WPS1 4107 C2 Page 6 of 15

6 RESPONSIBILITIES AND AUTHORITIES

6.6 Inform QC inspector when weld and NDT is finished.

7.1 Properly documented evidence of previous qualification of previous performance qualification of

7.5 All welders shall be qualified with approved WPS.

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8.1 Fillet and Groove weld

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Figure 1. Positions of test plate for fillet welds

Figure 2. Positions of test plate for groove welds

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Figure 3. Positions of test pipe or tubing for groove welds

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9 TEST COUPON PREPARATION

10 QUALIFICATION OF WELDERS AND WELDING OPERATORS

Formulas of repair rate follow up to:

10.2 WELDING OPERATOR

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10.3 TEST COUPON

10.4 TEST TO BE APPLIED

Each test piece shall be inspected as below:

• 100% VISUAL INSPECTION,

10.5 ACCEPTANCE CRITERIA FOR TEST

10.6 TEST METHODE

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APPENDIX 2: WELDER QUALIFICATION TEST RECORD

TRANSPORTATION , ENGINEERING, PROCUREMENT,

Date: Date: Date: Date:

Sign Sign Sign Sign

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APPENDIX 3: WELDER & WELDING OPERATOR CERTIFICATE FORM

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