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ELABORATION OF TECHNICAL DOCUMENTS FOR WELDING

Procedure

CONTEC
Comisso de Normas Tcnicas

This standard replaces and cancels the previous revision . n Indication of clause, item, table or figure,which has its contents been altered with respect to the previous revision.

The Responsible CONTEC Subcommittee provides guidance on the interpretation of this Standard when questions arise regarding its contents. The Department of PETROBRAS that uses this Standard is the responsible for adopting and applying the clauses thereof. Mandatory Requirement : a provision established as being the most adequate and which shall be used strictly in accordance with this Standard. If a decision is taken not to follow the requirement ("non-conformity" to this Standard) it shall be based on well-founded economic and management reasons, and be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by the verb forms "shall", "it is necessary...", "is required to...", "it is required that...", "is to...", "has to...", "only ... is permitted", and other equivalent expressions having an imperative nature. Recommended Practice (nonmandatory) a provision that may be adopted under the conditions of this Standard, but which admits (and draws attention to) the possibility of there being a more adequate alternative (not written in this Standard) to the particular application. The alternative adopted shall be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by the verbal form "should" and equivalent expressions such as "it is recommended that..." and "ought to..." (verbs of a nonmandatory nature). It is indicated by the expression: [Recommended Practice]. Copies of the registered "non-conformities" to this Standard that may contribute to the improvement thereof shall be submitted to the Responsible CONTEC Subcommittee. Proposed revisions to this Standard shall be submitted to the Responsible CONTEC Subcommittee, indicating the alphanumeric identification and revision of the Standard, the clause(s) to be revised, the proposed text, and technical/economic justification for revision. The proposals are evaluated during the work for alteration of this Standard.

SC - 26
Welding

Foreword
PETROBRAS technical standards are prepared by Working Groups GTs (consisting of PETROBRAS specialists and PETROBRAS Subsidiaries specialists), are commented by Local Representatives (representatives of the Industrial Units, Engineering Projects, Technical Divisions and PETROBRAS Subsidiaries), are approved by Responsible Subcommittees SCs (consisting of specialists belonging to the same speciality, representing the various PETROBRAS Departments and PETROBRAS Subsidiaries), and approved by CONTEC General Assembly (consisting of representatives of the Superintendencies of the PETROBRAS Departments and PETROBRAS Subsidiaries that use PETROBRAS technical standards). A PETROBRAS technical standard is subjected to a revision at any time by the Responsible Subcommittee and must be reviewed every five years and if not revised, either revalidate or cancelled. PETROBRAS technical standards are prepared in accordance with standard PETROBRAS N-1. For complete information about PETROBRAS standards see PETROBRAS Technical Standards Catalog.

PROPERTY OF PETROBRAS

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PREFACE

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This Standard is the English version (issued in SEP/98) of Standard PETROBRAS N-2301 REV. A OCT/95.

1 SCOPE

1.1 The standard establishes the required conditions for the elaboration of technical documents to be used in planning, execution, control, recording, and certification of welding operations. n 1.2 The standard is applicable to welding operations used in the fabrication, construction, assembly, or maintenance of equipment.

2 COMPLEMENTARY DOCUMENTS The following documents are referenced in the text and contain valid rules for this Standard. Decreto Lei n 240 de 28 de fevereiro de 1967; Decreto Lei n 62292 de 22 de fevereiro de 1968; Decreto Lei n 81621de 03 maio de 1978; PETROBRAS N-133 -Welding; PETROBRAS N-381 - Technical Drawings and Other General Documents Execution; PETROBRAS N-1438 - Soldagem; PETROBRAS N-1672 - Formulrio para Documentos Tcnicos em Geral for PETROBRAS N-1738 - Descontinuidades em Juntas Soldadas, Fundidas, Forjadas e Laminadas; PETROBRAS N-1852 - Fabricao e Montagem de Estruturas Martimas Fixas de Ao; FBTS - 001 - Inspeo de Soldagem - Qualificao de Pessoal; API Std 1104 - Standard for Welding Pipe Lines and Related Facilities, 1994; ASME Boiler and Pressure Vessel Code - Section IX Edition, 1992; AWS D 1.1-92 - Structural Welding Code - Steel.

3 DEFINITIONS The definitions contained in PETROBRAS N-1438 standard are adopted for the purposes of the present standard.

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4 GENERAL CONDITIONS

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n 4.1 The standard shall be used together with the design standard, fabrication and assembly of equipment and materials; prevailing the last ones in conflict cases.

4.2 Each document specified in this standard shall be elaborated when required in PETROBRAS N-133 standard or in the design, fabrication and equipment assembly standards or in other contract documents.

4.3 All forms shall be elaborated in accordance with PETROBRAS N-1672 standard.

4.4 All metrological units shall be those legal in Brazil (see Brazilian Metrological Law in 2.1). When the nature of the subject matter indicates that the use of British (f.p.s.) units may be appropriate, said units shall be placed between parentheses, immediately following the corresponding Brazilian legal unit.

4.5 All documents shall be filed in a fire-proof place, removed from inflammable products and protected from rain and moisture. n 4.6 All documents shall be approved by a welding inspector certified in accordance with FBTS-N-001 standard.

5 SPECIFIC CONDITIONS n 5.1 Documentation for Planning of Welding. The document shown here, when required in accordance with item 4.2 of this standard, have to be elaboreted according to the text bellow and approved before the welding. 5.1.1 The Welding Plan shall contain at least: a) cover page, citing: - title of document; - equipment or material identifications; - identification of the fabrication or construction and assembly standard; - index of presented documents; b) list of joints to be welded (LJS), elaboreted according to the ANNEX A of this standard; c) applicable welding procedures (EPS), including those for repair work, elaboreted in accordance with ANNEX B of this standard;

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d) welding procedure qualification records submitted (RQPS), elaborated in accordance with ANNEX C of this standard; e) welder and welding operator certificates, elaborated in accordance with ANNEX D of this standard.

5.1.2 The welding procedure qualification plan shall contain at least: a) cover page, citing: - title of the document; - equipment identification; - identification of the qualification standard; - index of the presented documents. b) list of the test pieces to be welded, citing: - identification code of the test piece; - welding procedure specification code; - welding processes; - specification of parent metal, diameter (if applicable), and thickness of each member of joint; - type of joint; - type of chamfer; - welding position; c) non-destructive testing plan, in a table form, listing the test pieces and the nondestructive tests applicable before and after welding and the heat treatment (when required); d) mechanical and macrographic testing plan, containing: - drawings of test pieces, indicating rolling direction, the location of the test specimens with their respective identificationd; - table listing test specimens, mechanical tests to be performed, and standards applicable to performance the tests, preparation of test specimens, and acceptance criteria.

5.1.3 The plan for welder and welding operator certification shall be elaborated in a similar way with the same minimum contents of the welding procedure qualification plan cited in item 5.1.2 of this standard, in addition to criteria on disqualification and training.

5.1.4 The production testing plan shall contain at least: a) cover page, listing: - title of the document; - equipment identification; - identification of fabrication or construction and assembly standard; - index of the presented documents; b) list of the production tests to be executed, in a table form, listining; - welding procedures; - length of the weld foreseen for each welding procedure;

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- phase of fabrication, construction or assembly of the equipment in which each piece has be welded; c) list of test pieces to be welded, elaboreted in accordance with item 5.1.2 b) of this standard; d) non-destructive testing plan, elaboreted in accordance with item 5.1.2 c) of this standard; e) mechanical and macrographic testing plan, elaboreted in accordance with item 5.1.2 d) of this standard.

5.2 Documentation for Welding Execution and Control The documents shown here, when required according to item 4.2 of this standard, have to be elaboreted and approved to be used in the welding execution and control and shall be available to welders, operators, supervisors, and welding inspectors.

5.2.1 The instruction of execution and inspection of welding shall be elaborated in accordance with ANNEX E of this standard.

5.2.2 The list of the qualified welders and operators shall be elaborated in accordance with ANNEX F of this standard.

5.2.3 The performance control of the welders and welding operator shall be elaborated in accordance with ANNEX G of this standard.

5.3 Documentation for Welding Records Whenever required under item 4.2 supra, the documents cited herein shall be elaborated for use as welding execution records.

5.3.1 The welding record report shall be elaborated in accordance with ANNEX H of this standard.

5.3.2 The heat treatment record report shall be elaborated in accordance with ANNEX I of this standard. ____________

/ANNEX A

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ANNEX A - INSTRUCTIONS FOR THE ELABORATION OF THE JOINTS LIST TO BE WELDED (LJS)

1 GENERAL CONDITIONS

1.1 A LJS shall be elaborated for each drawing fabrication and/or construction and assembly.

1.2 On one single drawing, those joints having the same characteristics defined in item 2.1 below shall be listed only once.

2 SPECIFIC CONDITIONS The LJS shall contain, at least, the following information: a) identification of reference drawing; b) identification of parent metal, diameter (if applicable), and thickness of each member of joint; c) type of joint; d) type of chamfer; e) welding position; f) possibility of root access; g) identification of applicable welding procedure.

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/ANNEX B

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ANNEX B - INSTRUCTIONS FOR THE ELABORATION OF THE WELDING PROCEDURE (EPS) n 1 GENERAL CONDITIONS

1.1 The EPS shall be elaborated based on design, equipment fabrication, consumable, and parent metal specifications and in accordance with the experience of whoever performs the welding, observing the requirements set out in PETROBRAS standard N-133. After welding the test piece, welding parameter ranges shall be revised so that the values effectively used are compatible with the tolerances permitted in the applicable qualification standards. n 2 SPECIFIC CONDITIONS The EPS shall contain, at least, all information mentioned in the applicable qualification standards, in addition to: a) identification of qualification standard; b) sketch of joint and chamfer; c) sketch of sequence of passes; d) trademark of consumables.

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/ANNEX C

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ANNEX C - INSTRUCTIONS FOR THE ELABORATION OF THE WELDING PROCEDURE QUALIFICATION RECORDS (RQPS) AND PRODUCTION TESTING RECORDS (RETP)

1 GENERAL CONDITIONS 1.1 Whenever applicable, the following documents shall be annexed to the RQPS and RETP: a) welding records report, elaborated in accordance with ANNEX H hereto, in the case of RQPS; b) heat treatment records report, elaborated in accordance with ANNEX I hereto; c) records report on non-destructive test results, elaborated in accordance with applicable standards; d) mechanical and macrographic testing plan, elaborated in accordance with item 5.1.2 d) of the present standard; e) records report on machanical and metallographic test results, elaborated in accordance with items 2.2 through 2.7 hereto; f) quality certificate for the consumables and parent metals, in the case of RQPS. n 2 SPECIFIC CONDITIONS

2.1 The RQPS and RETP shall contain, at least, the following information: a) identification of the welding procedure; b) identification of the production test in the case of RETP; c) list of annexed documents and the their identifications; d) identification of applicable qualification standards, in the case of RQPS, or of equipament fabrication or assembly standards, in the case of RETP.

2.2 The records report on tension test results shall contain at least the following information: a) entity responsible for the test; b) identification of testing standard; c) identification (serial number) of test machine; d) identification, date of issue and name of the entity that issued the gauging certificate for the test machine; e) identification of the standard for preparation of test specimens; f) identification of test piece and specimens; g) type and dimension of test specimens; h) identification of standard for evaluation of results; i) location of fracture; j) specified and measured tensile strenght; 11

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k) elongation (when applicable); l) final report.

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2.3 The records report on the bending test results shall contain at least the following information: a) entity responsible for the test; b) identification of testing standard; c) type of test; d) diameter of plunger and distance between the support rollers on the test device; e) identification of the standard for preparation of test specimens; f) identification of the test piece and specimens; g) type and dimensions of test specimens; h) identification of standard for evaluation of results; i) bending angle; j) identification and dimensions of detected discontinuities; k) final report. n 2.4 The records report on the impact test results shall contain at least the following information: a) entity responsible for the test; b) identification of testing standard; c) identification (serial number) of the test machine and thermometer used; d) identification of the designer of the used profile; e) identification, date of issue, and name of the entity that issued the gauging certificate for the test machine and thermometer used; f) test temperature; g) identification of the standard for preparation of test specimens; h) identification of the test piece and specimens; i) type and dimensions of test specimens; j) orientation of test specimen in relation to rolling direction, when applicable; k) location of notch; l) identification of standard for evaluating of results; m) absorbed energy and/or lateral expansion and/or percentage of fragile fracture, whichever is applicable, with specified and obtained values; n) final report. 2.5 The records report on macrographic test results shall contain at least the following information: a) entity responsible for the test; b) identification of standard for preparation of test specimens; c) identification of the test piece and specimens; d) macrophotograph of test specimens, indicating magnification used; e) reagent used; f) identification of standard for evaluation of results;

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g) sizing of the reinforcement of the fillet weld legs and the effective and real throats. h) magnification used for visual inspection; i) identification and dimensions of detected discontinuities; j) final report.

2.6 The records report on hardness test results shall contain at least the following information: a) entity responsible for the test; b) identification of testing standard and type of hardness; c) identification (serial number) of test machine and standard sample used for gauging the machine; d) identification, date of issue, and name of entity that issued the gauging certificate for the test machine and for the standard sample used; e) identification of test piece and specimens; f) sketch of test specimen with indication of different weld zones and location of spots of hardness profile; g) specified and measured hardness values; h) identification of standard for evaluation of results; i) final report.

2.7 The records report on the nick-break test results shall contain at least the following information: a) entity responsible for the test; b) identification of testing standard; c) identification of standard for preparation of test specimens; d) identification of the test piece and specimens; e) dimensions of the test specimens; f) identification of standard for evaluation of results; g) identification and dimensions of detected discontinuities; h) final report.

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/ANNEX D

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ANNEX D - INSTRUCTIONS FOR THE ELABORATION OF THE WELDER AND WELDING OPERATOR CERTIFICATES (CQS)

1 GENERAL CONDITIONS The CQS shall be issued for each approved test of a welder or welding operator.

2 SPECIFIC CONDITIONS

2.1 The CQS shall contain at least: a) name of welder or welding operator; b) identification code (seal) of welder or welding operator; c) identification of applicable qualification standards; d) identification of welding procedure used; e) welding process; f) all essential variables, with values effectively used in qualification and qualified strengths; g) types of tests and examinations performed; h) identification and type of test specimens used; i) results of tests and examinations performed, for each test specimens; j) identification, date of issue, and name of institution issuing the records reports on tests and examinations performed;

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/ANNEX E

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ANNEX E - INSTRUCTIONS FOR THE ELABORATION OF THE WELDING EXECUTION AND INSPECTION INSTRUCTIONS (IEIS)

1 GENERAL CONDITIONS

1.1 Welding parameters in the IEIS shall be based on the values specified in the qualified welding procedure and on the tolerances permitted in applicable qualification standards.

1.2 The IEIS shall be detailed for each joint to be welded. However, when the quantity of weldments is so high that individualization is impracticable or unsuitable, identical joints may be grouped. In any case, the individual joint shall be traceable to its applicable welding procedure.

2 SPECIFIC CONDITIONS

2.1 The IEIS shall contain at least:

2.1.1 Drawing and identification of the equipment to be welded, indicating location of joints to be welded.

2.1.2 Individual identification of joint or group of joints to be welded, as described in item 1.2 supra.

2.1.3 Specific information on welding execution and inspection for joint or group of joints; that is: a) identification of welding procedure; b) sketch of chamfer; c) specification of parent metal, diameter (if applicable), and thickness of each member of joint; d) sketch of joint build-up sequence; e) welding parameters, cited for each weld pass; that is: - welding process; - classification, trademark, and diameter of welding electrodes, wires, or rods; - type and intensity of current; - polarity, voltage, and speed (if applicable); - classification and trademark of flow (if applicable); - type and flow rate of purge and shielding gases (if applicable);

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- deposition technique, if applicable, rectilinear or oscillant and indication of minimun or maximum value for width of pass; - position and progression of welding (if applicable); f) initial and interpass cleaning method; g) gouging technique (if applicable); h) pre-heating temperature; i) interpass temperature; j) post-heating time and temperature (if applicable); k) indication of whether or not postweld heat treatment is required and identification of execution procedure (if applicable); l) type, extension, and those activities responsible for the execution and monitoring of non-destructive and other applicable tests, as well as definition of points of retention (before or after root pass, at each layer, before or after postweld heat treatment).

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ANNEX F - INSTRUCTIONS FOR THE ELABORATION OF THE LIST OF CERTIFIED WELDERS AND WELDING OPERATORS (RSQ)

1 GENERAL CONDITIONS

1.1 A RSQ shall be issued for each applicable qualification standard.

1.2 Each certification of a certain welder or welding operator shall be transcribed separately on the RSQ.

2 SPECIFIC CONDITIONS The RSQ shall contain at least: a) identification of the qualification standard; b) name and identification code (seal) of the certified welder or welding operator; c) number of the welder or welding operator certificate; d) all essential applicable variables, with qualified ranges.

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/ANNEX G

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ANNEX G - INSTRUCTIONS FOR THE ELABORATION OF THE WELDER AND WELDING OPERATOR PERFORMANCE CONTROL SHEETS (CDS)

1 GENERAL CONDITIONS

1.1 A CDS shall be issued at time intervals that comply with the criteria in equipment design or fabrication and assembly standards or in contract documents.

1.2 Two separate control sheets shall be drawn up, one for radiographs and another for ultra-sound.

2 SPECIFIC CONDITIONS The CDS shall contain at least: a) welder or welding operator identification code; b) total number or radiographs taken or total length inspected during a certain period, as applicable; c) total number of failed radiographs or sum of flawed lengths during a certain period, as applicable; d) percentage of flaws, calculated by dividing the figure cited in item (c) supra by the figure cited in item (b) and then multiplying by 100 (one hundred); e) accumulated amounts for items (b), (c), and (d) supra, through the date of issue of the CDS; f) accumulated amount for item (d) in the previous CDS.

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/ANNEX H

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ANNEX H - INSTRUCTIONS FOR DRAWING UP THE WELDING RECORD REPORTS (RRS)

1 GENERAL CONDITIONS A RRS is applicable to the welding of test pieces, as required in item 1.1 a) of ANNEX C of the present standard, and in the fabrication, assembly, and maintenance of equipment, when required under items 4.2 and 5.3 of the present standard.

2 SPECIFIC CONDITIONS The RRS shall contain at least the following information: a) identification of equipment or test piece; b) identification of joint; c) weld repair number, if applicable; d) identification of welding procedure; e) specification of parent metal, batch, diameter (if applicable), and thickness of each member of the joint; f) identification of the welding execution and inspection instruction, if applicable; g) identification (serial number) of ammeter, voltmeter, and contact thermocouple; h) identification, date of issue, and name of the entity issuing the gauging certificate for the ammeter, voltmeter, and contact thermocouple; i) name and seal of welders and/or welding operators executing welding; j) all information specified in the corresponding welding procedure, with the values effectively used during welding itself, cited according to joint build-up sequence.

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/ANNEX I

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ANNEX I - INSTRUCTIONS FOR THE ELABORATION OF THE POSTWELD HEAT TREATMENT RECORD REPORTS (RRTT)

1 GENERAL CONDITIONS The RRTT is applicable to the recording of postweld heat treatments of test pieces, as required under item 1.1 b) of ANNEX C of the present standard, and in the fabrication, assembly, and maintenance of equipment, when required under items 4.2 and 5.3 of the present standard.

2 SPECIFIC CONDITIONS The RRTT shall contain at least the following information: a) type of postweld heat treatment executed; b) identification of applicable heat treatment procedure; c) identification of applicable execution standard; d) execution parameters; that is: - initial and final control temperatures; - minimum and maximum heating rates; - minimum and maximum treatment temperatures; - minimum and maximum treatment times; - minimum and maximum cooling rates; - maximum temperature difference between thermocouples; e) identification of equipment or test piece; f) identification (serial number) of temperature recorder used; g) identification, date of issue, and name of the entity issuing gauging certificates for the temperature recorded and thermocouples used; h) indication of execution method; that is: - oven heat treatment; - local heat treatment. i) indication of means of heating used; that is: - fuel oil; - gas; - electrical resistance. j) sketch of oven (if applicable), indicating location of equipment inside, of jet burners, and of electrical equipment inside, of jet burners, and of electrical resistances as well as the overlap regions whenever the equipment is not fully inside the oven; k) sketch of the welding joint, indicating location and distribution of electrical resistances and width of heat-affected zone, whenever local heat treatment is performed; l) type, quantity, and identification (number and color on graph) of thermocouples used; m) method for attaching thermocouples to part;

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n) sketch of equipment or test piece, indicating identification, location, and relative distance between thermocouples; o) record of test piece temperature versus time (time x temperature graph), with identification of thermocouples used; p) final technical statement, concluding whether the heat treatment was executed in accordance with the applicable procedure and standards.

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