SOHAR REFINERY IMPROVEMENT PROJECT

Method Statement for Welding control system

Document No : BEC-OFD0137-MS-007,REV 0
BEC Project Number : OFD0137
DPJV Contract Number : 120476 / JI-02022
Package Number : 2 & 6

24-12-2014

Issue for approval

Rev.

Date

Description

V.R.N

Prepared

S.J

G.V.A

Reviewed

Approved

Approved

DPJV

Bahwan Engineering Co LLC, PO Box 703, PC 112, Sultanate of Oman

Tel: +968 24597510, Fax: +968 24597511 www.bahwanengineering.com

Method statement for

Welding control system

Sohar Refinery Improvement Project SRIP

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

INDEX
1. OBJECTIVE

2. SCOPE

3. ABBREVATION

4. CODES&STANDARDS

5. ROLESANDRESPONSIBILITIES

6. MANPOWER

7. EQUIPMENTANDTOOLS

8. SEQUENCEOFACTIVITIES

9. SCOPEOFWORK

10. EXAMINATION

11. ATTACHMENT

Sohar Refinery Improvement Project SRIP

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Method statement for

Welding control system
Project No: OFD0137

1. OBJECTIVE
This document describes the sequence of events during all processes involved in the control of
welding, inspection and non-destructive testing of Carbon steel, low alloy , Austenitic stainless
steels, Alloy@ 400/825 for piping and structural welding work and shall be read in conjunction
with the applicable project specification, and relevant codes of Welding & Testing.

2. SCOPE
This method statement is applicable for the welding of the following materials
Carbon steel/Carbon steel (nace)
Low temperature carbon steel
Low alloy steels
1.1/4 Cr 1/2 Mo
2.1/4 Cr 1Mo
5 Cr 1/2 Mo
9 Cr 1 Mo
Austenitic stainless steel,
SA312 TP 304 L
SA 312 TP 316 L
SA 312 TP 321
Nickel-Copper alloy.
UNS N04400(ASTM B 165)
Nickel-Iron-Chromium-Molybdenum-Copper alloy.
UNS N08825(ASTM B 423)
on package number (2 and 6) work for SOHAR REFINERY IMPROVEMENT PROJECT (SRIP).

3. ABBREVIATIONS
AWS
:AmericanWeldingSociety
WPS
:Weldingprocedurespecification
PQR
:Procedurequalificationrecord
WQT
:Welderqualificationtest
ASME
:AmericansocietyofMechanicalengineers
ANSI :AmericanNationalStandardsInstitution
Company :SoharRefineryImprovementProject(SRIP)
Contractor
:DaelimPetrofacJointVenture
SubContractor
:BahwanEngineeringCo.LLC(BEC)
ISO :InternationalStandardsOrganization
ITP :Inspection&testplan
CIMS :Constructionintegratedmanagementsystem

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

PPE :PersonnelProtectiveEquipment
RA :RiskAssessment

4. CODES&STANDARDS
:GeneralrepairprocedureforPiping

S-000-5220-008-Rev 0
: Specification for welding of pressure piping SW.611
ASME Sec II part C
: Specification for Welding Electrodes & Filler Metals
ASME Sec II Part B
: Specification for nonferrous material
ASME Sec II Part A
: Specification for ferrous material
ASME Sec IX
: Welding and brazing Qualification
ASMEB31.3
:ProcessPiping
ASMEB31.1
:Powerpiping
AWSD1.1
:StructuralWeldingCodesteel
ASMESect.V
:NonDestructiveExamination
F0005530063RevA
:ITPforerectionandtestingofAG&UGweldedpiping
Welding consumable control procedure

5. ROLES&RESPONSIBILITIES
ConstructionManager

ShallReporttoSiteManager.

He shall be responsible for the implementation of this Method Statement of welding control
system.
He shall also be responsible for communicating all element of this Method Statement and
reference documents to down the level and arranging all resources to perform welding .

Shall be responsible for the execution of work in accordance with project HSE and
Qualityrequirements.

QA/QCManager

ReporttoSiteManager.

Responsibilities for quality control of the welding, welding consumable controlling,

installation&testing.

He shall liaise with Customer and contractor for Quality related matter.

ShallreviewInspectionreports,testcertificates&prepareTQfortechnicalinformation.

Shallensurethattherequirements&specificationsstipulatedinthismethodstatementare
appliedandmaintainedthroughouttheprojectconstructionperiod

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

QA/QCEngineer

ShallreporttoQA/QCManager

He shall be responsible for the quality of welding control system

with strict adherence.
He shall ensure that welding consumable is used after proper authorization of welding inspector.
He shall also monitor the compliance of storage and issue of electrodes.

QCInspector

ShallreporttoQCEngineerWelding/Piping.

He shall be responsible for reviewing and endorsement of the quality in welding control
system.

He shall be responsible for carries out daily inspection of fit-up, weld visual, preheat controlling,
welding consumable storage, baking, holding of electrodes and as per manufacturer
recommendations and approved WPS.
He shall also be verifying the issue of welding consumable at store
He shall be verifying the Calibration of Baking, Holding ovens and portable quivers

WeldingForeman

ShallbereportingtoQC/Pipingengineer

He shall be ensure of welding quality and handling of welding consumables on site

He shall be responsible for preparing the welding consumable request as per WPS
requirement.
He shall ensure that all unused electrodes have been returned to the baking oven at the end of the
shift every day.

Shallconducttoolboxtalkpriortostartofwork&ensurecompliancewithWPS

Materialcontroller

ShallreporttoMaterialManager

Shallensurethatallmaterialsarestored&segregatedaspermaterialspecification&size
schedulewise.

Shallensurethatallboughtoutprojectmaterialsareinspected&certifiedbyconcern
authority.

Shallensurethatallmaterials/spoolsareissuedforinstallationinaccordancewithMIR.

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

SafetyOfficer

ShallreporttoHSEManager

Ensure valid work permit for all activities performed during installation and permit
conditionarecomplied.

Ensureweldingboothpreparationinstandardandsafemanner

Ensurethatemployeesinvolvedintheweldingworksaretrained/qualified

EnsurethatproperPPEsarebeingusedbyemployeesduringwork.

Conduct tool boxtalkin ordertoexplain possible hazards,associatedrisks&control

measures

IdentifyspecifichazardsandassistconstructionSupervisiontoensuresafeprogressof
workactivity.

Control unauthorizedentry toworkarea byproperbarricading& displaying warning

signboardsandindicators.

CoordinatewithcontractorsiteHSEstaffforeffectivecontrolofactivityatsite.

6. MANPOWER

SiteManager

ConstructionManager

QCManager

QA/QCEngineer

WeldingSupervisor/Foreman

QualifiedWelders

QCInspector

Materialcontroller

HSEOfficer

Storekeeper

7. EQUIPMENT&TOOLS

WeldingMachines

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

BakingOven

HoldingOven

PortableOven /Heated quivers

Argoncylinder

Weldingconsumables

Electricresistantheatingmachine

Project No: OFD0137

8. SEQUENCEOFACTIVITIES

Welding Procedure Specification ( WPS ) / Welding Procedure Qualification Test ( WPQT )

Welding of Test Coupon for new procedure qualification.

Examination Of Test Coupon

Destructive Testing of Test Coupon

Approval of WPS

Welder Performance Qualification Tests

Welding stages and Controlling system

Weld Fit-up
Welding Condition
Welding Application
Preheating
Repair

9. SCOPEOFWORK
Welding Procedure Specification ( WPS ) / Welding Procedure Qualification Test ( WPQT )

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

Welding Procedure Specifications (WPS) , and Welding Procedure Qualification Test (WPQT)
shall conform to the requirements of ASME Sec IX, ASME B 31.3 and Project specification
requirements.
The detail work shall be carried out to determine the number of WPQTs required to cover
the whole scope of material type and wall thickness to be used in the project.
Pre-qualified WPQR shall be submitted to DPJV for approval. The requirement for additional
WPQT shall be determined in consultation with DPJV. A proposal for additional WPQT
(Proposed WPS) shall be submitted to DPJV for approval, containing the type and number
of test required as per ASME Sec IX/Project specification .

PROPOSED WPS used to provide the parameter information for welding the WPQT, shall
on acceptance of testing results, be revised to include any deviations required during
WPQT and the parameter adjusted in accordance with the code ASME Sec IX.

Test welding shall not commence until the WPS proposal has been stamped APPROVED with
the date and the contract number, and signed by DPJV.

Welding Procedure which shall be newly qualified, their procedure qualification test shall be
witnessed by DPJV.
The pre-qualified WPQRs proposed to use shall satisfy the following criteria

PQR is fully in accordance with ASME SEC IX

WPS is amended to reflect the project specific details.
WPS and PQR are owned and controlled by the Sub-contractor.
All the WPS and WPQR shall be uniquely numbered. A document revision
commencing with 0 shall also be referenced to WPS to allow various changes.

indicator

Welding of Test Coupon for new procedure qualification.

Prior to the commencement of test welding, the following documents must be available at site
for verification by DPJV
Original copy of the WPS proposal, endorsed APPROVED FOR QUALIFICATION
Original or verified copies of the material certificates for the items of the test coupon.
Original or verified copies of the batch test certificates for the welding consumable.
Approved consumable handling procedure.

The following information shall be recorded for each pass of the test weld on Actual Data
Sheet Format and shall form part of PQR.

Pass number and pass sequence.

Welding process
Consumable diameter, classification
Consumable trade name
Electrode polarity

Sohar Refinery Improvement Project SRIP

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Method statement for

Welding control system
Project No: OFD0137

Gas composition
Gas flow rate
Arc voltage range
Current Polarity and range
Wire feed speed.
Travel speed.
Preheat temperature
Interpass temperature
Average and Maximum Heat Input

The test weld information shall be recorded on welding parameter sheets shall be attached to a
completed PQR. Pass sequence shall be shown in sketch on the WPQT form. The actual Welding
records of the test welding shall be signed, dated, and endorsed by the contractors welding examiner.

Before start of welding, the WPS No, Position, Top & Bottom in case of 5G & 6G position
shall be indicated on test coupon with heat resistant marker.

Inspection Request minimum 24 hrs before shall be submitted to DPJV for witnessing the
test Welding

Examination of Test Coupon

After completion of welding the test coupon shall be cleaned properly and no grinding shall be done
prior to the visual inspection by the witness parties. If found acceptable all witness parties shall sign
on test coupon as a release for further testing or heat treatment.

The final visual examination shall be done after 24 hours have elapsed of welding. The visual
examination report shall be prepared and signed by all test witness parties. If the test weld is
visually accepted, it shall be offered for radiographic or other examination. Radiography shall be
performed in accordance with clause 344.5 of the ASME B31.3

Where post weld heat treatment is necessary, this shall be applied after the minimum 24 hours
period and before NDT. The test coupon shall be at ambient temperature prior to NDT

Destructive of test coupon

Testing of procedure qualification shall be performed in accordance with ASME Sec IX /Project
specification .

Sohar Refinery Improvement Project SRIP

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Method statement for

Welding control system
Project No: OFD0137

Approval of WPS

After successful completion of nondestructive testing, destructive testing and heat treatment the PQR
shall be submitted for final approval. The PQR will consists of WPQT format, Actual reading
sheet, NDT report, Heat Treatment report, Destructive test report, Material Test. Certificates,
Welding consumable Test .Certificates. All the reports and certificates must show endorsement and
signature of Sub-contractor

On the basis of above PQR, the WPS shall be made and submitted for approval. Production
welding shall not commence until the WPS
has
been
endorsed
APPROVED
FOR
CONSTRUCTION by DPJV

Welder Performance Qualification Tests

All welders for the project shall be tested as per ASME Sec IX /Project specification.

Welder Performance test coupon shall be prepared and welded as per WPS which is stamped
as APPROVED FOR CONSTRUCTION and shall be welded using parameters within
WPS. The parameters shall be monitored during welding through DC clamp meter. The test
coupon size, thickness, position shall be determined according to qualification requirement.

Welded test coupon shall be subjected to visual examination, and radiography testing to the
requirements of ASME IX QW 302 & Project specification. The criteria for visual inspection shall
be in accordance with ASME B 31.3 Table 341.3.2. After visual acceptance of radiography
examination shall be performed in accordance with ASME Sec IX.

A welder who fails to meet the acceptance criteria after the first re-test shall not be allowed
a second re-test before three days. Before testing the welder again the contractor shall demonstrate
that the welder has undergone training during that period.

Welder Performance Qualification thickness /Diameter limit shall be as per ASME Sec IX
QW-452 table QW 452.1(a) &(b) / QW 452.3, QW 452.4,QW 452.5,QW 452.6

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

Welding stages and controlling system

Fit-up stage

Tack welds shall be done by qualified welders only.

The extremities of the tack welds shall be dressed by grinding.

Fit up shall be carried out by using either bridge techniques or direct tacking on root. Where
root tack welding is specified in the WPS, the welding parameters shall be those for the root
pass of the approved WPS, including minimum preheat temperature requirements, and shall be
performed in accordance with WPS/ ASME B31.3 Table 330.1.1

For root tacks in pipe up to 4 inch diameter, a minimum of three tack welds shall be
deposited at equal spaces around the joint. For root tacks in pipe exceeding 4 inch diameter, a
minimum of four tack welds around the joint shall be made. Tack weld shall be minimum of
25 mm long wherever practical. When direct tacking on root, tack weld shall be fused with the
root pass weld, except for those having crack which shall be removed prior to root pass
welding.

Where bridge or bar tacks are used, these shall be welded using the electrode and parameters
shown in the approved WPS for the fill passes. In Bridge technique small metallic bullets
shall be cut from same piping material or the same consumable going to be used,
and
tacked in the groove at as many places as necessary depending on the diameter of the pipe.
Ensure no damage in the groove, or root gap or root face and tack welds shall not touch
the root gap or the root face. Welding shall not encroach on the root area.

Non-welded fit up clamps are preferred for alignment of all pipe, however temporary
attachment may also be used for alignment purposes. Temporary attachments used during fit
up shall be of the same or of the composition of the parent material and shall be welded
using the appropriate qualified WPS. Temporary attachments shall be removed by grinding
without reducing the wall thickness of the pipe and shall be done MT or PT Examination with
approval of DPJV.

WeldingCondition

No welding shall be done if there is impingement of rain, snow or high wind in the weld area
except that weld area is protected against strong wind to keep welding arc and shielding gas in

Sohar Refinery Improvement Project SRIP

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Method statement for

Welding control system
Project No: OFD0137

popper weldable condition. Welding shelters shall be provided at all the times to the weld area.
In windy conditions the pipe ends shall be sealed to prevent through draughts.

If material temperature below 05 OC, preheating up to 500 C or as per the relevant WPS
whichever is higher shall be carried out before start of the welding. Preheat shall be applied to a
band width of at least 75 mm. Method of preheat shall be as per the WPS. Propane heating torch shall be
used for preheating and the preheat temperature shall be checked by thermo stick/crayons.

Weld surfaces shall be thoroughly cleaned and dried before welding. Moisture shall be removed to a
bandwidth of at least 75 mm either side of the joint by means of blowers, or in exceptional
cases a torch may be used to produce preheat of 50 OC.

7.3

Welding Application

Qualified welders with the qualified welding procedures shall carry out welding. For
identification of welds, each weld have welders ID number, WPS and date of welding shall be marked
adjacent to the weld immediately after completion of the welding. The performance of each
welder shall be monitored closely. No welders are allowed to perform any welding work
without carrying his ID at the place of work.

The storage, baking & issue control of welding consumable shall be done through Method
Statement for Welding Consumable Control

Arc strike shall be situated in the fusion path. Root runs shall be made without interruption
and welds shall not be allowed to cool below the preheat temperature until root and hot
pass has been completed. If any arc strikes found outside of fusion path shall be ground to a
smooth profile. Ground area shall be examined by MT or PT and thickness checked.

To avoid arc strike good earth connection shall be ensured and periodic examination of the earth
cable and attachment shall be carried out. Any arcing from the poor connection shall be
considered as arc strike. For carbon steels, tightly screwed brass or copper (contact surface)
earthing clamps shall be used to avoid arc strike.

For set on branches, the branch pipe O.D and thickness at welding location shall be used in
determining the WPS qualification range. For Set in branches, the O.D and thickness of the
main pipe shall be considered for WPS qualification range.

Thorough inter-run cleaning and slag removal shall be carried out by grinding or chipping
by pneumatic or mechanical tool before deposition of subsequent layers. Visible defects such
as cavities, and other deposition faults shall be removed by grinding prior to deposition of
further weld metal. Cleaning of stainless steel metal alloy or nonferrous metal shall be done
only with hand and power tools which are dedicated to stainless steel and shall not have been
used on, or contaminated by, carbon steel or other materials.

Sohar Refinery Improvement Project SRIP

Method statement for

Welding control system

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Project No: OFD0137

Argon gas purging shall be done from the inside of pipe while welding materials such as
stainless steel, non-ferrous or carbon steel with stainless steel . The argon gas should be
99.99 % pure and flow rate should be as specified in WPS.

Purging dams

Movable dams tied together with rope or cord and pulled through the system by attachment rope.
Hinged rubber or hardboard disks of a suitable diameter with rubber or sponge edges shall
be used to form the dam approximately 55 to 150 mm either side from the weld center
line. The chamber being completed by sealing the root gap of the butt with masking tape.

After purging operation is completed the purge gas flow rate shall be reduced to that
shown on the applicable WPS. Welding shall be started only after reducing the gas flow
rate.

The purging shall be maintained until the

WPS and Project specifications.

completion of minimum thickness as specified in the

Preheating

Preheating of the parent metal prior to welding, where specified in the applicable WPS and
ASME B 31.3 Table 330.1.1, shall be carried out using gas heating torches or electrical resistance
heating method.

Preheating shall be applied when the base metal temperature is below 5 OC or condensation of
moisture on the weld area is possible. A minimum preheat shall be applied as per approved
welding procedure specification or project specification. A limited preheat may also be applied in
highly constrained conditions with the approval of company.
Minimum preheat and maximum interpass temperatures shall be as per the approved
WPS/ASME B 31.3.
During welding, preheat maintenance required shall be adopted by electric resistant method with
approved procedure
The heated area shall extend for a minimum of 75 mm either side of the joint and shall be
maintained over the full length of the joint until the weld is completed.
The preheat temperature shall be checked by temperature crayons /digital thermometer to
assure that the required preheat temperature is obtained prior, and is maintained during the
welding operation

Interruption of welding should be avoided. Where interruption is unavoidable, a minimum of three

passes or one third of the joint thickness, whichever is greater, shall have been deposited. The
weld shall be wrapped in a dry thermal insulating blanket for slow cooling. Upon resumption
of welding, preheat in accordance with the approved WPS shall be applied.

WELD REPAIR

Sohar Refinery Improvement Project SRIP

Doc Ref: BEC- OFD0137-MS-007, Rev-0

Method statement for

Welding control system
Project No: OFD0137

Cracks shall not be repaired. When cracking is observed in the completed weld, the weld shall be
cut out entirely. For partial penetration repairs, the total length of excavation shall not exceed
40% of the total weld length.
Weld repair shall be carried out by qualified welder only.
Excavationshallbebymachiningorgrinding. After excavation, visual and PTorMPT inspection
shall be performed to confirm defect removal. At the ends and the sides of the excavation there
shall be a gradual taper from the base of the excavation to the surface of the weld metal. The
profile shall be such that adequate access for welding is achieved.

10.0 EXAMINATION OF WELD JOINTS

10.1Visual examination
10.2 Liquid penetrant examination
10.3 Magnetic particle examination
10.4 Radiography examination
10.5 Ultrasonic examination
10.6 PWHT examination
10.7 Hardness examination
10.8 P.M.I examination

The extent of examination such as( 10.2 to 10.8 ) radiography, ultrasonic, penetrant testing,
magnetic particle testing, hardness testing, positive material identification ,Heat treatment etc., shall be
identified with each pipe class during execution of the project and shall be followed according
to project specification. From (10.2 to 10.8) shall be carried out approved NDT Sub-contractor
Company.
All completed weld shall be visually examined by QC/Welding Inspector and inspection status
shall be suitably identified in Daily Weld Inspection Report and encoded in C.I.M.S system.
The NDT sub contractor shall perform the NDE according to the NDE requests made as
per the approved NDT procedures on a daily basis. The NDT subcontractor shall involve
Sub-contractors QC inspectors and DPJV inspection personnel for witnessing the NDT as per
applicable ITP.

11.0 ATTACHMENT
Job safety analysis/Risk assessment