welding specification sp4/01 - wi37.mts.104 engineering … · wi37.mts.104 revision 5 dft...

WELDING SPECIFICATION SP4/01 - ENGINEERING

WI37.MTS.104 Revision 5 DFT

ENGINEERING

Any PRINTED copies of this procedure are UNCONTROLLED Page: 1 of 35

1.0 PURPOSE

This Work Instruction describes the process and system used to ensure that sound engineering practice and statutory requirements are met in regard to Welding. The adoption of AS/NZS ISO 3834 for specifying quality requirements for fusion welding provides assurance that weld quality is maintained throughout the life cycle of the equipment. This work instruction previously referenced SP4/01.

2.0 SCOPE

This applies to all forms of welding carried out on SIMEC Mining and Liberty Primary Steel Whyalla plant.

3.0 REFERENCES

3.1 AS/NZS ISO 3834 - Quality Requirements for Fusion Welding of Metallic Materials (refer Parts 1 to 5) 3.2 ISO 14731 - Welding Coordination Tasks and Responsibilities 3.3 AS 179 6 - Certification of Welders and Welding Supervisors 3.4 AS 2812 - Welding, Brazing and Cutting of Metals – Glossary of Terms 3.5 WI37.MTS.105 - Welding Management Flowcharts 3.6 FORM31.01 - Scope of Work 3.7 WI37.MTS.184 - Closure Welds for Pipework (under development) 3.8 WI37.MTS.185 - Hot Taps for Pipework (under development)

4.0 DEFINITIONS

Company Liberty Primary Steel or SIMEC Mining businesses in Whyalla CE Central Engineering Manager Engineering Manager of Central Engineering, Liberty Primary Steel Contractor Defined as Manufacturer in AS/NZS ISO 3834 for all welding operations who are Company approved vendors. Manufacturer As defined in AS/NZS ISO 3834 and includes and is not limited to internal and external resources carrying out fabrication work for the Company. Welding Co-ordinator Company representatives nominated by Manager Engineering or Contractor representatives, who reviews the technical and quality requirements of welding work prior to commencement, monitors welding conformity being performed and validates welding conformity at completion.



ENGINEERING


ISO 14731 provides guidelines on the tasks, responsibilities and competencies of a welding co-ordinator function. Closure Weld The technique of carrying out a final pipe connection weld that cannot be practically pressure tested to assess the integrity of the weld joint. Hot Tap Weld The technique of welding and sealing a branch fitting to a pipe that is in service and pressurised using a mechanical method of creating an opening in that pipe by drilling or cutting within the attached fitting for pressure containment of the fluid service during welding. ITP Inspection and Test Plan sets out quality assurance controls, inspection points before and during manufacture / fabrication of items. These include but are not limited to materials certificates, dimensional checks, welding procedures, welder qualifications, painting and NDE. testing along with Witness, Surveillance and Hold Points. MDR Manufacturer Data Report is a report produced by the Manufacturer and submitted to the Company Welding Coordinator for review and approval, certifying that all items have been constructed, inspected and tested in compliance with the requirements of the applicable standard(s), design drawings and specifications. The relevant sections shall be indexed. This report shall include and is not limited to (where applicable); material test certificates, welder qualifications, qualified weld procedures and supporting WPQR, inspection records, NDE / NDT reports, heat treatment records, pressure test certificates, ITP., weld maps and weld traceability records, weld consumable certificates, dimensional records, coating records calibration certificates, statutory approvals, concessions/deviations, certificates of any other tests or inspections as required by applicable standards or specifications. NDE / NDT Non Destructive Examination (or Testing) Weld Traceability Is the ability to retrieve by records and drawings for each weld to a specific location, and provides information on the; weld procedure used, the identification of the welder, date when welded, unique identification number of the weld, drawing number, weld consumable batch number, materials welded, NDE / NDT report numbers, inspector identification and inspection results. WPQR Weld Procedure Qualification Record that contains all the recorded weld parameters, materials, personnel and test results supporting the development of a proven weld procedure according to specified requirements. Scope of Work Either documented in Form 31.01 Scope of Work for tendering or an internal document detailing the scope of work for internal use.



ENGINEERING


5.0 PROCEDURE

5.1 Registration

5.1.1 The Company Welding Procedures shall be registered in the Company’s quality document system.

5.1.2 The Welding Coordinator is responsible for registering any new or revised

Company Welding Procedures.

5.2 Responsibility

5.2.1 CE is responsible for the control and content of Company Welding Procedures. The authority for changes and or new Company Welding Procedures is the Manager Engineering or their nominee.

5.2.2 The Contractor is responsible for the control and content of their own Welding

Procedures.

5.3 Issue of the Company Welding Procedures to Contractors

5.3.1 Company Welding Procedures are intended for Company use only. It is preferred that the Contractor provides their own Welding Procedures which must be approved by the Welding Coordinator.

5.3.2 Controlled Copies of Company Welding Procedures shall only be issued by

the Supply Department to all approved Contractors. Uncontrolled copies shall not be issued. Other supporting documentation will not be provided by the Company.

5.4 Minimum Quality Criteria for Equipment Classes

5.4.1 Part I Minimum Quality Criteria for Equipment Classes shall be referenced to determine the minimum quality criteria based on the equipment classes being considered.

5.4.2 Part II General Requirements for All Welding applies to all equipment classes. 5.4.3 Part III Structural Welding applies to all structural work including and not limited

to beams, columns, bracing, supports, stairs, platforms, ladders, and other related aspects.

5.4.4 Part IV Boilers, Pressure Equipment, Pressure Pipework and Cryogenic

Pipework applies to pipework carrying flammable or corrosive liquids or gases or hydraulic fluid or plumbing.

5.4.5 Part V Welding of Oxygen, Nitrogen and Argon Pipework applies to pipework

carrying Oxygen, Nitrogen and Argon. 5.4.6 Part VI Flammable Gas Pipework applies to all pipework carrying natural gas,

liquefied petroleum gas (LPG), blast furnace gas and coke ovens gas.



ENGINEERING


5.4.7 Part VII Brazed and Soldered Connections for Pressure Pipework applies to all pipework brazing and soldering of pipework other than domestic water pipework.

5.4.8 Part VIII Storage Tanks applies to all low pressure storage tanks including and

not limited to process tanks, open tanks, closed tanks, hazardous material tanks.

5.4.9 Part IX Closure Welds for Pipework applies to pipe welds where a final closure

weld is not practical and not feasible to be proof tested by a pressure test method.

5.4.10 Part X Hot Taps for Pipework applies to pressure equipment when it is not

feasible or is impractical to take the equipment or piping out of service, or to purge or clean by conventional methods.

6.0 DOCUMENTATION

6.1 Appendix 1 Welding Specification 6.2 Appendix 2 Weld Traceability Record Sample 6.3 Appendix 3 Weld Map Sample 6.4 Appendix 4 NDE / NDT Request Form Sample 6.5 Appendix 5 Inspection and Test Plan Sample 6.6 Appendix 6 Manufacturers Data Report Index Sample 6.7 Appendix 7 Closure Weld Inspection Record Sample 6.8 Appendix 8 Hot Tap Inspection Record Sample 6.9 Appendix 9 Welding Flowchart Sample


Appendix 1 SIMEC Mining and Liberty Primary Steel

WELDING SPECIFICATION Specification Scope This specification covers all welding and fabricating work including hard

surfacing. PART I Minimum Quality Criteria for Equipment Classes PART II General Requirements for all Welding PART III Structural Work PART IV Boilers, Pressure Equipment and Pressure Pipework PART V Oxygen, Nitrogen and Argon Pipework PART VI Flammable Gas Pipework PART VII Brazed and Soldered Connections for Pressure Pipework. PART VIII Storage Tanks PART IX Closure Welds for Pipework PART X Hot Taps for Pipework General fabrication items such as spares which may not be covered by AS/NZS 1554 Parts 1 to 7 are to meet the permissible levels of weld imperfections as determined by Table 6.2 of AS/NZS 1554.1 SP unless otherwise noted.


PART I MINIMUM QUALITY CRITERIA FOR EQUIPMENT CLASSES

Criteria to be Considered for the Following Equipment Classes

Criteria

Structural Cranes and

Lifting Devices

Pressure Piping AS4041 or equivalent

Boilers and Pressure Vessels

Storage Tanks

GP SP/FP Class 1&2 Class 3 Closure Welds & Hot Tap Welds

Hazard Levels A,B,C,D

API 620 or Equivalent

Relevant Parts of WI37.MTS.104

Part II,III Part II,III Part II,III Part II,IV,V,VI,VII Part IX, X Part II,III Part II, VIII

1. Obtain Design Approval Lead Structural Engineer Statutory Regulator

Lead Mechanical Engineer

Welding Coordinator

Statutory Regulator Welding

Coordinator

2. Obtain Plant Registration NO Statutory Regulator

Pressure Equipment Officer Statutory Regulator

(A,B,C only) Pressure

Equipment Officer

3. Submit ITP to Welding Coordinator for review and approval

NO YES Compulsory

4. Ensure that all Welding Procedures are Qualified

Compulsory Refer to AS/NZS 1554

Parts 1 to 7 or equivalent

Compulsory Refer to AS/NZS 3992 or equivalent (eg. ASME IX)

5 Ensure that Welders are Competent and Qualified.

Compulsory

6. Material Certificates required

YES Compulsory YES Compulsory

7. Heat Treatment certificate required

NO YES

8. NDE / NDT report required Visual Only YES Compulsory YES Compulsory

9. Hydrostatic Test certificate required

Not Applicable YES Not Applicable Compulsory Leak Test

10. Submit MDR report to Welding Coordinator for review and approval

NO YES Compulsory

LEGEND:

NO: This criteria does not have to be considered.

YES: This criteria must be considered, however a code or specification may exempt this request

Compulsory: This criteria shall be carried out.


PART II - GENERAL REQUIREMENTS FOR ALL WELDING 1. Conformity to Drawings and Specifications

All work must be carried out in strict accordance with any drawings or specifications issued by the Company. The Welding Coordinator will only develop Welding Flowcharts if the drawings and specifications are registered and approved as Issued For Construction. Welding Flowchart(s) shall be developed by the Welding Coordinator when there are welding activities and prior to a Scope of Work being issued. All work shall comply with the latest editions, revisions and supplements of all relevant specifications, standards, codes and regulations whether referenced in this specification. If any alterations are found necessary in either design or welding data specified on the drawing or this specification, the Company must approve such alterations or amendments in writing. It is the Contractor's responsibility to ensure that this written agreement is obtained.

2. Non-Compliant Work

2.1 Work carried out by the Contractor that does not meet the required specifications and / or standards, will be repaired and re-inspected by the Contractor at the Contractor's cost. The Welding Coordinator decision on this matter shall be final.

2.2 Only two repair attempts are permitted for all materials, and failure on the second attempt will

require total weld removal at a minimum 100mm each side of the defect area. 2.3 Welding shall be free of slag and weld spatter, whether a protective coating is applied or not.

3. Inspection

3.1 Visual, NDE / NDT, destructive, or specialist inspectors shall meet the qualification and experience requirements as required by the applicable welding standard or specification, or as agreed by the Welding Coordinator.

3.2 The Contractor shall carry out and bear the full cost of inspections nominated by a Standard or

by the Company at Tender stage. 3.3 The Company reserves the right to carry out any type of inspection in addition to the above.

This includes visual, NDE / NDT, destructive and any other form of inspection. The cost of inspections in addition to those required above (3.1) will be incurred by the Company if the work is found to be satisfactory. If a weld is found to be non-compliant, then Section 2 applies.

3.4 Company representatives must at all times be given right of access for inspection purposes.

The cost of providing this access at the work site will be incurred by the Contractor, unless otherwise agreed to by the Company. This includes the cost of all scaffolding, or other access systems to enable the Company's representatives to carry out the necessary inspections.

4. Welding Procedures

4.1 Tack Welding is considered part of the same quality and workmanship requirements as the weld.

4.2 Welding of dissimilar metals shall have a dedicated qualified and approved Welding Procedure.


4.3 Welding for hard surfacing shall have a dedicated qualified and approved Welding Procedure. 4.4 The Contractor shall be responsible for using a technically sound and proven Welding

Procedure, that is supported by a WPQR meeting the applicable standard. 4.5 If the Company provides a Welding Procedure for a specific task, it remains the Contractor's

responsibility to ensure that they can successfully perform the welding operation defined in the Company’s Welding Procedure.

4.6 Pre-qualified procedures are preferred as they are proven to be reliable, conservative and cost

effective in reducing mechanical testing requirements. This does not eliminate the requirement for a WPQR.

4.7 Repair of new welds shall utilise the same Weld Procedure as used in production.

5. Qualifications of Welding Personnel

5.1 Welding and welding operators shall be qualified in accordance with the relevant Codes and Standards prior to commencement of welding. Welding qualification by the first production weld is permitted only if approved by the Company.

5.2 Qualified Welders shall produce suitable evidence of qualification as specified in 5.1, otherwise

they shall be prohibited from performing welding work for the Company.

5.3 In all cases the Contractor is to maintain a list of welding personnel and their qualifications. This list shall be submitted to the Company on request.

6. Welding Supervision

6.1 In all cases the Contractor shall provide appropriate supervision during welding operations. 6.2 Welding Supervisors shall be appointed and have the authority and control of the quality of

welding operations. 6.3 Welding Supervisors shall meet the qualification/competency requirements of the applicable

Welding Standard or Specification. A Certificate 10 to AS 1796 is deemed competent for the supervision of all welding work.

6.4 The Welding Supervisor is responsible for ensuring quality documentation, such as; weld

maps, weld traceability, ITP’s, NDE / NDT requests and MDR documentation are compiled and completed as required in Part I.

7. Welding Consumables

7.1 General

7.1.1 Welding consumables shall be in accordance with the specified Welding Standard or Specification.

7.1.2 Welding consumables shall be positively identified in packaging or stampings, with

batch certificates supplied.

7.1.3 Any welding consumables that cannot be positively identified, shall be discarded appropriately.


7.1.4 Welding consumables shall be stored in a clean, dry and sealed storage area, in accordance with the Manufacturer’s recommendations.

7.2 Ferrous Consumables.

7.2.1 All welding consumables used shall meet hydrogen-controlled requirements of 5 - 10ml per 100g of deposited weld metal.

7.2.2 Where not covered by Manufacturer’s recommendations, hydrogen-controlled

electrodes shall be stored and used under the following conditions:

o Electrodes shall be stored in their unopened packets or cartons in a reasonably dry place adequately protected from the effects of weather.

o Electrodes which have been wet, or which have had the flux covering damaged

shall not be used whether dried or not and discarded appropriately.

o Electrodes shall be drawn from heated ovens and put in hot boxes set at 110oC for direct use.

7.2.3 Cellulosic welding electrodes (eg. E4111) are only limited to be used where specified

in an approved qualified Welding Procedure. 7.2.4 All low carbon and carbon manganese steel consumables shall meet Grade 2 impact

requirements or better, unless otherwise specified in an Australian Standard or classification.

7.2.5 Submerged arc flux, gas metal arc and flux-cored wire shall be clearly identified and

stored in a dry location at a temperature above 20oC. The identification shall state manufacturer, grade and batch number.

7.3 Non-Ferrous Consumables.

7.3.1 Non-Ferrous consumables shall be stored separately from Ferrous materials to eliminate cross contamination.

8. Buried Pipelines and Pipework

Unless specified otherwise by the Company: o All pipework under roadways shall be subject to 100% radiography continuing a distance of 3

metres on either side of the roadway. o All buried pipework that carries lethal, hazardous or harmful contents must be radiographed to

meet Standard or Code requirements. If any joint fails radiography, the Company reserves the right to require 100% radiography. This includes pipework encased in concrete.

9 Prohibited Welding Processes

GMAW is prohibited, unless written authority is obtained from the Company.


10. Material Certification

10.1 Material Test certificates shall be obtained by the Contractor before Manufacturing commences.

10.2 All Material Test certificates shall be incorporated into the MDR and forwarded to the Welding

Coordinator for review and approval. 11. Weld Traceability Marked up drawings (eg. weld maps) detailing all welded joint locations and weld identification

numbers shall be provided by the Contractor with corresponding weld traceability records on all welding work, except for Structural Welding classified as AS/NZS 1554.1 GP.

12 NDE / NDT

12.1 NDE / NDT service providers shall have a certified quality system to NATA and AS ISO / IEC 17025. Personnel performing NDE / NDT shall be certified to Level 2 according to AS 3998 / AS ISO 9712, or equivalent as agreed by the Company.

12.2 NDE / NDT shall be performed according to specified standards and approved drawings. NDE

/ NDT requests shall be issued by the Company or the Contractor to the NDE / NDT service provider before commencing work.

12.3 NDE / NDT service providers shall make available all records and reports to the Company and

the Contractor for review and approval. 13. Stainless Steel Welding

13.1 All stainless steel welding and materials shall be managed suitably to prevent cross contamination with ferrous materials. This includes segregated/sheltered areas and use of separate non-ferrous, cutting, grinding or cleaning discs or brushes.

13.2 All stainless-steel welds shall be cleaned and descaled after weld completion on the same shift.

Purging of stainless-steel pipework shall be undertaken as specified by the Weld Procedure.


PART III - STRUCTURAL WORK 1. Application

This specification applies to all structural work as listed in the applicable standards below. 2. Applicable Standards

2.1 All materials and workmanship supplied by the Contractor shall conform to the latest amendments of the following Standards. The Contractor is also required to conform to other relevant standards referenced in these documents.

2.2 The following Standards also apply:

AS/NZS 1554.1 Welding of Steel Structures

AS/NZS 1554.2 Arc Stud Welding (Steel Studs to Steel)

AS/NZS 1554.3 Welding of Reinforcing Steel

AS/NZS 1554.4 Welding of High Strength Quench and Tempered Steels

AS/NZS 1554.5 Welding of Steel Structures Subject to High Levels of Fatigue Loading.

AS/NZS 1554.6 Welding of Stainless Steel for Structural Purposes

AS/NZS 1554.7 Welding of Sheet Steel Structures

AS/NZS 2980 Qualification of welders for fusion welding of steels

AS/NZS 1665 Welding of Aluminium Structures

AS 1566 Copper and Copper Alloys - Rolled Flat Products

AS 1567 Copper and Copper Alloys - Wrought Rods, Bard and Section

AS 1674.1 Safety in Welding and Allied Processes - Part 1 Fire Precautions

AS 1674.2 Safety in Welding and Allied Processes - Part 2 Electrical

AS 1796 Certification of Welders and Welding Supervisors

AS 1988.1 Welding of Ferrous Castings – Part 1 Steel Castings

AS/NZS 2576 Welding Consumables for Build-up and Wear Resistance

AS 3990 Mechanical Equipment - Steelwork

AS 4100 Steel Structures

AS/NZS 5131 Structural Steelwork – Fabrication and Erection


3. Application of SP and FP Categories to AS/NZS 1554

3.1 AS/NZS 1554 Part 1 Weld Category SP shall be applied for structural purposes. 3.2 AS/NZS 1554 Part 5 Weld Category FP shall be applied for fatigue purposes. 3.3 Welding to AS/NZS 1554 Part 6 (Stainless Steel) shall meet the requirements of internal weld

quality Level 1B, external weld quality Class B and a surface finish Grade II. 3.4 Unless approved in writing by the Company, the levels of NDE / NDT specified in the respective

parts of AS/NZS 1554 shall be the minimum to be performed in all cases.

4. Application of GP Category to AS/NZS 1554

4.1 AS/NZS 1554 Part 1 Weld Category GP shall be applied for general purpose use. GP welds for structural items must be clearly annotated on the approved design drawing.

5. NDE / NDT for Cranes and Lifting Equipment

5.1 All welds shall be subject to 100% magnetic particle examination.

5.2 Fabricated Girders

5.2.1 All girder tension flange butt welds shall be subjected to 100% radiographic or ultrasonic examination.

5.2.2 The lower 30% of all girder web butt welds shall be subjected to 100% radiographic

or ultrasonic examination.

5.2.3 All web to flange girder welds shall be subjected to 100% ultrasonic examination.


PART IV - BOILERS, PRESSURE EQUIPMENT AND PRESSURE PIPEWORK 1. Application

This specification applies to pressure vessels, pressure pipework and pressure components manufactured to comply with the AS/NZS 1200. Any repair, alteration or maintenance work carried out on boilers, pressure equipment or pressure pipework is to be done in accordance with this part.

2. Applicable Standards

2.1 All materials and workmanship provided by the Contractor shall conform to the latest amendments of the following Standards. The Contractor is also required to conform to other relevant standards referenced in these documents.

2.2 All Standards listed in Part III, Section 2.2 apply to this part where applicable. The

following Standards also apply: AS/NZS 1200 Pressure Equipment AS 1210 Pressure Vessels AS 1228 Pressure Equipment – Boilers AS 1432 Steel Structures AS 1572 Copper and copper alloys - Seamless tubes for engineering purposes AS 1579 Arc welded steel pipes and fittings for water and wastewater AS/NZS 1596 The storage and handling of LP Gas AS 1697 Installation and Maintenance of Steel Pipe Systems for Gas AS 2129 Flanges for Pipes, Valves and Fittings. AS 2885 Pipelines - Gas And Liquid Petroleum Known As The Saa Pipeline

Code AS/NZS 3788 Pressure Equipment - In-service inspection AS 3814 Industrial and commercial gas-fired appliances AS 3920 Pressure Equipment - Conformity assessment AS/NZS 3992 Pressure Equipment - Welding and brazing qualification AS 4037 Pressure Equipment - Examination and testing AS 4041 Pressure Piping. AS 4458 Pressure Equipment - Manufacture AS/NZS 5601 Gas installations Set ASME BPVC.IX Section IX – Welding Brazing and Fusing Qualifications ASME BPVC.VIII.I Section VIII – Rules for Construction of Pressure Vessels Div 1 ASME BPVC.VIII.I Section VIII – Rules for Construction of Pressure Vessels Div 2

Alternative rules ASME BPVC.VIII.I Section VIII – Rules for Construction of Pressure Vessels Div 3

Alternative rules for High Pressure Vessels ASME B31.1 Power Piping ASME B31.3 Process Piping ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries BS 4677 Specification for Arc Welding of Austenitic Stainless Steel Pipework for

Carrying Fluids

2.3 The use of socket welded connections should be avoided, but where used shall comply with the requirements of AS4041, particularly for the thermal expansion gap.


3. Hydraulic Systems

3.1 All butt welds shall have a GTAW root run for all pipe sizes. 3.2 MMAW is allowable only on hydraulic pipe work greater than DN50 unless otherwise approved

by the Company. 3.3 GTAW shall be used on smaller pipe work <DN50. 3.4 Tack welding or welding using GTAW for non-ferrous pipework shall be internally purged using

a suitable shielding gas. 3.5 Oxy fuel gas welding or brazing is not permitted on hydraulic pipework. 3.6 Socket welded joint connections shall only be used on hydraulic pipework after the Contractor

obtains approval from the Welding Coordinator and Hydraulics Officer. All socket welded joint connections shall be in accordance with AS4041 or equivalent.

4. Repairs and Alterations

4.1 Any repairs or alterations to boilers, pressure equipment or pressure pipework shall be designed and approved by competent persons as per Part I of this document.


PART V - WELDING OF OXYGEN, NITROGEN, AND ARGON PIPELINES 1. Application

This specification applies to all pipework carrying oxygen, nitrogen and argon and it is not designed to limit or restrict any requirement the Company's Power and Services Manager requires in addition to this specification. The Company will supply such additional requirements in writing to the Contractor.

2. Applicable Standards and Specifications


2.2 All Standards listed in Part IV, Section 2.2 apply to this part where applicable. The

following Standards also apply:

Ferritic Steels

AS 4041 Pressure Piping ASME BPVC.IX Section IX – Welding Brazing and Fusing Qualifications

Austenitic Steels

AS 4041 Pressure Pipework ASME BPVC.IX Section IX – Welding Brazing and Fusing Qualifications BS 4677 Specification for Arc Welding of Austenitic Stainless Steel Pipework for

Carrying Fluids

Non - Ferrous Materials

AS 4041 Pressure Piping ASME BPVC.IX Section IX – Welding Brazing and Fusing Qualifications

3. Specific Requirements

3.1 Design Approval The pipework must satisfy the requirements of AS4041 and Company Specification QP38.08 Standard for the Transportation and Distribution of Oxygen by Pipeline.

3.2 Pressure Testing and Leak Testing

All pressure testing and leak testing will be in accordance with the requirements of Company Specification QP38.08 Standard for the Transportation and Distribution of Oxygen by Pipeline. Documentation of pressure testing is required by the Company.

3.3 Cleanliness

Company Specification QP38.08 Standard for the Transportation and Distribution of Oxygen by Pipeline specifies the cleanliness required for internal Oxygen pipework, therefore any welding operations will require specific cleaning quality procedures and contamination control to be approved by the Company prior to commencement of work.


4. Radiography

4.1 Standard of Acceptance for Radiography (All Materials) The standard of acceptance for Radiography is AS 4037 Class 1. In addition to the requirements of AS 4041 the maximum root penetration and maximum internal protrusion limit due to misalignment or mismatched bore sizes is 1mm in total on Oxygen pipework.

4.2 Levels of Radiography

4.2.1 Above Ground Pipework NDE / NDT requirements and weld acceptance levels shall be as per AS4037 for the nominated Design Class of piping unless noted otherwise.

4.2.2 Buried Pipework

100% radiographic examination shall be conducted at welded joints on all underground pipework and pipework to be encased in concrete.

5. Socket Weld Connections

Socket welded connections generally are not permitted on Oxygen, Nitrogen and Argon pipelines. The Contractor must seek written approval from the Company if socket welded connections are intended to be used. Generally, consideration will only be given to the use of these connections on pipelines of DN10 or less.

6. Soldering and Brazing

The Contractor shall receive written approval from the Company to solder and braze joints. Brazing and soldering must be performed in accordance with Part VII. Generally, welding will be the only acceptable method of joining Oxygen, Nitrogen and Argon pipelines and consideration will only be given to allow soldering or brazing on copper pipework of DN20 or less.


PART VI – PIPEWORK FOR FLAMMABLE GAS 1. Application

Welding of pipework conveying Town Gas, Natural Gas, Liquefied Petroleum Gas in the vapour phase, Tempered Liquefied Petroleum Gas, Blast Furnace Gas, Coke Ovens Gas, Simulated Gas or any similar substance.




following Standards also apply: AS 1697 Installation and Maintenance of Steel Pipe Systems for Gas AS 4041 Pressure Piping AS/NZS 5601 Gas installations Set


2.1 Design Approval

The pipework must satisfy the requirements of AS4041 Class 2A piping or AS1697 as a minimum.

2.2 Pressure Testing and Leak Testing

All pressure testing and leak testing shall be in accordance with the requirements of AS/NZS 5601. Piping which is to be installed in an inaccessible location shall be tested prior to the piping being made inaccessible. Documentation of pressure testing is required by the Company.

2.3 Welded Flange Joints

Welded flange joints shall be minimised where butt-welding pipes end to end is not possible. The use of weld neck flanges is preferred.

3 Radiography

3.1 Standard of Acceptance for Radiography (All Materials)

The standard of acceptance for Radiography is AS 4037 Class 2A piping unless otherwise specified.

3.2 Levels of NDE / NDT

3.2.1 Above Ground Pipework NDE / NDT requirements and weld acceptance levels shall be as per AS4037 for the nominated Design Class of piping unless noted otherwise.

3.2.2 Buried Pipework

100% Radiographic examination shall be conducted at welded joints on all buried pipework and pipework to be encased by concrete.


4. Socket Weld Connections

Socket welded connections generally are not permitted on flammable gas pipework. Sockets are to comply to ASME B16.9 Factory-Made Wrought Buttwelding Fittings or with BS 3799 Specification for Steel Pipe Fittings, Screwed and Socket-Welding for the Petroleum Industry. Welding to comply with AS4041 Class 2A unless otherwise specified.

5. Soldering and Brazing

The Contractor must receive written approval from the Company to solder and braze joints. Brazing and soldering must be performed in accordance with Part VII of this specification. Generally, welding will be the only acceptable method of welding flammable gas pipework. Consideration will only be given to allow soldering or brazing of copper pipework of DN20 or less.


PART VII - BRAZED AND SOLDERED CONNECTIONS FOR PRESSURE PIPEWORK 1. Application

Brazing and soldering of pipework other than domestic water pipework. 2. Applicable Standards



following Standards also apply: AS 2812 Welding, brazing and cutting of metals – Glossary of terms AS 4839 The safe use of portable and mobile oxy-fuel gas systems for welding,

cutting, heating and allied processes AS/NZS 3992 Pressure Equipment – Welding and Brazing Qualification ASME BPVC.IX Section IX – Welding Brazing and Fusing Qualifications

3. Approval

The Contractor must obtain written approval from the Company to use a brazed or soldered joint on pressure pipework.

4. Qualification of Personnel

Personnel engaged in the brazing or soldering of pressure pipework are required to demonstrate competency. Qualifications to AS 1796 certificates are not required.

4.1 Competency Tests - Standard of Acceptance

Competency tests are to be conducted in accordance with ASME BPVC.IX ARTICLE XI or AS/NZS 3992 Section 14.

5. Brazing or Soldering Procedure

The Company must approve in writing the Brazing or Soldering Procedure for use. The procedure must comply with ASME BPVC.IX ARTICLE XI or AS/NZS 3992 Section 12.


PART VIII – STORAGE TANKS 1. Application

This applies to low pressure storage tanks such as tanks complying with AS 1940 or equivalent, including tanks complying with API 620 or equivalent or any other tanks containing hazardous materials.



2.2 All Standards listed in Part III, Section 2.2 and Part IV, Section 2.2 applies to this part where

applicable. The following Standards also apply: AS 1692 Steel tanks for flammable and combustible liquids AS 1940 The Storage and Handling of Flammable and Combustible Liquids AS 2304 Water storage tanks for fire protection systems AS 3780 The Storage and Handling of Corrosive Substances AS/NZS 4452 The storage and handling of toxic substances API 620 Design and Construction of Large, Welded, Low Pressure Storage Tanks API 650 Welded Steel Tanks for Oil Storage AS/NZS 1554 Structural Steel Welding ASME BPVC.IX Section IX – Welding Brazing and Fusing Qualifications

3. Repairs and Alterations

3.1 Any repairs or alterations to storage tanks shall be designed and approved by competent persons acceptable to the Company.


PART IX – CLOSURE WELDS FOR PIPEWORK 1. Application

This applies to pipe welds where a final closure weld is not practical and not feasible to be proof tested by a pressure test method. eg. hydrostatic pressure test.

2. Applicable Standards / Documents

2.1 Preparation, production and inspection of Closure Welds must be carried out in accordance with WI37.MTS.184 Closure Welds for Pipework (under development).

2.2 All materials and workmanship supplied by the Contractor shall conform to the latest

amendments of the following Standards. The Contractor is also required to conform to other relevant standards referenced in these documents.


following Standards also apply: AS 4037 Pressure Equipment - Examination and testing AS 4041 Pressure Piping ASME B31.1 Power Piping ASME B31.3 Process Piping

3. Approval

The use of Closure Welds is a two-step approval process by the Company. 3.1 Approval to use a Closure Weld shall be obtained from the Welding Coordinator before any

design commences.

3.2 Approval of the design of a Closure Weld shall be obtained from the Lead Mechanical Engineer before implementation.


4.1 Design Approval

The pipework must satisfy the requirements of the standards listed in Section 2.2 of this Part as a minimum. The design of any closure weld shall allow for suitable access for welding, monitoring, inspection and NDE / NDT during production. Parent materials and weld layers shall be inspected using a suitable NDE / NDT method. Closure weld design calculations shall be checked by an independent competent person.

4.2 Supervision

The Contractor shall ensure that all closure welds at all stages of preparation and production are continuously monitored by a qualified Welding Supervisor approved by the Company. The Welding Supervisor shall verify that the preparation of the weld and each weld sequence is in accordance with the specified Weld Procedure. This verification shall record all welding parameters and conditions.


4.3 Inspection

Each closure weld shall be inspected 100% using suitable visual and NDE / NDT methods to detect surface and subsurface defects. This will be captured on a Closure Weld Inspection Record by the Welding Supervisor or nominated Welding Inspector.

4.4 Documentation A unique Welding Flowchart shall be developed for any closure weld and not imbedded in the Welding Flowchart for the overall job. Documentation covering sub-section 4.1 to 4.3 inclusive of this part shall be required.


PART X – HOT TAPS FOR PIPEWORK 1. Application

Hot tapping of pressure equipment is performed when it is not feasible or is impractical to take the equipment or piping out of service, or to purge or clean by conventional methods.

2. Applicable Standards / Documents

2.1 Preparation, production and inspection of Hot Taps must be carried out in accordance with WI37.MTS.185 Hot Taps for Pipework (under development).

2.2 All materials and workmanship supplied by the Contractor shall conform to the latest

amendments of the following Standards. The Contractor is also required to conform to other relevant standards referenced in these documents.


following Standards/Codes also apply: API 2201 - Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries

3. Approval

The use of a Hot Tap process is a two-step approval process by the Company. 3.1 Approval to use a Hot Tap process shall be obtained from the Welding Coordinator before

any design commences.

3.2 Approval of the design of a Hot Tap process shall be obtained from the Lead Mechanical Engineer before implementation.


4.1 Design Approval

The pipework must satisfy the requirements of the standards listed in section 2.2 of this Part as a minimum. The design of any Hot Tap weld joint must allow for suitable access for welding, monitoring, inspection and NDE / NDT during production. Parent materials and weld joints shall be inspected using a suitable NDE / NDT method. Hot Tap weld design calculations shall be checked by an independent competent person.

4.2 Supervision

The Contractor shall ensure that all hot tap welds at all stages of preparation and production are continuously monitored by a qualified or approved Welding Supervisor. The Welding Supervisor shall verify that the preparation of the weld and each weld sequence is in accordance with the specified Weld Procedure. This verification shall record all welding parameters and conditions.


4.3 Inspection

Each hot tap weld shall be inspected 100% using suitable visual and NDE / NDT methods to detect surface and subsurface defects. This will be captured on a Hot Tap Weld Inspection Record by the Welding Supervisor or nominated Welding Inspector.

4.4 Documentation A unique Welding Flowchart shall be developed for any Hot Tap weld and not imbedded in the Welding Flowchart for the overall job. Documentation covering sub-section 4.1 to 4.3 inclusive of this part shall be required.


Appendix 2 - Weld Traceability Record Sample

WELD TRACEABILITY RECORD SHEET- Reference Weld Map/Dwg No.-

PROJECT DESCRIPTION: CLIENT: PO/WO No.

COMPONENT/DRAWING No.: JOB LOCATION: Plant:

WELD DETAILS Inspection Scope % Inspection Results-

C/DNC Inspector Details

Weld

Type *

Weld

No.

Piece/Spool no.

Welder I/D

Date Welde

d WPS No

Consumable Batch

No.

Thickness Pipe/Plate welded

Material Grades welded

Heat Nos.

Visual

RT UT PT MT Visual NDT

NDT Report

No

Inspector Name

Initial

Date

COMMENTS: *WELD TYPE CODE and WELD DESCRIPTION is as follows: WW= Window Weld, SW = SOCKET WELD, BR = BRANCH WELD, BW = BUTT WELD, FW = FILLET WELD, PW= PAD

WELD;

NOTE: 'S' Indicates 'SHOP' Weld and 'F' Indicates 'FIELD' Weld / Example ...... 'FSW' = FIELD Socket Weld OR 'SSW' SHOP Socket Weld.


APPENDIX 3 - Weld Map Sample

WELD MAP SAMPLE Weld Map No.xyz

PROJECT DESCRIPTION: CLIENT: PO No.

COMPONENT/DRAWING No.: JOB LOCATION: Plant:

SPOOL NOs or PIECE NOS.:

Notes 1: Ensure orientation to due North or fixed plant position is noted on the sketch 2. Ensure spool no. or piece nos. welder ID and weld no. are identified on the weld map DRAWN By: Date:


APPENDIX 4- NDT Request Form Sample

Company Logo/Name

NDT Request No: NDT Contractor:

Requested by: Request Date:

CLIENT: Site Contact: PO or WO Order: Location:

JOB

DESCRIPTION:

CONSTRUCTION SPECIFICATION/CODE. Choose an item.

ACCEPTANCE SPECIFICATION/CODE.: Choose an item.

WELDING PROCESS: Choose an item.

MATERIAL

SPEC.: Choose an item. To Choose an item. LOCATION/ABOVE or BELOW GROUND- % NDT Required-

DRAWING No. Piece/Spool No./Line no. MATERIAL SIZE

AND THICKNESS

WELD

TYPE

TEST

METHOD

WELD

No./s

WELDER

I.D.No. COMMENTS / SKETCH

Choose an item. Choose an item.









WELD TYPE LEGEND WELD TYPE CODE and WELD DESCRIPTION is as follows: SW= SOCKET WELD, BR = BRANCH WELD, BW = BUTT WELD FW = FILLET WELD, PW =PAD WELD

TEST METHOD LEGEND THE TEST METHODS ARE AS FOLLOW: RT = RADIOGRAPHIC EXAMINATION, MT = MAGNETIC PARTICLE EXAMINATION, PT = PENETRANT EXAMINATION, LT=LAMINATION TEST HT = HARDNESS TEST, UT = ULTRASONIC EXAMINATION, PMI = POSITIVE MATERIAL IDENTIFICATION, OT=OVALITY TEST, UTT =ULTRASONIC THICKNESS TEST, PMI, POSITIVE MATERIAL IDENTIFICATION. DT, DESTRUCTIVE TESTING, BOROSCOPE


APPENDIX 5 – Inspection Test Plan Sample

Company: ABC Fabrication INSPECTION & TEST PLAN- Project Description: (Example Weld & Test Pipe) Step No.

Activity Description Specification Acceptance Criteria How Recorded Responsibility ITP Sign off*NOTE Remarks

Fab 3rd Party Client

1 Develop ITP & submit for client approval

SP4/01 Client requirement This document ABC Supervisor H H H

2 Check drawings issued are correct for the job

xyz As per SOW This document ABC Supervisor W W

3 Weld Procedures and welder Qualifications submitted to client for approval, prior to welding

AS 3992 Sp4/01

Welders and weld procedures qualified to as 3992 and AS 4041 Class2

WPS WQR

ABC Supervisor H H H Client to send approval notification

4 Material received and checked Job specification- Bill of materials

- correct to bill of materials. - material certificates supplied - materials undamaged

This document ABC Supervisor H W W

5 Cutting of material

XYZ As 4041 Class 2- edges correct

This document ABC Supervisor/welder

W W W

6 Transfer Heat Nos of cut materials

SP4/01 Sp4/01 Heat Nos. indelibly marked on items cut.

AB Supervisor/welder

W W W

7

Material certificates filed in MDR XYZ Sp4/01 MDR ABC Inspector W W W

8 Pipes fitted into position and pipe supports

Drawing xyz Drawing xyz This document ABC Supervisor/welder

H W W

9 Welds prepared and tacked - check dimensions

Drawing WYZ As 4041 WPS


This document, Record key dimensions on as- built drawings

ABC Fabrication Supervisor/welder. ABC Inspector

H W W

10 Weld Pipe joints Drawing WYZ As 4041 WPS


Record weld details and no. on weld map & traceability record QA 001, QA 002

ABC Fabrication Supervisor/welder

. ABC Inspector

M M W ABC inspector to inspect weld fit up, monitor parameters to WPS

11 Visually Inspect completed welds Drawing WYZ As 4041 class 2 WPS

Drawing WYZ As 4041 WPS, AS 4037 Cl 2

Record on weld trace sheet and weld map QA 001, QA 002

ABC Inspector H W W ABC Inspector to raise NDT request

12

Undertake NDT- 10% RT AS 4041 Class 2 AS 4037 Class 2 piping

Nata report NDT Contractor H H H NDT to comply prior to Hydro test

13 Undertake Hydrostatic Test - check water quality and supports

Drawing XYZ AS 4037 – 30MINS @ 1200 kPa- No leaks of bulges

Pressure Test record QA 003

ABC Supervisor ABC Inspector

H H H Pressure gauges must be calibrated

14 Completed ITP and MDR submitted for approval

SP4/01, SOW ITP, MDR complete and correct

ITP, MDR ABC Inspector H H H

H= Hold Point (do not proceed past until verified correct), W= Witness the activity, R= Review documents or records. Ensure sign off initials are dated, and names recorded.


APPENDIX 6 - MDR Index Sample

MANUFACTURING DATA REPORT TABLE OF CONTENTS

SECTION DESCRIPTION

SECTION A Inspection and Test Plans

SECTION B Material Certificates

SECTION C Certificate of Compliance

SECTION D Welding Records- weld maps, weld traceability and weld consumables

SECTION E Welder and Welding Operator Qualification Records

SECTION F Non-Destructing Testing Records

SECTION G Painting and Coating Records

SECTION H Heat Treatment Records

SECTION I Dimensional Records

SECTION J Non-Conformance Reports and Concessions

SECTION K Pressure Test Records

SECTION L Mechanical and Performance Test Records

SECTION M Electrical Certificates and Reports

SECTION N Instrumentation Certificates and Reports

SECTION O Drawings

SECTION P Miscellaneous Certificates / Reports / Records

SECTION Q Statutory Documents for Cranes / Hoists / Lifts

SECTION R Documentation for Pressure Vessel, Heat Exchanges and Others


APPENDIX 7 – Closure Weld Inspection Record Sample (WI37.MTS.184 - under development)


APPENDIX 8 - Hot Tap Inspection Record Sample (WI37.MTS.185 - under development)


APPENDIX 9 – EXAMPLE WELDING FLOWCHART SAMPLE


APPENDIX 9 – EXAMPLE WELDING FLOWCHART SAMPLE (2/4)