Professional Documents
Culture Documents
Santos Specification
Title: Welding
Table of contents:
FOREWORD ......................................................................................................................... 2
1 SCOPE ...................................................................................................................... 3
2 STANDARDS, CODES OF PRACTICE, REFERENCES ........................................... 3
2.1 Codes ............................................................................................................. 3
2.2 Australian And International Codes................................................................. 4
2.3 Santos Standards ........................................................................................... 4
2.4 Definitions....................................................................................................... 5
2.5 Identification and Responsibilities ................................................................... 6
3 TECHNICAL CONSIDERATIONS ............................................................................. 9
3.1 Weld Procedure Specification Development ................................................. 10
3.2 Weld Procedure Qualification ....................................................................... 10
3.3 Welding Operator Qualification ..................................................................... 11
3.4 Control Of Welding Consumables ................................................................. 11
3.5 Quality Assurance Of Welding Operations .................................................... 11
4 REVISION NOTES................................................................................................... 14
5 APPENDICES.......................................................................................................... 15
FOREWORD
Santos Engineering Standards apply to all Santos facilities and are based on
Australian Regulations and Standards. When applied outside of Australia, Local Regulations,
Codes of Practice and Environmental Regulations shall take precedence.
The Santos Engineering Standards are generated, implemented and reviewed in accordance
with the Santos Engineering Management Standards (EMS).
Use of this Santos Engineering Standard is MANDATORY. If any part of this Standard
appears inadequate, unsuitable or not cost effective, consult with the Custodian to agree a
suitable solution. This may result in a revision to the Standard.
Deviations from Santos Engineering Standards shall be approved in writing via the Santos
Engineering Standards Waiver process. Approval of waivers is vested in the Santos Chief
Facilities Engineer or his delegate.
1 SCOPE
2.1 Codes
Workmanship and materials shall conform to requirements of the latest edition of the
following codes and standards.
2.4 Definitions
Pressure Vessel – A vessel subject to internal or external pressure, including any vessel
that falls within the definition of a boiler or pressure piping or tank described below. It
includes interconnected parts and components, valves, gauges and other fittings up to first
point of connection for external pipe work.
Piping System – A section of pipe work including piping and pipe work components such as
flanges and fittings, valves, anchors, supports, linings, insulation and protection.
Atmospheric storage tank – A container subject mainly to hydrostatic pressure.
ITP – Inspection Test Plan
FIC – Field Installation Checklist
Weld Procedure Specification (WPS) – Weld(ing) Procedure Specifications are sometimes
referred to as Weld(ing) Procedures. These terms are interchangeable, and are normally
abbreviated to WPS.
A Welding Procedure Specification is a controlled document that defines a range of
essential welding variables and other variables based on parameters qualified by test
welds or determined by applicable codes, standards and specifications. A Qualified WPS
includes reference to the Weld Procedure Qualification on which it is based.
Welding Procedure Qualification Record (WPQR) – The term Weld(ing) Procedure
Qualification Record is sometimes abbreviated as PQR.
Weld Procedure Qualification Records are quality assurance documents that record the
development, inspection and testing of a WPS.
Welding Work Pack (WWP) – Quality Management System dossier including Work Order,
Job Plan, ITP, FICs, WPS, WPQR, welder's review of work scope and welder's check that
required equipment, consumables, relevant procedures and documentation are provided at
site.
Weld Types –
BR – Branch fitting including WOL TOL BW – Butt Weld
PW – Pad Weld FW – Fillet Weld
HT – Hot Tap SW – Socket Weld
Welding Processes –
FCAW - Flux Cored Arc Welding SAW - Submerged Arc Welding
GMAW - Gas Metal Arc Welding SMAW - Shielded Metal Arc Welding
GTAW - Gas Tungsten Arc Welding OFW - Oxyfuel Gas Welding
Essential welding variables – Essential variables are those variables defined in AS/NZS
3992 Section 5, AS/NZS 3992 Section 9 and ASME IX that are included in a Welding
Procedure Specification where a change reduces the ability of a welder to make a weld with
required mechanical properties and soundness.
Essential variables include:
Parent material specification Weld joint detail
Welding consumables Welding Process
Welding Position Welding energy input
Welding direction Welding current and polarity
Range of Material thickness Preheat requirements
Range of Pipe Diameters Post Weld Heat Treatment
For qualified weld procedure specifications, variations to essential variables listed in AS/NZS
3992 Table 5.1are not permitted and qualification of a new weld procedure may be required.
Refer section 3.1
Other welding variables – Other variables are items of AS/NZS 3992 Table 4.1 which are
not classified as essential variables by AS/NZS 3992 Table 5.1. Further definition is provided
in AS/NZS 3992 Table 9.1.
Variations to other variables on qualified weld procedure specifications are permitted. These
require deviation or concession request and Santos Construction Representative’s written
approval. See section 3.1 for procedure.
o Welding Standards
o Welder Identification requirements
o Schedule of work.
Review and audit of welding Quality Assurance.
Informing Senior Metallurgist, Santos Welding Coordinator and Welding Supervisor(s)
of proposed welding activities.
Permit Authority directing that work shall cease at any time should this be deemed
necessary.
3 TECHNICAL CONSIDERATIONS
General.
Production welding shall not be carried out unless both Welding Procedure Specifications
and Welder Qualifications are qualified in accordance with specified codes and statutory
requirements and accepted by Santos Senior Metallurgist.
Each Welding Company is responsible for timely qualification of Weld Procedure
Specifications and welders.
Santos will automatically reject welds completed by unqualified welders or any welds not
identified and recorded to code requirements. It is the Welding Company’s responsibility to
prove that all welds conform to applicable standards. This may require 100% radiography.
For site work, welders shall complete site safety inductions and training in work permit
procedures prior to any welding. Personal protective equipment shall be worn in accordance
with Santos personal protective equipment policy.
Repair of registered pressure vessels usually requires Statutory Approval. Details of
proposed repairs including Weld Procedure Specifications shall be sent to Santos Senior
Metallurgist who will, as required, apply for and advise of Statutory Approval.
Refer 1515-020-SPC-0001 Pressure Vessels.
Weld inspection and sentencing shall be carried out in accordance with AS 4037.
Radiographic examination (or ultrasonics under circumstances agreed by all parties) is
performed for every material thickness and material grouping and for each welding process
and procedure, progressively throughout the entire job.
Where 5% or 10% radiography is specified, at least that percentage of all welds within the
relevant line class shall be radiographed for 100% of their circumference. Similarly, the
specified percentage of all welds made by each welder shall be examined. Acceptance
criteria for 5% or 10% radiography is the same as specified for 100% radiography.
As gamma radiography has limited sensitivity when used with heavy wall material, all welds
requiring radiography through material over 19 mm thick shall be 100% ultrasonically tested
instead. If single wall single image radiography is possible, this material thickness limit is
extended to 30 mm.
Welds that cannot be radiographed because of their location or joint type or material shall be
examined by ultrasonic, liquid penetrant or magnetic particle method. Radiography is
generally not required for welds on slip-on flanges or socket welds or seal welds.
For each weld found to be defective, two additional welds made by the same welder who
produced the defective weld are subjected to radiographic examination. These additional
examinations are made immediately after a defective weld is found and are in addition to the
minimum examination requirements for the line class as specified in drawings or
specifications. Additional examinations are progressive so that two additional welds are
examined for each tracer examination found not to comply. Weld repairs shall be re-
examined by the same method used to detect the original defect.
Illumination - Inspection shall be carried out under suitable lighting conditions. The Welder or
Qualified Welding Supervisor may request additional lighting through the Santos
Construction Representative if required.
3.5.8 Repairs
If the Santos Construction Representative considers a weld to be grossly defective, or if a
weld does not comply with a Weld Procedure Specification, it shall be cut out and the joint re-
welded. All associated costs shall be the Welding Company’s responsibility.
Repair of weld defects shall be made using an approved welding procedure.
All repairs and modifications are subject to an appropriate level of quality control consistent
with Class and Standard to which pressure equipment is designed - in accordance with
AS3920.1and AS4458. A Santos Senior Metallurgist shall review and accept all repair
procedures.
4 REVISION NOTES
Revision 3
This standard was previously TIMS document [1515-120-S-050-0].
Revision 3 reflects the migration of Santos engineering documentation from The Technical
Information Management Systems (TIMS) to myPlant OP during 2014. No technical update
changes have been made to this standard but where possible the update has addressed:
Compliance with the new Santos naming conventions
Links, including Redirect documents, to Santos Intranet, Extranet and external web
sites
Keyword replacements (eg. replace TIMS with myPlant)
Inclusion of reference to the Santos Engineering Management Standards (EMS)
which were launched in 2014.
Revision 2
Document updated (January 2009) as part of continuous improvement. All changes are for
improved useability and no technical changes have been made since the last revision.
Revision 1
General revision, removal of procedural items
Revision 0
Initial issue, comprising input from…
CBU (R Schulz, G Bryan, H Moss)
SABU meeting minutes rjs27501, May 2001
Review comments as filed by Custodian
5 APPENDICES
Number Systems
Records of Welding Procedure Specifications and Weld Procedure Qualifications shall be
identified using the following nomenclature and guidelines
Identification Format Px-SYy-Zz
Px Material Type
Material being welded is identified by P number designation from AS 3992 and
ASME Section IX.
P1 – Carbon Steel P8 – Stainless Steel
Where a joint is between two materials of a dissimilar type, two P number's
are listed separating them with a ‘/’. e.g. P1/P8.
SYy Sequential Registration
‘S’ indicates a Santos procedure. Yy is registration sequence: S01, S02...
Approved Welding Procedures are controlled documents.
Registration is responsibility of Santos Welding Coordinator.
Zz Welding Process
Each welding process is designated by a two character Alpha code.
GT - Gas Tungsten Arc Welding SM - Shielded Metal Arc Welding
GM - Gas Metal Arc Welding FC - Flux Cored Arc Welding
SA - Submerged Arc Welding OF - Oxy Fuel Gas Welding
Where different processes are used for root and fill passes, the two processes
will be listed, separating them with a ‘/’. e.g. GT/SM.
Templates of proforma welding documents use sequential number (xxx)
WWP-xxx Template for Welding Work Pack
WPS-xxx Data sheet for Welding Procedure Specification
WPQR-xxx Data sheet for Welding Procedure Qualification
ITP-xxx Template for Welding Inspection Test Plan
FIC-xxx Template for Welding Field Installation Checklist
Draft documents use alphabetic revision – e.g. Rev A, Rev B etc.
Controlled Documents and use numeric revisions – e.g. Rev 0, Rev 1 etc.
Controlled Documents require identification signatures and dates of Preparer, Reviewer and
Approver for each revision.
Heat Time
Flux /
Weld Pass Details Filler Metal Description Welding Parameters to next
Gas Input pass
No. Direct’n Posn. Type Size Class. Type Amps Volts Polarity Speed kJ/mm Sec.
CONSUMABLE DETAILS
TYPE DESCRIPTION SPECIFICATION & CLASS BRAND NAME
FILLER METAL -ROOT
-FILL
FLUX
SHIELDING GAS FLOW RATE L/m
PURGE GAS FLOW RATE L/m
TUNGSTEN ELECTRODE TYPE SIZE CLEANING METHOD
NOTES : reference Santos Engineering Specification 1515-120-SPC-0050
Heat Time to
Flux /
Weld Pass Details Filler Metal Description Welding Parameters next
Gas Input pass
No. Direct’n Posn. Type Size Class. Type Amps Volts Polarity Speed kJ/mm Sec.
CONSUMABLE DETAILS
TYPE DESCRIPTION SPECIFICATION & CLASS BRAND NAME
FILLER METAL -ROOT
-FILL
FLUX
SHIELDING GAS FLOW RATE L/m
PURGE GAS FLOW RATE L/m
TEST PLATE IDENTIFICATION TEST RESULTS - REPORT No.
TEST COUPON No. VISUAL TENSILE
WELDER NAME RT BEND
DATE UT IMPACT
STICKOUT MT/PT HARDNESS
TUNGSTEN SIZE OTHER MACRO
NOTES:
Santos Welding
Representative
Santos Project
Responsibility
Construction
Coordinator
Operations
Supervisor
Company
Engineer
Engineer
Qualified
Operator
Welding
Welding
Welding
Welding
Activity
Santos
Santos
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