Tec Pec

EPSCC1 Contractor
Job nr. LY010
GREAT MABRUK DEVELOPMENT PROJECT
WELDING
3 21/12/2004 Approved V. V. M.
Birlan Ricci Mazzi
2 16/12/2004 Issued for approval according to CCOD 60 V. V. M.
Birlan Ricci Mazzi
1 20/10/2004 Issued for approval V. V. M.
Birlan Ricci Mazzi
0 22/09/2004 Issued for comments V. V. M.
Birlan Ricci Mazzi
REV DATE DESIGNATION BY CHECK APPR
STATUS CODE : A = Issued for comments - B = Issued for approval - C = Approved – I = Information only
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN

WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER
COMPAGNIE DES PETROLES TOTAL LIBYE

EPSCC1 Contract N° : GMD/84/2002/MA
Doc. Title : WELDING

REVISION STATUS
C.P.T.L. Doc. N°: TEC-GRL-WEL-301-10001 3 C
Doc. Title : TEC-GRL-WEL-301-10001- Rev. 3

File: TEC-GRL-WEL-301-10001_WELDING_REV3.DOC 1 / 16
EPSCC1 Contractor
Job nr. LY010
CONTENTS
COVER PAGE ..........................................................................................................................1

CONTENTS ..............................................................................................................................2
1. SCOPE AND FIELD OF APPLICATION.............................................................................4

2. REFERENCE DOCUMENTS .............................................................................................4
2.1 STANDARDS ..........................................................................................................4
2.2 CONTRACT DOCUMENTS .....................................................................................4
3. ABBREVIATIONS AND DEFINITIONS ..............................................................................4
3.1 ABBREVIATIONS....................................................................................................4
3.2 DEFINITIONS ..........................................................................................................5
4. ELECTRODES AND FILLER WIRES.................................................................................6
5. PRELIMINARY OPERATIONS ..........................................................................................6
5.1 WELDING PERSONNEL .........................................................................................6
5.2 WELDING PROCEDURE SPECIFICATIONS (WPS) ...............................................7
5.3 WELDING PROCEDURE QUALIFICATION .............................................................7
5.3.1 General .......................................................................................................7
5.3.2 Testing of welded joints - Butt welds ............................................................7
5.3.3 Records (WPS and WPQR) .........................................................................7
5.4 REPAIR PROCEDURES .........................................................................................8
5.5 QUALIFICATION OF REPAIR PROCEDURES ........................................................8
5.5.1 Identification of WPS and WPQR.................................................................8
5.6 WELDER QUALIFICATION .....................................................................................8
5.7 WELDER IDENTIFICATION ....................................................................................9
5.7.1 Schedule of Welders:...................................................................................9
6. MARKING OF WELDS ......................................................................................................9
7. PRODUCTION WELDING ...............................................................................................10
7.1 SWABBING, PIPE BEVELLING AND CLEANING ENDS OF JOINTS ....................10
7.2 ALIGNMENT OF PIPE ...........................................................................................10
7.3 PREHEATING AND INTERPASS TEMPERATURE ...............................................10
7.4 POST-WELD HEAT TREATMENT (PWHT) ...........................................................11
7.5 PIPE MOVE-UP.....................................................................................................11
7.6 GOLDEN WELDS..................................................................................................11
7.7 INTER-RUN CLEANING/GRINDING OF WELDS...................................................11
7.8 ARC STRIKES.......................................................................................................11
7.9 PROXIMITY OF WELDS........................................................................................12


EPSCC1 Contractor
Job nr. LY010
7.10 WEATHER CONDITIONS......................................................................................12

7.11 END PROTECTION...............................................................................................12
8. INSPECTION AND TESTING OF PRODUCTION WELDS...............................................12
8.1 GENERAL .............................................................................................................12
8.2 HARDNESS TEST (ONSHORE PIPELINES) .........................................................13
9. REPAIR AND REMOVAL OF DEFECTS..........................................................................13
9.1 PREPARATION FOR RE-WELDING......................................................................13
9.2 INSPECTION OF WELD REPAIRS........................................................................13
9.3 RECORD OF REPAIRS.........................................................................................13
10. DOCUMENTATION .........................................................................................................14
10.1 PIPE AND WELD LOG ..........................................................................................14
10.2 PIPE BOOK ...........................................................................................................14
10.3 FINAL DOSSIER ...................................................................................................14
11. QUALITY CONTROL/QUALITY ASSURANCE.................................................................15
11.1 QUALITY CONTROL .............................................................................................15
11.2 CONTENTS OF THE QA/QC RECORD BOOK ......................................................15
12. TECHNICAL QUERIES/NON-CONFORMANCE REPORTS ............................................16
13. RESPONSIBILITY ...........................................................................................................16
14. ATTACHMENTS..............................................................................................................16
- Welding Procedure Specification (WPS)
- Welding Procedure Qualification Record (WPQR)
- Welder Qualification Record (WQR)
- Welding Parameters Control Record
- Weld Visual Inspection Record


EPSCC1 Contractor
Job nr. LY010
1. SCOPE AND FIELD OF APPLICATION

This procedure will be applied to the Project “ GREAT MABRUK DEVELOPMENT PROJECT -
EPSCC1 CONTRACT: Pipelines and Cables: no. GMD/84/2002/MA".
2. REFERENCE DOCUMENTS
2.1 STANDARDS
ISO 9000: 2000 Quality Management systems - Fundamentals and vocabulary
ISO 9001: 2000 Quality Management systems – Requirements
API 1104 ed. 2000 Standard for Welding of Pipelines and Related Facilities.
API 5L Specification for Line Pipe.
ASME/ANSI B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols.
ASME/ANSI B31.8 Gas Transmission and Distribuion for Piping Systems.
2.2 CONTRACT DOCUMENTS

- CONTRACT AGREEMENT
14.3 COMPANY ITEMS
EXHIBIT C WORK TIME SCHEDULE
EXHIBIT H QUALITY ASSURANCE AND QUALITY CONTROL
EXHIBIT I COMPANY ITEMS
GS PLR 403 Installation of onshore pipelines

GS PLR 421 Site welding of carbon steel pipelines to API 1104 (Intermediate and Severe
Sour Service)
TEC-PPL-WEL-019-0009 PROJECT PARTICULAR SPECIFICATION SITE WELDING OF
CARBON STEEL PIPELINES (Sour Effluent)
3. ABBREVIATIONS AND DEFINITIONS

3.1 ABBREVIATIONS
- COMPANY: COMPAGNIE des PETROLES TOTAL LIBYE (CPTL) ............ (COMPANY)
- CONTRACTOR: Sicim.S.p.A.. .............................................................................. (SICIM)
- SITE Construction Manager.......................................................................................(CM)
- Gas Tungsten Arc Welding ..................................................................................(GTAW)
- Shielded Metal Arc Welding ................................................................................ (SMAW)
- Post-weld heat treatment .....................................................................................(PWHT)


EPSCC1 Contractor
Job nr. LY010
- Project Particular Specification ................................................................................ (PPS)

- Welding Procedure Specification ............................................................................ (WPS)
- Welding Procedure Qualification Record.............................................................. (WPQR)
- Welder Qualification Record ................................................................................. (WQR)
- Site Queries .............................................................................................................. (SQ)
- Deviation Request ..................................................................................................... (DR)
3.2 DEFINITIONS
- APPROVAL means CUSTOMER's written assent. APPROVAL shall in no way be construed as
relieving CONTRACTOR of any of his obligations, responsibilities or liabilities under the
CONTRACT or at law. APPROVE or APPROVED shall be construed accordingly.
- CHANGE ORDER means any modification to the CONTRACT mutually agreed between the
PARTIES .
- COMPANY ITEM(S) means any itemised and non itemised equipment and materials to be
incorporated into the NETWORKS by CONTRACTOR and expressly specified as being
supplied to CONTRACTOR by COMPANY.
- COMPANY REPRESENTATIVE means the person appointed by COMPANY as its duly
authorised representative vis-à-vis CONTRACTOR with respect to the CONTRACT .
- FINAL DOCUMENTATION means with respect to the whole NETWORKS, including all process
and utilities systems and equipment of the NETWORKS, all printed documentation and data on
electronic, optical and magnetic media related to the design, detailed engineering, equipment
and materials supply, construction, commissioning start up, operations and maintenance, such
as "as-built" drawings, certificates of inspecting and/or certifying entities (whether official or not),
descriptive and operating manuals and instructions, maintenance and safety manuals and
instructions, documentation (with the necessary information and data to start up, operate and
maintain the related equipment including spare parts and special tools identification) and
including such documentation, to be obtained from SUBCONTRACTORS (including contractors
of ASSIGNED CONTRACTS) and all other related documents as stipulated in the CONTRACT
DOCUMENTS.
- NETWORKS means the permanent facilities being constructed or to be constructed at SITE
resulting from the WORK.
- PROJECT means engineering and construction of pipelines and cables networks at the Mabruk
Fields in Libya.
- SITE means the location where the NETWORKS are to be constructed and the vicinity thereof.
- WORK means all and any part of the works and services required to be performed by
CONTRACTOR under the CONTRACT for the full and complete realisation of the NETWORKS,
and as may be modified by CHANGE ORDERS.
- WORKSHOP(S) means any location(s), other than WORKSITES, including offices, premises
and workshops, where any equipment, materials or manufactured items, including
CONTRACTOR ITEMS, shall be engineered, manufactured and assembled. WORKSHOPS
include similar offices, premises and workshops of SUBCONTRACTORS (including contractors
of ASSIGNED CONTRACTS).
- WORKSITE(S) means the SITE and/or all and any construction location(s), where any major
parts of the NETWORKS (such as pressure vessels, exchangers, tanks, pipings, instruments,
electricals, pumps, power generation units, ……), shall be fabricated and assembled, excluding


EPSCC1 Contractor
Job nr. LY010
all other offices, premises and workshops of CONTRACTOR, SUBCONTRACTORS (including

contractors of ASSIGNED CONTRACTS).
- COMPANY INSPECTOR: The COMPANY's authorized Representatives or members from
COMPANY elected Inspection Agencies for the time being or from time to time duly appointed
in writing by the COMPANY to act as its Representatives for the purpose of the contract shall be
referred to herein as the "Inspector".
- SITE QUERY (SQ) Written request for clarification regarding exact meaning or interpretation of
a given contractual requirement, specification, procedure or drawing.
- DEVIATION REQUEST (DR) Written request for authorisation to deviate from the contractual
requirements of a given specification, procedure or drawing.
- Base materials: Pipes and fittings supplied by COMPANY or CONTRACTOR
4. ELECTRODES AND FILLER WIRES

Welding consumables shall conform to ASME/AWS, Section II, Part C or approved equivalent
standard.
SICIM shall obtain manufacturer's test certificates (3.1.b certificates according to EN 10204 Std) for
each batch of consumables used on the job.
These certificate shall be supplied to the Inspector for approval.
No welding consumables shall be used without proper batch test certificates.
The certificates shall include the following minimum information for each welding consumables:
- Chemical composition.
- Tensile properties.
- Impact tests properties.
Typical values are not accepted, all informations shall be issued from tests.
Welding consumables shall be supplied in sealed, dirt and moisture proof containers.
All welding consumables shall, as a minimum, be stored and handled in accordance with the
written manufacturer’s recommendations.
For each batch of consumable used on job a test certificate in according to EN 10203: 3.1b type
shall be supplied.
The certificates include the chemical composition, tensile properties and impact test properties, all
informations shall be issued from test.
For low hydrogen coated electrodes, their hydrogen content (when determined through glycerin
method), shall not more 5 ml/100g of deposed weld metal.
5. PRELIMINARY OPERATIONS
5.1 WELDING PERSONNEL
SICIM shall nominate a Welding Engineer for preparation of welding procedures, selection and
qualification of welders and monitoring of welding performance during execution of the work.


EPSCC1 Contractor
Job nr. LY010
5.2 WELDING PROCEDURE SPECIFICATIONS (WPS)

The WPS for both the main welding procedures and weld repair procedures will be submitted to
COMPANY before the start of qualification tests.
The WPS shall be accompanied by a summary table showing: process, consumables, direction of
welding, type of weld, WPS no., test weld wall thickness and scope of qualification.
The welding procedure qualification tests shall not be undertaken until the Inspector has given his
approval of the principle on the said WPS.
5.3 WELDING PROCEDURE QUALIFICATION

5.3.1 General
All welding procedure qualification tests shall be conducted in the presence of the Inspector.
SICIM shall notify the COMPANY of the date and location of the welding procedure qualification
tests at least seven (7) working days before the start of the tests.
COMPANY shall give final acceptance and approval of all welding processes, systems and
procedures.
Non-Destructive Testing procedures will conform to the requirements of section 11 of the contract
spc. GS PLR 421 and, anyway, subject to COMPANY prior approval.
The Inspector shall witness all non-destructive examinations and destructive testings and shall
review and approve all related results.
All mechanical testings shall be carried out by a CERTIFIED TESTING FACILITY subject to prior
approval of the COMPANY.
5.3.2 Testing of welded joints - Butt welds

Visual and non-destructive testing Test welds shall be fully visually inspected and fully
radiographed.
All mechanical tests will be performed according 8.4.2 of GS PLR 421.
5.3.3 Records (WPS and WPQR)

A form based upon that in API 1104 or similar shall be used for recording all test performance
conditions and results of the welding procedure qualification test (see attached blank form).
The data sheets of as-deposited runs (format to be approved by Inspector) shall also be fill in
during performance of each test welds and shall form part of the final Welding Procedure
Qualification Record (WPQR).
Records shall be established by SICIM and co-signed by SICIM and Inspector who attended the
tests.
Copy of Records shall be available on Site when the production welding is performed.
All WPQRs will imperatively include a copy of the Mill Certificates of the test base materials and
consumables used for the test.
Each revision of the documents shall be given a new revision identification number updated in
sequential order and revisions shall be marked in order to identify the changes.


EPSCC1 Contractor
Job nr. LY010
5.4 REPAIR PROCEDURES

Weld repairs are permitted for defects located in the filling and cover passes (i.e. partial penetration
repairs) and shall be at least 50 mm long.
Repairs at root or including the root shall be minimized and such repairs shall be subject to special
approval of the Inspector on a case to case basis. Anyway, repairs at root or including the root (i.e.
through thickness repairs or internal repairs) shall not exceed 10% of individual weld length.
Only one repair of weld root shall be permitted in the same area.
Outside weld root, two repair attempts shall be permitted in the same area of weld.
Should the repair weld(s) fails to meet the NDT requirements, then the whole weld shall be cut out.
Such repairs of repairs shall be limited to one per weld.
Single-run repairs are permitted where the whole of the weld cap is replaced to the original
procedure (such repairs do not require separate qualifications). For any other single-run repair
(internal or cap repair), qualification tests shall be required.
Weld repairs to pipe or fitting body or bevels shall not be permitted.
5.5 QUALIFICATION OF REPAIR PROCEDURES

Qualification of weld repair procedures shall be carried out at the same time as the qualification
tests of main procedures.
As per GS PLR 421 specification, for welding of Intermediate and severe sour services repair
procedure qualification tests will include the prescription of the § 13.2 of GS PRL 421, unless a
different repair scheme is proposed by SICIM and approved by COMPANY.
5.5.1 Identification of WPS and WPQR

Each WPS will be identified, according to the Document Identification Procedure (MGT-GRL-PMT-
001-10002), by a specific code.
This code will be formed as follow:
- TEC-GRL-WEL-250-1 followed by 4 digits from 0001 to 9999
(example: TEC-GRL-WEL-250-10001)
WPQR will be identified, according to the Document Identification Procedure (MGT-GRL-PMT-001-

10002), by a specific code.
5.6 WELDER QUALIFICATION

Each welder shall be qualified in accordance with the requirements of API 1104 and requirements
of the GS PLR 421 specification before commencement of production welding.
Only Single Qualification is accepted. .


EPSCC1 Contractor
Job nr. LY010
SICIM shall use only skilled workmen for welding.

Each welder employed by SICIM shall be required to pass a welding test for the type and methods
of welding he will perform, including for attachment welds.
No welder shall do any phase of welding on the pipeline for which he has not been tested and
previously approved by the Inspector.
SICIM shall use welding materials and equipment the same or equivalent (to COMPANY's
satisfaction) to those to be used on the line.
The welder shall make a test weld under simulated field conditions as appropriate.
All tests shall be witnessed and approved by Inspector.
Welder Qualification Records (WQR) will be identified, according to the Document Identification
Procedure (MGT-GRL-PMT-001-10002), by a specific code.
5.7 WELDER IDENTIFICATION

Each welder/operator shall be given a unique identification number which he shall mark in paint
against all welds produced by him.
The unique identification number will be formed by letter W followed by 3 digits from 001 to 999
(example: W001).
A list of qualified personnel (with photographs) shall be kept up to date by SICIM and made
available for Inspector for review.
Any welder found responsible for a high level of defects/repairs in production shall be removed
from production.
At the discretion of Inspector, the welder in question may be retested after an agreed period of
retraining.
5.7.1 Schedule of Welders:

SICIM will provide upon a weekly basis COMPANY with a schedule of welders employed on the
CONTRACT cross-referenced to personnel number, the procedures and position to which they are
qualified and the dates for re-qualification.
On completion of the CONTRACT, SICIM will provide a schedule, containing the above
information, of all welders who will have worked on the CONTRACT for inclusion in the FINAL
DOCUMENTATION.
6. MARKING OF WELDS
All welds shall be marked with paint stick by the welders according to numbers assigned to them by
SICIM at the time of their qualifications.
Should any welder leaves the job, his number shall be voided and not duplicated on the project.


EPSCC1 Contractor
Job nr. LY010
No punch or steel stamping shall be permitted.

Prior to radiography of the circumferential weld, SICIM shall paint the weld location number on the
covering of the pipe adjacent to the weld at a point where it shall remain visible after field coating.
These numbers shall be used by the surveyors to locate and record the welds and for the
radiographers for identification of the welds.
The numbers shall be applied with a spray can or a brush and water-proof paint of a contrasting
colour to the outside of the pipe. .
7. PRODUCTION WELDING
7.1 SWABBING, PIPE BEVELLING AND CLEANING ENDS OF JOINTS
Immediately prior to aligning pipe for welding, the bevelled ends of each joint of pipe for a minimum
distance of 40 mm shall be thoroughly cleaned of paint, rust, adhesions, dirt and any other foreign
matter by use of power-driven wire buffing wheels, disc sanders, or by other methods previously
approved by Inspector for each case.
Fusion faces shall be visually inspected for laminations after cleaning to a bright finish.
Any bevel showing evidence of laminations shall be cut back, re-bevelled and retested .
SICIM is to re-cut and bevel all damaged pipe ends when deemed necessary to the Inspector.
When the re-cut is located at a distance of more than 25 mm from the original bevel, then the re-cut
end shall be ultrasonically inspected for laminations over a zone extending 100 mm from the new
field bevel. Otherwise, the new bevel shall be subject to MPI, as a minimum.
All required field bevels on line pipe must be made with a bevelling machine. Hand bevelling shall
not be permitted.
All field bevels shall be cut and finished at right angles to the longitudinal axis of the pipe evenly
and without rough surfaces.
Automatic flame bevelling is acceptable for tie-ins, subject to cleaning of the level faces to bright
metal.
7.2 ALIGNMENT OF PIPE

The approved WPS will report the applicable modality for the alignment of pipe and the type of the
related line-up clamp.
7.3 PREHEATING AND INTERPASS TEMPERATURE

In any event, prior to commencement of welding, sufficient heat shall be applied to remove all
traces of moisture. The preheat temperature required by the qualified WPS shall be maintained
throughout the entire welding of the joint.
Preheat shall be applied in a uniform manner using gas burner or electrical means except that
hand held torch heating shall not be permitted other than where external line-up clamps are used.
The method shall be subject to approval by the Inspector.
Temperature shall be measured using contact pyrometer or indicating crayons of the melting type.
Colour changing type shall not be permitted.


EPSCC1 Contractor
Job nr. LY010
The minimum preheat temperature shall be maintained and measured over a distance of at least
50 mm either side of the joint.
The preheat temperature shall be checked at the 6 o'clock position (as a minimum) on each pipe
prior to the start of welding of each run and where an upset in the continuity of welding has
occurred.
The interpass temperature measured immediately before the start of the subsequent weld run shall
not be less than the minimum preheat temperature and shall not exceed the maximum interpass
temperature recorded during procedure qualification.
In no instance shall this exceed 250°C, unless a qualification test has been made.
7.4 POST-WELD HEAT TREATMENT (PWHT)

For the Project no PWHT will be executed.
7.5 PIPE MOVE-UP

Pipe move-up in double jointing station for example, shall not occur until the root and hot pass are
completed.
The use of the "hinged method" (i.e. moving vertically the pipes at joint to close or adjust the root
gap while part the weld filling has been made on a pipe sector) shall be forbidden.
7.6 GOLDEN WELDS

Golden welds (i.e. non-hydrostested welds) shall be minimized.
Any golden weld shall be subject to the following NDT: 100% radiography , 100% UT and 100%
MPI, as applicable.
7.7 INTER-RUN CLEANING/GRINDING OF WELDS

Each weld pass shall be cleaned using power tools to remove all welding slag and foreign matter
prior to welding the successive pass.
7.8 ARC STRIKES

Arc strikes shall not be permitted outside the weld bevel.
Should arc strikes occur outside the weld bevel area they shall be removed by grinding and
inspected by magnetic particle examination to ensure freedom from cracks.
The remaining wall thickness shall be checked ultrasonically.
If the reading is below the specified minimum wall thickness, the defective pipe section shall be cut
off. Repair welding shall not be permitted.


EPSCC1 Contractor
Job nr. LY010
7.9 PROXIMITY OF WELDS

As per GS PLR 421 specification, for welding of Intermediate and severe sour services, adjacent
circumferential welds shall be separated by a minimum of one pipe diameter or 750 mm, whichever
the least.
Branches, fittings and attachments shall be sited away from other welds on the pipeline.
The minimum separation shall be the greater of:
- A diameter of Branch/Fitting
- Six (6) times the wall thickness of thickest component
- 150 mm.
Attachment relating to anodic bonding leads shall be located at least 150 mm from any seam or
circumferential weld.
7.10 WEATHER CONDITIONS

Welding shall not be carried on when the weather conditions are unsatisfactory and likely to impair
the quality of the welds.
SICIM shall provide wind breaks and welder's platforms when conditions, in opinion of Inspector,
warrant their use.
7.11 END PROTECTION

The open end of pipe strings shall be securely closed at the end of each day's or shift's work and
lunch breaks by suitable proprietary designed covers. They shall be placed over the pipe ends to
prevent the entrance of water, trash, small animals or other objects.
These covers shall not be removed until the work is to be resumed.
Where the line is left apart at intervals to be later tied-in, ends shall likewise be fully closed.
Metal covers shall not be tack welded to the pipe.
8. INSPECTION AND TESTING OF PRODUCTION WELDS

8.1 GENERAL
Each joint shall be thoroughly cleaned using power driven wire brushes, and all slag, spatter, etc.,
removed prior to weld examination.
Any bonding media, or any inks or dyes used for crack detection, shall be removed.
All completed circular welds shall be examined 100% visually externally to the pipe prior to being
examined 100% by radiography.
All tie-in welds shall be witnessed and the fit-up and weld quality visually examined in full, by the
Inspector.
Ultrasonic and MPI equipment shall be available on Site to supplement radiography on any
doubtful area nominated by the Inspector.


EPSCC1 Contractor
Job nr. LY010
8.2 HARDNESS TEST (ONSHORE PIPELINES)

As per GS PLR 421 specification, for welding of Intermediate and severe sour services, random
VICKERS hardness HV5 or HV10 tests of circumferential weld caps shall be carried out by SICIM
at the discretion of Inspector.
Each weld selected for hardness test shall be checked at the 4, 8, and 12 o'clock positions.
The hardness transverse shall cover the weld cap, HAZ and pipe material, over a range 10 mm
each side of the HAZ.
9. REPAIR AND REMOVAL OF DEFECTS

9.1 PREPARATION FOR RE-WELDING
Defects shall be removed by grinding.
The cavity shall be finished to a bright and smooth finish. The removed portions shall be sufficiently
deep and long to remove the defect.
At the ends and sides of the cavity, there shall be gradual taper from the bottom of the groove to
the surface of the weld metal.
The width and profile of the cavity shall be such as adequate access for rewelding is met.
Before starting the repair the cavity will be NDT examined (visual and MPI or PT).
In the event that the defect is close to the weld root and the whole thickness of the weld seam is to
be removed, the new gap opening at the weld root shall remain within the qualified root gap
tolerances defined in the WPS.
Weld found with cracks shall be repaired by complete removal of the weld i.e. by cutting out a
section of pipe containing the weld.
9.2 INSPECTION OF WELD REPAIRS

All welds repairs shall be re-inspected using the same inspection technique and requirements as
for the original weld.
If defects have not been removed or new defects have been added as a result of a repair attempt,
a repair shall be permitted, in accordance with the approved repair welding procedure.
9.3 RECORD OF REPAIRS

A full record of all repairs shall be maintained by the CONTRACTOR.
SICIM will maintain records of weld repair and rejection rates throughout the fabrication programme
for both structural and piping systems.
Records shall reflect rejections on the basis of number of weld rejects and on the basis of length of
weld repaired.
Analysis will be conducted on a weekly basis to determine the cause of rejections and to identify
the need of implement corrective actions.


EPSCC1 Contractor
Job nr. LY010
10. DOCUMENTATION
10.1 PIPE AND WELD LOG
SICIM Welding Engineer shall maintain a Welding Log (within a pipe tracking system) and shall
update it as the work progresses.
This document will include, but is not restricted to, the following information:
- Number, origin, steel grade, nominal diameter and nominal thickness of each pipe, flange or
fitting in its order of installation
- Actual length of each pipe laid/welded and cumulative length
- Date each weld or repair was made
- Number of each weld and welder/operator(s) used
- Location of each weld with respect to the pipeline kilometric point or with respect to one end of
the pipeline, as appropriate or agreed with COMPANY
- Location of obstacles, accessories, anodes, potential test points, etc., and their location with
respect to neighbouring welds
- Information pertaining to weld inspections carried out (results, defects found, repairs, etc.)
- Cut off lengths.
This document shall be available to the Inspector at all times for information and review.
10.2 PIPE BOOK

The Pipe Book shall be drawn up onto a computer-readable format as per the Project
Requirements and shall reflect:
- the characteristics of the pipe: thickness, grade, SUPPLIER, number, length, heat number,
- the cumulative length,
- the welds numbers,
- the bent pipes,
- the plan drawing and cross-section,
- the date the welding was executed,
- the identification locators for the welds,
- the radiographed welds,
- and the geographical location of certain welds in relation to natural or artificial permanent
surface location points.
10.3 FINAL DOSSIER

Upon completion of the fabrication and/or installation work, SICIM shall provide COMPANY with a
final dossier including at least the following documents:
- The laying/welding log
- the Welding Procedure Specifications (WPS) for main welds and repair welds


EPSCC1 Contractor
Job nr. LY010
- the Welding Procedure Qualification Test Records (WPQR) for main welds and repair welds
- As per GS PLR 421 specification, for welding of Intermediate and severe sour services, the H2S
embrittlement test procedure and test reports
- The welder and welding operator qualification certificates
- The radiographic and ultrasonic inspection procedure and qualification test reports
- The NDT operator qualification certificates
- The technical data sheets of welding consumables , and the Mill certificates
- The non-destructive inspection reports
- The Inspection and Test Plan.
- As per GS PLR 421 specification, for welding of Intermediate and severe sour services, copy of
the specification GS PLR 421 and related applicable PPS.
The final dossier will be completed and submitted to COMPANY within one month after completion
of site welding.
If not otherwise agreed with COMPANY, 3 originals and 3 copies of the final dossier shall be
provided to the COMPANY.
11. QUALITY CONTROL/QUALITY ASSURANCE

11.1 QUALITY CONTROL
Prior to commencement of any work SICIM shall prepare and submit a Inspection & Test Plan
which describes the systematic control of the construction, inspection and testing, as dictated by
the overall contract quality programme.
The Inspection & Test Plan shall set forth “witness”, “hold”, “review” and “monitor” points.
The SICIM Welding Engineer shall maintain quality records as documentary evidence of
compliance with quality requirements. Quality records shall be available to the Inspector for
analysis and review.
11.2 CONTENTS OF THE QA/QC RECORD BOOK

The Quality Assurance Record Book shall include items :
- Weld procedures and qualifications
- Weld repair procedures
- Welders qualifications
- NDT procedures
- Material/Welding and NDT location drawings
- NDT reports for examination of welds
- NDT operative qualifications
- Visual examination certificates
- Dimensional check reports
- Vendor Certificates of conformity


EPSCC1 Contractor
Job nr. LY010
This list can be changed according to the Final Dossier contents (see related comma of this
procedure).
12. TECHNICAL QUERIES/NON-CONFORMANCE REPORTS

Any SICIM’s requests for clarifications or deviations to COMPANY specifications shall be submitted
to COMPANY through Site Queries (SQ) or Deviation Request (DR) as per approved SICIM
project procedure.
A deviation to specification shall not be considered as accepted if it has not been submitted to and
accepted by COMPANY through a SQ/DR.
Work performance or test result which is found, at a later date or derivated by defect analysis, not
in conformance with COMPANY specifications or agreed procedure shall be subject to a Non-
Conformance Report (NCR) to be issued by SICIM for submission to COMPANY.
NCR report shall indicate corrective action intended by SICIM
NCR will not be originated by single defect. Only recurrent defects will be analyzed and subjected
of NCR or Corrective Action.
13. RESPONSIBILITY
The SICIM Welding Engineer shall be responsible for the implementation of this Procedure for the
Project.
The Site Construction Manager shall be responsible for the compilation and submission to PM for
internal approval, before submission to COMPANY for final approval, of proposed queries and shall
responsible for the collection of copy of documentation relevant the site query/deviation request
and for updating the log.
14. ATTACHMENTS
Blanck forms:
- Welding Procedure Specification (WPS)
- Welding Procedure Qualification Record (WPQR) .......................... (TEC-GRL-WEL-302-10001)
- Welder Qualification Record (WQR) ............................................... (TEC-GRL-WEL-302-10002)
- Welding Parameters Control Record............................................... (TEC-GRL-WEL-302-10003)
- Weld Visual Inspection Record ........................................................ (TEC-GRL-PLR-302-10009)


EPSCC1 Contractor WPS N°:
Job nr. LY010 APPLICABLE PQR:
WELDING PROCEDURE SPECIFICATION FOR
REV DATE DESIGNATION BY CHECK APPR
STATUS CODE : A = Issued for comments - B = Issued for approval - C = Approved – I = Information only
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN

WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER

Doc. Title:
REVISION STATUS
C.P.T.L. Doc. N°:
Doc. Title :
File: Page: 1 / 2
EPSCC1 Contractor WPS N°:
Job nr. LY010 APPLICABLE PQR:
THIS PROCEDURE IS IN ACCORDING WITH SPEC. GS PLR 421 AND API STD 1104
PROCEDURE TO BE USED FOR:
WELDING PROCESS(ES):
BASE MATERIAL:
OUTSIDE DIAMETER RANGE:
WALL THICKNESS RANGE:
PROJECT O.D. AND W.T.:
JOINT DESIGN AND WELDING SEQUENCE
FILLER METAL
AWS AWS TUNGSTEN
BEAD TRADE NAME MANIFACTURER SIZE Ø mm
SPECIFICATION CLASSIFICATION SIZE Ø mm
NUMBER OF BEADS :
WELD POSITION :
DIRECTION OF WELDING :
SHIELDING GAS : FLOW RATE :
PURGING GAS : FLOW RATE :
WELDING PARAMETERS
HEAT INPUT
CURRENT TRAVEL SPEED WIRE SPEED
BEAD POLARITY AMPERE VOLTS ( kJ / mm )
AC or DC ( cm / min ) ( m / min )
Aver. Of PQR
NUMBER OF WELDERS :
TIME LAPSE BETWEEN END OF ROOT BEAD AND START OF HOT BEAD :
TIME LAPSE BETWEEN END OF HOT BEAD AND START OF SUBSEQUENT BEADS :
MINIMUM NUMBER OF BEADS BEFORE JOINT ALLOWED TO COOL :
TYPE OF LINE-UP CLAMP :
REMOVAL OF LINE-UP CLAMP :
PIPE MOVE-UP AFTER :
CLEANING :
PREHEATING MIN. TEMP. :
TYPE OF HEATER TO BE USED :
INTERPASS TEMP. MIN. : MAX. °C POSTHEATING
REMARKS:

Doc. Title :
File: Page: 2 / 2
EPSCC1 Contractor RECORD No.:
WELDING PROCEDURE
Job nr. LY010 QUALIFICATION RECORD
WPQR IN ACCORDANCE TO WPS No.: WELD No.:
WELDING GENERAL DATA WELDER(S)

PROCESS(ES): NAME: STAMP No.
POSITION: NAME: STAMP No.
DIRECTION: NAME: STAMP No.
BASE MATERIALS TEMPERATURE

STEEL TYPE AND GRADE: AMBIENT °C:
O.D.: PREHEAT °C:
W.T.: INTERPASS MAX °C:
FILLER METAL
AWS AWS SIZE BATCH TUNGSTEN
BEAD TRADE NAME MANIFACTURER
SPECIFICATION CLASSIFICATION Ø mm HEAT SIZE Ø mm
GAS
SHIELDING GAS: FLOW RATE:
PURGING GAS: FLOW RATE:
WELDING SEQUENCE JOINT DESIGN
WELDING PARAMETERS
FILLER METALS CURRENT ARC HEAT
TRAVEL WIRE
BEAD AC SPEED SPEED TIME INPUT
SIZE POLARITY VOLTAGE AMPERAGE (sec) (KJ/mm)
AWS OR (cm/min) (m/min)
(Ø mm) (+/-) (V) (A)
DC
EXAMINED BY : CHECKED BY: APPROVED BY:
DATE: DATE: DATE:

TEC-GRL-WEL-302-10002 - Rev. 0 1/2 File: TEC-GRL-WEL-302-10001_Rev0_Welding_Procedure_Qualification_Record_Rev0.doc
WELDING PROCEDURE
Job nr. LY010 QUALIFICATION RECORD
NON DESTRUCTIVE TEST

APPLICABLE SPECIFICATION :
RECORD
VISUAL EXAMINATION: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
No.
DATE
RECORD
MAGNETIC PARTICLE TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
No.
DATE
RECORD
LIQUID PENETRANT TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
No.
DATE
RECORD
RADIOGRAPHIC TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
No.
DATE
RECORD
ULTRASONIC TEST : ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
No.
DATE
REMARKS:
DESTRUCTIVE TEST
APPLICABLE SPECIFICATION :
BEND TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
LABORATORY NAME: RECORD No. DATE
NICK BREAK TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
TENSILE TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
IMPACT TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
HARDNESS TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

MACRO EXAMINATION: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

MICRO EXAMINATION: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

CTOD TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

CHEMICAL ANALYSIS TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

CORROSION TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

ADDITIONAL(S) TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

REMARKS:
THE STATEMENTS IN THIS RECORD ARE CORRECT.

THE TEST JOINTS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF THE SPECIFICATION.
QUALIFIED THE
THIS WELDING PROCEDURE QUALIFICATION RECORD NOT QUALIFIED THE WPS
WPS
DATE: DATE: DATE:

TEC-GRL-WEL-302-10002 - Rev. 0 2/2 File: TEC-GRL-WEL-302-10001_Rev0_Welding_Procedure_Qualification_Record_Rev0.doc
WELDER QUALIFICATION RECORD
Job nr. LY010
WELDING TEST IN ACCORDING TO WPS No.: JOINT TYPE:
WPS APPLICABLE TO: WELD No.
WELDER
STAMP No.: FOTO
SURMAME AND NAME:

DATE OF BIRTH:
PLACE OF BIRTH:
WELDING GENERAL DATA BASE MATERIALS

PROCESS(ES): STEEL TYPE AND GRADE:
POSITION: O.D.:
DIRECTION: W.T.:
WELDING SEQUENCE JOINT DESIGN
NON DESTRUCTIVE TEST

APPLICABLE SPECIFICATION(S):
VISUAL EXAMINATION: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED RECORD No. DATE
MAGNETIC PARTICLE TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED RECORD No. DATE
LIQUID PENETRANT TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED RECORD No. DATE
RADIOGRAPHIC TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED RECORD No. DATE
ULTRASONIC TEST : ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED RECORD No. DATE
REMARKS:
DESTRUCTIVE TEST
APPLICABLE SPECIFICATION(S):
ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED
ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

REMARKS:
THE STATEMENTS IN THIS RECORD ARE CORRECT.

THE TEST JOINTS WERE PREPARED, WELDED AND TESTED IN ACCORDANCE WITH THE REQUIREMENTS OF THE SPECIFICATION.
WELDER QUALIFICATION TEST RESULTS IS: ACCEPTABLE NOT ACCEPTABLE
STEEL TYPE RANGE QUALIFIED:
DIAMETER RANGE QUALIFIED:
THICKNESS RANGE QUALIFIED:

DATE: DATE: DATE:

C.P.T.L. EPSCC1 Contract N° : GMD/84/2002/MA
TEC-GRL-WEL-302-10002 - Rev. 0 File: TEC-GRL-WEL-302-10002_Rev0_Welder_Qualification_Record_Rev0.doc
WELDING PARAMETERS
Job nr. LY010 CONTROL RECORD
APPLICABLE WPS : WELD No. :
WELDING PROCESS (ES) USED : WELDING POSITION :
JOINT TYPE : WELDING DIRECTION :
WELDER/S :
PIPE
BASE METAL BASE METAL
1
FORGING 2
PLATE
STEEL TYPE AND GRADE
OUTSIDE DIAMETER (mm)
THICKNESS (mm)
SERIAL No.
RUN No. :
RUN TYPE :
PREHEATING/INTERPASS TEMPERATURE :
WELDING DETAILS
(°C)
ELECTRICAL CHARACTERISTICS :
(AC/DC)
ELECTROD POLARITY :
(+ / -)
AVERAGE AMPERAGE :
(A)
AVERANGE VOLTAGE :
(V)
WELDING TRAVEL SPEED :
(mm/min)
HEAT IMPUT (IF REQUIRED) :
(kJ/mm)
AWS SPECIFICATION AND CLASSIFICATION :
MANIFACTURER :
FILLER METALS
TRADE NAME :
SIZE :
(Ø mm)
COATING TYPE :
STRUMENTS USED FOR CONTROLS :
REMARK(S):
THE WELD IS IN ACCORDING TO WPS YES NO
DATE: DATE: DATE:

C.P.T.L.
TEC-GRL-WEL-302-10003 - Rev. 0 File: TEC-GRL-WEL-302-10003_Rev0_Welding_Parameters_Control_Record_Rev0.doc
RECORD No.:
EPSCC1 Contractor
WELD VISUAL
Job nr. LY010 INSPECTION RECORD
GENERAL DATA
SECTION: BASE MATERIAL:
LINE: DIMENSIONS:
INSPECTION DATA
PIPE No.
TO PIPE No. OR EXTERNAL SURFACE
WELD WPS USED WELDER UNDERCUT SPATTER ARC STRIKES REPAIR EVALUATION
FITTING No. PROFILE POROSITY
No. No. STAMP No. (1) (1) (1) (YES/NO) (2)
(1) (1)
REMARK(S)
ABREVIATIONS: (1) PASS = ACCEPTABILE NOT PASS = NOT ACCEPTABLE (2) A= ACCEPTABILE NA = NOT ACCEPTABLE
IMPERFECTIONS MPERFECTIONS RESULTS RESULTS
DATE: DATE: DATE:

TEC-GRL-PLR-302-10009 - Rev. 0 File: TEC-GRL-PLR-302-10009_Rev0_Weld_Visual_Inspection_Record.doc

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EPSCC1 Contractor

Job nr. LY010

GREAT MABRUK DEVELOPMENT PROJECT

REV DATE DESIGNATION BY CHECK APPR

TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : WELDING

Doc. Title : TEC-GRL-WEL-301-10001- Rev. 3

Job nr. LY010

COVER PAGE ..........................................................................................................................1

1. SCOPE AND FIELD OF APPLICATION.............................................................................4

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

7.10 WEATHER CONDITIONS......................................................................................12

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

1. SCOPE AND FIELD OF APPLICATION

2.2 CONTRACT DOCUMENTS

GS PLR 403 Installation of onshore pipelines

3. ABBREVIATIONS AND DEFINITIONS

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

- Project Particular Specification ................................................................................ (PPS)

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

all other offices, premises and workshops of CONTRACTOR, SUBCONTRACTORS (including

4. ELECTRODES AND FILLER WIRES

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

5.2 WELDING PROCEDURE SPECIFICATIONS (WPS)

5.3 WELDING PROCEDURE QUALIFICATION

5.3.2 Testing of welded joints - Butt welds

5.3.3 Records (WPS and WPQR)

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

5.4 REPAIR PROCEDURES

5.5 QUALIFICATION OF REPAIR PROCEDURES

5.5.1 Identification of WPS and WPQR

WPQR will be identified, according to the Document Identification Procedure (MGT-GRL-PMT-001-

5.6 WELDER QUALIFICATION

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

SICIM shall use only skilled workmen for welding.

5.7 WELDER IDENTIFICATION

5.7.1 Schedule of Welders:

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

No punch or steel stamping shall be permitted.

7.2 ALIGNMENT OF PIPE

7.3 PREHEATING AND INTERPASS TEMPERATURE

COMPAGNIE DES PETROLES TOTAL LIBYE

Doc. Title : TEC-GRL-WEL-301-1001- Rev. 3

Job nr. LY010

7.4 POST-WELD HEAT TREATMENT (PWHT)

7.5 PIPE MOVE-UP

BEND TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

NICK BREAK TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

TENSILE TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

IMPACT TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED

HARDNESS TEST: ACCEPTABLE NOT ACCEPTABLE NOT REQUIRED