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Standard Operating Procedure

 DOCUMENT NO. :
Welder/Welding Operator Performance W-QC-A-004
Qualification Procedure ISSUED DATE :
26/11/07

UNIT ISSUING : ACCEPTED BY : PAGE REVISION

Quality Control QC Manager 2 of 15 1

ORIGINATOR ACCEPTED BY REVIEWED BY DISTRIBUTION

Master : CDCC

Copy : ENG

Copy : MC
Irsyafriandi Yanferizal
Welding Engineer QC. Manager Authorized Inspector Copy : PDCC
ISSUED EFFECTIVE
REV. NO BRIEF OF REVISION
DATE DATE Copy : PM
Change of Company Name from PT.
1 26/11/07 26/11/07 Truba Jaya Engineering to PT. Truba Copy : PROD
Jaya Engineering

Copy : PROC

Copy : QC

Copy : SM
W-QC-A-001.E4
TABLE OF CONTENT

No. Descriptions Page

COVER PAGE 1 of 14

TABLE OF CONTENT 2 of 14

1 TITLE 3 of 14

2 SCOPE 3 of 14

3 OBJECTIVES 3 of 14

4 REFERENCES 3 of 14

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Welder/Welding Operator Performance W-QC-A-004
Qualification Procedure ISSUED DATE :
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5 GENERAL 3 of 14
6 DESCRIPTION OF PROCEDURE 4 of 14
6.1. Welder Qualification and Validation 4 of 14
6.1.1. New Welder Qualification Testing 4 of 14
6.1.2. System for Employing Contracted Welder 6 of 14
6.1.3. Pre-qualified Welders 7 of 14
6.1.4. Welder Qualification Revalidation System 7 of 14
7 LIST OF EXHIBIT 8 of 14
7.1. EXHIBIT 1 : Schedule Of Test 9 of 14
7.2. EXHIBIT 2-1 : Welder Qualification Certificates 10 of 14

7.3. EXHIBIT 2-2 : Welding Operator Qualification Certificate 11 of 14

7.4. EXHIBIT 3–1 : Approved Welder/Welding Operator Master 12 of 14

Register/Log
7.5. EXHIBIT 3-2: Monthly Welder/Welding Operator Continuity 13 of 14
Log 14 of 14
7.6. EXHIBIT 3-3: Project Welder/Welding Operator Register/Log

1.0. TITLE

Welder/Welding Operator Performance Qualification Procedure

2.0. SCOPE

This procedure covers the qualification of Welders and Welding Operators

to be assigned in the construction of Boiler and Boiler External Piping in
accordance with the requirement of the ASME Code. It shall be apply
both for permanent employees of the company and as well the
subcontracted welders.

3.0. OBJECTIVES

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Welder/Welding Operator Performance W-QC-A-004
Qualification Procedure ISSUED DATE :
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3.1. The purpose of this procedure is to define the activities required to ensure
that welder’s qualifications conform to the specified requirements.

3.2. This procedure applies to all personnel carrying out welds on Boiler and
Boiler External Piping assembled by the company. The procedure may be
varied however, concurrence of the AI, shall be sought for his
acceptance.

3.3. This procedure forms part of the company Quality Control Manual.

4.0. REFERENCES

4.1. QC Manual, Doc. No. M-A-001

4.2. Referencing Code of Construction
4.3. ASME Code Section IX, applicable year Edition and Addenda

5.0. GENERAL

5.1. The company will employ only, qualified welders.

5.2. The following background Codes shall be applicable to welder

qualification:

5.2.1. ASME Section IX Applicable year Edition and Addenda

Should the Customer’s Specification found more stringent; then it shall be

applied in addition to Code requirements.

5.3. The Company’s policy is to qualify the Boiler, Boiler External Piping or
Code’s welders in accordance with ASME Section IX applicable year
Edition and Addenda.

5.4. Welder qualification test coupons and specimens are subject to visual,
NDT and/or mechanical testing as applicable.

5.5. If the period between the evidence of continuous performance exceeds 6

months for each process qualified, the welder qualification will be deemed
to have lapsed, or if the AI has specific reason to question the ability of
the welder, then welder shall be re-qualified.

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Welder/Welding Operator Performance W-QC-A-004
Qualification Procedure ISSUED DATE :
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5.6. The inputs as result of performance in the welder career log sheet
revalidate the relevant welder qualification, subject to AI reviews and
acceptance.

6.0. DESCRIPTION OF PROCEDURE

6.1. Welder Qualification and Revalidation

6.1.1. New Welder Qualification Testing

6.1.1.1. Welder qualification is initiated with a Schedule of Test forms (Exhibit 1).
The Welding Engineer shall complete this form. The completed form is
to be delivered to the Shop Supervisor & QC. Inspector before the test is
to be run. The information on the form will include but not be limited to
the following:

a. Test Date
b. Test Time
c. Location of Test
d. Originator
e. Job, if applicable
f. Welder’s Name
g. Welder’s Stamp Number
h. Welding Process
i. Welding Position
j. Welding Procedure Number
k. Material Specification
l. Test Piece Dimensions
m. Details of Backing Material
n. Coupon Number
6.1.1.2. The Schedule of test will then be sent to the QC. Engineer who will
circulate the Test Notice to the following, sufficiently in advance to the
test is due to start.
a. Authorized Inspector
b. Customer (if applicable)

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c. Originator
6.1.1.3. The welder will then be tested under the joint control of the Shop
Supervisor, QC. Inspector and Welding Engineer. The AI will attend or
witness the test when he considers necessary to do so.

6.1.1.4. Upon completion, the QC Inspector shall examine the test coupon
visually.

6.1.1.5. The welder’s test coupons may be qualified by alternative means i.e. RT,
subject to AI approvals.

6.1.1.6. QC Inspector requests non-destructive testing conducted by NDT Level II

of all test coupons that meet the visual acceptance criteria.

6.1.1.7. The NDT Practitioner shall ensure that the test coupon is tested as per
the instruction on the NDT Request and sign acceptance on the Schedule
of test. The NDT report will be sent to the Quality Department.

6.1.1.8. If required by the specification, the test coupon that has satisfied the NDE
requirements together with the Schedule of Test will be returned to
Welding Engineer for mechanical test specimen preparation, then
paragraph 6.1.1.9. through 6.1.1.10 shall applied.

6.1.1.9. The Welding Engineer will prepare a request for mechanical testing
accompany with the test coupon to the mechanical testing laboratory for
testing purposes.

6.1.1.10. The Laboratory shall ensure that the test specimen would be destructively
tested in the present of the QC. Inspector and, if necessary Authorized
Inspector upon request.

6.1.1.11. Those welders, whose test coupon when considered by Welding Engineer
or QC. Inspector fails to satisfy the requirements for visual examination
and non-destructive testing or mechanical testing, shall be subjected to
re-test in accordance with the requirements of the original Schedule of
Test.
6.1.1.12. The Welding Engineer shall be responsible for the preparation of the
welder qualification documentation which shall include:
a. Welders name, stamp no, as well as the process and positions for
which he is being qualified.
b. And original welder’s qualification certificate (see Exhibit 2 for typical
example).

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Qualification Procedure ISSUED DATE :
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c. The original Schedule of Test.

d. A copy of each non-destructive test report.
e. A copy of each mechanical test report, if applicable.
6.1.1.13. The Welding Engineer shall sign and stamp the certificate, and submitted
to the following personnel:
a. The Authorized Inspector, for review purposes only.
b. The Customer, upon request.
6.1.1.14. The Welding Engineer shall file the copy documentation for the welder
qualification.
6.1.1.15. The Welding Engineer shall compile the Approved Welder/Welding
Operator Master Register/Log (Exhibit 3-1) and Project Welder/Welding
Operator Register/Log (Exhibit 3-3) for each process by showing
materials, positions, thickness and diameter ranges qualified.
a. This register shall be updated monthly.
b. This register shall be issued to the Production and Quality
Department.
c. It will be available for review by the Customer and Authorized
Inspector.
d. The Welding Engineer will be responsible for updating the master log.
e. The Welding Engineer shall be responsible for producing a list of
welders whose qualifications are about to be expired.
6.1.1.16. The Welding Engineer shall compile the Monthly Welder/Welding
Operator Continuity Log (Exhibit 3-2) for each process.

6.1.2. System for Employing Contracted Welders

6.1.2.1. The Production Department shall notify the Welding Engineer at least 7
days prior to the welder commencing the work.

6.1.2.2. The Production Department shall then introduce a list of proposed Project
labor involved. Copies of the proposed list and forms will be distributed to
Welding Engineer would give recommendation to the Production
Department within 48 hours. The contracted welders for Code
construction shall be qualified by Welding Engineer prior to his work.

6.1.2.3. The employers of contract welders shall then be notified in due course of
acceptable welders.

6.1.2.4. Original Welder Qualification Certificates are to be submitted by the

Welding Engineer in sufficient time in-advance to the AI prior to
commence of work to enable the AI for necessary acceptance.

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Qualification Procedure ISSUED DATE :
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6.1.2.5. Welding Control for contracted welder shall be in accordance with Quality
Control Manual para. 6.6.2.

6.1.3. Pre Qualified Welders

Welders Certificates together with following documents shall be made
available for review to AI:
- Test data
- Material Certificate
- Result of Visual, NDT & Mechanical Testing
- PWHT Reports, if applicable
If AI has satisfied himself that welder meets all requirements, he may
endorse the welder’s certificate valid for period of 6 months subject to
monthly entry of his activities in Monthly Welder/Welding Operator
Continuity Log.

6.1.4. Welder Qualification Revalidation System

6.1.4.1. Welding Engineer shall record on monthly basis the last date of
production welding per welder per process in “Monthly Welder/Welding
Operator Register/Log“. The register shall be made available for review
by AI upon request.

6.1.4.2. The Welding Engineer or his designee shall review on 6 monthly basis the
validity of the welders certificate for each process he is qualified. The
certificate shall be endorsed by QC Engineer and AI.

6.1.4.3. If a welder qualification requires revalidating, but is not currently using

the qualified process, the following alternatives are available:

a. The welder shall carry out a Production weld using that process. The
Quality Control Department will inform the production department of
welder identification.

b. The welder shall be subjected to standard welder qualification test for

the process in accordance with the requirements of the relevant WPS.

c. Should the alternatives in (a) and (b) above is selected, the welder’s
qualification shall be considered to have been expired, and he cannot
be involved on any production weld until he has been re-qualified.

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Welder/Welding Operator Performance W-QC-A-004
Qualification Procedure ISSUED DATE :
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d. At no time, a welder whose qualification has expired be involved on a

production weld, it is the sole responsibility of the Production
Department concerned to provide the necessary data to Welding
Engineer to enable the welder to be re-certified. Fail to do so will
result in the rejection of welds made by the affected by QC. Engineer
and/or the AI.

7.0. LIST OF EXHIBIT

7.1. EXHIBIT 1 : SCHEDULE OF TEST

7.2. EXHIBIT 2-1 : WELDER QUALIFICATION CERTIFICATES

7.3. EXHIBIT 2-2 : WELDING OPERATOR QUALIFICATION

CERTIFICATE

7.4. EXHIBIT 3–1 : APPROVED WELDER/WELDING

OPERATOR MASTER REGISTER/LOG

7.5. EXHIBIT 3-2 : MONTHLY WELDER/WELDING OPERATOR

CONTINUITY LOG

7.6. EXHIBIT 3-3 : PROJECT WELDER/WELDING OPERATOR

REGISTER/LOG

EXHIBIT 1: SCHEDULE OF TEST

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EXHIBIT 2-1: WELDER QUALIFICATION CERTIFICATE

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EXHIBIT 2-2: WELDING OPERATOR QUALIFICATION CERTIFICATE

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EXHIBIT 3-1: APPROVED WELDER/WELDING OPERATOR MASTER REGISTER/LOG

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EXHIBIT 3-2: MONTHLY WELDER/WELDING OPERATOR CONTINUITY LOG

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EXHIBIT 3-3: PROJECT WELDER/WELDING OPERATOR REGISTER/LOG

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