DP-W-5 General Welding Requirements

SPEC : DP-W-5 REV : 04 DATE : 03/08 BY : FE APP : RD TITLE : GENERAL WELDING REQUIREMENTS

E&E\SPEC\W5 PAGE 1 OF 7

DUBAI PETROLEUM STANDARD SPECIFICATION GENERAL WELDING REQUIREMENTS REV DATE BY REMARKS 04 03/08 Fac Engr Dropped the C on DPC only 03 08/06 BM Periodic Review- No change in the Specification 02 09/92 NCF Minor Revision to Section 6.0 and Added Section 7.0 Temporary Welds 01 08/90 RCR General Revision 0 10/88 NCF Original Issue.



TABLE OF CONTENTS ITEM: 1.0 SCOPE

2.0 CONTRACTOR'S OBLIGATIONS

3.0 WELD PROCEDURE SPECIFICATIONS & PROCEDURE QUALIFICATION

RECORDS

4.0 REPORTS AND RECORDS

5.0 INSPECTION AND EXAMINATION

6.0 WELD REPAIRS

7.0 TEMPORARY WELDS



1.0 SCOPE 1.1 This specification defines minimum requirements associated with welding, testing,

and non-destructive examination of work performed for Dubai Petroleum at onshore and offshore locations.

1.2 All welding shall conform to the requirements stated herein, applicable COMPANY

welding specification and any design or fabrication code requirements, as further defined in relevant DP welding specification and/or Bid Document.

1.3 This specification is intended to complement and be used in conjunction with

specifications DP W1, W2, W3 and W4 as appropriate. 2.0 CONTRACTOR'S OBLIGATIONS 2.1 When required by company NDE reports shall be submitted by CONTRACTOR for

COMPANY review and approval by 0900 hrs and 1400 hrs that day. 2.2 All indications, including those believed to be non-relevant shall be reported to

COMPANY by CONTRACTOR. 2.3 The CONTRACTOR, when requested by COMPANY, shall remove and identify

welds for laboratory examination together with twelve inches of parent metal on each side of the weld and ship in accordance to COMPANY instructions. No alteration to the cover or root beads shall be permitted.

2.4 The CONTRACTOR shall prepare any material or fabricated item, when requested

by COMPANY for special evaluation, analysis or testing in accordance with COMPANY instructions.

2.5 The CONTRACTOR shall submit as part of CONTRACTOR's bid proposal for

COMPANY's review and approval: a. Only those proposed welder and welding procedure qualifications which are

in compliance with the referenced DP welding specifications and are pertinent to the project work scope being done.

b. Proposed quality control procedures pertinent to the work being performed.



2.6 All welding shall be done only by welders or welding operators who have been fully qualified in accordance with the applicable DP specification and design or fabrication code requirements.

2.7 CONTRACTOR shall ensure that all welding activities are supervised by an

adequate number of qualified supervisors as required to produce the quality of work mandated in COMPANY specifications. If the level of supervision is deemed inadequate, COMPANY shall so notify the CONTRACTOR in writing and CONTRACTOR shall be required to immediately rectify the situation at no additional cost to the COMPANY.

3.0 WELD PROCEDURE SPECIFICATIONS & PROCEDURE QUALIFICATION RECORDS 3.1 Weld Procedure Specifications (WPS) and Procedure Qualification Records (PQR)

shall be qualified in accordance with the latest revision of the applicable DP welding specification(s). AWS pre-qualified welding procedures are not acceptable.

3.2 DP previously qualified WPS and PQR's will be accepted provided they have been

qualified under the current DP welding specification(s). The only exception to this is pipeline and pipeline riser welding which shall be qualified on each and every project. Previously qualified DP or other pre-qualified welding procedures will not be acceptable for pipelines or pipeline riser welding qualification.

3.3 All welders and welding operators shall be qualified by testing prior to any

production welding unless the welder or welding operator qualifications are: current, meets the requirements of the applicable COMPANY welding specification and have previously been approved by DP.

3.4 A COMPANY inspector shall witness all welder and/or welding operator testing. 3.5 All costs associated with WPS, PQR, or welder qualification shall be the sole cost

of the CONTRACTOR and shall be included in the lump sum price. No additional cost for welding/welder qualification will be paid by the COMPANY.

3.6 Any weld procedure which, for whatever reason, produces welds with a frequency

of defects greater than 1O percent, on a per weld basis for COMPANY UT and RT examined welds shall, at the discretion of the COMPANY, be withdrawn from production and re-qualified. No welding shall take place under this procedure until re-qualification is complete. All costs associated with re-qualification shall be borne by the CONTRACTOR.



4.0 REPORTS AND RECORDS The CONTRACTOR shall ensure that the following items are sent to COMPANY. 4.1 Pre-fabrication Mill test reports on material, CONTRACTOR's quality control and related

procedures, welding procedures to be used, COMPANY approved welders or operators to be used, NDE procedures, stress relieving procedure and hydrostatic/pneumatic test procedures shall all be submitted prior to the start of fabrication.

4.2 Post-fabrication NDE reports and drawings, stress relieving records, records of hydrostatic/

pneumatic tests, etc. shall be bound and submitted to COMPANY as a complete quality assurance job data book.

4.3 Storage The CONTRACTOR shall store one set of the above reports and records with

radiographs and log sheets for three years. Final disposal shall be only after a formal written request to COMPANY and written COMPANY approval.

5.0 INSPECTION AND EXAMINATION 5.1 All examination of the work shall be in accordance with applicable COMPANY

welding specification(s) and fabrication code(s). 5.2 COMPANY reserves the right to inspect the material, fabrication or workmanship

relating to COMPANY specifications and shall have free entry at all times to any site that concerns the work. CONTRACTOR shall arrange for and provide all required NDT services and personnel per applicable code and COMPANY specifications for all welding. The CONTRACTOR shall provide by means of scaffolding, ladder, platforms, walkways, lighting, etc., safe access for thorough and complete inspections. The COMPANY representative will be sole authority for interpretation of what constitutes safe access, all NDT reports, acceptable radiographs, substitution of ultrasonic examination for radiography, etc. and will be the sole authority as to the acceptability of a weldment. All work not in conformance with the specification and/or drawings will be rejected as



unacceptable. Necessary repairs shall be made by the CONTRACTOR with no additional cost to COMPANY and the corrected items approved by COMPANY before acceptance.

5.3 COMPANY may, at its sole discretion, inspect any or all of the field weldment

sections (piping, structural components, etc.) by the use of either radiographic or ultrasonic techniques, or destructive mechanical testing, as may be applicable.

5.4 All efforts will be made by both parties to ensure that inspection procedures result

in minimum lost time to CONTRACTOR; but should such lost time be incurred, all equipment and labor downtime costs associated with CONTRACTOR's work force shall be borne by CONTRACTOR.

5.5 NDE shall be carried out no later than 72 hours after completion of the weldment.

CONTRACTOR shall ensure that the requisite number of NDE personnel are provided to comply with this requirement. After completion, all NDE reports shall be furnished to the COMPANY within 2 working days. These reports shall detail a complete history of the fabrication and inspection sequences. The reports will form the basis of final inspection and acceptance by the COMPANY.

5.6 Should CONTRACTOR fail to complete NDE within the time period in Paragraph

5.5 above, COMPANY reserves the right to subcontract third party NDE inspectors to perform the required work and back charge CONTRACTOR at invoiced cost plus 15 percent. This action by the COMPANY shall not release the CONTRACTOR from any part of his contractual responsibilities to perform the work.

5.7 The COMPANY reserves the right to increase the level of inspection and NDE

specified in COMPANY welding specifications if, in the opinion of the COMPANY, the CONTRACTOR'S quality performance record is unsatisfactory. Should it become necessary for the COMPANY to augment its own inspection work force to cope with an increased level of inspection, the CONTRACTOR shall be required to reimburse the COMPANY for the documented cost of additional COMPANY inspection personnel.

5.8 The inspection and NDE requirements may be subsequently reduced at the

COMPANY'S discretion on reversion to an acceptable quality performance record.



6.0 WELD REPAIRS 6.1 CONTRACTOR welds which do not meet COMPANY welding specifications or the

referenced codes and standards shall be rejected and repaired. The CONTRACTOR shall remove or excavate the areas by arc gouging or grinding, using COMPANY approved procedures. All re-welding shall be to COMPANY approved welding procedures. The CONTRACTOR shall be responsible for all costs, labor and material, to rectify defective welding.

6.2 Only two repairs shall be attempted in the same weld area, if the second repair is

not accepted the weld shall be removed. 6.3 Should it be necessary for the Company to augment its inspection work force due

to the volume of Contractor's remedial work, then the Contractor shall be required to reimburse the Company for the documented cost of additional Company inspection personnel.

7.0 TEMPORARY WELDS Temporary attachment welds shall be kept to a minimum. All welds shall be made using

Company approved welders and welding procedures. Temporary attachments shall be removed by cutting 1/8" above surface, and grinding flush with a surface. Removal by hammering or air-arc gouging shall not be allowed.

Documents

DP-W-5 General Welding Requirements