Quality/Welding inspection during Offshore Pipeline and Platform Installation

By Rahman Suwandhi

Personal Data

Name: Rahman SuwandhiGraduated: Technical of Metallurgy 1997Residence: BatamOffice: EMAS AMC Pte Ltd – SingaporePosition: Quality/Welding EngineerMain Business: offshore EPCI oil & gas companyContact No: +62 8127041931/+65 94524360Email: r.suwandhi@emas.com or suwandhi.rahman@gmail.com

Basic Requirements

Qualification and certification required to support on the job scope of work are:• Welding i.e. CSWIP 3.1, CWI-AWS• NDT Level II i.e. ASNT, PCN• Painting/Coating i.e. BGAS, NACE

Production flow chart

Material Receiving

Cutting & Fit up weld Joint

Welding process

Visual & NDT inspection

Painting/Coating Inspection

Welding inspector role:To ensure quality of material and welding meet to the requirementNDT inspector:To check weld joint using different methods i.e. RT, UT, MT/PT complied to the acceptance criteriaPainting/Coating Inspector:To control & monitor of quality coating meet to the requirement

Quality Documents:- ITP (Inspection Testing Plan)- PQP (Project Quality Plan)- TQ (Technical Query)- NCR (Non Conformance Record) - Procedures: Welding, NDT, Painting, PWHT, Hydrotest- Qualified personnel: QC Inspector, Welder, NDT, Painting Inspector- Certificates & Reports: material cert, equipments & tools cert, material & welding traceability record, NDT report, painting report, PWHT & Hydrotestreport - MDR (Manufacturing Data Record)

Code/Standard/SpecificationMust understand on the following:• Variety of code i.e. material, general

requirements, testing procedure• Product application: structure, pressure vessel,

pipeline, piping process, storage tank etc.• International published i.e. AS, ASTM, API, AWS,

ASME, BS, DIN, EN, EEMUA, ISO, JIS, KS, SNI• Client’s Specification: Total, Shell, Chevron, Exxon,

ENI• Third party/class requirements i.e. ABS, LR, GL,

BV, BKI, DNV

Material InspectionTo check the following:

• Surface condition check i.e. mill scale, material damage, rusty, coating protection

• Dimension check i.e. length, width, thickness, diameter

• Purchase/Delivery Order, hard stamp

• Material certificates check

Mill Certificates

Welding Procedure & welder qualification test

PWPS

Prepare test coupon & Record parameters

NDT

DT

WPS

Result

Acc

RejectPQR

Propose Welder

Prepare test coupon

NDT

DT

Result

Welder Certificate

Acc

Reject

Welding InspectionTo check the following:

• Before welding: approved procedures in place, material, consumables & equipments/tools certificate available, joint prep & preheat within tolerance

• During welding: control parameters i.e. HI, interpasstemp, PWHT

• After welding: visual check

Welding InspectionVariables to be control & monitor during

production weld:

• Material group i.e. specification, thickness, diameter

• Joint design, edge preparation

• Welding position & progression

• Welding parameters: voltage, current, travel speed, Heat Input

• Preheat & interpass temperature

• Post weld heat treatment

WPS (Welding Procedure Specification)

Visual InspectionTo check the following:• Weld bead, toe blend,

weld consistency, arc strike, spatter, grinding mark, mechanical damage, surface colour, misalignment, angular distortion, longitudinal distortion

• Refer to the acceptance criteria as per code/standard i.e. AWS D1.1, API 1104, ASME IX, DNV OS F101 etc.

NDT Inspection

• NDT methods: RT, UT, MT/PT

• Basic testing

• Procedure Qualification Test

• Approval NDT procedure

• Acceptance criteria

Painting/Coating Inspection

• Type: Paints, HSS, 3LPP, Concrete

• Procedure qualification test

• Painting inspection i.e. DFT, pull test, salt test

• Acceptance criteria

Qaulity/Welding Inspection during offshore pipeline & platform installation

Any question?