Welding Welding Procedure Qualification PDF

SOUTH AUSTRALIAN WATER CORPORATION
TS 30a
TECHNICAL STANDARD
WELDING SPECIFICATION
WELDING & WELDING PROCEDURE

QUALIFICATION
Issued by: Manager Engineering
Issue Date: 04 May 2009

© SA WATER 2007
This is an intellectual property of the South Australian Water Corporation. This
document is copyright and all rights are reserved by SA Water. No part may be
reproduced, copied or transmitted in any form or by any means without the
express written permission of SA Water.
The information contained in these Standards is strictly for the private use of the
intended recipient in relation to works or projects of SA Water.
These Standards have been prepared for SA Water’s own internal use and SA
Water makes no representation as to the quality, accuracy or suitability of the
information for any other purpose.
It is the responsibility of the users of these Standards to ensure that the
application of information is appropriate and that any designs based on these
Standards are fit for SA Water’s purposes and comply with all relevant Australian
Standards, Acts and regulations. Users of these Standards accept sole
responsibility for interpretation and use of the information contained in these
Standards.
SA Water and its officers accept no liability for any loss or damage caused by
reliance on these Standards whether caused by error, omission, misdirection,
misstatement, misinterpretation or negligence of SA Water.
Users should independently verify the accuracy, fitness for purpose and
application of information contained in these Standards.
The currency of these Standards should be checked prior to use.
APPROVAL TO DEVIATE FROM THIS STANDARD

Approval may be granted by the Asset Owner to deviate from the requirements
as stipulated in this Standard if the functional requirements (e.g. Asset Life) for
the asset differs from those stated in the Standard, but is assessed as still being
acceptable by the Asset Owner’s nominated representative.
Any approval to deviate from the stated requirements of this Standard will not be
seen as creating a precedent for future like project. Any request to deviate from
this Standard must be carried out on a project by project basis where each
alternate proposal will be individually assessed on its own merit.
CHANGE RECORD
The following lists the major changes to the December 2004 edition and
published in the June 2005 edition of TS 30a:
1. Reformatted from DS to TS (Departmental Standard to Technical

Standard), and updated referenced Australian Standards.
2. Conversion to a Technical Standard and complete review of DS 30’s
content resulted in the development of a new document TS 30a which
supersedes DS 30.
TS30a - Welding Specification_3.docx 04 May 2009 Page

PLANNING & INFRASTRUCTURE
Issued by: Manager Engineering Uncontrolled on printing 2 of 38
3. Reviewed by the WTIA and adopted by the Water Industry across
Australia with some minor wording changes and the removal of the
WELDING SAFETY RULES from the appendicis.
4. Welding OHS is now referred to in SECTION 3 part d).
5. The SAMPLE FORMS in Appendix B have been reviewed and updated to
show a more accurate example of the welding documentation required in
the Technical Standard.
The following lists the changes made to the July 2007 edition of TS 30a
1. Cross reference to TG 61 - Practical Understanding and Interpretation of
Technical Standard TS 30a Welding Specification, in the Scope and
referenced document sections.
2. Inclusion of a note in the scope to highlight the designer’s responsibility.
The following lists changes made in May 2009

1. Item (o) added to Section 6.3.
2. Section 9.3 added.
These changes include the requirements for pickling and passivating stainless
steel welds.

CONTENTS
© SA WATER 2007............................................................................................................... 2
APPROVAL TO DEVIATE FROM THIS STANDARD ........................................................... 2
CONTENTS .......................................................................................................................... 4
TABLES & FIGURES............................................................................................................ 4
REFERENCED DOCUMENTS .............................................................................................. 5
SECTION 1: SCOPE ............................................................................................................. 6
SECTION 2: DEFINITIONS ................................................................................................... 6
SECTION 3: STANDARDS/CODES ..................................................................................... 7
SECTION 4: APPROVAL TO COMMENCE WORK.............................................................. 8
SECTION 5: QUALITY ASSURANCE .................................................................................. 8
SECTION 6: WELDING PROCEDURES............................................................................... 9
6.1 SA Water Welding Procedures ................................................................................ 9
6.2 Qualification of Welding Procedure Specifications................................................ 9
6.3 Welding Procedure INFORMATION ........................................................................12
SECTION 7: WELDING PERSONNEL ................................................................................13
7.1 Welding Supervisor; (Welding Coordinator) ..........................................................13
7.1.1 Welding Supervisors Authority ........................................................................13
7.1.2 Welding Supervisors Responsibility .................................................................13
7.1.3 Welding Supervisors Qualifications .................................................................15
7.2 Welding Inspector (Welding Coordinator) .............................................................15
7.2.1 Welding Inspectors Qualifications....................................................................15
7.3 Welders ....................................................................................................................15
7.3.1 Qualification, Certification, Experience ............................................................15
7.3.2 Identification of Welders ..................................................................................16
SECTION 8: INSPECTION & TESTING ...............................................................................16
SECTION 9: PROCESSES & CONSUMABLES ..................................................................18
9.1 Welding & Cutting Processes .................................................................................18
9.2 Welding Consumables ............................................................................................18
9.3 PASSIVATION OF STAINLESS STEEL WELDS ......................................................18
SECTION 10: SCHEDULE ...................................................................................................19
APPENDIX A: SAMPLE FORMS ........................................................................................24
TABLES & FIGURES

Figure 6. 1 - Welding Procedure Qualification Process ................................................... 10
Figure 7.1 - Welder Qualification Process ........................................................................ 14
Figure 10.1 - Selection of Weld Quality Requirements .................................................... 20

REFERENCED DOCUMENTS
AS/NZS 1553: Covered electrodes for welding

AS 1554: Structural Steel Welding
AS 1796: Certification of welders and welding supervisors
AS 2214: Certification of welding supervisors – Structural steel welding
AS/NZS ISO 3834: Quality Requirements for Welding
AS 4041: Pressure Piping
ASTM A380 Standard Practice for Cleaning, Descaling and Passivation of
Stainless Steel Parts, Equipment and Systems
GB SA Water’s Green Book (EWS) of Standard Drawings

TG 61 Practical Understanding And Interpretation Of Technical Standard TS
30a Welding Specification
SECTION 1: SCOPE
This Technical Specification applies to all metal fabrication and repair work,
(excluding emergency repairs on Bursts or Ruptures) involving welding, carried
out by SA Water and Contractors/ Sub Contractors.
It prescribes weld preparation, qualification of welding procedure and personnel,

workmanship and inspection requirements for welds related to the arc welding by
manual metal-arc and other processes approved by the authorised welding
coordinator.
Welding shall be carried out in accordance with the requirements of the Drawings
and this Specification using approved plant and equipment.
This Technical Standard should be used in conjunction with TG 61, Practical

Understanding and Interpretation of Technical Standard TS 30a Welding
Specification.
Note: it is the responsibility of the Designer to specify the welding standard. Some
guidance to this is provided in TG 61.
SECTION 2: DEFINITIONS
Authorised Welding Coordinator (or Designate)

the person authorised to sign for all welding matters on behalf of SA
Water;
GB SA Water’s Green Book (EWS) of Standard Drawings;
Integrated Quality Document

a document which is designed and produced in accordance with the
principles outlined in AS/NZS ISO 3834. 1 Quality Requirements for
Welding;
ITP the detailed Inspection and Test Plan(s) for the proposed work;
MDR Manufactures Data Report as required by the Welding Service

Provider as part of contract conditions (See Appendices for standard
MDR form);
NDT/NDE means Non Destructive Testing / Examination;
PQR Procedure Qualification Record;
Schedule description / requirements of Quality Assurance Requirements

and Contractors Notifications & Submissions;
Specified described / requested in the Contract Specification or on the Contract

Drawings;
SA Water’s Representative

SA Water’s Representative in this Technical Standard will be
nominated by SA Water.
Technical Specification
means this Technical Standard;
Welding Coordinator
a person who carries out one or more welding coordination tasks (as
defined in AS/NZS ISO 3834);
Welding Service Provider (WSP)

the person, organisation or contractor as defined in the Contract or
its subcontractor who will undertake the welding work;
Work means metal fabrication and repair work, involving welding, carried
out by SA Water and Contractors or Sub Contractors to which this
Technical Specification applies;
Weld Procedure Specification WPS

a Qualified Weld Procedure which has been tested and proven;
WTIA Welding Technology Institute of Australia;
SECTION 3: STANDARDS/CODES
a) Australian Standards
All metal fabrication and welding shall comply with the Australian
Standard(s) or Code(s) of Practice (including amendments) stated in the
Contract Specification, noted on the Contract Drawings, and in the work
order detail.
The applicable edition(s) of standards/codes are those current 2 weeks

prior to tender close date.
The relevant standard/code is deemed the minimum standard applicable

unless otherwise stated in the specification.
b) SA Water Corporation Standards

All metal fabrication and welding of pipe fittings & flanges as applicable
shall comply with the current edition of the Green Book or as specified in
the contract documentation, and work order detail. All flanges shall be
attached to pipework as per GB, Drawing or as specified by SA Water’s
Representative.
c) SA Water Corporation Standard Forms

SA Water maintains a register of standard Weld Forms, these forms shall
be used, or an equivalent approved by the Authorised Welding Coordinator.
Standard SA Water Weld Forms are available from the Authorised Welding
Coordinator or Designate on request.
d) Occupational Health and Safety

This technical specification does not obviate the contractors or
subcontractors responsibilities to provide a safe workplace, systems and
methods in accordance with local Occupational Health and Safety
Regulations. Refer to WTIA Tech Note 7-04 Health & Safety in Welding, &
WTIA Tech Note 22-03 Welding Electrical Safety.
SECTION 4: APPROVAL TO COMMENCE WORK
The Welding Service Provider shall formally request SA Water’s Representative’s

approval to commence cutting or welding work. Approval to commence will not
be given prior to the SA Water’s Representative’s approval of the following;
a) the Quality Plan required in Section 5 QUALITY ASSURANCE; and
b) a schedule of qualified welding procedures, in accordance with Section 6

WELDING PROCEDURES.
c) detailed list of welding personnel & their qualifications, in accordance with

Section 7 WELDING PERSONNEL.
SECTION 5: QUALITY ASSURANCE
The Welding Service Provider shall:
a) be responsible for all quality assurance activities necessary to ensure that

the Works comply with the specified requirements of section 10
SCHEDULE;
b) provide sufficient information, in respect of any proposed subcontractors, to

enable SA Water’s Representative to assess their suitability for the Works;
c) establish and maintain a quality assurance system as required in section 10

SCHEDULE;
d) require subcontractors' operations to be in accordance with the contract

quality assurance system requirements and provide management and
oversight to ensure that they are;
e) submit not less than 10 working days prior to commencement of work, a

Quality Plan to the Requirements of AS/NZS ISO 3834 Part 4 Elementary
Requirements (minimum) to SA Water’s Representative detailing how the
quality assurance requirements are to be applied to each element of the
Works.
The Quality Plan shall contain the following:
i) a system element outline;
ii) the Welding Service Provider’s organisation chart for the Works;
iii) organisation chart(s) for any subcontractor(s) work;
iv) a list of qualified welding procedures for the welding work including
test results for the welding procedures;
v) detailed ITP’s for the Works;
vi) details of Weld Map; a standard SA Water Weld Form shall be used;
WMAP [TS30a-05 - WMAP] or a SA Water approved equivalent;
vii) the intended format and presentation arrangements for the MDR; a
standard SA Water Weld Form shall be used; MDR [TS30a-06 -
MDR] or a SA Water approved equivalent;
viii) Details of the quality system showing each element of the system and
how they relate to each other.
f) present the Quality Plan and the MDR as Integrated Quality Documents.
Note: The Part 4 Elementary Requirements of AS/NZS ISO 3834 are the
minimum requirements at present, with provision to specify Part 3 - “Standard” or
Part 2 - “Comprehensive” in the next 18 to 24 months, see figure 10.1.
SECTION 6: WELDING PROCEDURES
6.1 SA WATER WELDING PROCEDURES
SA Water maintains a Database of Qualified Welding Procedure Specifications

(WPS) these are controlled by the Engineering & Projects Division Copies of the
WPS’s can be obtained from the Authorised Welding Coordinator on request.
The Authorised Welding Coordinator should be contacted to ascertain if a
suitable WPS is available for use, prior to the qualification of additional WPS’s.
6.2 QUALIFICATION OF WELDING PROCEDURE SPECIFICATIONS
a) Welding procedures for all fillet or butt welds or any combination of each,
shall be proven qualified by the Welding Service Provider, who shall submit
to SA Water’s Representative a PQR; a standard SA Water Weld Form
shall be used; PQR [TS30a-01 - WQR] or a SA Water approved equivalent.
All proposed welding procedure qualifications shall be submitted no less
than 10 working days prior to the planned commencement of welding work
to which the procedures will apply.
The flow chart below shall be used as a guide in developing a PQR & WPS.

KEY
Develop Process
Proposed
Welding
Procedure
(PWP) Decision
Document
Weld test piece

using the
parameters
specified in the
PWP Revise
Proposed
WPS with
modified
Record the actual parameters
parameter used
during welding on a
Procedure
Qualification Record
(PQR)
Submit the test piece

Review test reports
for required Non
Failed Testing and determine
Destructive &
possible causes for
Mechanical Testing
failure
(as specified by the
required standard)
Passed Testing
From the data recorded on

the PQR & relevant test
reports, formalise the
Welding Procedure
Specification (WPS)
including all ranges per the
required standard
Issue WPS as required (i.e.

into system for further use,
to welders to complete job,
etc,)
Figure 6. 1 - Welding Procedure Qualification Process

b) Where welding procedures are similar, a welding procedure qualification is
required for each, where the essential variables (as per the specified
standard/code), vary between them outside of the prescribed limits in the
specified standard/code.
c) Any new welding procedure(s) shall be qualified when the essential

variables on the welding procedures being used, vary outside of the
prescribed limits in the specified standard/code. These welding
procedure(s) qualifications shall be submitted to SA Water’s
Representative for review and approval.
d) The Welding Supervisor / Piping Supervisor or Forman (see

Clause 7.1) shall prepare the Weld Procedure Specification (WPS); a
standard SA Water Weld Form shall be used; WPS [TS30a-02 - WPS]. If
the contractor wishes to use an existing Qualified Procedure this along with
supporting documentation can be submitted to the Authorised Welding
Coordinator for review and approval;
i) Should SA Water require witnessing of the Welding Qualification Test

the Contractor shall give a Minimum of 48 hours notice; prior to the
commencement of such a test. A copy of the WPS shall be made
available to SA Water’s Inspector prior to commencement of the test;
ii) The Welding Service Provider is responsible for ensuring all

necessary testing is performed to qualify the WPS in accordance with
the relevant standard for which the procedure is intended;
iii) The Welding Supervisor shall hard stamp or permanently mark the
WPS number on the test coupon. Test report shall indicate the unique
WPS number assigned to the Welding Procedure;
iv) The Welding Supervisor shall prepare a Procedure Qualification

Record (PQR), a standard SA Water PQR Weld Form shall be used;
PQR [TS30a-01 - PQR] or a SA Water approved equivalent. The form
details all welding parameters during the qualification process. SA
Water’s Inspector if present may sign the document verifying the test
coupon as visually acceptable, prior to Mechanical & Non-Destructive
Testing as Required;
v) On completion of welding the qualification test piece the Welding

Supervisor shall perform a 100% visual examination of the completed
weld(s) to verify compliance with the relevant standard. The test
coupon(s) shall be submitted to a NATA approved testing laboratory
for mechanical and non-destructive testing, as appropriate. On receipt
of the test report documentation qualifying the PQR the Welding
Supervisor shall prepare the Procedure Qualification Record; The
Standard SA Water PQR Weld Form shall be used; PQR [TS30-01
Rev:0] or a SA Water approved equivalent;
vi) Copies of all Qualified PQR documentation (Including Test

Certificates) shall be forwarded to the Authorised Welding
Coordinator;

6.3 WELDING PROCEDURE INFORMATION
The Welding Service Provider shall ensure copies of the Procedure Qualification
Records (PQR) and Weld Procedure Specifications (WPS) are available on site
at all times.
Each PQR & WPS shall be submitted to SA Water’s Welding Coordinator for
review and approval. The Procedure Qualification Records (PQR) and Weld
Procedure Specifications (WPS) shall be produced using standard SA Water
Weld Form; PQR [TS30-01 Rev:0] & WPS [TS30-02 Rev:0] or a SA Water
approved equivalent, and shall contain all of the major parameters / essential
variables and at least the following information (note there are no variable in a
PQR):
a) a sketch of the joint design;
b) material(s) grade-type;
c) material thickness - all parts;
d) method of material(s) preparation;
e) welding process(es) to be used;
f) voltage, amperage and travel speed;
g) number and sequence of runs;
h) classification of electrode/wire;
i) diameter of electrode/wire;
j) shielding gas/gas mixture/flux type/classification;
k) temperature of preheat, inter run heat and post heat applications

if applicable;
l) heat input (kJ/mm) for each weld pass
m) welding standard/code and classification, (e.g. AS 1554.1 SP,

AS 4041 Class 1).
n) the type and extent of testing of welds to be carried out in accordance with
the specified testing requirements. PQR test certificate reference numbers
shall be clearly stated on the PQR.
o) surface treatment post welding. All stainless steel welds are to be pickled
and passivated using a pickling gel to ASTM A380.

SECTION 7: WELDING PERSONNEL
7.1 WELDING SUPERVISOR; (WELDING COORDINATOR)
Not less than 10 working days prior to commencement of Work, the Welding
Service Provider shall identify and nominate a suitably qualified Welding
Supervisor, who will be responsible for the co-ordination of all operations in
respect of the welding work.
7.1.1 Welding Supervisors Authority
The Welding Supervisor, shall have delegated authority to deal directly with SA
Water’s Representative on all issues relating to the welding work, including:
a) Welding procedure management;
b) Welding quality management;
c) Supervision activities;
d) Inspection and testing activities; and
e) Collation & sign-off on the MDR,
7.1.2 Welding Supervisors Responsibility
The Welding Supervisor shall be responsible for
a) Satisfactory qualification of all welding operators;
b) Welder qualification test are carried out in accordance with the required
standard;
c) All welder qualification tests are documented on the Welder Qualification

Record; The Standard SA Water Weld Form shall be used; WQR [TS30a-
03 - WQR] or a SA Water approved equivalent,
d) testing of weld / welder qualification test pieces are carried out by a NATA
approved Laboratory in accordance with the requirements of the relevant
standard;
e) all welders and welding operators are allocated a unique identification

number;
f) maintain a register of qualified welders detailing qualifications;
g) ensure that welder’s performance is kept under review. Where

unsatisfactory welding performance is revealed, that is where percentage
repair rate is in excess of 5%, an investigation into the cause and
subsequent corrective action shall be implemented. If cause is due to the
welder being unable to meet the specification then that welder shall be
taken of that job and consideration be given to additional training. Such

reviews and / or re-training shall be indicated on the welders performance
records;
h) submit copies of all weld related documentation to the Authorised Welding

Coordinator;
The flow chart below shall be used as a guide in preparing a WQR.
KEY
Y
Carry out Welder Process
Qualification
Testing in
accordance with
the required Decision
standard & WPS
Document
Weld test pieces

(per required
standard & WPS)
Review test reports
and determine
possible causes for
Record parameters failure
on Welder
Qualification Record
(WQR)
Submit the test piece

for required Non
Destructive & Failed Testing
Mechanical Testing
(as specified by the
required standard)
Passed Testing
Record the test

report details on
the WQR and file
Figure 7.1 - Welder Qualification Process

7.1.3 Welding Supervisors Qualifications
The Supervisor (Welding Coordinator) shall hold as a minimum:
current certification to AS 1796 Certificate 10; or

current certification to AS 2214; or
another current qualification/certification acceptable to SA Water’s
Representative.
The Welding Service Provider shall provide details of the Welding Supervisor’s
qualification(s), certification and experience records to SA Water’s
Representative.
7.2 WELDING INSPECTOR (WELDING COORDINATOR)
The Welding Service Provider shall identify and nominate a suitably qualified
Welding Inspector in no less than 10 working days prior to commencement of the
Works.
Where welding is to occur concurrently at sites remote from each other, the
Welding Service Provider shall identify and nominate an appropriate number of
Inspectors.
7.2.1 Welding Inspectors Qualifications
The Inspector (Welding Coordinator) shall hold as a minimum:
current W.T.I.A. Welding Inspection Certification; or

another current qualification/certification acceptable to SA Water’s
Representative.
The Welding Service Provider shall provide details of the Inspector’s

qualification(s), certification and experience records to SA Water’s
Representative.
7.3 WELDERS
7.3.1 Qualification, Certification, Experience
Not less than 10 working days prior to planned commencement of welding, the
following information shall be provided to SA Water’s Representative for each
welder:
a) documentary evidence of the qualification/certification currently held;
b) trade training background;
c) documentary evidence confirming that each welder is qualified for each

welding procedure that they will apply to the welding works.

7.3.2 Identification of Welders
a) provide in the MDR, on completion of the welding work, a weld map

showing the welds carried out by each welder. A Standard SA Water Weld
Form shall be used; WMAP [TS30a-05 - WMAP] or a SA Water approved
equivalent, weld maps may not be required for minor structural welding as
approved by the Welding Coordinator. Minor structural welds shall be
identified on as constructed drawings for testing tractability purposes, thus
are still required for the Welding/NDT Log.
b) maintain records clearly identifying the welders to each completed weld,

welded pipe joint, weld repair and/or fabricated assembly/unit, which
records shall to be made available to SA Water’s Representative.
SECTION 8: INSPECTION & TESTING
a) Inspection and Test Plan:

i) provide an inspection and test plan for all welding work to SA

Water’s Representative, not less than 10 working days prior to
commencement of the welding work. A Standard SA Water sheet
shall be used; ITPCK [TS30a-07 - ITPCK] or SA Water approved
equivalent,
ii) ensure that the inspection and test plan contains the necessary
elements to ensure the completed welding work complies with the
specified standards/codes and/or other specified requirements;
b) Testing of Welds:
i) carry out testing of all welds in accordance with the specified

standards/codes and/or other specified requirements.
A minimum 10% NDT of a type to be specified by SA Water;

shall be carried out on all fabrications, unless specified higher
in the contract specifications;
ii) provide test certificates, issued by a NATA accredited laboratory, for

both Destructive and Non Destructive Testing (except pressure
testing of pipe joints), as part of the MDR;
c) Pressure Testing:
i) where required by the contract specification, Pressure Testing shall

be carried out and recorded on a Standard SA Water Weld Form;
Pressure Test Record [TS30a-08 - PTR] or a SA Water approved
equivalent, and included in the MDR.

ii) notify SA Water’s Representative within the agreed prior notice time
prior to undertaking pressure testing, to enable SA Water’s
Representative to witness such testing.
d) Testing Records:
i) maintain testing records for all weld testing, a Standard SA Water

Weld Form shall be used; Welding/NDT Log [TS30a-04 - NDTLOG]
or a SA Water approved equivalent, and provide such records to SA
Water’s Representative on request.
ii) provide testing records which shall be clearly traceable, by sketch or

designation, to the actual weld(s) being reported on. A Standard SA
Water Weld Form shall be used; WMAP [TS30a-05 - WMAP] or a SA
Water approved equivalent.
iii) all test reports shall be included in the MDR.
iv) provide 2 copies of the MDR to SA Water’s Representative on

completion of the welding work.
e) Additional Testing of Welds:
Undertake, in addition to the specified testing requirements applying to the

welding work, any additional weld testing instructed by SA Water’s
Representative. Where testing detects non-compliance with relevant
specified standards/codes/and specifications, the cost of weld repair and
retesting shall be borne by the Welding Service Provider.

SECTION 9: PROCESSES & CONSUMABLES
9.1 WELDING & CUTTING PROCESSES
Where the Welding Service Provider intends to incorporate in a welding

procedure, welding or cutting process(es) other than those listed in the relevant
standard, SA Water’s Representative shall be notified of such intent prior to the
development of the welding procedure.
9.2 WELDING CONSUMABLES
All welding consumables to be used in welding procedures shall comply with the
relevant standards/codes.
The Welding Service Provider shall store and handle consumables; in particular
Hydrogen controlled electrodes, in compliance with the requirements of
AS 1553 and WTIA Technical Note 3, and the manufacturers recommendations.
9.3 PASSIVATION OF STAINLESS STEEL WELDS
All stainless steel welds are to be pickled and passivated post welding to re-
establish the protective oxide layer. The preferred method is to apply a pickling
paste to ASTM A380. Mechanical and/or electropolishing methods may be
adopted, subject to approval from the Materials Sciences Unit, where access or
safety considerations apply.
Confirmation of successful passivation shall be performed by visual inspection.

No coloured oxide or heat tint permitted.
Note that pickling gels contain highly dangerous chemicals. Before commencing
pickling operations an MSDS of the pickling gel is to be obtained and reviewed
and a Job Safety Analysis performed. Any instructions for safe use included in
the MSDS must be complied with.
Pickling and passivation requirements for stinless steel welds are to be included
in the Notes sections of the PQR, WPS and WQR.

SECTION 10: SCHEDULE
The Schedule is provided to;
specify the required Contract Quality Assurance System;

assist the Welding Service Provider to identify all notices, submissions,
approvals etc and their contractual time requirements;
provide a check list format to enable the Welding Service Provider to record
and update the status of the various items;
The Welding Service Provider shall comply with all the requirements included in
the Schedule, use and maintain the Schedule and provided updates to SA
Water’s Representative.
The flow chart below shall be used as a guide for the selection of quality
requirements.

Welding
quality NO No further
requirements action
in the contract
YES
YES AS/NZS ISO

9001 or
NO
AS/NZS ISO
3834
Contract Welding Quality requirements
Use AS/NZS Select appropriate

ISO 3834 elements
Comprehensive Standard Elementary

AS/NZS ISO 3834-2 AS/NZS ISO 3834-3 AS/NZS ISO 3834-4
KEY
Process
Decision
Approval by Authorised Welding Coordinator
Document
Figure 10.1 - Selection of Weld Quality Requirements

SCHEDULE OF THE CONTRACTOR’S REQUIRED
QUALITY ASSURANCE SYSTEM - NOTIFICATIONS AND SUBMISSIONS
1.0 QUALITY ASSURANCE SYSTEM
Quality Assurance Systems Allowed

Yes No
1.1 AS/NZS ISO 9001
1.2 AS/NZS ISO 3834 Yes No
Part 2 comphensive Yes No
Part 3 standard Yes No
Part 4 elemetry Yes No
1.3 Alternative
1.4 Default
Where no contract specific requirements are specified above, the following
default applies;
AS/NZS ISO 3834.1
SA Water’s Plan/
Section Item Submission Precondition Representative Actual
Approval/Outcome Dates
5 Detailed Welding Details for assessment Type of system Accept/Reject

management Within 10 working
system days
2.0 Subcontractor to be used Yes No

If yes
SA Water’s Plan/
5 Sub Contractor full Details for assessment Subcontractors Accept/Reject

Details to be used. Within 10 working
days

3.0 Intent to use Alternative Processes Yes No
If yes
SA Water’s Plan/
9 Welding Intent to use Before Approve/Reject

Process/es alternative process. development Within 10 working
(welding or cutting) of Welding days
Procedure
4.0 10 Days Prior to Planned Commencement of Works.

SA Water’s Plan/
5 Quality Plan As detailed Approved Yes/No

6.2 Qualification of Schedule of qualified Accept/Reject
Welding procedures
Procedures (PQR)
6.3 Welding Procedure All major Accept/Reject
Information (WPS) parameters/essential
variables and as per
6.2 advise copies held
available to
workplace.
7.1 Supervisor Nominate qualified Accept/Reject
person responsible.
7.1.3 Supervisor details Qualification/ Yes/No
certification and
experience, records.
7.2 Inspector Qualification, Yes/No
certification and
experience.
7.3.1a) Welder As detailed Acceptance Yes/No
& b) qualification,
certification, etc.
7.3.1 c) Welder qualified to Details for each Acceptance. Yes/No
Qualified Welding welder
procedures.
8 Inspection/Test Inspection & Test Accept/Reject
Plan Plans (ITP’s)
5.0 Before Welding Commences

SA Water’s Plan/
4 Commencement Request approval to All Pre Yes/No

commence conditions met

6.0 Identification and Traceability after Welding Done
SA Water’s Plan/
7.3.2 Identification of Records Work Done Accept/Reject

welders to welds.
7.3.2 a) Traceability of Weld Map Work Done Accept/Reject
welds Compliance.
7.0 Testing
SA Water’s Plan/
8 b) Testing Test Certificates Work Done Accept/Reject

(destructive or non- NATA Compliance
destructive) Approved.
Lab.
8 c) Pressure testing Test Results Work Done
Witness and
Accept/Reject
8 d) Testing records Supply as part of Work & Tests Accept/Reject
MDR done Compliance
8.0 Requalification when Essential Variables fall outside Standard/Code Limits

SA Water’s Plan/
6.2 New Procedure Qualification of New Change after Accept/Reject

Welding Procedure work Review/Approval
(PQR & WPS) commences

APPENDIX A: SAMPLE FORMS
Standard SA Water Weld Forms available:
Issue Comments
Form Name Form Number REV:
Date
Procedure Qualification
TS30a-01 - PQR 0 13/01/05
Record (PQR)
Weld Procedure Specification
TS30a-02 - WPS 0 7/01/05
(WPS)
Welder Qualification Record
TS30a-03 - WQR 0 7/12/04
(WQR)
Welding / Non Destructive TS30a-04 -
0 7/12/04
Testing Log (W/NDTLOG) W/NDTLOG
Weld Map dwg Template
TS30a-05 - WMAP 0 7/12/04
(WMAP)
dwg Template
Weld Map - Blank (WMAP) TS30a-05a - WMAP 0 7/12/04
Blank
Manufacture’s Data Report
TS30a-06 - MDR 0 7/12/04
(MDR)
Inspection Test Plan Checklist
TS30a-07 - ITPCK 0 7/12/04
(ITPCK)
Non Destructive Test Report
TS30a-08 - NDTR 0 7/12/04
(NDTR)
Pressure Test Record
TS30a-09 - PTR 0 16/12/04
(PTR)
Piping Fabrication Checklist
TS30a-10 - PFCK 0 16/12/04
(PFCK)


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SOUTH AUSTRALIAN WATER CORPORATION

WELDING & WELDING PROCEDURE

Issued by: Manager Engineering

Issue Date: 04 May 2009

The currency of these Standards should be checked prior to use.

APPROVAL TO DEVIATE FROM THIS STANDARD

1. Reformatted from DS to TS (Departmental Standard to Technical

TS30a - Welding Specification_3.docx 04 May 2009 Page

The following lists changes made in May 2009

TS30a - Welding Specification_3.docx 04 May 2009 Page

TABLES & FIGURES

TS30a - Welding Specification_3.docx 04 May 2009 Page

AS/NZS 1553: Covered electrodes for welding

GB SA Water’s Green Book (EWS) of Standard Drawings

It prescribes weld preparation, qualification of welding procedure and personnel,

This Technical Standard should be used in conjunction with TG 61, Practical

Authorised Welding Coordinator (or Designate)

GB SA Water’s Green Book (EWS) of Standard Drawings;

Integrated Quality Document

MDR Manufactures Data Report as required by the Welding Service

NDT/NDE means Non Destructive Testing / Examination;

PQR Procedure Qualification Record;

Schedule description / requirements of Quality Assurance Requirements

Specified described / requested in the Contract Specification or on the Contract

TS30a - Welding Specification_3.docx 04 May 2009 Page

Welding Service Provider (WSP)

Weld Procedure Specification WPS

WTIA Welding Technology Institute of Australia;

The applicable edition(s) of standards/codes are those current 2 weeks

The relevant standard/code is deemed the minimum standard applicable

b) SA Water Corporation Standards

c) SA Water Corporation Standard Forms

d) Occupational Health and Safety

SECTION 4: APPROVAL TO COMMENCE WORK

The Welding Service Provider shall formally request SA Water’s Representative’s

a) the Quality Plan required in Section 5 QUALITY ASSURANCE; and

b) a schedule of qualified welding procedures, in accordance with Section 6

c) detailed list of welding personnel & their qualifications, in accordance with

SECTION 5: QUALITY ASSURANCE

The Welding Service Provider shall:

a) be responsible for all quality assurance activities necessary to ensure that

b) provide sufficient information, in respect of any proposed subcontractors, to

c) establish and maintain a quality assurance system as required in section 10

d) require subcontractors' operations to be in accordance with the contract

e) submit not less than 10 working days prior to commencement of work, a

The Quality Plan shall contain the following:

i) a system element outline;

iii) organisation chart(s) for any subcontractor(s) work;

SECTION 6: WELDING PROCEDURES

6.1 SA WATER WELDING PROCEDURES

SA Water maintains a Database of Qualified Welding Procedure Specifications

6.2 QUALIFICATION OF WELDING PROCEDURE SPECIFICATIONS

TS30a - Welding Specification_3.docx 04 May 2009 Page

Weld test piece

Submit the test piece

From the data recorded on

Issue WPS as required (i.e.

Figure 6. 1 - Welding Procedure Qualification Process

TS30a - Welding Specification_3.docx 04 May 2009 Page