Requirements for

Welding Works
Brazil CSPSteelPlant Project
Quality Control Dept.

JooVitorBarbosaSilva

ProjectQuality Engineer

Requirements forWelding Works

This presentation has the intent to introduce about the

requirements that shall be applied during welding works
performed for the construction of all Steel Plant.
These parameters shall be used as a reference for POSCOs
Construction Engineers and all Subcontractors.

Requirements forWelding Works

Index

Subcontractors Welders Management

Welders Qualification Process

Calibration of Welding Machines, Dry Ovens and Portable Dry Ovens

Applicable Codes for Construction

Welding/NDT/PWHT Flowchart
Visual Test
NDT and PWHT
Hardness Test
SNQC: Welding Inspectors Levels 1 and 2 / NDT Inspectors

General Requirements

Definition
Instructions for the use of POSCOs WPS

Inspection and Tests

Receipt Inspection
Storage Conditions
Treatment of Electrodes
Layout of Welding Material Storage Room and Dry Ovens

Welding Procedure Specification WPS

Request for welders test

Test parameters (test coupon, positions, welding process, ...)
Test Execution and Mechanical Test or Volumetric Test(RT or UT)
Issuance of WPQR
Approval by POSCO QA/QC and ID Card
Range of Qualification

Welding Material Control

Organizational Chart Sample

Responsabilities

ASME
AWS
API

NonConformities

Issuance of NCRs
Corrective Actions
Recurrence / Interruption of Work

Requirements forWelding Works

Subcontractor Welders Management
Thearrange forthe welders managementshould be according to the
description shown below.
Quality Control:
Quality Managers
Quality Engineers
Welding Inspectors
VisualTestInspectors

Construction Engineers

Welding Supervisor1

Welding Team
Leader

Welders

Helpers

TEAM1

Welding Supervisor2

Welding Team
Leader

Welders

Helpers

TEAM2

Welding Team
Leader

Welders

Helpers

TEAM3

Welding Team
Leader

Welders

Helpers

TEAM4

Requirements forWelding Works

Subcontractor Welders Management
Responsabilities

Construction Engineers

Welding Supervisors

Distribute the welders in accordance with the work fronts determined in advance by the
supervisor welding. Request the presence of the welding inspector for inspection / approval of
welded joints, soon as they become completed. Give instructions to the welders, and allow
welders perform activities within the limits of their qualifications.

Welders

Distribute and supervise the welders team according to the criticity of each work and the specific
qualification/habilities of these teams. Monitoring the welders performance with the quality
control informations, provide training when necessary or requested. Assure that the works are
being performed according to POSCOs instructions.

Welding Team Leaders

Inform the welding supervisors about the schedule and criticity of works; Order welding
machines, tools and consumables, according to the necessity planned in management meetings;

Perform welds according to the provided WPS, according to the instructions of welding team
leaders and welding inspectors. The welders cant unrespect the limits described in him range of
qualification.

Helpers

Give support to the welders according to the instructions of welding team leaders;
Transportation and assembly of welding machines, tools and other applicable devices; Get
consumables on the welding material storage room (using the Welding Material Issued Card).

Requirements forWelding Works

Welders Qualification Process

Only qualified welders with the ID Card should do welding.

Welders to perform welds on reinforcement bars for concrete or welds for electrical
installations will not be submitted to the complete qualification process, these welders
will be considered as a tackwelders.

The welders, prior to perform welding works, shall be qualified in

accordance with ASME IX or AWS D1.1 (depending of the equipment
to be welded). Welders shall be submitted to a performance
qualification test to determine their ability to make sound welds
using a specific group of filler metal and welding process in one or
more position. Each qualified welder shall be identified by a number
or other identification to be used to identify his work. The
requirements are described in the PWI Project Work Instruction
Welder and Welding Operator Qualification (CSP1ZZ000
CZ71100002).

Requirements forWelding Works

Requirement forQualified Welders
When the joint to be welded is described in the Project Drawing (by welding symbology
or detailing of joint), only qualified welders will be allowed to perform the work.

ALL POSCOs STAFF COULD STOP, OR NOT ALLOW THE WORK IF THIS
CONDITION IS NOT BEING ATTENDED.

Welding Symbology

Detailing of Joint

Requirements forWelding Works

Requirement forQualified Welders
Pay special attention on the drawings that can looks like drawing for civil works. The indication of welds defines that the
requirements for welders qualification shall be followed and the visual inspection, after welding completion shall be
performed.

Welding Symbology

Welding Symbology

Requirements forWelding Works

Welders Qualification Process
Request forWelders Test

Welders test will be performed by a third company (ENGEFER Ltda)

Subcontractor shall send to POSCO QA/QC the Request for Welders Qualification
Test.

Shall be provided only Name, CPF, Welding Process and Desired range of positions, thickness and
diameter, and Equipment to be welded for these welders to define the applicable code.

Requirements forWelding Works

Welders Qualification Process
TestParameters

Based on the applicable code and according to the Request for Welders Qualification
Test, POSCO QC Engineer will define which WPS will be used as a reference for
welders qualification test.
Should be taken into consideration the Qualification Range of each applicable code
before determining the size of test piece, process, welding position, base metal, etc.
to minimize test times.
Sample:
Positions
Thickness
Code
(Norma)
ASME IX

AWS D1.1

Tested
(Testado)
PIPE (TUBO) 6G
PLATE
2G
(CHAPA)
3G
3F
PLATE
3G
(CHAPA)
3F

Qualified
(Qualificado)
ALL (TODOS)
1G,2G,1F,2F
1G,3G,1F,2F,3F
1F,2F,3F
1G,2G,3G
1F,2F,3F except T,Y and
K connections
1F,2F,3F

CODE
(Norma)
ASME IX

Tested
(Testado) (mm)
(GROOVE)
CHANFRO
t < 13
t 13 (*)

FILLET
(NGULO)
4.8~10

AWS
D1.1

9.5 below
9.5~25.4
25.4 and over
12.7

Range Qualified
(Faixa Qualificada)(mm)
GROOVE
FILLET
(CHANFRO)
(NGULO)
Max. 2t
All
Ilimitado
All
All
19 below
All
Max. 2t
All
Ilimitado
All
All

Requirements forWelding Works

Welders Qualification Process
TestExecution and Mechanical Testor Volumetric Test(RTor UT)

Welding shall be in accordance with approved WPS.

Test piece shall not be over ground during welding.

Welder/Test No and Position No, etc shall be marked on the each test piece.

The welder will be supervised by the Welding Inspector Level 1 during the test, with the in
tent to check welder ability and if the parameters described in the applicable WPS are
being followed.

After the conclusion of welding, the Welding Inspector will perform the Visual Test on
the piece of test, according to the acceptance criteria described in the referred PWI
Project Work Instruction

Will be issued, by the Welding Inspector Level 1, a Welder Monitoring Qualification

Record, describing the conditions applied during the welder test.

If approved on Visual Test, the test coupon will be submitted to mechanical test or NDE
Volumetric Examination (RT or UT), according to the applicable code.

Requirements forWelding Works

Welders Qualification Process
TestSpecimens

The quantity of test specimens required to be performed for each test coupon (1 test
coupon is required for each test position) are described on the applicable code. As a
sample could be listed the QW452.1 of ASME IX, shown below:

Requirements forWelding Works

Welders Qualification Process
Issuance of WPQR

In case of Approval on Mechanical Test or NDE Examination, the tested

welder will be considered approved.

The WPQR (welder performance qualification record) will be issued by

a Welding Inspector Level 2, certified on the SNQC (National System of
Qualification and Certification).

The completed document will be composed by:

WPQR Issued and Signed by Welding Inspector Level 2

Welder Monitoring Qualification Record Issued/Signed by the Welding Inspector Level 1
Record of Mechanical Test or NDE Volumetric Examination

Requirements forWelding Works

Welders Qualification Process
Issuance of WPQR

Requirements forWelding Works

Welders Qualification Process
Approval by POSCOQA/QCand IDCard

The complete WPQR shall be submited for approval of POSCO QA/QC, after
checked by the quality manager of subcontractor.
In the absence of any remarks, the document will be approved and the Welder
ID Card will be issued.
After the issuance of Welder ID Card, the welder will be allowed to perform
welding works.

Requirements forWelding Works

Welders Qualification Process
Rangeof Qualification

Any welder can unrespect the limits described in his qualification; These limits are
described in the WPQR, List of Qualified Welders and Welder ID Card.
The respect of Range of Qualification shall be assured by the welding supervisor and
welding team leaders. It will be checked by the Welding Inspectors of Subcontractors and
POSCO QA/QC Staff.

Requirements forWelding Works

Sequence of Welders Qualification Process
(1)SUBCONTRACTOR

(2)POSCOQA/QC

REQUESTTHETEST(ACCORDINGTOTHEATTACHMENT1)TOPOSCO
QA/QC.

REVIEWTHEREQUESTANDDEFINEWHICHWPSSHALLBEUSED.
SENDTHEREQUESTTOENGEFERANDACOPYTOTHESUBCONTRACTOR.

SOLICITAROSTESTES(DEACORDOCOMOANEXO1)AOCONTROLEDE
QUALIDADEDAPOSCO(POSCOQA/QC).

REVISARASOLICITAOEDEFINIRQUALEPSDEVESERUTILIZADA.
ENVIARASOLICITAOENGEFEREUMACPIAPARAA
SUBCONTRATADA

(3)ENGEFER

(4)ENGEFER

EXECUTIONOFTEST;
IFAPPROVED,GOTOTHENEXTSTEP.

ISSUETHEWPQR ANDSENDTOSUBCONTRACTOR.
SENDAPICTUREOFEACHWELDERSBYEMAIL.(THISITEMCANBE
PERFORMEDBYTHESUBCON.
EMITIROCQS EENVIARASUNCONTRATADA
ENVIARUMAFOTODECADAUMDOSSOLDADORES,POREMAIL.(ESTE
ITEMPODESERFEITOPELASUBCONTRATADA.

EXECUODOTESTE;
SEAPROVADO,IRPARAAPRXIMAETAPA.

(5)SUBCONTRACTOR

(6)POSCOQA/QC

CHECKANDSIGNTHEWPQR.

REVIEWANDSIGNTHEWPQR.

SENDTHEWPQRTOPOSCOQA/QC,FORAPPROVAL.

ISSUETHEWELDERIDCARD.

VERIFICAREASSINAROCQS.
ENVIAROCQSPARAOCONTROLEDEQUALIDADEDAPOSCO,PARA
APROVAO.

REVISAREASSINAROCQS,EEMITIROCARTODEIDENTIFICAODO
SOLDADOR.

(7)SUBCONTRACTOR
WELDERSTARTSTOWORKATSITE.
SOLDADORCOMEAATRABALHARNAOBRA.

Requirements forWelding Works

Welding MaterialControl

To assure the quality of welded joints, subcontractors shall take care about the
consumable that will be used. A lack of control during the transportation,
receipt, storage, treatment and the consecutive use of these materials, could
affect the quality of final product.

All welding materials shall be purchased according to the welding instruction.

Only certified materials shall be used, according to POSCO instructions and

approval.

Definition of Welding Consumable Material used to be deposited or to

protect the weld. As electrodes, rods, fluxes and protective gases.

The requirements for control of welding materials are described in the

procedure entitled PWI Welding Material Control (Doc. N.: CSP1ZZ000
CZ71100001)

Requirements forWelding Works

Welding MaterialControl
Receipt Inspection
The activities described below will be performed by the Subcontractor.

When the welding materials are received at site, the SPRE (Site Procurement
Engineer) shall request the Welding Inspector of to do a receiving inspection.

The Welding inspector shall sign the Receiving Inspection Report when the
result of the inspection is positive. Subcontractor shall submit for approval of POSCO
QA/QC a specific procedure for receiving of welding material.

The welding materials rejected shall not be used and shall be treated in
accordance with Management of Non conformities at Site.

Requirements forWelding Works

Welding MaterialControl
Storage

All welding materials shall be stored in Welding Material storage room after
completion of the receiving inspection.

The welding materials shall be stored in the Welding Material storage room in
clean dry conditions to protect it from moisture, as per applicable codes,
standards and/or manufacturer's instructions.
The welding materials shall be stored in the original sealed packages, on
wooden supports, classified by type, size and heat / lot number.
Any welding materials rejected by receiving inspection shall be quarantined.
The Procurement Engineer is responsible for access control of the the Welding
Material storage room, which shall remain locked except when closely
supervised.

Requirements forWelding Works

Welding MaterialControl
Storage Unaceptable Conditions

Requirements forWelding Works

Welding MaterialControl
Treatment of Electrodes

The conditions for treatment of electrodes are described on the AWS

Specification, like AWS SFA5.1 SPECIFICATION FOR CARBON STEEL ELECTRODES
FOR SHIELDED METAL ARC WELDING. These conditions are listed in the PWI
Welding Material Control, and both shall be used as a reference to establish the
drying condition and prepare the Welding Material Dry Condition Table.

The welding materials cant be used before the adequate treatment.

The welding inspector shall check if these conditions are being followed, and provide technical
support and training if necessary.

Requirements forWelding Works

Welding MaterialControl
Required Layoutof Welding MaterialStorage Room
Documents
Storage

Storage Racks
Storage Racks

Dry
Oven
1

Dry
Oven
2

Dry
Oven
3

Dry
Oven
4

Desk
/PC

Receipt Window

Storage Racks

H
S

HS. Heating System

To
maintain
the
adequate temperature
on the storage room.
The heat from the dry
ovens can do this job.

Storage Racks
Entrance
Indicated quantity of dry ovens (minimum):
Dry Ovens:1
HoldingOvens:1Remark:Dry ovens can work asaholdingoven.

T. Thermohigrometer
To
monitoring
of
internal and external
temperature of storage
room.
D. Dehumidifier To
maintain the moisture
in the storage room
within
acceptable
conditions.
The
necessity could depent
to the local conditions.

Requirements forWelding Works

Welding ProcedureSpecification WPS
Definition

WPS: A document providing the required welding variables for a specific application to
assure repeatability by properly trained welders and welding operators. (from AWS A3.0
Welding Terms and Definitions)

PQR Procedure Qualification Record: Is a record of welding variables used to produce

an acceptable test weldment and the results of tests conducted on the weldment to
qualify a welding procedure specification.

All welding shall be performed in accordance with welding Project Work Instruction (PWI)
and Welding Procedure Specification (WPS) which have been qualified by contractor
laboratory and field shop in accordance with the requirement of ASME IX or AWS D1.1.
The qualified WPS are listed in the document CSP1ZZ000ZM26000001.

The Welding Inspector is the responsible to verify if welding works are being performed
according to the applicable WPS, give instructions for the envolved workers and inform
the necessity of qualification of another WPS, when a planned work is not covered for
the available WPS.

Requirements forWelding Works

Welding ProcedureSpecification
Sample of WPSand WPSList

NO.

WPS NO.

R
BASEMETAL No.
E
V P-No. Gr. P-No. Gr.
No.
No.

P-WPS-001

P-WPS-004

P-WPS-006

29

P-WPS-029

P-WPS-008

P-WPS-009

10

P-WPS-010

11

P-WPS-011

SUPPORT
PQR No.
RANGE
P-PQR-001

1,2

1,2

1,2

1,2

1,2

1,2

5A

5 ~ 52

GTAW

GTAW

SMAW

5 ~ 52

1.5 ~ 20

SMAW

1.5 ~ 20

GTAW

1.5 ~ 15.2

1,2

5B

5B

5B

G 16

F-No. A-No.
ALL

G 16

G8

ALL

ALL

S 12

ALL

G 15.2

ALL

GTAW

SMAW

5 ~ 66

G 12

ALL

S 66
P-PQR-008

MAX.

5B

FILLER MATERIAL
POSITION

P-PQR-007
5A

RANGE

1,2
P-PQR-006

W/M thk.

S 12
P-PQR-004

FCAW

QUALIFIED

B/M THK.

F 36

P-PQR-004

1,2

GTAW

QUALIFIED

1,2
P-PQR-002

WELDING
PROCESS

GTAW

SMAW

5 ~ 200

G 16

ALL

S 200
P-PQR-009

GTAW

1.5 ~ 15

G 15
-

ALL

SFA-No.
(AWS)

SIZE

AWS
CLASS

5,18

2.4

ER70S-6

5.20

1.4

E71T-1C

5,18

2.4

ER70S-6

5,18

2.4

ER70S-6

5,1

3.2,4.0

E7016

5,1

3.2 4.0

E7018

5,28

2.4

ER80S-B2

5,28

2.4

ER90S-B3

5,5

5,28

3.2,4.0,
5.0
2.4

5,5

5,28

3.2,4.0,
5.0
2.4

PREHEAT
TEMP.
Min()

T19:Min 10 600 ~ 640

T>19:Min 95 Min.15min

Ar/
CO2

Ar

10

Ar

10

120

Ar

205

205

E9015-B9
ER90S-B9

SHIELD
GAS

T19:Min 10
T>19:Min 85

E9016-B3
ER90S-B9

PWHT
TEMP.
()

205

700 ~760
Min.15min

720 ~780
Min.30min

720 ~780
Min.30min

Ar

Ar

Ar

Requirements forWelding Works

Welding ProcedureSpecification
Sample of WPSand WPSList

Requirements forWelding Works

Inspection and Test

"After welding, the required nondestructive examination including visual inspection shall
be performed." CSP1ZZ000CZ71100003 General Welding Procedure, item 9.10:

The main activities that will be performed after welding are:

VT Visual Test
PT Penetrant Test
MT Magnetic Test
RT Radiographic Test
UT Ultrasonic Test
PMI Positive Material Specification
Hardness Test, after conclusion of PWHT Postweld Heat Treatment

There are Specific Procedures for each one of these activities. In the case of PT, MT, RT,
UT, PMI and PWHT the procedures and inspections will be made by KUMGA.

Welding/NDT/PWHTFlowchart

Requirements forWelding Works

Requirements forWelding Works

Inspection and Test
VisualTest

Visual examination is performed on all welds:

(1)
Prior to welding: to check for grooves and pipe internal cleanliness,
inside diameter alignment and observance of pipe spacing according to WPS.

(2)
After welding: to check for the absence of any defect and the good
condition of welds and tube surface ( weld reinforcement, cracks, lack of fusion on
surface, incomplete penetration when inside surface is readily accessible).

(3)
According to Brazilians requirements, the professional that can do the visual
inspection of welded joints are the Welding Inspector (Levels 1 or 2, FBTS Brazilian
Foundation of Welding Technology) and the Visual Examination Inspector (Level 2 or 3,
ABENDI Brazilian Association for Nondestructive Tests and Inspection), both qualified
according to the National System of Qualification and Certification SNQC.

A inspector report for visual examination of welded joints shall be issued by the quality
control of subcontractor, and after that, reviewed by POSCO CE and QC.

Requirements forWelding Works

Inspection and Test
VisualTest

Requirements forWelding Works

Inspection and Test
NDTand PWHT
NDT
After the Visual Examination, when approved, the subcontractor shall request the
execution of required NDT for KUMGA, company that will perform the NDE examination
and issue the inspection reports.

The staff in charge of NDE of welds shall be qualified and certified for each examination
method in accordance with NBR NM ISO 9712 (NonDestructive Testing Qualification
and Certification of Personnel).

PWHT
For PWHT, when necessary, the subcontractor shall request the PWHT company, in this
case KUMGA, to prepare and execute the heat treatment. The issued Report and Heat
Treatment Chart shall be checked and approved by the Welding Inspector of
subcontractor prior to be send for approval of POSCO QA/QC.

The performance control of preheat and postweld heat treatment shall be in accordance
with the procedures of the PWHT company and the applicable Project Work Instruction
(PWI).

Requirements forWelding Works

Inspection and Test
Hardness Test

When PWHT is applied to welded joints, the hardness test shall be performed to check
the hardness values, which is in accordance with the values specified by applicable
standards, will indicate that there has been success in heat treatment.

The responsible to perform the hardness test is the Welding Inspector of subcontractor,
that can use a helper to prepare the surface for test. The measurent of hardness can be
made by different tools, according to the description below:

EQUOTIP
HardnessTester

BRINELL
HardnessTester

Telebrineller

Ultrasonic
HardnessTester

MIC10

Measurementprecisionaveragevalue0.5%(atL800).thatis4L
InstrumentBattery1.5V6ea.About60hours lifeat 20
Temperatureaverage: 050
RS232INTERFACE
Weight : 4.6Kg(Includingcase),
Bodyweight :800g
Size:18017580mm
Weight:4.5Kg(portable)
SimpleOperation
CertifiedAccuracy:BarTestblock3%,microscopeWithin0.05mm
Weatherproof
Conversion:HV,HB,HRC,HRB&N/
UsetoHandHeldIndentor.
Displayoftheaveragevalue.
Warninggivenwithmemoryoverflow.
internalmemoryforupto1800measurements.Memorycardforupto590measurements.
Measureinanydirection.

Requirements forWelding Works

Inspection and Test
SNQC:WeldingInspectorsLevels1and2

In Brazil, the welding inspectors are qualified according to de code NBR 14842
Requirements for qualification and certification of welding inspectors and the
responsible organization to qualify the inspectors is called FBTS (Brazilian foundation of
welding technology).

This system is called SNQCIS (national system of qualification and certification welding
inspectors, in Portuguese IS means Inspetores de Soldagem) and the qualified
professional has a number that can be checked at www.fbts.org.br if this professional is
really qualified and if the qualification is valid.

There are two levels of Welding Inspectors, 1 and 2

Requirements forWelding Works

Inspection and Test
SNQC:WeldingInspectorsLevels1and2
WELDING INSPECTOR LEVEL 1
The professional hired by the subcontractor who is responsible to monitoring the welding
works and assure that the procedure are being used, makes visual inspection, analyzes the
charts of PWHT, receive welding consumables and materials, doing the respective inspection,
to execute the hardness test on welded joints if required, to monitor the welders tests
qualification and another tasks depending on the scope of the service.
All subcontractors doing welding services needs to have their own welding inspector level 1.
The quantity required will depend of the size on the work.

Requirements forWelding Works

Inspection and Test
SNQC:WeldingInspectorsLevels1and2
WELDING INSPECTOR LEVEL 2
The responsible to qualify the welding procedures, preparing and signing the welding
documents (WPSs, PQRs, WPQRs, List of qualified welders) according to the code that he is
qualified.
The welding inspector level 2 can sign only welding documents regarding the code that he
is qualified, and should be punished if does not respect this condition.
Applicable Codes
API 1104
API 650
ASME B31.1
ASME B31.3
ASME B31.4
ASME B31.8
ASME B31.2
ASME VIII DIV 1
ASME VIII DIV 2
AWS D1.1

Sample:
To build a oil storage tank, is necessary a welding inspector level 2 qualified at least in two codes, in this
case API 650 (for the tank) and the welding procedures for ladder and platform assemblies, handrails,
stairways, and other miscellaneous assemblies, but not their attachments to the tank, shall comply with
either AWS D1.1.

Requirements forWelding Works

Inspection and Test
SNQC:NDTInspectors

In Brazil, the the NDE personnel are qualified according to the code NBR NM ISO 9712
Nondestructive testing Qualification and certification of personnel and the
responsible organization to qualify the inspectors is called ABENDI (Brazilian association
of nondestructive tests and inspection).

This system is called SNQCEND (national system of qualification and certification

nondestructive testing) and the qualified professional has a number that can be checked
at www.abendi.org.br if this professional is really qualified and if the qualification is valid.

There are different levels and sublevels of NDT inspectors, the scope of work for each one
of these professionals can be checked in the ABENDI code NA001, which is based on
NBR NM ISO 9712.

Requirements forWelding Works

Inspection and Test
SNQC:NDTInspectors
NDT INSPECTOR LEVEL 2
The professional responsible to make the tests and interpret the results and judge as
acceptable or not, according to the approved procedure. Is the responsible to prepare and
sign the reports.
Sample:
LPN2G (penetrant liquid inspector)
PMN2SY (magnetic particle inspector)
EVN2S (welding visual examination inspector)
USN2S2.1 (ultrasound inspector welding examination)
USN1ME (ultrasound inspector thickness measure)

Requirements forWelding Works

Inspection and Test
SNQC:NDTInspectors
NDT INSPECTOR LEVEL 3
The responsible to prepare and sign the procedures for nondestructive testing, according to
the method that he is qualified. In some cases, is who will coordinate the NDT services and
the inspectors team.
Sample:
LPN3 (penetrant liquid)
EVN3 (welding visual examination)
PMN3 (magnetic particle)

Requirements forWelding Works

Inspection and Test
IssuanceofProcedures,RecordsandWeldingDocuments
The sample below shows how the procedures and reports are issued/signed:
Welding Documents

NDT Documents

In the case of reports for Visual Test, the signature can be by a Visual Examination Inspector or by a Welding Inspector

Requirements forWelding Works

NDECertification Levels and Sublevels from abendi NA001

Requirements forWelding Works

GeneralRequirements

The equipments and tools that are used to perform welding works can make a lot of
influence on the quality of welded joints, so its necessary take care about these
equipments.

The Welding Machines shall be calibrated by the Welding Inspector of subcontractor, according to the specific
procedure. Calibrated machines shall receive a identification TAG, describing the Equipment number, date of
calibration and date of expiration.

The Welding Team Leader / Welding Supervisor / Welding Team Leader shall request the Quality Control of
subcontractor to calibrate the welding machines, when expired the current calibration.

The warehouse department shall provide only calibrated welding machines; When uncalibrated, the quality
control of subcontractor shall be requested to do it.

The temperature meters of Dry Ovens shall be calibrated by a certified laboratory;

The portable dry ovens shall be in good conditions, and calibrated by the Welding Inspector, receiving a TAG,
similar from that used for welding

These items could be checked by POSCO and CSP, when visiting the sites. In case of irregularities, will be
issued NCRs (non conformance reports) and will take the appropriate administrative action.

Requirements forWelding Works

GeneralRequirements

Instruments and devices, like Total Station and Ultrasonic Test Instrument, from
Korea and with a certificate of calibration issued by a international certified
laboratory will be recalibrated only after the expiration date of these
international certificates.
The requirements to be followed when performing welding works shall be
according to the applicable standard codes, procedures and POSCOs
instructions.
POSCO instruction are entitled PWI Project Work Instructions. Regarding
welding works, the main documents that can be used as a reference are:

WPS LIST
AVAILABLE WPSs
PWI Welder and welding operators qualifications
PWI Welding Material Control
PWI General Welding Procedure
PWI General Repair Welding

In case of absence of procedures/instructions for a specific activity or if was verified the

necessity of changes in current procedures, POSCO CE can request support of QC Engineer to
review procedures or issue new procedures to be submitted for approval of POSCO Quality
Manager.

Requirements forWelding Works

GeneralRequirements
Safety Conditions

All personnel involved with Welding Works shall be submitted to safety

trainings to avoid accidents caused for the risks generated during the activities.

The main risks presents on welding works are related to:

Radiation
Heat
Noise
Fumes and Gases
Electricity

TheadequateProtectiveEquipmentshallbeusedin
accordancetotheexposedrisk.

The subcontractors shall issue safety procedures on which shall be included

points related to welding works. The procedures shall be according to Brazilian
regulations and POSCO and CSP requirements.

Any disrespect to safety conditions will be considered a critical nonconformity

and the work will be immediately stopped.

Requirements forWelding Works

Applicable Codes forConstruction

The equipments to be fabricated during the construction of CSP Steel Plant

shall be according to the international standard codes, and the choice of the
applicable Code is made by the client. Can be mentioned as a reference codes
to be used:

ASME American Society of Mechanical Engineers

AWS American Welding Society

ASME I Rules for construction of power boilers

ASME B31.1 power piping
ASME VIII pressure vessels
ASME V non destructive examination

AWS D1.1 Steel Structute

API American Petroleum Institute

API 650 Welded Steel Tanks for Oil Storage

Requirements forWelding Works

NonConformities
Issuance of NCRs and Corrective Actions

In case of occurrence of irregularities, the Quality Control will Issue the NCR
Nonconformance Report, according to the methodology described in the
Project Quality Manual.

The NCRs will be officially issued after approval of the Quality Manager

The dispositions to be taken will be approved by the Construction Engineers

and Site Manager of the respective plant. These dispositions can be Useasis,
Repair, Rework or Reject.

After the corrective action, the QC will check and approve, if solved the
irregularity, to close the NCR.

Requirements forWelding Works

NonConformities
Recurrence /Interruption of Work

In case of recurrence of same irregularities, without being taken corrective

actions for the first opened NCR, administrative actions below will be taken:

1 recurrence (checked during the second visitation):

Disposition: Open other NCR.

2 recurrence (checked during the second visitation):

Disposition 1: Open other NCR.

Disposition 2: The activities will be stopped since the corrective actions be applied.

Requirements forWelding Works

Requirements forWelding Works

NonConformities
Preventive Work
With the intent to avoid the recurrences of non conformities, POSCO QA/QC is
training for subcontractors.