SP-1173 Specification for Welding on on-Plot Pipework

Petroleum Development Oman L.L.C.

UNRESTRICTED Dec 2004

Document ID : SP-1173 Filing key : xxxx

Specification for Welding of On-Plot Pipe work (Amendments/Supplements (Amendments/Supplements to ASME B31.3)

Keywords:

ASME B31.3 Inspection On-plot Piping Procedure Qualification Record Production Welding Testing Welding Procedure Specification Welder Qualification

This document is the property of Petroleum Development Oman, Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

Specification for Welding of On-Plot Pipework

Version 1.2

Authorised For Issue

Signed :........................................................... UER (TTO/1) CFDH Materials and Corrosion

The following table lists the four most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No. Version 1.0

Date O5/04/00

Author OTT/15 OTT/15

Version 1.1

04/06/00

OTT/15

Scope / Remarks Revision and re-formatting of original issue of ERD 43-01. Appendix D added, minor textual corrections.

Version 1.2

25/12/04

TTO/15

Updated based on past experience

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Specification Specificatio n for Welding of On-Plot Pipe work

Contents 1. Introduction .................................................... ........................................................... .......... 1 1.1 Purpose...................................................... ........................................................... ............ 1 1.2 Changes to the Specification.... ..................................................................... ................... 1 1.3 Effective Period....................................................................... ......................................... 1 1.4 Review and Improvement .......................................................... ...................................... 1 1.5 Process Owner's Responsibility ............................................................ ........................... 1 2. Specification for On-Plot Welding ........................................................... .......................... 2 2.1 Specification Requirements ....................................................... ...................................... 2 2.2 Process Deliverables .......................................................... .............................................. 2 2.3 Performance Performance Levels / Indicators....................................................................................... 2 2.4 Performance Monitoring ........................................................... ....................................... 2 Appendix A Glossary of Definitions, Terms Terms and Abbreviations.......................................... 3 Appendix B Amendments/Supplements to ASME B31.3...................................................... 6 Contents of Appendix B: Chapter V Fabrication, Assembly and Erection ............................................................... .... 6 328 Welding ................................................................ ........................................................... 6 328.2 Welding Qualifications ..................................................................... .................... 6 328.2.1 Qualification requirements...................... ........................................................ 6 328.2.2 Procedure qualification by others....................................... ........................... 14 328.2.3 Performance qualification by others ....................................................... ...... 14 328.2.4 Qualification records............................................................... records ............................................................... ...................... 14 328.3 Welding Materials........................................................................ ....................... 14 328.3.1 Filler Metal........... ..................................................................... .................... 14 328.3.2 Weld backing material ............................................................. ..................... 17 328.3.3 Consumable inserts ......................................................... .............................. 17 328.4 Preparation For Welding..................................... ................................................ 17 328.4.1 Cleaning ........................................................ ................................................ 17 328.4.2 End preparation ....................................................... ...................................... 17 328.4.3 Alignment........................................................ .............................................. 18 328.5 Welding Requirements .......................................................... ............................. 19 328.5.1 General ................................................... ....................................................... 19 328.5.2 Fillet and socket welds ......................................................... ......................... 22 328.5.4 Welded branch connections ..................................................... ..................... 22 328.6 Weld Repair ........................................................ ................................................ 22 330 Preheating ............................................................. ........................................................ 23 330.1 General............................................... ........................................................... ...... 23 330.1.1 Requirements and recommendations............................................................. 23 330.1.4 Preheat zone ........................................................... ....................................... 23 330.2 Specific Requirements ...................................................................... .................. 23 330.2.4 Interrupted Welding .............................................................. ........................ 23 331 Heat Treatment .............................................................. .............................................. 23 331.1.1 Heat Treatment Requirements................................. ...................................... 23 331.1.4 Heating and cooling. ..................................................... ................................ 24 331.1.6 Temperature Verification ............................................................... ............... 24 331.2.2 Exceptions to Basic Requirements.... ............................................................ 24 331.2.6 Local Heat Treatment......................................... ........................................... 24 336 Handling and Storage .................................................... .............................................. 25 336.1 General............................................... ........................................................... ...... 25 336.2 Storage ......................................................... ....................................................... 25 336.3 Pipe Handling ........................................................ ............................................. 25 Chapter VI Inspection, Examination and Testing......................................................... ...... 26 340 Inspection................................................................ Inspection ................................................................ ...................................................... 26 340.4 Qualifications of The Owner’s Owner’s Inspector....................................... Inspector....................................... ..................... 26

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341 Examination.......................... ............................................................ ............................ 26 341.2 Responsibility for Examination ....................................................... ................... 26 341.3 Examination Requirements................ ................................................................. 26 341.3.2 Acceptance Criteria ........................................................... ............................ 26 341.4 Extent of Required Examination.................................................. ....................... 26 341.4.1 Examination Normally Required................................................................... 26 342 Examination Personnel.................................................................. ........................... 27 342.1 Personnel Qualification and Certification........................................................... 27 343 Examination Procedures ................................................................... .......................... 27 344 Types of Examination .............................................................. .................................... 28 344.1 General............................................... ........................................................... ...... 28 344.2 Visual Examination................................................................. ............................ 28 344.3 Magnetic Particle Examination................................................................... ........ 28 344.4 Liquid Penetrant Examination .......................................................... .................. 28 344.5 Radiographic Examination.................................................................................. 28 344.5.1 Method .......................................................... ................................................ 28 344.6 Ultrasonic Examination ............................................................ .......................... 29 344.6.1 Method .......................................................... ................................................ 29 345 Testing ......................................................... ............................................................... ... 29 345.1 Required Leak Test............................................................... .............................. 29 346 Records........................................................ ........................................................... ....... 29 346.1 Documentation.................................. ............................................................... ... 29 347 Certificate of Conformity ....................................................... ..................................... 30 Table 1 Extent of Non-Destructive Testing for Welds ........................................................ 31 Figure 1 Hardness Indent Locations ................................................................. ............. 33 Figure 2 Orientation and Location of Charpy Impact Specimens .............................. 34 Appendix C References.................................................................. ........................................ 35 Appendix D WPS and PQR Forms...................................................................... ................. 36 User Comment Form ...................................................... ........................................................ 43

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1.

Introduction

1.1

Purpose

Version 1.2

This specification is a revision of SP-1173 version 1.1, Specification for Welding On-Plot Pipe work, issued in June 2000. The purpose of this document is to define the minimum technical requirements for the fabrication, welding, inspection and non-destructive testing of carbon, low alloy and austenitic stainless steels for on-plot pipe work. This specification shall be used where the applicable code has been designated by the Company as ASME B31.3, Process Piping. SP1173 version 1.2 is based o n ASME B31.3-2002.

1.2

Changes to the Specification This Specification shall not be changed without approval from the Custodian, CFDH Materials and Corrosion), who owns this Specification. If you think any part of this specification is not correct, write your comments on a copy of the User Comments Form. The form is included as the last page of this Specification. Send the copy with your comments and personal details to DCS.

1.3

Effective Period The requirements of this specification shall remain in force indefinitely unless superseded by an authorised revision.

1.4

Review and Improvement This specification will be reviewed and updated once every three years. The review authority will be CFDH Materials and Corrosion.

1.5

Process Owner's Responsibility The owner of this specification is the CFDH of Materials and Corrosion, is responsible for authorising all proposed deviations or amendments to the specification and for the instigation of periodic reviews and updates in accordance with Clauses 1.2 and 1.4

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2.


Specification for On-Plot Welding This specification gives the minimum requirements for the welding, fabrication and inspection of carbon steel, low alloy steel and austenitic stainless steel on-plot pipe work. The specification is restricted to applications for which the applicable Code for pressure piping is designated by the Company as ASME B31.3, Process Piping. This document is not applicable to the welding of duplex/super-duplex stainless steel and high alloyed austenitic stainless steels such as UNS S31254, Nickel alloy, Class 1 pipelines,* Class 2 and 3 pipelines,* pressure vessels, storage tanks, or structural steelwork. It is also not applicable to the welding of materials other than those listed above except as specifically agreed with the Company CFDH Materials and Corrosion. * Pipeline classes are defined in SP 1211 (November 2004), Pipeline Engineering.

2.1

Specification Requirements Welding, fabrication and inspection shall be in accordance with the requirements of ASME B31.3 (latest version), as amended and supplemented by Appendix B of this specification. The Clause numbering in Appendix B follows that of ASME B31.3 (2002). Where clauses of ASME B31.3 are not amended or supplemented by Appendix B, they shall apply in their entirety.

2.2

Process Deliverables Process deliverables comprise shop or field welded carbon, low alloy or austenitic stainless steel pipe work and related welded fabrications designed to ASME B31.3 and normally intended for on-plot oil, gas or water service.

2.3

Performance Levels / Indicators See relevant ASME B31.3 weld inspection and testing acceptance criteria and the amendments given in Appendix B of this specification.

2.4

Performance Monitoring Requirements for monitoring welding process variables, welder performance and weld quality are detailed in relevant sections of ASME B31.3/ASME IX and the amendments given in Appendix B of this specification.

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Appendix A Glossary of Definitions, Terms and Abbreviations Certain terms and abbreviations used in this document are defined below. definitions shall be considered to supplement those given in ASME B31.3.

The listed

General Definitions Contractor

The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility. The Company may undertake all or part of the duties of the Contractor.

Manufacturer/ Supplier

The party, which manufactures or supplies equipment and services to perform the duties specified by the Contractor for the Company.

Company

Petroleum Development Oman LLC. The Company will generally specify the technical requirements. The Company may also include an agent or consultant authorised to act for, and on behalf of, the Company.

User

The Company, Consultant or Contractor who uses this document.

Corporate Functional Discipline Head

The person within the Company responsible for the discipline to which this specification belongs.

shall

Any deviation to the requirement shall be approved by the CFDH.

should

Any deviation to the recommendation shall be approved by Company Welding TA-2.

may

Indicates a possible course of action.

Specific Definitions Batch or Lot

As defined in AWS A5.01, Clause 5 (Classification) and Clause 6 (Testing)

Nominal Thickness

Nominal thickness T shall have the following meanings: - butt joint; parent metal thickness, which for joints between dissimilar thicknesses is that of the thinner material. - fillet weld; parent metal thickness, which for joints between dissimilar thicknesses is that of the thicker material. - set-on branch connection; thickness of branch pipe - set-through branch connection; thickness of main pipe.

Owner

Term used in ASME B31.3 that shall be understood to mean the Company.

Verified copy

A photocopy of an original document, which has been re-endorsed and signed by the organisation producing the photocopy to verify that none of the information has been adulterated.

Welding Co-ordinator

The Contractor nominated authority on the quality aspects of welding. The Welding co-ordinator shall be a Welding Engineer meeting the recommendations for European Welding Engineer (refer ISO 14731). However, other national/international qualifications may be considered at the discretion of the Company. The Welding Co-ordinator shall be approved by the Company TA-2 (Welding).

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Examples of Piping Steels Non-impact tested carbon steel, (CS)

ASTM A 106 B, A 105, A234-WPB

Impact tested carbon steel, (LTCS)

ASTM A 333 Gr. 6, A350 LF2, A420 WPL 6

3 ½ % Nickel Steels

ASTM A350 LF3, A420 WPL3

Abbreviations ASNT

American Society for Non-destructive Testing

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

AWS

American Welding Society

CFDH

Corporate Functional Discipline Head

CS

Carbon Steel

CSWIP

Certification Scheme for Welding Inspection Personnel

D

Nominal Outside Diameter

DCS

Document Control Section

EMR

Extra Moisture Resistant

FN

Ferrite Number

GTAW

Gas Tungsten Arc Welding

HAZ

Heat Affected Zone

HV

Vickers Hardness

ITCS

Impact Tested Carbon Steel

MDMT

Minimum Design Metal Temperature

MT

Magnetic Particle Testing

NACE

National Association of Corrosion Engineers

NDT

Non-Destructive Testing

PAMS

Portable Arc Monitoring System

PCN

Personnel Certification in NDT

PQR

Procedure Qualification Record

PT

Liquid Penetrant Testing

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PWHT

Post Weld Heat Treatment

RT

Radiographic Testing

SAW

Submerged Arc Welding

SMAW

Shielded Metal Arc Welding

t

Thickness of Deposited Weld Metal

T

Nominal Thickness, (see also Specific Definitions above)

TA

Technical Authority, as defined in ERD-00-02 and PDO GU-272.

UT

Ultrasonic Testing

WPS

Welding Procedure Specification

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Appendix B Amendments/Supplements to ASME B31.3 Chapter V Fabrication, Assembly and Erection 328

Welding Delete introductory paragraph and replace as follows: Welding shall be performed in accordance with the requirements of ASME B31.3 (latest edition) and the amendments and supplements of this specification. The Contractor shall maintain and operate a quality system that shall be in accordance with ISO 9001: 2000 and SP-1171. A quality system based on alternative standards to those of ISO-9001 may be considered for agreement by the Company. All welding and related activities shall satisfy the requirements of ISO 3834-2 and additional requirements of this standard (certification by Third Party Inspection Agency is recommended but not mandatory). It is recommended to follow the guideline given in PD CR 13576.

328.2 Welding Qualifications 328.2.1 Qualification requirements Delete the last clause from 328.2.1 (e), starting at: “except that a procedure.........” Add the following at the end of 328.2.1:

328.2.1.1

General

The Contractor shall submit WPSs and a weld register or weld map detailing the weld joints for Company approval at least two weeks prior to commencement of welding activities, taking into consideration material grade, thickness, diameter etc. The Contractor may select the following options for the WPS qualification:1. Use PDO pre-qualified PQRs in accordance with PR-1272. 2. Qualify WPSs in accordance with this specification. 3. The Contractor's own PQRs may be employed subject to the following: - PQR is fully in accordance with this specification. - WPS is amended to reflect the project specific details. WPS and PQR are owned and controlled by the Contractor. Note: Any welding procedure qualified to meet project specific requirements for which the Company has paid/reimbursed the cost of qualification shall be owned by the Company. The Company will keep original PQR copies.

328.2.1.2

Welding Procedure Specification.

The WPS should be in the format shown in Appendix D of this specification and shall contain the following details in addition to the requirements ASME B31.3: • Material maximum carbon equivalent. • Service conditions, (sour / non-sour) • Minimum design metal temperature (MDMT) • Filler metal Trade name, Manufacturer and, Plant of origin. • Shielding gas flow rate and composition for each pass. • Backing gas flow rate and composition for each pass. • Number of weld passes where gas backing is required. • Qualified weld deposit thickness for each process, filler wire and/or electrode used. • If pulse welding is used, the range of pulse parameters. • Welding parameters & Heat input range. • Method of clamping/tacking, including details of removal. • Holding time and temperature for baking electrodes, including re-baking requirements.

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The following non-technical details shall also be included in the WPS: • Date • Revision number • Contract number • Project Title • Contractor Logo • Signature and endorsement of Contractor • Client: PDO Test welding shall not commence until the WPS proposal has been stamped 'Approved for Qualification' with the date and the contract number, and signed by a Company welding Technical Authority level 2.

328.2.1.3

Essential Variables

The essential variables and supplementary variables (if applicable) shall be in accordance with ASME IX and the modifications in this specification. If any changes are made beyond the indicated limits, the welding procedure shall be set up as a new WPS and shall be completely re-qualified. (a)

Welding process

Any change in the welding process or change from manual to automatic operation or vice versa. It is not permitted to change a multi-run deposit into a single run (or single run on each side) or vice versa for a given process. In a multi-process procedure test, the approval is only valid for the sequence of welding processes used.

(b)

Base materials

For sour service or low temperature application i.e. MDMT is below – 29 C, 1. an increase in the carbon equivalent value greater than 0.03 units shall also be considered an essential variable, if CE of production material (pipe, fittings etc.) is between 0.36 to 0.40 or minimum heat input applied in any pass is less than 0.8 KJ/mm 2. any increase in CE if CE of production material is more than 0.40 For non-sour service and non-low temperature application i.e. MDMT is above or equal to – 29o C. 3. an increase in the carbon equivalent value greater than 0.04 units shall also be considered an essential variable, if CE of production material is between 0.38 to 0.43 or minimum heat input applied in any pass is less than 0.8 KJ/mm 4. any increase in CE if CE of production material is more than 0.43 Qualifications carried out on 3 ½ % Nickel steels shall only qualify that material. For welding 3 ½ % Nickel steels to other material where impact properties are required, specific procedures shall be qualified using the particular combination of dissimilar materials.

o

Welding procedure tests conducted on impact tested materials for low temperature service less than 5 mm thick need not be impact tested. However, such procedures shall not qualify for thickness greater than 5 mm. For API 5L Grade X 60 or higher grade, Welding procedures shall be qualified for each specific material grade separately. (c)

Thickness

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The thickness limits tabulated below shall be applied to welds that are not subject to PWHT. Where PWHT is specified, the thickness limits of ASME Section IX shall apply.

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Thickness of Welded Coupon (1) (mm) < 4.8 4.8< T < 19 (2)

Material**

Welding Process

Range of Qualified Thickness (mm)

All All

(Manual / Automatic) Manual Manual

25> T<35

C Steel

Manual

Base Metal, T Min. Max. T 2T 0.5T 2T or 19 whichever is less 0.5T 35

Weld Metal, t Max. 2t 2t

35

(3)

Notes: (1) The controlling thickness for branch welds and for butt welds between materials of dissimilar thickness shall be as defined in Appendix A, Specific Definitions. (2) For grades where impact testing is required, when the test is carried out on a thickness < 12 mm, approval is limited to 12 mm max. Thicker sections require supplementary impact testing (3) This limit shall apply only when all requirements specified under section 331.2.2 of this specification are met.

(d)

Diameter (D)

A change in pipe or branch diameter outside the following ranges: D < 168.3 mm; 0.5 D to 2 D D > 168.3 mm; > 0.5 D and plates For set-in branch welds, D is the outside diameter of the run pipe and for set-on branch welds, the outside diameter of the branch pipe. Approval given for a welded plate qualification also covers pipes of D > 600 mm.

(e)

Joint design

•

(f)

Welding position

Where a joint bevel angle of less than 60° is used for qualification, a decrease of more than 5 d egrees shall require re-qualification. • For non-sour service, single bevel and double bevel (K) preparations qualify single vees and double vees (X) respectively but not vice versa. For sour service, single-sided and double-sided preparations shall be separately qualified. • All other preparation shapes require separate qualification. However, for SMAW only, changes between single and compound angle V preparations without re-qualification may be permitted, subject to the approval of the Company welding TA-2. Removable backing strips or inserts, if permitted, require separate qualification. PQRs qualified in the 6G or 2 G and 5 G positions with the same essential variables shall cover all positions in production welding. When neither impact testing nor maximum root hardness values of < 250 HV are specified, welding procedure qualification in the 3G or 5G or 6G position qualifies all other positions.

(g)

Welding progression

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When either impact tested materials are used and/or sour service is specified, impact test specimens shall be taken from the weld made in the highest heat input position and hardness test specimens shall be taken from the weld made in the lowest heat input position in order to approve for all positions. A change f rom uphill to downhill or vice versa.

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(h)

Filler metal/electrode and flux

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For sour service or when impact tested materials are used: Any change in size, classification, plant of origin or trade name. It is permissible to change the specific make of filler metal to another with the same compulsory part of the classification when an additional test piece is welded. The test piece shall be welded using the identical welding parameters as the original weld procedure test and only weld metal impact test specimens shall be tested and hardness survey carried out For non-sour service or when non-impact tested material are used: Any change of consumable classification. Only one size variation between the electrode (SMAW) or filler metal (GTAW) size used for qualification test and for subsequent production welding may be permitted. However, for the root pass of single side welds, any increase in consumable size is considered as an essential variable. For SAW and FCAW welds, any change in size, classification or trade name. Any change in Tungsten electrode size shall be considered as an essential variable. Consumables with a “G” classification shall be restricted to the brand and type of electrode used for PQR. The nominal chemical composition of the specified brand and type shall be identified on the WPS.

(i)

(j)

Shielding or backing gas flow Shielding or backing gas composition

A change of more than ±20% in shielding or backing gas flow or the discontinuance of backing gas purging at a stage earlier than that of the qualification test. Any change.

(k)

Number sequence passes

and For sour service or when impact tested materials (ITCS) are used, any of change in the sequence of capping passes, (use of temper bead technique).

(l)

Electrical characteristics

A change of electrode polarity or current type, including the addition or deletion of pulsating current.

(m)

Welding parameter s

Any change in welding current greater than 15% of that qualified. The stick-out length for FCAW, GMAW, and SAW shall not be changed beyond the range specified in the WPS.

(n)

Heat input

The calculated average heat input per pass shall not be decreased by more than 20 % for non-sour service or by more than 10 % for sour service. For stainless steels, any change greater than + 15 %. When impact testing is required as per ASME B 31.3, any change greater than + 5 % Note: As an alternative for SMAW, the maximum bead size and minimum length of weld bead per unit length of electrode used in the welding of the test sample may be used to monitor production welding.

(o)

Preheat or interpass temperatur e

Any reduction in preheat temperature. Any increase of more than 50°C when supplementary variables are applicable. Any increase of more than 100°C when supplementary variables are not applicable. For 3½% Nickel steels, any increase in preheat tem perature and any reduction in preheat temperature more than 25°C.

(p)

Post weld heat treatment

328.2.1.4

The addition or deletion of PWHT and any change in heat treatment holding temperature of more than + 20°C.

Test welding

The Contractor shall give the Company a minimum of 48 hours notice of the intention to proceed with test welding so that the Company may organize witnessing arrangements.

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Prior to the commencement of test welding, the Contractor shall have available at the test site the following documents for verification by the Company: • • •

•

Original copy of the WPS proposal, endorsed ‘Approved for Qualification’ Originals or verified copies of the material certificates for the items of the test coupon Originals or verified copies of the batch test certificates for the welding consumable, (see 328.3.1). Approved consumable handling procedure.

Test welding shall not commence until the Company has reviewed and accepted the documentation. All test welding shall be witnessed by a Company representative having a welding technical authority level 3 or higher. The Contractor’s Welding Coordinator who is approved by the Company shall supervise the entire welding procedure qualification process. The Contractor shall be responsible for examination and shall have a Company approved welding examiner (Sr. Welding Inspector) present throughout test welding and NDT of the welds. NDT shall only be performed by Company registered NDT Subcontractors. The Contractor shall have a minimum of one Company approved calibrated portable arc monitoring system with hard copy facility available to record welding parameters. No test welding is permissible without recording the welding parameters using a calibrated portable arc monitor . The following information shall be recorded for each pass of the test weld and shall form part of the PQR: • • •

• • • • • • • • • •

Pass number & pass sequence Welding process Consumable diameter, classification (non-consumable electrode diameter, classification if applicable) Consumable trade name (including flux for SAW) Electrode polarity Gas composition Gas flow rate Arc voltage Current Wire feed speed Travel speed Preheat temperature Interpass temperature

The test weld information shall be recorded on welding parameter sheets which shall have Contractor name and logo, and shall be attached to a completed PQR form which should be as shown in Appendix D of this specification. Pass sequence shall be shown in the sketch on the PQR form. The original portable arc monitoring system print-out shall be included as part of the PQR. The welding records of the test welding shall be signed, dated, and endorsed by the Contractor's welding examiner (Welding Inspector) and Welding Co-ordinator and the Company welding TA-3 present at the time of test welding. If post-weld heat-treatment is required, a heat treatment record chart shall be produced and shall be endorsed by the Contractor welding co-ordinator, the heat treatment subcontractor if employed, and the Company welding TA-3 if present during heat treatment. The chart shall be included in the PQR. All required post weld heat treatment shall be completed before final non-destructive and destructive testing. No testing of weld test pieces shall commence without completion of the welding parameter reports verified and signed off by the Company welding TA-3 present at the time of test welding

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Average Heat input per pass shall be calculated using the total arc time, weld length and average voltage and average current used per pass.

328.2.1.5

Examination of the test coupon

The examination of the test coupon shall not take place until a minimum of 24 hours have elapsed after completion of test welding. Where post-weld heat treatment is necessary, this shall be applied after the minimum 24 hour period and before NDT. The test coupon shall be at ambient temperature prior to NDT. All examinations shall be performed in accordance with clauses 340 to 344.7.2 of ASME B31.3 and this specification. The visual inspection report shall be signed by Contractor's inspector who carried out the visual examination and the Company representative who witnessed the examination. If the test is witnessed by third party agency, their representative shall also sign the visual inspection report. If the test weld is visually accepted, it shall be offered for radiographic or other examination as required examination. Radiography shall be performed in accordance with clause 344.5 of the ASME B31.3 and SP-1176. The radiographic report shall be signed by the technician and the Contractor's welding coordinator prior to presenting the radiographs to the Company welding TA-3 with interpretation qualification for viewing. After viewing, the Company representative shall sign and endorse the radiographic report and it shall be incorporated into the PQR. If the disposition of the test weld is acceptable it shall be subjected to destructive testing at a Company registered test laboratory.

328.2.1.6

Destructive testing of the coupon

Testing for procedure qualification shall be performed in accordance with ASME IX and the additional requirements in Paragraphs (a) to (c), following. All testing shall be witnessed by the Company welding TA-3 or a Company approved third party inspection agency if agreed by the Company Welding TA-2 authority in writing. The Contractor shall confirm the availability of the Company Representative. In the event of the Company welding TA-3 not witnessing the testing, the Contractor shall be responsible for the engagement and hiring of the inspection agency. All test reports shall be endorsed and signed by the testing organisation, the Contractor, and the inspector who witnessed the testing. Where an inspection agency has witnessed the testing, the agency shall sign and stamp with their organization seal, all test reports and also issue a Certificate of Conformance, which states that the testing practices and procedures were in compliance with ASME B31.3 and this specification. The test reports and certification shall be included in the PQR.

(a) Macroscopic examination and hardness tests. Preparation Specimens shall be prepared for macroscopic examination by grinding or other suitable method to 600 grit paper finish. The prepared surface shall be etched using a suitable etchant to reveal the pass sequence, HAZ, defects etc. The sections of the weld taken for macroscopic examination shall be used for hardness Testing. Method The hardness shall be measured in accordance with ASTM E92 using 10 kg Load. For pipe butt welds the hardness indentations shall be as shown in figure 1 of this specification. For pipe of less than 9.5 millimetres, the mid-thickness hardness traverse may be omitted. The macro-sections shall be examined at a magnification of x5 and the macro-photographs or computer printouts of macro photographs of the same magnification showing the hardness indentations included in the PQR.

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Requirements The macro-sections shall not show defects exceeding the acceptance standards given in section VI of ASME B31.3. Each specimen shall exhibit a smooth and regular profile and the reinforcement shall blend smoothly with the parent metal. For material designated to meet sour service requirements of NACE MR0175, the maximum root and mid-thickness hardness shall be 250 HV10. A maximum cap hardness of 275 HV10 shall be permitted if the thickness of test specimen is more than 9.5 mm. Where sour service requirements are not designated, maximum hardness shall not exceed 325 HV10.

(b) Charpy V - Notch impact testing Impact testing shall be as required by ASME B31.3, except as modified below. When the nominal pipe wall thickness is less than or equal to 19 mm, one set of three specimens shall be taken at each of the following positions: • Root weld centre line. • Root fusion line (50% intersection of notch). • Root fusion line + 2 millimetres. When the wall thickness exceeds 19 mm, an additional set of three specimens shall be taken at each of the following positions: • Cap weld centre line. • Cap fusion line (50% intersection of notch). • Cap fusion line + 2 millimetres. When the wall thickness exceeds 19 mm and no PWHT is applied, impact-testing of the weld is mandatory. The test temperature and acceptance criteria shall be in accordance with ASME B31.3. Impact testing is not required if non-impact tested grades of carbon or carbon manganese steel are welded to impact tested g rades (ITCS).

(c) Corrosion test For austenitic stainless steel welds, and dissimilar metal welds involving austenitic stainless steel, one specimen shall be subjected to an intergranular corrosion test in accordance to A262 Practice E. The specimen shall be a root bend type in the as welded condition. The acceptance criterion shall be no intergranular corrosion.

328.2.1.7

Re-tests

With the exception of Charpy tests and hardness tests, if any one mechanical test specimen fails to meet the minimum requirements, the test coupon shall be considered as failed, and a new test coupon shall be welded. The Contractor shall notify the Company of the test failure. For Charpy tests, if the specified minimum average value has been achieved and more than one specimen is below the specified minimum average value, or one specimen is below the specified minimum individual value, a re-test of three further specimens shall be made. The test results shall be accepted if all three individual retest values are equal to or exceed the specified minimum average value. If only one hardness result exceeds the specified maximum, then a minimum of three further indentations shall be made in close proximity to that which failed such that they do not mutually interfere. If all of the further tests are below the maximum specified hardness the test

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shall be accepted. The Contractor shall notify the Company of the test failure and obtain written Company approval to proceed with re-tests.

328.2.1.8

Approval of the WPS

Subsequent to successful non-destructive and destructive testing, the Contractor shall submit the original PQR showing endorsement and signatures of the Contractor, the testing subcontractor, and the Company welding TA-2/3. The Contractor shall also submit a copy of the WPS to be used for production welding and, if necessary, a revised welding procedure register for review and approval by the Company. Production welding shall not commence until the WPS has been endorsed ‘Approved for Fabrication’ with the date and the contract number, and signed by a Company Welding TA-2. Only those WPSs shown on the approved WPS register shall be used in production. For C & C-Mn steels with SMYS <360N/mm2 and austenitic stainless steels (316L) PQRs qualified by contractor may be acceptable to the Company without the need to be witnessed by the Company, provided the following conditions are met: •

Witnessed by Company approved Welding Engineer.

•

Endorsed by a competent third party inspector.

•

Meets all requirements of this specification.

328.2.1.9

Performance Qualification

Welders and welding operators shall be qualified in accordance with the requirements of ASME IX and of this specification. For sour and low temperature applications, any change in heat input range which necessitates re-qualification of the WPS shall also require requalification of the welder. For sour and low temperature applications, welding parameters shall be monitored and recorded using a calibrated portable are monitor. Test welding shall be performed in accordance with a WPS endorsed as ‘Approved for Fabrication’. Welding and testing shall be witnessed by a Company welding TA-3. Butt weld test pieces shall be subjected to visual examination, and bend testing to the requirements of ASME IX, QW-302. Bend tests may be replaced with radiographic examination for non-sour applications and when non-impact test materials (non-ITCS) are used. Visual examination, radiography and bend testing shall be applied for thicknesses greater than 19 mm. The Company shall be given a minimum of 48 hours notice of intention to perform welder qualification in order to witness the test welding. A welder who fails to meet the acceptance criteria shall be allowed an immediate re-test. A welder who fails to meet the acceptance criteria after the first re-test shall not be allowed a second re-test within seven days. The Contractor shall demonstrate that the welder has undergone training in that period. Failure to demonstrate training shall prevent the welder from being re-tested. Performance qualification data shall be recorded by the Contractor on format similar to ASME form E00008 (QW-484). The form shall then be endorsed and signed by the Contractor and the Company TA-3 who witnessed the test welding. The Contractor shall assign to each welder a unique identification number, letter, or symbol to ensure traceability to specific welds. If the welder ceases to work for the Contractor, the unique identification shall not be re-assigned to another welder. The Contractor shall issue each qualified welder a badge, endorsed by the Company, bearing the welder’s name, photograph, identification and WPSs for which the qualification is valid.

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Welders not wearing badges shall be suspended from production welding until such time as the badge can be produced.

328.2.1.10

Performance Qualification Validity.

Welders shall undertake qualification in accordance with clause 328.2.1.9 of this specification: • Prior to commencing work on any WPS not covered by their existing qualifications • After a period of one year from the date of the original qualification if the welder’s repair rate exceeds 3 % of NDT tested joints over a period of one year. • When the welder’s repair rate exceeds 5% of NDT tested joints per month over a period of three consecutive months. If there is any specific reason or concern by the Company welding TA-3 to doubt the welder’s ability to deposit welds that meet this specification, i.e. poor workmanship etc or when the welder’s repair rate exceeds 15% of NDT tested joints for a month or when the welder has not welded with the process for 3 months or more. Welders shall have a valid Company qualification within the validity defined in this specification or they shall be qualified using the ‘Approved for Fabrication’ WPS. The Contractor shall keep a welder performance record for all qualified welders. This shall show continuing performance with objective evidence including statistical details of weld repair rate. These records shall be accessible to PDO at all reasonable times for verification and endorsement by a Company Welding TA-3. Performance qualifications can be renewed for further six month periods based on this endorsed performance record. At any time, if a welder’s performance is not satisfactory; the Company welding TA-3 has the right to withdraw that welder’s qualification card and approval.

328.2.2 Procedure qualification by others Delete existing section and replace as follows: Procedure qualifications made by another contractor or sub-contractor shall not be accepted except as permitted by section 328.2.1.1 of this specification.

328.2.3 Performance qualification by others Delete existin g section and replace as follows: Performance qualifications made by another contractor or sub-contractor (employer) shall not be accepted.

328.2.4 Qualification records Add the following: The Company has the ownership of the approved PQRs of all welding procedures qualified during the execution of Company projects when Company is reimbursed or paid the cost for the qualification. The Contractor shall submit original copies of such PQRs to the Company after their completion and approval.

328.3

Welding Materials

328.3.1 Filler Metal Add the following, including new sub-sections 328.3.1.1 to 328.3.1.4: Company approved manufacturers shall be used.

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Low hydrogen consumables (defined as less than or equal to 10 ml of hydrogen per 100 g of deposited weld metal) shall be used for the applications listed below. Low hydrogen consumables should be used whenever possible for other applications: 1 2 3 4 5 6 7

All piping, if the wall thickness exceeds 12.7 mm, (non-low hydrogen electrodes permitted for the root pass only) All piping, if sour is specified, (non-low hydrogen electrodes permitted for the root pass only) All piping, if operating temperature below 0 ºC is specified Repair welds Tie-in joints All fillet welds Branch welds (set-on or set-in) where the branch pipe thickness is g reater than 12.7mm, (non-low hydrogen electrodes permitted for the root pass only)

If base metal is exempted from impact toughness testing, the weld metal shall have a toughness equal to or greater than 27 J at either 00 F (-180 C) or the minimum design metal temperature, whichever is lower. The weld metal shall be certified by the filler metal manufacturer according to ASME Section II (Part C), if approved the Company welding TA-2, shall be established by the PQR. Austenitic Stainless steel welding: Unless otherwise specified, for materials requiring PWHT or materials in high temperature service (see ASME Section II, Part D, Table 6-360), the Ferrite number (FN) for the deposited weld metal shall not exceed 11 FN measured prior to PWHT. The minimum Ferrite Number for filler metal shall be 3 FN except as noted below. 1. 2.

The minimum FN for type 347 shall be 5 FN When welding stainless steels for cryogenic service, non magnetic applications or special corrosive service, consumable with a lower FN may be used.

328.3.1.1

Consumable Certification for Non-Sour Service.

Consumables shall have a Certificate of Compliance issued by the Manufacturer in accordance with ISO 10474 grade 2.1 and it shall have the following minimum information: • • • • •

Lot or Batch No. (In accordance with AWS 5.01, see Appendix A) Place of manufacture Date of manufacture Electrode trade name, size and AWS identification The Specification to which it complies.

328.3.1.2

Consumable Certification for Critical Applications

Critical applications include the following: • Sour service • Low temperature service • Post Weld Heat treatment is applied Note: Contractors/Vendors must review and understand the definitions of Batch/Lot and Classification as given in AWS-5.01. Covered electrodes must comply with Class C3.

Other applications may be identified by the Company. The consumables shall be delivered according to the manufacturer’s data sheet and certified in accordance with ISO 10474 grade 3.1.B. The inspection certificate shall be traceable to the plant of origin and shall include the date of manufacture and the specifications used for the tests. Certification shall contain chemical analysis of weld metal including C, Si, Mn, P, S and any other intentionally added element. The levels of impurities maximised in the data sheet or classification code shall be stated or a guaranteed maximum may be given. The data sheet shall contain guaranteed values of mechanical properties, including impact test data, applicable

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over the recommended welding parameter range. If the consumable is to be used for welds in the PWHT condition, then the properties shall also be documented in the PWHT condition. Batch testing of the welding consumables using contract materials, as part of weld procedure qualification, is also acceptable. All filler metals shall have classification society (e.g., Lloyd's, DNV) type approval. Filler metals proposed by Contractor/Vendor that do not conform to an AWS specification shall be submitted to the Company for approval. Testing is required (at the Contractor’s/Vendor’s expense) to verify consumable mechanical properties whenever: •

•

The deposited filler metal does not fall within any of the AWS filler metal specifications. Manufacturer’s typical consumable certification or other supplier certification are not available.

When PWHT is required for either of th e above, all-weld metal test coupons shall be po st weld heat treated with the nominal temperature and maximum time to be used in production. The tensile strength, yield strength, and elongation shall meet the base metal properties. For carbon steels, the maximum nickel content of the deposited weld metal shall be 1%. For low temperature service, the welding consumables shall comply with the design code requirement.

328.3.1.3

Storage and handling of filler metals and fluxes

Electrodes, filler wires and fluxes shall be stored in a dry storage room in accordance with the manufacturer's instructions. Consumables shall remain in their original containers which shall be marked with the manufacturer's name, the consumable trade name, and the batch number. Consumable in containers that are not identifiable and traceable shall be removed from the job site to the satisfaction of the Company. The storage room shall have a maximum relative humidity of 50%, which shall be monitored in accordance with an agreed procedure. Consumables delivered in containers that exhibit physical damage, shall be examined for damage. Consumables that show signs of damage or deterioration shall be disposed of to the satisfaction of the Company. All manual electrodes shall be properly identifiable up to the time of usage, each electrode being distinguishable by a coding marked near the grip end. Electrodes without a code marking shall not be used. Wire spools shall be stored in cabinets with the supplier's wrapping in place and shall remain clearly identifiable up to the point of usage. Unidentifiable wire shall not be used. Flux shall be handled and stored in accordance with the flux manufacturer's recommendations. The Contractor shall furnish the Company with data-sheets for the flux prior to its arrival at site. Flux shall remain identifiable and traceable. Recycling shall not be permitted. Basic low-hydrogen electrodes, after removal from the containers, shall be baked in ovens in accordance with the manufacturer’s instructions, such that the diffusible hydrogen content does not exceed 10ml/100g of deposited weld metal. Electrodes supplied in hermetically sealed containers and Extra Moisture Resistant (EMR) electrodes shall be used as per manufacturer’s instructions. The electrodes shall be transferred to holding ovens set at 150°C after baking, from where they shall be issued to heated quivers maintained at a minimum of 70oC. The maximum stacking height shall be four layers. The baking ovens and the holding ovens shall have automatic heat controls and a temperature read-out display. A ‘map’ or other acceptable method shall be employed so as to identify the contents and their location in the baking and holding ovens. Oven internal storage arrangements shall not allow intermixing of different electrodes (manufacturers and/or sizes).

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Consumable control shall be such that any basic coated electrodes shall be used within four hours of issue to a quiver. Those electrodes not used within four hours shall be returned to the baking oven for re-baking. Where this is not possible due to operational reasons, vacuum seal packed electrodes shall be used, (for which the requirement for issue into a heated quiver shall still apply). Electrodes shall be baked a maximum of two times, i.e. one initial bake and one re-bake. The Contractor shall have a system for identification of re-baked electrodes. Prior to the commencement of qualification or production welding, whichever is sooner, the Contractor shall submit a consumable handling procedure to the Company for review and approval. Test welding or production welding shall not commence until the consumable handling procedure has been approved by Company TA Level 2 or higher.

328.3.1.4

Shielding gases

The shielding and purge gas shall be certified as complying with ISO 14175 or AWS 5.32 or equivalent. The purity or component concentrations of the gas shall be as specified on the WPS and shall be the same for procedure qualification and production welding. Other requirements on the use of shielding gases are included in sections 328.1 and 328.5.

328.3.2 Weld backing material Delete existing section and replace as follows: Permanent backing rings shall not be used. Removable backing rings may be used if agreed by the Company Welding TA-2 authority.

328.3.3 Consumable inserts Add the following: Consumable inserts may be used only with the agreement of the Company welding TA-2.

328.4

Preparation For Welding

328.4.1 Cleaning Delete existing section and replace as follows: Fusion faces and the surrounding surfaces within a minimum of 25 mm of the joint shall be free from heavy scale, moisture, oil, paint, or any other substance which may have a deleterious effect on weld quality.

328.4.2 End preparation (a) General Del ete existing clause (1) and replace as follows: (1) Bevels shall normally be machined or prepared by grinding. Preparation of weld edges by plasma cutting is permissible provided a mechanically guided torch is used. Prepared edges shall meet the cleanliness requirements of clause 328.4.1 of this specification. For stainless steel welding, equipment used for grinding and cleaning of edge preparations shall be dedicated for stainless steel work. Wire brushes shall be of stainless steel. Ad d the following new clauses (3) - (5): (3) The cut surface shall be ground to a smooth, bright uniform finish by removing approximately 0.5 mm of metal. After grinding, the weld edges and surrounding material

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shall be cleaned and visually examined to ensure freedom from cracks, notches or other defects which may affect weld quality. Any bevelled edge that has been damaged shall be restored by machining or grinding within the tolerances required by the welding procedure to be applied. Restoration involving welding shall not be permitted. (4) All new weld bevels shall be visually inspected. If any indication is observed then the entire bevel shall be removed and the pipe shall be ultrasonically examined for laminations over a zone of 50 mm back from the new bevel edge. The acceptance criteria shall be that the maximum dimension of the minor axis of the lamination shall not exceed 6.3 mm and 2 the maximum product of the major and minor axes shall not exceed 50 mm . (5) For preparing branch connections, a zone 50 mm wide around the outside diameter of the proposed hole shall be checked by UT for laminations. After cutting and preparation, the complete bevel shall be MT or PT examined. The procedure and acceptance criteria shall be those specified for cut back in the preceding paragraph, 328.4.2(a), clause (3).

(b) Circumferential welds Delete existing clause (4) and replace as follows: (4) The deposition of weld metal to rectify internal misalignment shall not be permitted.

328.4.3 Alignment (a) Circumferential welds Add the following to clause (1): Misalignment due to unequal internal diameter is permitted to a maximum of 1 mm provided it is distributed equally around the circumference. If the misalignment exceeds the above value, provided it is caused by dimensional variations within the specified tolerance or the use of two piping components of different nominal thickness and the same out side diameter, tapering of the internal diameter of the thicker member to a taper of 1:4 should be carried out. Wherever possible, such rectification should be carried out by machining in a shop rather than by grinding in the field. The machined area shall be MT/PT examined when practical. Add the following new sub-section:

(e) Weld separation The toes of adjacent circumferential welds shall be separated by a minimum distance equal to the nominal outside diameter of the pipe. Where the above requirement cannot be met, the minimum distance between the toes of adjacent circumferential welds shall not be less than five times the nominal wall thickness or 50 mm whichever is greater. Both joints shall be subjected to Radiographic, MT or PT and field hardness checks on the weld metal and HAZ (for sour service). This requirement is over and above the requirements specified elsewhere in this specification. The field hardness procedure shall be qualified in accordance with ASTM E110-82 or to a procedure prepared by the Contractor and agreed with the Company. The procedure shall be approved by the Company before qualification. Hardness checks shall be made on 12, 6 and 3 or 9 o’clock position. For circumferential welds on longitudinally welded pipes, the longitudinal welds shall be so positioned that: • the weld is at the upper segment of 120° of the p ipe • any two adjacent longitudinal welds shall be at least 45° apart or 200mm apart, whichever is less When it is not possible to meet the above separation requirements between two longitudinal welded joints, the minimum separation shall be the greater of five times the nominal wall thickness or 50 mm provided that the weld joint is fully radiographed and meets the acceptance criteria of this specification.

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328.5

Welding Requirements

328.5.1

General

Version 1.2

All piping materials should conform to the requirements specified in Chapter III of ASME B31.3. The appropriate material certificates shall be verified and approved by the contractor Quality Assurance Engineer and made available for review to the Company before the commencement of welding / fabrication.

(a) WPS Add the following: All welding shall be in accordance with the ‘Approved for Fabrication’ WPS.

(b) Weld identification Delete existing sub-section and replace as follows The Contractor shall maintain records of the weld number, welder identification and NDT results for each weld for inclusion in the document package. The production records shall also include the results of monitoring and verification of the welding parameters (volts, amps, travel speed and heat input) representing one pass per WPS, per welder, per day (excluding the capping runs) unless agreed otherwise with Company Welding TA-2 authority.

(c) Tack welding Delete existing sub-section and replace as follows Where root tack welding is specified in the WPS, the welding parameters shall be those for the root pass of the approved WPS, including any minimum preheat or ambient temperature requirements, and shall be performed by welders qualified in accordance with this specification. The extremities of the tack welds shall be dressed by grinding. For root tacks in pipe up to 114.3 mm outside diameter, a minimum of three tack welds shall be deposited at equal spaces around the joint. For root tacks in pipe exceeding 114.3 mm outside diameter, a minimum of four tack welds around the joint shall be made. Tack welds shall be a minimum of 25 mm long wherever practical. Where bridge or bar tacks are used, these shall be welded using the electrodes and parameters shown in the approved WPS for the fill passes. Welding shall not encroach on the root area. The bridge or bar material shall match the composition of the parent material. All tack welds which are not incorporated into the root of th e weld shall be removed by grinding. Tack welds shall be visually inspected before welding of the joint. Defective tack welds shall be removed by grinding prior to welding of the joint. If post-weld heat-treatment is specified, any areas outside the bevel where bridge pieces were attached shall be MT or liquid penetrant examined after grinding and before heat treatment.

(d) Peening Delete existing sub-section and replace as follows Peening shall not be performed at any time.

(e) Weather protection Delete existing sub-section and replace as follows Work shall not be performed when the weather and/or degree of protection does not permit satisfactory workmanship.

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For site welding, shelters giving adequate protection at all times to the weld area from wind, rain and moisture shall be provided. In windy conditions the pipe ends shall be sealed to prevent through draughts Weld surfaces shall be thoroughly cleaned and dried before welding. Moisture shall be removed to a bandwidth of at least 75mm either side of the joint by means of blowers, or in exceptional cases a torch may be used to produce a controlled preheat of 50°C. Add the following new sub-sections (g) to (m):

(g) Application of welding processes Gas Tungsten Arc Welding (GTAW) GTAW shall be used for the root and second pass of all stainless steel pipes. GTAW shall also be used to weld the root and second pass of carbon steel pipes, branch fittings and flanges < 60.3 mm diameter. Category D applications are exempt from this requirement. The manual GTAW process shall be restricted to uphill progression. U-groove preparation without root gap should be used for automatic welding. Back purging shall be required for GTAW and GMAW processes when welding materials having a nominal chromium content greater than 2 ¼ % unless the joint is back-ground or back gouged to sound metal. Whenever a back purging gas is selected to prevent oxidation or scale formation on the underside of the weld, the purge shall be maintained until at least 6.0 mm thickness of weld metal has been deposited. For all gas compression systems, GTAW or other approved non-slag welding processes shall be used for the root pass of carbon steel and low alloy steel piping.

Shielded Metal Arc Welding (SMAW) SMAW or GTAW or combination of both with uphill progression shall be used for welding of on-plot piping. Other process may be used if approved by Company. The following processes may be used with additional UT examination if agreed by the Company welding TA-2

Automatic Pulsed Gas Tungsten Arc Welding (GTAW-P) When used for root pass welding of single sided joints, welding shall be performed with the same make and model of welding system using the same equipment and/or program settings as those used in the procedure qualifications.

Pulsed Gas Metal Arc Welding (GMAW-P) GMAW-P may be used for any material thickness in any position. (See also note on back purging under GTAW, above).

Short Circuiting Gas Metal Arc Welding (GMAW-S) The use of GMAW-S shall be limited to the following conditions: • •

•

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The process shall not be used for branch connections For vertical welding, the root pass progression for material of any thickness may be either uphill or downhill. The hot, fill and cap passes for butt or fillet welds may be welded with this process provided the thickness of any member does not exceed 9.5 mm and vertical welding is performed with uphill progression.

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Flux Cored Arc Welding – Gas Shielded (FCAW-G) FCAW – with external gas shielding (FCAW-G) may be used for either groove or fillet welds for pressure boundary or attachments welding. FCAW-G is not acceptable for applications where the operating temperature is below 0º C or minimum design metal temperature is below minus 29º C. FCAW-G shall not be used for single side groove welds if sour service conditions exist.

(h) Welding Stainless Steel The tungsten electrode shall be AWS class EWTh-2. The GTAW power source shall have a high frequency starting circuit. Scratch starting shall not be used. The shielding gas shall be argon of purity 99.99% or better. Hand and power tools shall be dedicated to stainless steel and shall not have been used on, or contaminated by, carbon steel or other materials. Power brushes shall be made of stainless steel. Back purging shall be applied to all butt welds during welding of the first two layers or until at least 6 mm thickness of weld metal has been deposited, whichever is greater. All connections of current return cables shall be made directly to the work using stainless steel clamps (contact surface).

(i) Arc strikes Arc strikes shall be ground out to a smooth profile. The ground area shall be examined by MT or PT and thickness checked. The area shall be free from cracks. Where the thickness is below the specified minimum, that section of pipe shall be removed. The Contractor shall ensure a good earth connection and periodically examine the condition of the earth cables and attachments. Any arcing from a poor connection shall be treated as an arc strike. For carbon steels, tightly screwed brass or copper (contact surface) earthing clamps shall be used to avoid arc strikes.

(j) Inter-run cleaning Each run of weld metal shall be cleaned before a further run is deposited. Visible defects such as cavities, and other deposition faults shall be removed by grinding prior to deposition of further weld metal.

(k) Temporary attachments, Consumable inserts or backing rings may be used if agreed by the Company welding TA-2 authority.

(l) Minimum number of passes The minimum number of passes used to make a joint shall be three. For pipe butt welds where the joint thickness is < 3 mm and for high heat input processes, this requirement may be waived subject to the prior approval of the Company welding TA-2 authority.

(m) Transition joints between dissimilar metals Any additional qualification requirements for the transition joints shall be identified by the Company in the project specifications.

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328.5.2 Fillet and socket welds From 1st sentence, delete”(including socket welds)”. Add to sub-section (a), the following: Socket welding shall not be permitted. Add the following new sub-section: (c) A specific WPS shall be prepared for each fillet weld attachment detail. Subject to review and acceptance by the Company welding TA-2 authority, qualification of these details may be supported by appropriate butt weld PQRs. Otherwise separate qualification in accordance with ASME IX and this specification shall be qualified. Low Hydrogen electrodes or GTAW shall be used for fillet welds.

328.5.4 Welded branch connections Add the following new sub-section: (i) A specific WPS shall be prepared for each type of branch weld detail. For set-on branches, the branch pipe OD and thickness at the welding location shall be used in determining the WPS qualification range. (See Appendix A, Definitions).

328.6

Weld Repair Delete the entire section and replace as follows: All repairs shall be executed by welders qualified in accordance with ASME B31.3 and this specification. The Contractor shall maintain records of repair work. A separate WPS shall be produced for repair welding which shall be approved by the Company TA-2. The WPS may be supported by an appropriate pipe butt weld PQR. In addition to the items required by this specification, the WPS shall show the following: • •

The method of excavation. The NDT technique employed to ensure removal of defects.

Cracks shall not be repaired. When cracking is observed in the completed weld, the weld shall be cut out entirely. For partial penetration repairs, the total length of excavation shall not exceed 30% of the weld length. For full penetration repairs, the total length of excavation shall not exceed 20% of the weld length. Excavation shall be by machining or grinding. After excavation, visual and MT or PT inspection shall be performed to confirm defect removal. At the ends and the sides of the excavation there shall be a gradual taper from the base of the excavation to the surface of the weld metal. The profile shall be such that adequate access for welding is achieved. Undersize welds shall be rectified by the deposition of additional weld metal, using the same procedures as for the original weld. Surfaces shall be thoroughly cleaned before depositing further weld metal. After completion of repair welding, the full extent of the repair shall be inspected by the method prescribed for the original weld to a length extending 50 mm beyond each end of the repair. Should further unacceptable defects be found on re-inspection then the weld shall be cut out entirely.

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330

Preheating

330.1

General

Version 1.2

330.1.1 Requirements and recommendations Delete existing section and replace as follows: Preheating shall be applied when the metal temperature is below 5oC or condensation of moisture on the weld area is possible. A minimum preheat of 50oC shall be applied to a bandwidth of at least 75 mm either side of the joint. A limited preheat may also be applied in highly constrained conditions. Minimum preheat requirements shall be based on Table 330.1.1 and shall take account of the guidelines of BS EN 1101-2. Requirements for preheat listed in the relevant code shall be considered mandatory. Maximum inter-pass temperature shall be 250º C for carbon and low alloy steels and shall be 150º C for Austenitic stainless steel. Any deviations to these requirements shall be agreed by the Company welding TA-2. Acceptable methods of pre-heating are electrical resistance heaters or oxy-propane torches fitted with rosebud pattern nozzles. Welding or cutting torches shall not be used.

330.1.4 Preheat zone Delete existing section and replace as follows: The heated area shall extend for a minimum of 75 mm either side of the joint and shall be maintained over the full length of the joint until the weld is completed. A period of equalization shall be allowed, based on two minutes per 25 mm thickness, prior to confirmation that the specified temperature has been attained.

330.2

Specific Requirements

330.2.4 Interrupted Welding Delete existing section and replace as follows: Interruption of welding should be avoided. Where interruption is unavoidable, a minimum of three passes or one third of the joint thickness, whichever is greater, shall have been deposited. The weld shall be wrapped in a dry thermal insulating blanket for slow cooling. Upon resumption of welding, preheat in accordance with the approved WPS shall be applied.

331

Heat Treatment

331.1.1

Heat Treatment Requirements Add the following: If post weld heat treatment is required the Contractor shall submit a PWHT procedure for approval by the Company prior to performing any heat treatment. Only Company approved PWHT subcontractors shall be used. Any reductions in the post weld heat treatment temperature listed in B 31.3 are not permitted. For sour service, PWHT holding temperature should not be less than 610°C unless otherwise specified by the Company welding TA-2. The following process conditions require PWHT: 1. 2.

Caustic soda (NaOH) solutions Monoethanolamine (MEA) solutions (all temperatures)

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3. 4. 5. 6. 7.


0

Di-glycol amine (DGA) solutions above 138 C design temperature 0 Rich amine di-isoproponal (ADIP) solutions above 90 C design temperature 0 Lean ADIP solutions above 60 C design temperature Lethal /very toxic / hydrogen service conditions If carbon equivalent is greater than 0.45 and/ or carbon content greater than 0.25%

331.1.4 Heating and cooling. Delete existing section and replace as follows: The heating method shall be furnace, induction coils, or resistance heaters. Local flame heating shall not be used. The method of attaching resistance heater shall be detailed in the procedure. Flames shall not impinge directly on the weldment or parent material. When a furnace is used for heat treatment, the temperature shall not be above 400°C when the pipe is inserted. The heating and cooling rate above 400°C shall not exceed the following:For pipes of wall thickness up to 25 mm : 220°C per hour For pipes over 25 mm wall thickness (T): the greater of 5500/T°C per hour or 55 °C per hour. Where (T) is in mm. For P number 3, 4 & 5 Company's TA-1 for material and corrosion shall be consulted.

331.1.6 Temperature Verification Replace the first sentence as follows: Temperature control and monitoring shall be by thermocouple. Thermocouples shall be covered with thermal insulation. The thermocouples shall be attached to a chart recorder and the heat treatment chart shall be included in the welding documentation with weld number identified. Calibration of thermocouples shall be verified via calibration certificate.

331.2.2

Exceptions to Basic Requirements Add the following: PWHT may be waived if agreed by the Company welding TA-2 for weldments up to 35 mm in thickness in carbon steel where all of the following apply: •

• •

• •

•

331.2.6

The operating temperature of the pipe work is above 0°C or minimum design temperature is above or equal to minus 29°C and the operating conditions are non-sour. The weld has been made completely with low hydrogen electrodes. A minimum preheat has been applied of 100°C or as recommended by BS EN 1011-2, whichever is higher. The test coupon has a minimum thickness of 25 mm. Temper bead technique is employed, i.e. the final beads on the cap next to base metal are tempered by depositing a weld bead next to it without touching the base metal. Use of annealing electrodes (‘Lastex’) to temper the beads is not acceptable. The test coupon is impact tested. The test temperature shall be 0°C or minimum design temperature whichever is lower and the acceptance criteria shall be in accordance with the requirement of ASME B31.3.

Local Heat Treatment Add the following:

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Where local post-weld heat-treatment is used, the temperature gradient beyond the weld zone shall be such that a minimum of half the specified PWHT temperature is maintained at a distance either side of the weld given by 2.5 x (Rt)1/2 , where R = bore radius and t = wall thickness at the weld. Where possible, thermocouples shall be placed on the opposite side of heating surface or at least 25 mm away from the heated surface if placed on heated side. Add the following new section:

336

Handling and Storage

336.1

General All necessary precautions shall be taken throughout fabrication to minimise contamination of stainless steel materials resulting from direct contact with carbon steels, exposure to ferrous dust, swarf or other debris and from residual deposits on or near fusion faces. Specific requirements to prevent contamination during edge preparation, joint alignment or site fabrication, for cleaning fusion faces and welds beads and for preventing oxidation during welding, are included in Sections 328.4 and 328.5.1 of this specification. General precautions to be applied during the handling and storage of stainless steels are outlined in clauses 336.2 3, following. Surface oxidation or metallic contamination which will not respond to washing or degreasing treatments shall be removed using power tools or by a pickling treatment. Pickling procedures shall be subject to prior Approval by the Company. The Contractor shall ensure the safe use and disposal of chemical solutions and the thorough cleaning and drying of pipework. Washing shall be performed with potable water.

336.2

Storage (a) Components stored in an open site or within a fabrication workshop shall be protected from environmental contamination. (b) Stainless steels shall be clearly identified and segregated from other stored materials.

336.3

Pipe Handling (a) Supports, rollers and other pipe handling equ ipment shall be of compatible material or shall be suitably lined to prevent damage or contamination of the pipe work. (b) Slings and supports for lifting stainless steel pipe and assemblies shall be of Nylon or similar compatible material.

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Chapter VI Inspection, Examination and Testing 340

Inspection

340.4

Qualifications of The Owner’s Inspector Replace sub-section (b) as follows: (b) The Inspector shall have experience and qualifications approved by the Inspection TA-1 and shall be issued with a TA certificate in accordance with PDO-ERD-00-02 and GU-272. The Company may engage a third party agency to carry out inspection on its behalf. The third party inspector shall be qualified in accordance with section 342.1 of this specification and will be i ssued with a project-specific TA-3.

341

Examination

341.2

Responsibility for Examination Add the following new sub-sections (d) and (e): (d) The Contractor shall supply all labour, materials, and equipment necessary to perform the required examinations. (e) The Company shall have the final disposition on any weld. Any weld not accepted by the Company shall be rectified in accordance with ASME B31.3 and this specification.

341.3

Examination Requirements Insert the following in front of the first paragraph: Prior to welding, the Contractor shall examine free-issue materials for damage and compliance with the relevant materials specification. This examination shall include a review of the materials certificates. Items supplied without materials certificates shall not be used. All damage and discrepancies shall be reported immediately to the Company. After signed acceptance by the Contractor, any discovered damage shall be the responsibility of the Contractor.

341.3.2 Acceptance Criteria Replace first paragraph as follows: The acceptance criteria shall be as stated in ASME B31.3 and this specification.

341.4

Extent of Required Examination

341.4.1 Examination Normally Required (a) Visual Examination Delete existing sub-section and replace as follows: Visual examination prior to welding shall be in accordance with the provisions of section 328.4 and clause 341.3 of ASME B31.3 and this specification. All completed welds shall be visually examined and inspection status shall be suitably identified including the identification of examiner.

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(b) Other examination Delete existing sub-section and replace as follows: The extent of examination for all butt welds shall be in accordance with Table 1. Ultrasonic examination may supplement radiography and shall be used to interpret doubtful indications in the radiographs. Fillet welds shall be subjected to visual, and MT or PT at the same frequency as radiography for butt welds per fluid service and class. Branch connection welds shall be radiographically examined where possible. Where radiography is not possible, ultrasonic examination shall be employed. Where ultrasonic examination is not possible, the welder shall be qualified on branch connection joint as per clause 328.2.1.9. MT or PT shall be performed on the final production welds. The extent of examination shall be at the same frequency as for butt welds. When random NDT is specified, the extent of examination shall be applied to all welders. Joints to be tested shall be selected by Company Welding TA-3. In-process examination shall not substitute for the specified NDT.

342

Examination Personnel

342.1

Personnel Qualification and Certification Delete existing section and replace as follows: Welding examination personnel and Non-destructive examination personnel shall hold a valid qualification of one of the following listed below and should have at least 5 years previous experience as a qualified welding/NDT inspector. Acceptable qualifications for welding examiners are as follows: • • •

CSWIP Welding Inspector ERS Welding Inspector AWS Certified Welding Inspector

All non-destructive examination personnel shall be qualified and certificated for the method of NDT to be carried out in accordance with ISO 9712, to NDT Level 2 or higher. The roles and responsibilities of NDT personnel shall be as defined in the levels of competence in ISO 9712. Personnel certified to ASNT Level II in accordance with ASNT-TC-1A by examination are acceptable provided that the certifying Level III NDT has been approved by the Company. The Company approved Level III NDT shall continuously monitor the performance of NDT Personnel certified to ASNT Level II and shall take corrective measures whenever the performance of ASNT Level II technicians is not satisfactory. Level III NDT personnel shall meet the requirements specified in ASNT-TC-1A by examination. Equivalent inspection and NDT qualifications e.g. CSWIP/PCN Tester/Practitioner/ Interpreter (Welds), Level 2, may be accepted at the sole discretion of the Company Inspection TA-2. If, in the opinion of the Company, welding examination or non-destructive examination personnel fail to perform to a satisfactory standard they shall be disqualified from the works until such time that it can be demonstrated by the Contractor that they have achieved a satisfactory standard by undertaking, at the Contractor's expense, a test by a third party agency approved by the Company.

343

Examination Procedures Delete existing section and replace as follows:

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Written NDT procedures shall be approved by the Company Inspection TA-2 prior to test or production welding as applicable. Company approval shall be based on qualification tests. These may be qualified as part of the Welding Procedure Qualification tests. The procedures shall incorporate the requirements of SP-1176.

344

Types of Examination

344.1

General Insert the following before the existing sub- sections: The NDT procedures shall be project specific and shall show the project name and contract number. The acceptance criteria shall be as stated in Chapter VI of ASME B31.3. The Contractor shall submit the qualified NDT procedure for Company approval two weeks prior to test welding. If no test welding is required, the qualified procedure shall be submitted two weeks prior to the start of production welding. The Technician or the Inspector and the Contractor's Welding Co-ordinator shall sign and endorse the report form prior to presenting it to the Company. The weld shall be at ambient temperature prior to examination.

344.2

Visual Examination Delete existing section and replace as follows: Visual examination shall be performed in accordance with a documented procedure complying with Article 9 of ASME BPV Code Section V. The examiner shall maintain and sign records of in-process examination.

344.3

Magnetic Particle Examination Delete existing section and replace as follows: Magnetic particle examination shall be performed in accordance with a documented procedure complying with Article 7 of ASME BPV Code Section V and incorporating the requirements of SP-1176.

344.4

Liquid Penetrant Examination Delete existing section and replace as follows: PT shall be performed in accordance with a documented procedure complying with Article 6 of ASME BPV Code Section V and incorporating the requirements of SP-1176.

344.5

Radiographic Examination

344.5.1

Method Delete existing section and replace as follows: Radiographic examination shall be performed in accordance with a documented procedure complying with Article 2 of ASME BPV Code Section V and incorporating the requirements of SP-1176.

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344.6

Ultrasonic Examination

344.6.1

Method

Version 1.2

Add the following to the end of the first paragraph: Ultrasonic examination shall be performed to a documented procedure which shall incorporate the requirements of SP-1176.

345

Testing

345.1 Required Leak Test Add the following: Before hydro-test relevant pipe spool weld history records stating all the information as detailed in 346.1 shall be verified by the Contractor Quality Assurance Engineer and approved by the company TA-3. Clearance to proceed with testing shall be obtained from the Company TA-3 before hydro-test. Add the following new section:

346

Records Add the following new section:

346.1

Documentation The Contractor shall be responsible for compiling the following document packages which shall be submitted to the Company upon completion of the works: (a) Pre-production • •

•

•

•

• • • • • •

Copy of approved Welding Procedure Register Weld plan/map Copies of approved WPSs Copies of approved repair WPSs Original copies of all supporting PQRs List of approved welders and their identification Copies of PDO endorsed welders qualification cards List of approved NDT operators Copies of NDT operator qualification certificates List of company approved deviations to ASME B31.3 and this specification Copies of Company approved deviations to ASME B31.3 and this specification List of consumable batch certificates Copies of consumable batch certificates List of materials certificates Copies of materials certificates List of test equipment Copies of calibration certificates

(b) Post-production

•

List of as-built drawings As built drawings showing unique weld numbers List of weld history sheets, weld map Copies of weld history sheets which shall show for each weld - weld number - isometric and line number

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•


- material specifications and identification - the WPS employed - the welders' identity symbols - date welded - visual inspection disposition - NDT reports where applicable (to be attached to weld history sheet) - type of repair, if applicable, and WPS - NDT reports for repairs (to be attached to weld history sheet) - PWHT if applicable (chart to be attached to weld history sheet) - batch number of consumable employed Radiographs - indexed and stored in a fireproof container List of site test records Copies of site test records List of non-conformances/corrective actions issued during external or in ternal audits. Copies of non-conformances/corrective actions issued during external or internal audits. Declaration/certificate of compliance.

Add the following new section:

347

Certificate of Conformity On satisfactory completion of the piping work, the Contractor (or Manufacturer) shall issue a declaration of compliance with this specification. The format of “Declaration of Compliance” is shown in appendix 4. The “Declaration of Compliance” shall be signed by the Contractor‘s QA/QC In-charge who is approved by th e Company for the contract.

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Table 1 Extent of Non-Destructive Testing for Welds Material

Carbon Steel and 0.5%Mo Steel (P Nos. 1 & 3)

Austenitic Stainless Steel (P No. 8) and nonferrous alloys

Fluid Service

ANSI CLASS

Visual

RT

PT or MT

100%

Category D *** Category M, piping with severe cyclic conditions

All

100%

100%

Normal Utility

150

100%

2% Random

Normal Utility

300-600

100%

10% Random

Normal Utility

900-1500

100%

10%

Normal utility

>1500

100%

100%

10% MT

Normal Liquid Gas

All

100%

100%

10% Random MT

Low temperature service; 0 operating temperature 0 C 0 down to -50 C and when minimum design temperature below minus 0 29 C

All

100%

100%

100%

Normal, all other services

150-600

100%

10% Random

Normal, all other services

900 and above

100%

100%

10% Random MT

Lethal / Hydrogen / Very Toxic service *

All

100%

100%

100%

Category D

100% MT

100%

Category M

All

100%

100%

100% PT

Normal Liquid Gas

All

100%

100%

100% PT

Normal

150

100%

5% Random

5% Random PT

Normal

300

100%

10% Random

10% Random PT

Normal

600 and above

100%

100%

100% PT

Low temperature service; 0 operating temperature -50 C down to -1960 C

All

100%

100%

100% PT

(P No. 8)

All

All

100%

100%

100%

3 ½ Nickel steels, Cr, Mo steels, P4 and above

All

All

100%

100%

100%

All

All tie-in joints, road crossings **

All

100%

100%

100%

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Notes to Table 1:

* Helium leak test is mandatory as per ASME B31.3. For definition of lethal service refer ASME B31.3 ** This requirement applies to all services except category D fluids ***Class D fluid for fire water systems: 10% RT 1. Fluid service category as defined in ASME B31.3 2. The random inspection requirement shall be applied to each welder, per WPS, per size over a period of one month 3. If either GMAW or FCAW are used for root pass of single sided butt welds, 100% RT and 10% random UT shall be applied except for category D fluids 4. If thickness of piping is greater than 19 mm, 100% RT and 100% PT/MT shall be carried out on piping classes 300 and above, except for category D fluids..

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Figure 1

Version 1.2

Hardness Indent Locations

1.5 +- 0.5 mm X

X

XXX

X

X

X

XXX

X

X

0.5t X X

X X

XXX

X

X

X

XXX

XXX X

X

X XXX

X X

X X

1.5+- 0.5 mm

Hardness indentations in the HAZ spaced at 0.5mm One indentation of every set of 3 shall be as close to the fusion line as possible but shall not intersect it

1.5 +- 0.5 mm

0.5 X LEG LENGTH

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Figure 2


Orientation and Location of Charpy Impact Specimens

C/L t _ < 19 mm

Notch t

2mm

Weld m etal specimen

C/L Specimen axis t _ < 19 mm

Notch 2mm

FL

FL + 2

Heat affected zone specimens

C/L

2mm

t > 19 mm

2mm Weld metal specimens

C/L

FL

FL + 2

2mm

t < 19 mm

FL

FL + 2

2mm

Heat affected zone specimens

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Appendix C References In this specification, reference is made to the following publications: Note:

Unless specifically designated by date, the latest edition of each publication shall be used together with any amendments.

PDO Standards/DEPs Pipeline Engineering (November 2004)

SP-1211

Technical Authorities System

ERD-00-02

Guideline for Granting Technical Authority System

GU-272

Standard Welding Procedures for On-Plot Piping

PR-1272

Quality Assurance Specification for Engineering Works

SP-1171

Non-Destructive Examination

SP-1176

American Standards Process Piping (2002 Edition)

ASME B31.3

Boiler and Pressure Vessel Code, Section II, Materials

ASME II

Boiler and Pressure Vessel Code, Section V, Non-Destructive Examination

ASME V

Boiler and Pressure Vessel Code, Section IX, Welding And Brazing Qualifications

ASME IX

Recommended Practice for Non-Destructive Testing Personnel Qualification and Certification

ASNT SNT-TC-1A

Standard Test Method for Vickers Hardness of Metallic Materials

ASTM E92

Standard Test Method for Indenation Hardness of Metallic Materials by Portable Hardness Testers

ASTM E110

Filler Metal Procurement Guidelines

AWS 5.01

Specification for Welding Shielding Gases

AWS 5.28

Sulphide Stress Cracking Resistant Metallic Materials for Oilfield Equipment

NACE MR0175

British Standards Welding – Recommendations for welding of metallic materials – Part 2: Arc welding of stainless steels General criteria for supplier’s declaration of conformity

BS EN 1011-2 BS EN 45014

International Standards Quality requirements for welding – Fusion welding of metallic materials – part 2 Comprehensive quality requirements

ISO 3834-2 (Note 2)

Quality Management Systems – Requirements

ISO 9001:2000

Non-Destructive Testing - Qualification and Certification of Personnel

ISO 9712

Steel and Steel Products – Inspection Documents

ISO 10474

Welding consumables - Shielding gases for arc welding and cutting

ISO 14175

Welding Co-ordination - Tasks and Responsibilities

ISO 14731 (Note 1)

Note 1 Also published as EN 719 Note 2 Also published as EN 729

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Appendix D WPS and PQR Forms

Note:

Electronic copies of the forms included in this Appendix may be obtained from: The Head of Quality Management Services, PDO.

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DECLARATION/CERTIFICATE OF COMPLIANCE FOR PIPING FABRICATION AND INSTALLATION

Description of piping

Identification no./Drawing No. Installed by: For Design conditions: Design temperature: Medium contained: Designed by: We hereby declare that above piping work has been fabricated, installed, examined and tested in accordance with this SP-1173

Company:

Signature (Name, position, date) PROJECT QA/QC IN-CHARGE Specimen of declaration/certificate of compliance for piping work fabrication and installation

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SP-1173 Specification for Welding on on-Plot Pipework

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