Salman Offshore Facilities Laybarge Welding Specification

PETROIRAN DEVELOPMENT COMPANY
SALMAN OFFSHORE FACILITIES

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SALMAN OFFSHORE FACILITIES EPC-3

AMID CONTRACT NO. SALMAN 127 CONT 001
TECHNIP PROJECT NO. 9068G
JOB SPECIFICATION
SPECIFICATION FOR LAY BARGE
WELDING OF LINE PIPES
This document has completely changed from revision D1 to D2.

D2
11.07.04
RE-ISSUED AS FINAL
H.NOUROZI
S. VENUGOPAL
S. VENUGOPAL
J. BARRON
D1
20.12.03
ISSUED FOR APPROVAL
M.A.MOSTAFA
S. VENUGOPAL
S. VENUGOPAL
J. BARRON
D0
08.11.03
ISSUED FOR COMMENTS
M.A.MOSTAFA
S. VENUGOPAL
S. VENUGOPAL
J. BARRON
REV
NO.
DATE
DESCRIPTION
PREPARED BY
CHECKED BY
APPROVED BY
AUTHORIZED
BY
TECHNIP Project No.
TECHNIP Document No.
9068G
9068G-000-JSS-3520-512
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CONTENTS
1.
2.
INTRODUCTION
1.1
Scope
1.2
Definition of Terms
1.3
Quality Assurance System
1.4
Inspection
1.5
Codes and Standards
MATERIAL
2.1
Linepipe
2.2
Equipment
2.3
Welding Consumables
3.
QUALIFICATION OF WELDING PROCEDURE
4.
QUALIFICATION OF WELDING PROCEDURE FOR WELDS CONTAINING FILLERMETAL ADDITIVE

4.1
Welding Procedure Specification
4.2
Essential Variables
4.3
Welding of Test Joints - Butt Welds
4.4
Testing of Welded Joints - Butt Welds
4.5
All Weld Metal Tensile Test
4.6
Macro Examination / Hardness Surveys
4.7
Charpy Impact Testing
4.8
Chemical Analysis
4.9
Crack Tip Opening Displacement Test (CTOD)
4.10
Testing of Welded Joints - Fillet Welds

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Performance
QUALIFICATION OF WELDERS AND WELDING OPERATORS

5.1
General
5.2
Welding Inspection and Testing
5.3
Requalification
5.4
Validity of Welder and Welding Operator Qualification Certificates
PRODUCTION WELDING
6.1
General
6.2
Line Pipe End Preparation
6.3
Alignment
6.4
Proximity of Welds
6.5
Tack Welding
6.6
Temporary and Non-Structural Attachments
6.7
Movement of Pipe
6.8
Storage and Handling of Consumables
6.9
Preheating and Interpass Temperatures
6.10
Post-Weld Heat Treatment
6.11
Repair Welding
7.
WELD PROFILE AND SURFACE FINISH
8.
IDENTIFICATION OF WELDS
9.
WEATHER CONDITIONS
10.
INSPECTION AND TESTING

10.1
Visual Inspection
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10.2
Non-Destructive Testing (NDT)
10.3
Stages of Inspection
10.4
Radiography
10.5
Magnetic Particle Inspection (MPI)
10.6
Ultrasonic Examination
10.7
Acceptance Criteria For Inspection and NDT
10.8
MPI Testing
10.9
Dye Penetrant Testing
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10.10 Ultrasonic Testing

10.11 Random Hardness Testing
10.12 Metallic Inclusions
11.
DOCUMENTATION
11.1
Prior to Production Welding
11.2
On Completion of the Work
APPENDIX A
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1.
INTRODUCTION
1.1
SCOPE
1.1.1
This specification covers field and laybarge welding of pipes for the Salman Oil and
Gas Integrated Development project including the associated risers.
The new pipelines are listed below:
Ten 4 inch lift gas pipelines from new Salman GLP platform to designated tripods.
Eleven 8 and 10 inch oil gathering pipelines from existing designated tripods to a new
Riser Platform PP3 located at the Salman Complex.
Two 20 inch gas gathering pipelines from new 2SKB and 2SKC Platforms to new KPP
platform located at the Dalan Complex.
One 6 inch gas condensate pipeline from Dalan KPP to the new PP3 riser platform
located at the Salman Complex.
One 14 inch associated gas pipeline from the new GLP platform located at the
Salman Complex to Dalan KPP.
One 36 inch Flare gas pipeline with 2 inch piggy back pilot gas between KPP and the
new FPP Flare platform located near Dalan complex.
One 30 inch, 220 km long export gas pipeline from Dalan KPP to AP Mobarak
Platform via Sirri island.
1.1.2
This Specification defines the minimum Company requirements for the Offshore laybarge welding, laying and testing of the pipelines for the Salman Oil and Gas Field
Integrated Development Project. This specification also applies to ancillary pipeline
and riser welding in the field including Contractor fabrication yards.
1.1.3
The scope of this specification covers the welding of carbon steel line pipe including
bends made from material with specified minimum yield strength of 414 MPa (60,000
p.s.i.) and fittings supplied to ASTM or other standards of equivalent strength grades.
1.1.4
The following welding processes are pre-approved for use:
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Gas tungsten Arc Welding (GTAW)-Manual
Shielded Metal Arc Welding (SMAW)- Manual
Submerged arc welding (SAW)
Gas metal arc welding (GMAW)
Page 6 of 45
Root runs in pipe of diameters less than 60mm shall be made using GTAW process.
1.1.5
This specification also applies to pipeline risers and includes shore approach sections
towards landfall points of the export pipeline to AP Mobarak complex.
1.1.6
Welding and inspection activities within the scope of this Specification shall be carried
out in accordance with API 1104, and as amended by this Specification.
1.1.7
This specification shall be used in conjunction with the additional requirements given in
the Purchase requisition for the lay-barge welding of the line pipes.
1.1.8
This specification does not cover the reeling method of pipeline installation.
1.1.9
This specification does not apply to Hyper-baric method of welding.
1.2
DEFINITION OF TERMS
1.2.1
Terminology used within this Specification is defined as follows:
Company
Petro-Iran Development Company (PEDEC) or its authorised

representative.
Contractor
AMID / I.O.E.C or its authorised representative(s)
Supplier
Party(s) designated on the purchase order or contract for supply

of welding material.
Approval indicates prior Approval in writing, by the Company and where required, by
the Certifying Authority.
ASNT
American Society for Non-Destructive Testing
AWS
American Welding Society
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Basic Describes flux type for welding consumables which has a high soda and lime
content; basic fluxes may be baked to reduce moisture content such that the
electrode depositing weld metal has a controlled amount of diffusible Hydrogen. Low
Hydrogen Electrodes refer to hydrogen content below 10ml/100g of weld metal
deposited.
However, basic fluxes absorb moisture from atmosphere and will then have high
diffusible Hydrogen content.
TP
Third Party Inspection Authority appointed by the Company
CTOD
Crack Tip Opening Displacement
DAC
Distance Amplitude Correction
FCAW
Flux Cored Arc Welding (Includes FCAW (G) Gas shielded Flux
Cored Arc Welding and FCAW(S) Self Shielded Flux Cored Arc
Welding)
GMAW
Gas Metal Arc Welding
GTAW
Gas Tungsten Arc Welding
HAZ
Heat Affected Zone
IIW
International Institute for Welding
ISO
International Standards Organisation
IQI
Image Quality Indicators (Penetrameters)
May
indicates a possible course of action
MPI
Magnetic Particle Inspection
NDE (NDT)
Non Destructive Examination
PCN
Personnel Certification in Non-Destructive Testing
PWHT
Post Weld Heat Treatment
pWPS
Provisional Welding Procedure Specification
RE (RT)
Radiographic Examination
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SAW
Submerged Arc Welding
Shall
indicates a mandatory requirement
Shapes
any structural section except plate and tubulars
Should
indicates a recommended course of action
SMAW
Shielded Metal Arc Welding
UE (UT)
Ultrasonic Examination
Welder
Welder, including welding operator using automatic equipment
WPQ
Welding Procedure Qualification validating a WPS
WPQR
Welding Procedure Qualification Record of a WPQ
WPS
Welding Procedure Specification qualified by a WPQ
1.3
QUALITY ASSURANCE SYSTEM
1.3.1
The Contractor shall operate a Quality Assurance System (QAS) within his
organisation, which will ensure that the requirements of this Specification will be fully
achieved.
1.3.2
The Contractors quality system shall be based on ISO 9001 (or an approved
equivalent) and shall be described in a quality manual. The manual shall provide
details for the preparation of a quality plan, which shall include provisions for the
QA/QC of all welding consumables, weld procedures, line pipe welding equipment,
testing and final inspection. The quality plan shall ensure that all quality related
requirements are determined prior to commencement of the works and subsequently
satisfied throughout all phases of construction and inspection. Where changes are
made to the Contractors quality system/manual after Approval and commencement of
the works, these shall be submitted to Company for approval prior to their
implementation.
1.3.3
The effectiveness of implementation of the Contractor quality system may be subject

to monitoring by Company or its nominated representative and, may be audited
following an agreed period of notice.
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1.4
INSPECTION
1.4.1
Company reserves the right to inspect and reject the work at any and all stages of
construction.
1.4.2
The Contractor shall take still photographs of the pipeline on request by Company at
any stage of fabrication.
1.4.3
All nominated representatives of Company shall be allowed free access to all parts of
the laybarge where field welding of the pipeline, and associated operations as
described in this specification, will be performed.
1.4.4
The Contractor shall telex Company giving appropriate notice (Period to be agreed at
Bid Stage) prior to the start of pipe lay operations to enable TP inspection
arrangements to be made.
1.5
CODES AND STANDARDS
1.5.1
Fabrication of the pipeline under this specification shall comply with the latest edition
including all current addenda of the following specifications, and all referenced
publications within this specification:
Reference Codes & Standards
The following codes and specifications are referenced in this specification:
API Spec 5L
Specification for Linepipe
API 5LD
Specification for CRA clad or lined line pipe
API Spec 1104
Welding of Pipelines and Related Facilities
ASNT SNT-TC-1A Guidelines for Personnel Qualification and Certification in NonDestructive Testing
ASTM A320
Alloy Steel Bolting Materials for Low Temperature Service
ASTM A370
Standard Test Methods and Definitions for Mechanical Testing of

Steel Products
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ASTM A563
Carbon and Alloy Steel Nuts
ASTM A578
Specification for Straight Beam Ultrasonic Examination of Plain

and Clad Steel Plates
ASTM B568
Test Method for Measurement of Coating Thickness By X-Ray

Spectrometry
ASTM B695
Coatings of Zinc Mechanically Deposited on Iron and Steel
ASTM E747
Design, Manufacture and material Grouping Classification of Wire

Image quality Indicators (IQI) Used for Radiology
ASTM F436
Hardened Steel Washers
ASTM F568
Carbon and Alloy Steel Externally Threaded Metric Fasteners
ASTM F844
Washers, Steel, Plain (Flat), Unhardened for General Use
AWS A5
Filler Metal Specifications
AWS B1.11
Guide for the Visual Inspection of Welds
ASME B 31.4
Liquid Transportation Systems for Hydrocarbons
ASME B 31.8
Gas Transmission and Distribution Piping Systems
AWS C5.3-91
Recommended Practices for Carbon Arc air Gouging and cutting.
AWS QC1
Standard and Guide for Qualification and Certification of Welding

Inspectors
BS 4515
Welding of Steel Pipelines on Land and Offshore
BS 7448
Fracture Mechanics Toughness Tests - Method for Determination

of K1C, Critical CTOD and Critical J Values of Metallic Materials
BS 7910
Guide On Methods for Assessing the Acceptability of Flaws in

Metallic Structures
DNV OS-F-101
Submarine Pipeline Systems 2000
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EN 287
Approval Testing Of Welders - Fusion Welding
EN 288
Specification and Approval of Welding Procedures for Metallic

Materials
EN 462
Non-Destructive Testing - Image Quality Of Radiographs - Image

Quality Indicators
ISO 262
General Purpose ISO Metric Screw Threads
ISO 2553
Welded, Brazed and Soldered Joints - Symbolic Representation

on Drawings.
ISO 6520-1
Welding and Allied Processes- Classification of Geometric

Imperfections in Metallic Materials; Part 1 Fusion Welding, 1998.
ISO 9001
Quality Management Systems - Requirements
ISO 9001:2000 supersedes both ISO 9001:1994 AND ISO 9002:1994. The
requirements of both former standards are covered by the new ISO 9001.
1.5.2
ISO 9712
Non-Destructive Testing - Qualification and Certification of NDT

Personnel
ISO 3834
Quality Requirements for Welding: Fusion Welding of Metallic

Materials
ISO 10474
Steel and Steel Products - Inspection Documents
Company Specification
SL430-0000-SP-PL-1502
Specification for Seamless Line pipe
SL430-0000-SP-PL-1503
Specification for Longitudinally Welded Line pipe
SL430-0000-SP-PL-1504
Specification for Heat Induction Bends
SL430-0000-SP-PL-1508
Specification for Asphalt Enamel and Fusion Bonded

Epoxy Coating of Line pipe
SL430-0000-SP-PL-1509
Specification for Concrete Weight Coating
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Contract Document
All codes and Standards shall be in the editions stated above and with all published
amendments to latest editions. Where the Contractor is proposing to work to another
edition this shall be clearly stated by the Contractor in his bid.
The Contractor shall be in possession of all the above referenced Codes, Standards
and Specifications before commencement of welding fabrication. All such documents
shall be made readily available to personnel involved in executing the work, including
Company personnel.
The Contractor shall obtain written approval from the Company for any deviations from
the requirements of this Specification, referenced codes and Standards, contract
drawings or accompanying purchase order.
The requirements of this Specification shall take precedence over the referenced
Codes and Standards. Where this Specification does not stipulate any overriding
requirements, the referenced Codes and Standards shall apply in full.
1.5.4
Conflicting Requirements
The applicable specifications, standards, codes, and requirements for design,
construction and fabrication shall apply according to the following priority:
a)
Purchase order and Approved variations.
b)
Requisition and Data Sheets.
c)
This Specification.
2.
MATERIAL
2.1
LINEPIPE
The line pipe in seamless and SAW forms will be API 5L grade X 60 for the 30 export
pipeline, the 36 flare pipeline and the in-field pipelines.
The line pipe materials will be supplied conforming to the requirements of NACE MR
01-75 and this requirement shall also apply to the qualified welding procedures to be
used for this project.
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EQUIPMENT
All welding shall be performed using reliable equipment suitable for the work being
done.
The contractor shall establish a procedure to check and demonstrate to the Company
or its authorized representative that all welding machines are properly grounded to
avoid the occurrence of stray arcing.
Contractor shall provide the procedures for calibration of all welding equipment and
gauges and confirmation of calibration date.
Ammeters and voltmeters shall be fitted to all GMAW, SAW and FCAW equipment.
Portable Voltmeters and Ammeters shall also be available at the welding stations.
The contractor shall provide internal clamps of an approved design and employ only
insulated electrode holders and/or leads.
All electrical equipment shall be calibrated immediately prior to commencement of

production welding in accordance with agreed calibration procedures.
All production welding equipment shall be of the same type and model that will be
used for the qualification of automatic welding procedures.
WELDING CONSUMABLES
Filler metals used in fabrication welding shall be certified as conforming to AWS
Standard A-5.2.
All filler metals proposed to be used in welding fabrication shall be subject to individual
approval by the Company.
The yield strength of the deposited weld metal shall meet the upper quartile value for
the line pipe steel used. The maximum weld metal tensile strength shall not exceed the
line pipe specified minimum UTS plus 30%.
2.3.1
Batch Testing of Filler Metals

Batch testing is not required if Electrode / Filler Wires are supplied with EN 10204
3.1.C certificate.
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The following tests shall be made by the Supplier on the weld metal deposit in
accordance with Section 4.4:
Charpy V-notch impact test (weld centreline only)
All weld metal tensile
Hardness survey (Weld only)
Where a consumable is used for the welding of root pass only, weld metal chemical
analysis as well as hardness survey shall be carried out.
The certificate for the flux shall be 3.1C or 3.1B as verified by TP.
3.
QUALIFICATION OF WELDING PROCEDURE
3.1
The Contractor shall submit preliminary welding procedure specification (pWPS)

including preheating proposals for each welding procedure to be qualified using the
project material for review and approval by Company.
3.2
Welding procedure specifications shall also be proposed and qualified for all weld
repair configurations including half depth excavation followed by re-welding. (See
Figure 3)
3.3
Where a semi-automatic and or an automatic welding procedure will be used during

pipe laying, a manual back up weld procedure shall also be qualified. This weld
procedure shall be subjected to all the NDT and mechanical tests including SSC tests
(if required) as for the automatic welding procedures.
3.4
Separate weld procedure qualification tests are required for the welding of flanges,
valves and fittings. The contractor shall establish, by examination the relevant material
test certificates the need for qualification of additional welding procedures.
3.5
The SMAW welding of fittings shall be carried out using the uphill weld progression
technique and basic, low hydrogen electrodes. The butt welds on all fittings and fillet
welds in contact with the production fluids shall be subject to PWHT in accordance
with ASME B31.8.
3.6
The tie-in welds and butt welds for the riser pipes shall be made with basic low
hydrogen electrodes using the uphill technique.
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Longitudinal Seam Orientation

Two consecutive longitudinal seams (if any) shall be radially offset by 30 approx. and
positioned on the upper quarter of the line (i.e. +/- 45 from the vertical axis).
3.8
Internal Run Order

Internal root sealing runs shall not be permitted except on pipe to fitting welds where
PWHT will be carried out. Where internal welding is used as an integral part of a
mechanised GMAW process, the contractor shall furnish documented evidence that
the completed weld is resistant to Sulphide Stress Cracking.
Internal weld repairs shall not be permitted except on pipe to fitting welds where
PWHT is to be applied. However for GMAW process, it is allowed if misfire defect
length was less than 10mm and frequency of one misfire for every one hour operation.
Double-sided SAW girth welding shall not be allowed.
3.9
Application of Post Weld Heat Treatment

Welds in all materials not in accordance with the line pipe Specifications and having
CE value higher than allowed by that specification shall be subject to post weld heat
treatment. The holding temperature shall be 640C + 10C unless otherwise agreed
but should in no case be lower than 580C.
3.10
Sour Service Requirements
3.10.1
Hydrogen Induced Cracking Tests (Line Pipe)

The pipelines will be exposed to wet sour service conditions throughout the design life,
therefore, the welding procedures shall comply with NACE MR 01-75 requirements.
The welding procedures shall be qualified by hydrogen induced cracking (HIC) testing
as follows:
HIC tests shall be conducted on samples from each of the weld procedures proposed
to be qualified for the welding of line pipe on the lay barge. Testing shall be performed
in accordance with NACE TM02-84 using Solution A, as per NACE TM 01-77
The acceptance criteria for all tests (NACE solution A) shall be:
CSR = 1.5%
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CLR = 10%
CTR = 1.5%
3.10.2
Hardness test survey carried out 1.5mm from the outer and inner surfaces of a macrosection through the welded joint shall sample the parent material, HAZ, and the weld
deposit. The maximum hardness anywhere on the macro-section shall not exceed 248
Hv10.
3.10.3
Sulphide Stress Corrosion (SSC) Tests

SSC tests as per Appendix A shall be performed on girth welded joints representing
each type of welding procedure qualified for pipeline welding on the lay barge.
4.
QUALIFICATION OF WELDING PROCEDURE FOR WELDS CONTAINING FILLERMETAL ADDITIVE
4.1
WELDING PROCEDURE SPECIFICATION

The welding procedure specification proposed for qualification by the Fabrication
Contractor shall include all the information listed in Table 1 of this specification.
TABLE 1 - Welding Procedure Details and Changes Affecting Approval
Item
Welding procedure specification

details
Changes affecting approval (essential

variables)
Welding Process
The specific arc welding process (or

combination)
A change from one arc welding process to

another
Base Material
Specification
Specified standard and grade
Any change
Manufacturer (and plate steel mill for

SAW pipe)
Any change
Heat Treatment Condition
Any change
Composition (Note 1)
For line pipe - any change outside range

contractually agreed with the line pipe
manufacturer. For fittings - Any change greater
than that permitted by Table 2
Nominal outside diameter, D, of pipe
For mechanised GMAW - any change
Diameter
For other processes -Change in excess of 0.5
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details
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variables)
to 1.5D
Thickness
Nominal wall thickness t of pipe
A change outside the range 0.75t to 1.5 t
Joint configuration
Type of bevel
Any change
Angle of bevel
Any change outside approved tolerances (Note

2)
Size of root face

2)
Width of root gap

2)
Any use of (temporary) backing rings
Any addition or deletion, or change in material
Dimensions of fillet weld
Not essential variable
Electrode or wire
The following information is needed for each run:

Nominal diameter of electrode or wire
Any change for the capping layer or the first

two layers
Any increase for other runs
Trade name
Not Essential Variable
Classification
Any change
Any drying or pre-treatment for hydrogencontrolled electrodes
Any relaxation
Number of wires for each run
Any change
Number of runs
and number of
sides welded
Number of runs from each side
Any change from single to multi-run or vice

versa
Sides welded first and last (double sided

welds only)
Any change
Shielding gas or
Shielding gas
Change in gas selected
Flux
Composition of any gas mixture
A change exceeding 10% of the nominal

addition in a mixture.
Gas flow rate
Any change exceeding 10%
Trade name and type of flux
Electrical
characteristics
Current (ac or dc) and polarity
Any change.
Welding
Electrical stick-out (SAW, GMAW, FCAW)
Any change 5mm
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variables)
Arc Voltage
Any change 10%
Welding current
Any change 10%
Wire feed speed
Any change 10%
Travel speed
Any change 10%
Calculated value of heat input
No separate restriction
Welding Position
Angle of pipe axis to horizontal
Any change exceeding 25
Direction of
Welding
Vertical up or vertical down
Any change
Welding technique
Maximum amplitude of any mechanised

weave
Any Change
Frequency of any mechanised weave
Any Change
Dwell time at the side of any mechanised

weave

2)
Number of welders
Number of root run and of second run

welders
Any reduction
Time lapse
between runs
For cellulosic electrodes only: Time lapse

between start of the root run and the start
of the second run;
Any increase
Partially completed
joint
Number of runs before cooling to ambient
Any reduction
Line up clamp
Internal, external or alternative method
A change from internal to external, or from

internal clamp to alternative.
Number or runs before removal of clamp
Any reduction
Lowering off (on

land) or Barge
move-up (offshore)
Number of runs before this activity

commences
Any reduction
Preheating
Preheat temperature
Any reduction, or an increase exceeding 50C
Method of applying heat
Method of controlling temperature
Method of measuring temperature
Maximum and minimum interpass

temperature for each layer
Any change
Method of applying heat
Any change
Parameters
Post-weld heat
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variables)
Soaking temperature
Any change
Soaking time (specified as time/

thickness)
Any change
Welding procedure details for repair

welding
Any of the changes affecting approval listed

above
Welding procedure details for the weld to

be repaired
Any change affecting the approval of the

procedure for the weld on which the repair
welding procedure was qualified
Note 1 - CE calculated as per IIWValue tested 0.06% to + 0.03%.

Note 2 - To be agreed with Company after qualification of the welding procedure.
4.2
ESSENTIAL VARIABLES
The essential variables shall be as listed in Table 1 of this specification with the
following additional restriction for the welding of line pipe.
4.3
For mechanised GMAW, any change in diameter of wire.
WELDING OF TEST JOINTS - BUTT WELDS

The welding of test joints shall be made using either using the same welding, heating
clamping and support equipment, that is to be used in production or equipment
identical to it.
Welding shall be carried out using pipe nipples of sufficient length to properly
demonstrate the clamping, support and preheating method and in no case shall be
less than 3 meters in length.
The test joint material shall be selected from material of the highest carbon equivalent
(CE(IIW)) available at the time of welding. Table 1 Note (1) provides guidance for requalification of weld procedures with change in CE of line pipe material.
TECHNIP Project No.
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TESTING OF WELDED JOINTS - BUTT WELDS

After welding, the test joint shall be allowed to cool for 12 hours. It shall then be
subject to 100% radiographic examination prior to sectioning for mechanical tests.
In addition to radiography, welds made by GMAW (manual or mechanised) shall be
subject to 100% volumetric ultrasonic examination.
Non-destructive examination methods shall be in accordance with Sec.10, with the
exception that radiography shall be carried out using lead screens.
Acceptance criteria shall be as for production welds.
Table 2
Outside Diameter. 4 - 12 (Note 1)
Test Type
Outside Diameter > 12
Number of
Tests/Specimens
Clock Position of
Specimens
Number of
Tests/Specimens
Clock Position of
Specimens
2, 8
2, 4, 8, 10
All weld tensile
1 (where possible)
Not specified
Not Specified
Macro/hardness
12, 3, 6
12, 3, 6
1
(Note 2)
9 to 12
(Note 3)
2
(Note 2)
9 to 10, 4 to 6
(Note 3)
Weldmetal Chem.
Analysis
Not Specified
Not Specified
CTOD test
As specified in
Purchase Order
N/A
Transweld Tensile
Charpy Impact Tests
Full Ring stress

Corrosion Test
If Required
N/A
If Required
N/A
Note 1: Tests for pipe under 4 OD to consist of 2 macro/ hardness test specimens taken at the
3 and 6 oclock positions and one transweld tensile test
Note 2: A Charpy impact test consists of 4 sets of three specimens (Weld, FL, FL+2mm and
FL+5mm ) for pipe wall up to and including 20 mm thick and 5 sets of three specimens
(Weld [Root and Cap], FL, FL+2mm and FL + 5mm) for pipe wall greater than 20mm
thickness. See Fig 2.
Note 3: The positions given for the Charpy impact test are approximate. They may be adjusted
to allow removal of tensile and macro specimens from their indicated positions
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General Note:
Nick break and bend specimens are required by this specification for procedure
qualification since they also demonstrate the welders capability of making sound
welds using the parameters specified in the Contractors pWPS.
4.5
ALL WELD METAL TENSILE TEST
4.5.1
Method
The test specimen shall be taken within the weld deposit over the full gauge length.
Specimen dimensions and testing shall be in accordance with ASTM A370
4.5.2
Requirements
The yield strength and ultimate tensile strength values obtained shall be higher than
the minimum specified values (SMYS) for the parent material.
4.6
MACRO EXAMINATION / HARDNESS SURVEYS
4.6.1
Method
Sections shall be ground to, as a minimum 600 grit finish and etched for macro
examination. Examination at a magnification of x5 shall be made using a hand lens or
stereoscopic microscope.
Hardness survey shall be carried out by Vickers hardness test method using a 10Kg
load for welds made using SMAW process. For butt welds made using GMAW process
a 5Kg load shall be used. The position of the hardness impressions is given in Figure
1a.
4.6.2
Requirements
Each section shall show full penetration, be free from lack of fusion and cracks. Any
cavities or inclusions shall not exceed 5% of the surface area on each section.
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The maximum permitted value is 248 Hv10 for hardness impressions adjacent to the
internal surface and at mid thickness and 275 Hv10 for hardness impressions adjacent
to within 1.5mm of the cap reinforcement area.
4.7
CHARPY IMPACT TESTING
4.7.1
Method
For welds in pipe up to and including 20mm wall thickness, each test (as indicated in
Table 3, above) shall consist of three sets of four, transverse specimens notched at
weld centreline, fusion line (i.e. with the mid point of the notch intersecting the fusion
line) f.l. + 2mm and f.l. + 5mm (i.e. with the midpoint of the notch intersecting a line
5mm from, and parallel to, the fusion line). These specimens shall be taken from the
mid-thickness area of the section through the weld.
However, for welds in pipe over 20mm in thickness, additional impact test specimens
shall be taken from the root area and the specimen locations shall be as shown in
Figure 2.
Specimen preparation and testing shall be in accordance with ASTM A370.
Impact Test temperature shall be in accordance with Table 3
Design Temperature
Wall Thickness t (mm)
Test Temperature (C)
0C or above
t 20
-10
20 < t 30
-20
t > 30
-30
T 20
T 10
20 < t 30
T 20
t > 30
T 30
T C (Less than 0C)
TECHNIP Project No.
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Requirements
The minimum required energy for all impact tests shall be as follows:
Table 4
Specimen Size (mm)
(Note 1)
Average per Set of

Three (Joules) min.
Individual value min.

(Joules)
10 x 10
42
35
10 x 7.5
38
32
10 x 5
26
22
Note 1: Only specimens of the sizes stated in Table 4 above shall be tested.
Note 2: Line pipe materials with SMYS < 414 MPa see Table 6-3 Sec.6 of DNV-2000.
4.8
CHEMICAL ANALYSIS
4.8.1
Method
Chemical analysis shall be performed on a section of weld metal. Analysis shall be in
accordance with ASTM A370. The elements listed in the relevant line pipe
specification shall be analysed.
4.8.2
Requirements
The analysis shall confirm the manufactures stated limits for the chemical composition
of the weld metal. The results of analysis for other elements are for information.
4.9
CRACK TIP OPENING DISPLACEMENT TEST (CTOD)
4.9.1
Method
CTOD tests shall be conducted at the minimum design temperature for all pipeline
welding procedures and representative weld repair procedures. Each test shall consist
of three (3) specimens. CTOD testing will not be required for pipe to fitting welding
procedures.
TECHNIP Project No.
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Testing will be on preferred geometry (Bx2B) type specimens in accordance with BS

7448 Part 2.
4.9.2
Requirements
The results are for Company information.
4.10
TESTING OF WELDED JOINTS - FILLET WELDS
4.10.1
Preparation
Fillet weld test joints shall be allowed to cool to ambient temperature and then be
subject to 100% magnetic particle examination (Refer Section 10.5), prior to
sectioning.
Four weld sections shall be taken from the 12, 3, 6 and 9 oclock positions of the test
weld. For test welds other than full circumference welds the four sections shall be
equally spaced.
4.10.2
Method
Sections shall be ground to, as a minimum, 600 grit finish and etched for macro
examination. Examination shall be made using a hand lens or stereoscopic
microscope at a magnification of x5.
On two of the sections a hardness survey is to be carried out by Vickers hardness test
using a 10Kg load. The position of the impressions is given in Figure 1b.
4.10.3
Requirements
Cracks or other planar defects detected by magnetic particle examination shall be
unacceptable.
Each section shall show full penetration, be free from lack of fusion and cracks. Any
cavities or inclusions shall not exceed 5% of the surface area on each section.
The maximum permitted hardness for external fillet welds is 275 HV10 and 248 HV10
for internal fillet welds (i.e. those in contact with the sour production fluids.
TECHNIP Project No.
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PERFORMANCE
Should a test weld fail any of the required tests or the permitted retests, the cause of
the failure shall be established and rectified and the complete procedure test shall be
repeated.
No lay barge field welding shall commence until the appropriate welding and repair
procedures have been qualified and approved by the Company.
Should a qualified procedure show poor production performance the causes for the
poor performance shall be assessed and a modified welding procedure shall be
qualified and submitted to the Company for approval.
5.
QUALIFICATION OF WELDERS AND WELDING OPERATORS
5.1
GENERAL
All welders and welding operators shall be qualified in accordance with API 1104 and
this Specification.
Welders or operators shall be qualified for this project prior to the start of production
welding by making a complete test butt weld using the qualified welding procedure.
The test weld shall be made with the pipe in the same positions as for production
welding. Tests shall be conducted on the same material as that to be used in
production, and welding of test joints shall be carried out on the lay barge.
All welders qualified to work on this project will be provided with identity badges.
5.2
WELDING INSPECTION AND TESTING

Each test weld shall be subject to both visual and non-destructive inspection. Nondestructive inspection shall be in accordance with Section 10.0 of this Specification.
If the test weld is visually acceptable it shall be subject to mechanical testing as
detailed earlier.
TECHNIP Project No.
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REQUALIFICATION
Re-qualification of welders or welding operators for lay barge operation is required if
any change is made to the welding procedure which necessitates re-qualification of
the welding procedure.
5.4
VALIDITY OF
CERTIFICATES
WELDER
AND
WELDING
OPERATOR
QUALIFICATION
5.4.1
Re-qualification of welders and welding operators is required if any change is made to

the welding procedure that necessitates its re-qualification.
5.4.2
Renewal of a qualification certificate is required whenever a welder or welding operator

has not used the appropriate welding process for a period of more than three months
or whenever there is a reason to question the performance of production welding.
Validity of the certificate is maintained as long as acceptable performance of welding
fabrication is documented with regular non-destructive testing during lay barge
operations and the Contractor keeps records of periods of time and type of work for
each certified welder and welding operator.
6.
PRODUCTION WELDING
6.1
GENERAL
All production welding equipment shall be suitable for the job and capable of producing
welds of the specified quality.
All equipment shall be maintained in a good working order and any unsuitable
equipment shall be replaced immediately.
All welding shall be performed by qualified welders. They shall use qualified welding
procedures and welding consumables. Welding fluxes and gases shall be properly
identifiable and acceptance within the contractor's QA/QC control.
6.2
LINE PIPE END PREPARATION

Pipe lengths will be supplied with machined bevels specified in Company
specifications as appropriate. Should the Contractor elect to use a different groove,
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prior approval shall be obtained from the Company and incorporated in the procedure
and welder qualifications. For pipe-to-pipe fittings, pipe-to-flange, or pipe-to-pipe
welds where wall thickness changes are involved, the proposed joint design shall be
submitted for Company approval prior to use. In the event the bevel configuration is
changed from that supplied by the line pipe manufacturer the re-machined bevel faces
shall be 100% examined by wet MPI. However this test may be reduced to 20% upon
the Company approval based on satisfactory test result.
Details of end preparation machines shall be forwarded to Company for approval.
Any pipe bevel showing evidence of end area lamination shall be cut back until the
laminated section is removed and rebevelled. After rebevelling the pipe end shall be
ultrasonically inspected in accordance with ASTM A578. Any discontinuity (e.g.
lamination) causing a reflection echo > 50% DAC and accompanied by a 50% loss of
back wall reflection shall be cause for rejection when the discontinuity area is greater
than 30 mm2.
Pipe Bevels shall be cleaned by power tools to a bright finish prior to lining up the pipe
for welding.
6.3
ALIGNMENT
6.3.1
Details of line up clamps shall be forwarded to the Company for approval prior to
commencement of welding. For pipe welding internal line-up clamps shall be
mandatory unless otherwise agreed by the Company. End preparation machines and
line up clamps shall not damage the pipe or coatings. Line up clamps shall ensure
that pipe bores are aligned to the tolerances of BS 4515. Line up clamps shall not be
removed until both root and hot passes have been completed.
6.3.2
For the welding of fittings and flanges the line-up procedure shall be approved by the
Company. It shall conform to the requirements of BS 4515 and this specification.
6.3.3
Hammering or heating shall not be used for correction of misalignment. Spacer tools
are to be used to check final fit-up.
6.4
PROXIMITY OF WELDS
Girth welds shall be separated by a minimum distance of one pipe diameter. The
minimum distance between nozzle welds and between nozzle and girth welds shall be
4 times the nominal wall thickness of the run pipe. Distances shall be measured weld
toe to weld toe.
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TACK WELDING
Bar tacks are preferred, i.e. welds to bridging pieces within the weld bevel, not
affecting the root area and totally removed prior to completion of the final weld.
Where root tacks are to be used they must be at least 50mm long and must be at least
four in number for pipe over 4 in diameter. Root tacks incorporated into the final weld
must be welded to the same procedure, by a welder qualified for that procedure and
shall be ground to a feather edge at each end to ensure adequate fusion into the root
pass.
6.6
TEMPORARY AND NON-STRUCTURAL ATTACHMENTS

Temporary or non-structural attachments to the linepipe or pipelines are not permitted
without the written approval of the Company. The written request shall include details
of proposed welding procedures and controls on their location and methods of
removal.
The Contractor shall prepare a procedure for welding the doubler plates onto those
pipe lengths intended to carry anodes and for CAD welding the anode bonding strap
onto the doubler plate.
6.7
MOVEMENT OF PIPE
The pipes on both sides of the weld joint shall not be moved until both the root and hot
passes have been completed.
In the case of offshore pipe laying the barge shall not be moved until the root and
second pass have been completed.
6.8
STORAGE AND HANDLING OF CONSUMABLES
6.8.1
As a minimum the storage and handling of welding consumables shall conform to the
recommendations of the consumable manufacturer. A detailed storage and handling
procedure shall be submitted by the Contractor for approval by the Company.
6.8.2
Special care shall be taken to ensure that basic coated low hydrogen electrodes are
stored in a warm dry environment. Prior to use low hydrogen electrodes shall be baked
in accordance with the manufacturer's recommendations to achieve a hydrogen
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content of less than 10ml/100g of weld metal. In the absence of written

recommendations the electrodes shall be baked for two hours at 300C. After baking
the electrodes shall be transferred to a holding oven operating at 150C then issued
from the oven to heated quivers at 70C for use. Any low hydrogen electrode
remaining unused after 2 hours in a quiver shall be returned to the baking oven and redried for 2 hours at 300C before being returned to the holding ovens and re-issued.
No electrode shall be redried more than 2 times.
6.9
PREHEATING AND INTERPASS TEMPERATURES
6.9.1
Preheat shall be applied under the following conditions:

a)
When specified in the approved welding procedure, related to the carbon

equivalent (CE or Pcm) of the pipe.
b)
When required to ensure dryness in the joint.
c)
When the ambient temperature measured on the pipe is below that established
during the procedure qualification.
6.9.2
The requirements for preheat and the temperatures shall be formalised during welding
procedure qualification, taking into account pipe wall thickness, carbon equivalent and
welding process including weldability data available from line pipe manufacturer.
6.9.3
Preheat shall be applied in a uniform manner preferably by using gas ring or electrical
heating. However hand held gas torch heating is permitted if minimum of two torch
used for preheating of pipe sizes up to 14" and four for upper pipe sizes.
6.9.4
The preheat temperature shall be established over minimum distance of 75mm on

each side of the weld and shall be measured using a calibrated thermocouple or
melting indicator crayon. The actual preheat temperature shall not exceed the
specified temperature by more than 50C.
6.9.5
The minimum preheat temperature for repairs shall be 50C higher than that specified
for the original welding, up to a maximum of 150C.
6.9.6
The minimum preheat temperature for welding of fittings to line pipe and at tie-ins shall
be 150C.
TECHNIP Project No.
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6.9.7
If, notwithstanding the above requirements, HAZ hydrogen cracking is found, then the
whole weld procedure together with the level of preheat and the consumable handling
procedure shall be reviewed and reassessed.
6.10
POST-WELD HEAT TREATMENT

Post-weld heat treatment shall be used when so specified in the qualified welding
procedure. Only electrical methods shall be used for heating. Measurement of post
weld heat treatment temperatures shall be in accordance with ASME VIII part 1. Postweld heat treatment, when specified, shall be performed in accordance with a written
procedure approved by the Company.
6.11
REPAIR WELDING
6.11.1
General
6.11.2
No weld shall be repaired without informing and consent of the Company.
Only one attempt at a repair shall be made. Any further repair attempt shall require
prior approval by the Company.
Should the weld be removed (cut-out), re-bevelling performed shall ensure removal of
the prior heat affected zone material.
Repair Procedure
Weld repair procedures shall be qualified in the same manner, and at the same time,
as production welding procedures are qualified. In addition to the details of the
procedure qualification the repair welding procedure presented shall also include full
details of the following:
Method of defect removal;
Preparation of weld area;
Non-destructive inspection method for confirmation of defect removal;
Maximum and minimum repair cavity sizes;
TECHNIP Project No.
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9068G-000-JSS-3520-512

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Repair procedures which include the above requirements shall be subject to approval
by the Company.
The qualification test specified covers the typical weld repair situation. Company
reserves the right to require additional testing for very shallow or very deep repair
situations.
6.11.3
Defect Removal
Weld defects shall be removed by grinding, machining or air-arc gouging. If air arc
gouging is used then the defect area shall be subsequently cleaned by grinding. The
cut-out portion shall be sufficiently deep and long to remove the defect. At the ends
and side of the cut there shall be a gradual taper from the base of the cut to the
surface of the weld metal. The width and profile of the cut shall be such that adequate
access for re-welding is provided.
External defects such as undercuts and pin holes shall be repaired by re-capping the
weld for a minimum distance of 40mm past both ends of the defect. This distance
shall be measured parallel to the length of the weld. Re-capping shall only be
accepted if the maximum hardness is shown by procedure qualification to be within the
acceptance limits of this Specification.
7.
WELD PROFILE AND SURFACE FINISH
7.1
Welds shall meet the appearance criteria of BS 4515 Table 5. Welds shall be left aswelded for initial inspection and shall not be doctored with a torch or by mechanical
means to alter their appearance.
Grinding or mechanical dressing shall be permitted only when specified on the
Contract Drawings or after approval by the Company.
7.2
For coated pipes the Contractor shall arrange for the coating to be applied in the weld
area in accordance with Company Specifications after the weld has been inspected
and accepted. The Contractor shall also arrange for the repair of any damaged
coating.
7.3
Surface Imperfections
Prior to completion and field joint coating the Contractor shall remove all burrs, scars
and marks made by welding during fabrication.
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Surface imperfections such as gouges, grooves, shallow surface cracks, laps, slivers
and arc strikes may be removed by grinding to a smooth profile provided that the
resulting wall thickness is within the tolerances allowed by Company Specifications as
appropriate. Repair welding on the body of the pipe shall not be attempted.
Where defects that penetrate to the extent that after grinding the remaining wall
thickness will be below the minimum wall thickness the damaged portion shall be cut
out as a cylinder, and replaced to the requirements of this Specification.
Arc strikes are not permitted on pipe body during welding. Arc strikes, inadvertently
caused may be removed by grinding provided the remaining wall thickness is above
the minimum wall thickness required by line pipe specification. The ground surfaces
shall be examined by magnetic particle inspection to demonstrate removal of defect to
the satisfaction of the Company.
7.4
Dents
Unacceptable dents (as defined in the appropriate Company Specification) shall be
removed by cutting the pipe as a cylinder and replacing it to the requirements of this
Specification.
8.
IDENTIFICATION OF WELDS
Each welder shall mark in waterproof crayon that section of weld on which he has
worked with his code No. If different welders work on different sides a separate set of
numbers shall be put on each side. The root welder shall put his number at the top,
with each subsequent welder marking below it, in sequence. These numbers shall not
be removed until the weld is cleared by NDT.
Contractor shall submit detailed procedures for identification and marking of welds
including NDE for Company review and approval prior to mobilisation of welding
personnel on the lay barge.
9.
WEATHER CONDITIONS
All welding shall be performed in areas where prevailing weather conditions can have
no influence on weld quality.
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10.
INSPECTION AND TESTING
10.1
VISUAL INSPECTION
Page 33 of 45
The Company shall have the right of inspection and/or rejection at all times during the
welding and after the weld has been completed.
10.2
NON-DESTRUCTIVE TESTING (NDT)
10.2.1
Butt welds shall be 100% visually inspected 100% inspected using X-ray Radiography
for permanent film methods. Any approved fillet welds shall be 100% inspected by
magnetic particle inspection.
The Company reserves the right to require all suspect areas to be re-examined by
ultrasonic examinations for the purpose of clarifying acceptability or otherwise. The
Contractor shall have available suitably qualified technicians to ASNT level II.
Where welding is conducted using a gas shielded welding (GMAW) process the first
three production welds per day shall be examined by ultrasonic. The Company reserve
the right to increase this if lack of fusion or cracks are found which escape detection by
radiography. In case of using (GMAW) for only root pass and (SMAW) for the other
runs, ultrasonic test is not required.
10.2.2
The qualifications and competence of NDT Personnel used by the Contractor shall be
subject to approval by the Company.
NDT Supervisors shall have full knowledge or all Specification requirements and the
applicable codes and standards. Current copies of all pertinent documentation such
as this Specification and approved welding procedures shall be at the disposal of all
relevant personnel during all welding and associated operations.
10.3
STAGES OF INSPECTION
10.3.1
As a minimum, the inspection stages employed by the Contractor for welded joints
shall be as follows:
a)
Fit-up prior to first pass.
b)
Following root pass.
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Following completion of weld (after PWHT where appropriate).
Inspection of stage (a) will be visual and dimensional.

Inspection of stage (b) will normally be visual only.
Inspection at stage (c) will be visual and, as required by this Specification, using the
methods listed in Section 10.4 or 10.6 of this Specification.
10.3.2
Marking
The Contractor's quality control personnel shall clearly identify with a distinguishing
mark all parts or joints that have been inspected and accepted. The system of
marking shall be submitted to the Company for approval.
10.4
RADIOGRAPHY
10.4.1
General
Prior to the start of production radiography the Contractor shall submit a detailed
radiographic procedure for approval by the Company. As a minimum the procedures
shall include the details specified in BS EN 1435.
The radiation source shall consist of X-ray unless otherwise approved by the
Company. Tie-in weld radiography can be done by means of using - ray provided on
using D4 or equivalent films.
Wire type image quality indicators shall be used.
Only fine grain film shall be used. The use of fluoro-metallic intensifying screens shall
be permitted subject to satisfactory procedure qualification. Damaged screens shall
not be used.
10.4.2
Procedure Radiographs
Three radiographs shall be made of each welding procedure qualification weld. It is
the intent of this Specification to establish these radiographs as the quality level for all
production welding. Welding Procedures shall not be deemed Qualified unless these
radiographs have been accepted and approved by the Company. Should any variables
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in the welding procedure specification change, the radiographic procedure shall be

requalified.
For procedure qualification image quality indicators are to be placed on both the
source side and the film side of the weld. IQI sensitivity shall be:
Source side
better than 1.8%
Film side
better than 1.6%
Film density shall be a minimum of 2.5.

10.4.3
Production Radiography
Production radiography shall be in accordance with the approved radiographic
procedure, with image quality indicators on the film side only. When a circumferential
weld is carried out in a single shot four IQI's shall be used - one per quadrant.
Otherwise two shall be used per film length.
Interpretation of radiographs will be conducted by the Company.
10.4.4
Radiation Protection
The Contractor shall be responsible for the protection and monitoring of radiographic
personnel and shall ensure that work is carried out in accordance with the relevant
Health and Safety Regulations.
10.4.5
Qualification of Radiographers
Radiographers shall be qualified in accordance with the requirements of ASNT level II
or an approved equivalent.
10.4.6
Film Identification
As a minimum, the film identification shall include:
Company Name
Line number/spool No./Line size
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Weld Number
Date
Location of the film on the weld (Clock Positions)
10 cm divisions around the pipe
An indication of weld status. i.e. original, repair, re-repair etc.
Page 36 of 45
The zero datum shall be at the top of the pipe. Divisions for location of weld defects
shall run clockwise in ascending order viewed in the direction of pipelay.
10.4.7
Film Processing
Film shall be processed on site in such a way as to allow storage for up to 5 years
without deterioration. The Contractor shall submit a procedure for ensuring that film
processing chemicals have been removed prior to storage of the radiographs. The film
handling and storage procedure shall be subject to approval by the Company.
10.4.8
Film Storage
All unexposed film shall be stored in a clean dry place where surrounding conditions
will not be detrimental to the emulsion. If deemed necessary by the Company
unexposed film will be developed and the extent of fogging shall produce a density of
less than 0.3. The processed films shall be kept in an Air Conditioned room.
10.5
MAGNETIC PARTICLE INSPECTION (MPI)

The Contractor shall submit his MPI procedure to the Company for approval.
The Contractor's procedure shall be in accordance with BS 6072 or approved
equivalent using a wet particle method. The yoke method shall be used in preference
for all magnetic particle inspection, the use of the prod method shall be subject to
Company approval. Magnetic particle operators shall be qualified to ASNT-Level II or
approved equivalent.
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10.6
ULTRASONIC EXAMINATION
10.6.1
General
Page 37 of 45
The Contractor shall have facilities available for ultrasonic examination of welds in
accordance with Section 12.5 of BS 4515.
The Contractor shall submit his detailed procedure and technique sheets for ultrasonic
examination to the Company for approval prior to the start of production. The
Procedure shall include for the ultrasonic examination of welds between pipes of equal
and unequal wall thickness and between pipes and fittings where the wall thickness
differs.
10.6.2
Qualification of Ultrasonic Technicians

Ultrasonic Technicians shall be qualified to the appropriate level of ASNT-Level II or
approved equivalent scheme.
10.7
ACCEPTANCE CRITERIA FOR INSPECTION AND NDT

The acceptance criteria shall be as stated in Clause 13.1 and Table 5 of BS 4515 and
the following additional requirements:
10.7.1
Radiographic Testing
The diameter of any, individual gas pore shall not exceed 2mm or 20% of the nominal
wall thickness, whichever is the smaller.
All cracks are unacceptable.
Root Penetration
The weld root excess penetration at any point shall not exceed 3mm.
Centre-line Shrinkage in GMAW Welds
Centreline shrinkage (hot cracking) in mechanised GMAW welds is unacceptable.
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MPI TESTING
No additional requirements.
10.9
DYE PENETRANT TESTING

No additional requirements.
10.10
ULTRASONIC TESTING
Where ultrasonic testing is used to compliment radiographic inspection the acceptance
criteria shall be as for Section 10.7.1
Where automated ultrasonic inspection is used as the primary means of weld
inspection then acceptance criteria are to be agreed with the Company.
10.11
RANDOM HARDNESS TESTING

Random hardness tests shall be carried out on the first 50 completed girth welds in
order to ensure compliance with NACE MR 01-75 hardness (248 Hv10) requirement.
This shall consist of hardness testing the weld cap of the finished girth welds at three
equidistant positions around the circumference. Subject to compliance with the
acceptance criteria the testing frequency may be reduced to 1 in 10 welded joints.
10.12
METALLIC INCLUSIONS
The largest dimension of any tungsten inclusion shall not exceed 2mm or 20% of the
nominal wall thickness, whichever is the smaller. Adjacent inclusions shall be
separated by at least 50mm and there shall not be more than four inclusions in any
300mm length.
Copper inclusions are unacceptable and shall be excavated followed by re-welding
using the qualified repair weld procedure.
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11.
DOCUMENTATION
11.1
PRIOR TO PRODUCTION WELDING
Page 39 of 45
Copies of the following documents shall be supplied to the Company prior to

commencement of production welding:
Welding Procedure Specifications
Welding Procedure Qualification and Test Reports
Repair Welding Procedure and Test Reports
Welder Qualification Records
11.2
Non-destructive Inspection Procedures and Qualification Reports.
Quality Plan
ON COMPLETION OF THE WORK

On completion of the work, the Contractor shall submit the following documentation to
the Company.
Non-destructive Examination Reports for all welds, including repair welds, carried out.
List of Certified Welders.
Weld radiographs.
Pipe number / Joint number / Pipe location.
Welding Procedure Proposals.
Welding Procedure Specifications.
Welding Procedure Qualifications.
Welder Approval Qualifications.
NDE Operator Qualifications.
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NDE Procedures.
Records relating pipe number to welder, NDE, PWHT (if applicable)
Chemical analysis and other tests required by the specification.
Heat treatment records (if applicable).
Page 40 of 45
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FIG. 1 POSITION OF HARDNESS SURVEYS
Hardness Traverse
1.5mm from outer
surface
1.5mm
Specimen
centre line
Hardness traverse
root side
1.5m
m
FIG 1a: Butt Welds and Full Depth Repair Welds

Traverse through fillet cap
Traverse through fillet

root
FIG1b: Hardnesss Traverse on Fillet Welds
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Fig 2. Charpy Specimen Locations for Welding Procedure Qualification Tests
NOTES:
1. Charpy specimens to be etched to ensure correct notch location
2. Fusion line charpy should be taken from the steeper face if weld is not symmetrical
Centre Line of specimen intersects Centre Line of notch on fusion line for fl Specimens
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Figure 3. Charpy Test Locations for Partial Repair Weld Procedure
NOTES
1. Charpy Specimens to be etched to ensure correct notch location
2. Centre Line of specimen intersects Centre Line of notch on fusion line for fl specimens
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APPENDIX-A
Method Statement for HIC and SSC Tests
A.1
General
This procedure describes the testing of both the base material, the circumferential and
longitudinal (SAW) welds of line pipe to be exposed to wet sour gas or multiphase
fluids. The testing procedure forms part of the lay barge welding procedure
qualification requirement.
A.3
Welding Requirements
Welding shall be carried out by the Fabrication Contractor using the Company
approved welding procedure specification to be used on the pipe laying barge, utilising
the same make of electrodes (manual welding) or welding wire (automatic welding).
The girth weld shall be made on pipe sections from a selected heat representing the
highest carbon equivalent (CE) of the heats produced by the line pipe manufacturer
and as used for the conventional weldability tests.
Welding shall be performed in the 5G position.
The pipe sections shall be stamped by the Inspector and marked with:
a.
Heat number
b.
Unique pipe number
The top of the pipe shall be marked with a line and stamped TOP at each end at the
time of welding.
A.4
Specimen Preparation
Number, Location, Orientation and size of the specimens shall be based on NACE TM
0284-96.
A.5
Test Details
Test method shall be based on NACE TM 0284-96 for HIC and NACE TM 0177 for
SSC tests.
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Specimen Examination
Prior to testing, the complete test section shall be fully examined by ultrasonic testing.
UT examination will be repeated after 7 days exposure and at regular intervals
thereafter to determine initiation and or extension of any cracks. The test shall be
terminated following final UT examination after 30 day test period or earlier if ultrasonic
testing indicates excessive crack extension such that failure could occur.
The decision for early termination of the test based on the results of ultrasonic
indications will be subject to agreement between the Company and the Test house.
At the completion of testing period the internal weld surfaces will be examined by wet
magnetic particle examination (MPI). Any crack like or other surface indications found
by MPI or by UT examination during testing will be characterised by metallographic
examination of the relevant areas and reported with photomicrographs of
representative features found.
A.7
Acceptance Criteria.
a. No stress corrosion cracks greater than 1mm.
c. No HIC cracking greater than 1mm.
Crack area value < 3% based on results of ultrasonic indications and selected
metallography.
No delamination cracks greater than 5mm.
A.8
Reporting
Any test ring failure occurring within the 30 day test period shall be reported to
Company.
Following the completion of testing the Testing Contractor shall prepare and submit a
draft report within seven (7) working days for discussion of results. Following the
meeting the report shall be finalised and three (3) copies submitted to Company.
TECHNIP Project No.
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9068G-000-JSS-3520-512

Salman Offshore Facilities Laybarge Welding Specification

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PETROIRAN DEVELOPMENT COMPANY