'*Fl'1

AD@ Spec. No : Date :

WS-l Rev. 2

Page I of 54

f2.04.1990

SPECIFICATIONFORWET,DII.,.G WEIDIIiG INSPECTION AIiID OF AI.IDFIET,D FABR,ICATfD CARBON A}ID SITOP SXEEI,PROCFJSS INTLITT PIPITiG

Prepared By :

Reviewed BV : D.G. Thonas

Approved By : A.J. Dennis Head of Qualily Assurance &

Name : Desig :

M. Muthuraman Inspection Brgineer (WeIding )

snr.
Inspection
Ihg j.nee

sisn , y/. ffnf{,<^^.^o^

ADCO Spec. No : Date :

WS-l Rev. 2

Page 2 of 54

12.04.1990

TABT,E CONTEDTTS OF

1.0
2.O 3.0 4.0 5.0 6.0

Scope Definitions Appl icable Codes, Standards and Specifications General RequiremenLs Approved Welding Processes Welding Procedure Qualification 6.1 6.2 6.3 6.4 Welding Procedure Specifications welding Procedure Qualification Essential Variables Tests oualification (v{PS)

7.0

Welaler and welding operator Performance QualificaLion 7.1 7.2 '1 .3 General Considerations QualificationValiditY of welders ldentificaLion

8.0

Production Welding Requirenents General 8.I Welding Fquignent 8.2 Welding Processes 8.3 Weather Protection 8.4 Parent l4aherials 8.5 welding consunables 8.6 cutting and weld Joint Preparation 8.7 Cleaning Reguirements 8.8 Joinh Aligrnent 8.9 8.10 Tack welds Joint Backing Requirer0ents 8.lI 8.LZ Preheat Requi.rements 8.13 Inherpass Terperabure 8.14 Interrutfion of Welding 8.15 weld Beaal Sequence 8.16 Interpass Cleaning 8.17 Peening 8.18 SeaI and Socket Welding 8.19 AttachflFnt We1ds u. zu wero s[Eclng

63188/05438/2

AD@ Spec. Nc : Date :

WS-I Rev. 2

Page 3 of 54

12.04.1990

8.21 8.22 8.23 8,24 8.25 9.0

Workranship and weld Finish Welding Technique Welding Requirements for Carbon Steels Post Weld Heat Treat$ent weld ldenLificahion Exanination

Non-Destructive 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9

ceneral Visual Examination Radiographic Exarninatrion Ultrasonic Examination Magnetic Particle/Dye-Penetrant Exarnination Ultrasonic Ttrickness Measurements Brinell ltrardness TesLing Extent of Non-Destructive Examination I{DEPersonnel Qualifications

10.0

Repair of Defects 10. t 10 .2 I0.3 I0.4 ceneral Minor Surface Repairs Repairs Involving Welcli.ng NDEof Repair welds

1I.0

Docunentation (!iPS) Form Welding Procedure Specification Record (PQB.)Form Procedure Qualification Tests for and Nurnber of llechanical flpe Procedure Qualif ication vickers Hardness (Hf10) survey for Procedure
r\,.^1

Exhibit No. I (shr. I & 2) Exhibit N,o. a (Sht. I ihru' 3) Exhibit No. 3 Exhibit No. 4 Exhibit No. 5 Table 1

vuct-L r ! t\,aL

.: c:

^^!

rvr rD

i ^-^

welder cerbificahe

Form

Minimun ltequirenents Examination

for

Non-Destructive

63188/05438/3

ADCO Spec. No : Date :

WS-l Rev. 2

Page 4 of 54

12.04.1990

1.0

scoPE
1.1 prescribes the minimun requirements for welding This specification and Non-tlestructive Examination of process and utility piping for hhe Abu Dhabi Corpany for Onshore Oil Operations (ADCO). fhe requiremenLs apply to pipevrork associated with vendor supplied package, longitudinal equigrent seam welds of bulk Errchased piping conponents such as pipes, tees and elbws, pipework fabr icated as part of a contractual fabrication ancl field erected

prprng.

r.2
2.0

this specification shall apply to lhe main ContracLor and to all his sub-contractors.

DEFINITIONS Z.l For the turpose shall hold : 2.I.I of Lhis Specification the following definitions

rShallr, 'Should' anal rl,layr : the \.rord 'Shall' is to be understood as nandatory, 'Should' as strongly recomnended and r!,layr as a possible course of action to conply $rith the regulations of Lhis specification. Abu Dhabi Company for Onshore Oil referred to herein as COMPANY. Operations (ADCO) is

2.I.2 2.I.3 2.I.4

ltre Supplier, Vendor, Manufacturer, Fabrication Contractor or Erection Contractor is herein referred to as CONTRACTOR. Firms engaged by the Contractor for the performance of work are herein referred to as SUB-CONTRACIOR.

3.0

APPLICABLE CODES,STANDARDS SPECIFICATIONS AI{D The design, fabrication and inspection of pipework sha1l colllt)ly with the requirenents of ANSI 831.3 except as rcdified herein. The latest edition and addenda of the follo\^ring docurpnts at Lhe time of tender shall apply. In case the requi rements of this specification are in conflict of these docunenbs. this specification shall prevai-1. 3.1 American National Standards (ASME/ANSI : )
tsJI.J

with

any

Chenical Plant and Pehroleun Refinery Piping

ADO Spec. No : Date :

WS-L Rev. 2

Page 5 of 54

12.04.1990

3.2

ASME Boiler

and Pressure Vessel Code : Welding Rods, Electrodes and Filler Non-testructive Div.1 Pressure Vessels Welding and Brazing Qualifications Hrgineers, NACE: Sufphide },laterials Examination t4ebals

Section II Part C Section V Section VIII Section IX 3.3

National Association of @rrosion NACEMRO175

Standard Material Requirernents : Stress Cracking Resislant Metallic for Oilfield Equipflent

3.5

American SocieLy for Tbsti.ng and l,later ia1s, ASTt"l: 892 El10 894 Vickers Hardness of Metallic li{aterials l,laterials for

Hardness of Metallic Indenlalion by PorLable Hardness Testers Standaral Reconrnended Radiogaphic Testing

Practice

3.6

BS 5135

Process of Arc Welding of Carbon and CarbonManqaneseSteels 10 Fire Precautions and Safetv

AD@ Procedure Manual Volune Requlations. 4.0 REQUIREMENTS GENERAL 4.1

shal1 be All welding and quality control of welding fabrication done by the Contractor in accordance with hhe requiremenls of this Specification. the Contractor shall cofirply with the Conpany Safety Regulations slated in ADoOProcedure l,lanual Volune 10. as

4,2 4.3

The AI1 v/el.ding shall be as slEcified on the contract drawings. Contracbor I s isornetric drawings shall show all lrelds each with a unique identif ication nurnber.

63\8E/05438/5

ADCO Spec. No : Date :

WS-l Rev. 2

Page 6 of 54

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5.0

APPROVED WELDING PROCESSES

5.1

ltre following processes are approved for use on pipework :

a. b. c. d. e. Shielded Metal Arc Welding (St4Ali) C,asTungsten Arc Welding ( GTAW,or TIG) Gas Metal Arc Welding (cMA!{or MIG/MAG) Subnerged Arc Welding (SAW) Electric Resistance Welding - high frequency process longiLudinal seans only) (for

arc (I,IIG, l,tAGor G]4AW) welding shall Short circuiting lrith prior company approval.

be used only of filler

Manual GTAI'I(TIG) vrelding must be done with Lhe addition metal and high frequency starting unit. 5.4

Other processes such as cas Shielaled Flux-Cored Arc or Plasna Arc Welding nay be used only upon specific aFproval by the conpany Self shiel-ded flux-cored arc welding shall not QA&CDepartnent. be [Ennithed. The root pass vrelding of pipework of all fiaterials for noninal dianeter less than or equal to 51mn (2 inches) process. done by GTAv'l pipes of shall be

5.6

FulI welding of pipevrork of a1l naterials for pipes of nominal dianeter less than or equal to 5lfim (2 inches) and wal1 thickness process. less than 6nn should be done by GTAW A GTAv,l root pass shal1 be used for follovring piping systems : a. b. c. Gas turbine fuel systems piping syslems single sided butt welds on the

Seal and lube oil

Hydraulic oi1 systems

63788/0543F/6

AD@ Spec. No : Date :

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Page 8 of 54

12.04.1990

r. s.
c.

cas shielding - flow rate and composition

cas backing - initial duration conposition and duration Current, of purging, flow rate,

voltage and welding speed for each layer.

6.I.5

Ttre welding procedure specifications should be clearly identifiabLe and the Oontractor shoutd give precise debails of which welds are covered by the WpS, e.g. pipe size and service/applicahion. Unless specified otherwise, procedure a1l welding specifications shall be qualifieil by Lhe Contraicor and duly approved by the Conpany. WriLten approval by Lhe 0on6nny is use of any pre-qualified WpS. required prior to L,he

6.1.6

6.1.7 6.2

weldinq procedure Qualification 6.2.1 of the contractor When the vrelding procedure specifications to the have been accepted by the company and prior connrencefient of production welding' procealure qualification tests shall be carried out' under lhe ..surveillance of bhe authority, if coTrpany or Cory)any appoinLed certifying aPPl icable . tests shall be conducled in welding procedure qualification by this accordance wiLh Asl'[E Seclion Ix except as rpdified

6.2.2

specification. 6.2.3 the results of the qualification tests should be subrnitted as shown in Exhi.bit t{o. 2 as Procealureoua} if icat ion Recoral
(PQR).

6.2.4

\he Procedure Qualification following : a. b. c. d. e. f. tt. Contractorrs nane

Record (PQR) should include the

PQn. nuriber and date wPs number, revision Welding process Drpe (manua1, autonalic, Joint seni-auLonat ic ) design and sequence of passes grade, carbon equivaLent, and date

Base rnaterial specification, thickness and pipe dianeter

ADCO Spec. No : Date :

WS-1 Rev. 2

Page 9 of 54

12.04.1990

h. i.
l. k. 1.
n.

Filler ntal AWs classification, brand name, A. No. and F. No. Welding positrion and progression
Preheat temperature, IrFasurenent Interpass temperature Post weld heat treatrrnt, time, heating and cooling holding rates method of

size, nanufacturer,

application

and

ten[Erature,

holding

Shielding gas, composition and flow rate Backing gas composition anal flow rate Current tlpe and polarily t).pe and size (for cTAhl ) gas cup size (for GTAW GMAW) Orifice or & l4ethod of cleaning Tungsten electrode Method of back gouging WeLding current, each pass. arc voltage and welding speed for

q.

+'

6.2.5

the Contractor shall submit all vJelding procedures and Qualification Records (PQR'S) with the follovring back up certificates/reports for Corpany approval prior to the comenceflnt of production welding :
a. b. c. d. e. f. S. Welding procedure specifications necessary ( Exhibib No. 1). Mill certificates of the parent Ilptal (WPS), revised used. if

Batch Lest certificaLes IleaL treatfient llon-destructive Mechanical test Welding

of bhe welding consunables.

charbs, where applicable. exaninahion reports. reports including photo nacrographs.

procedure.

consumable

cont rovelect rode

redrying

6.2.6

Docunentation for previously qualified welding procedures may be subnifted to the Company ho support welding procedure specifications. Where it is considered that such docunenL,ation adequately proves the suitability of the welding procedures and neets the requirenents of this specification, requalification may be waived or Lhe nunlcer of tests reduced solely at the discretion of the Company.

63t8F/O543E/9

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Page l0 of 54

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6.2.7

Welding procedure quatification tests shall be performed under conditions sirnulating the worst envirorunental conditions expected during producLion welding.
NDE and nechanical testing shatl be conducted after vreld heat hreatnent where applicable. NDE sha1l be conducted by ASliII Ivel personnel. certified II or post

6.2.8 6.2.9 6.2.10

equivalent

Mechanical testing shall be carried out in accordance wibh Section 6 .4 and ASIr,lE Sec. IX by a Cory)any approved testing laboratory using calibrated instrunents. Wetding procedure qualifications will be approved by the Company based on satisfactory NDE and nechanical testing and submission of docunentation as stahed in Section 6.2.5. O^ly Corpany approved and qualified welding procedure specifications sha1l be used for production welding.

6.2.1I

6.2.12 6.3

Essential Variables Essential, supplementary and non-essential vari"ables shalt be defined and Iisted for each welding process as per /\SltE Sec. IX. Requalification of a welding procedure shall be lequired when any of lhe essential variables changes. Where notch toughness is required as part the procedure of tesls mechanical for qualification, a change in any supplementary essential variable shall call for requalification of the !,relding procedure. The following variables shall be t reated as essential variables in addition to those listed in ASMESec. IX. 6.3.1 Base t4aterial shall be limi.ted to P nunber as per /\SME Qualification IX, with the exception of those cases where impact properties are required. tests I'lhere inpact are required, qualification is Linited Lo the p nunber and Group number combinations of Lhe test piece. Base materials not. listed in ASI'G specifications but having equivalent chemical and nechanical properLies nay be classified in a listed P nunber and, where applicable, croup nurber subject to the alproval of
l-ha a^lrch(r

Each base nretal vrithin a given P nunber or Group nurber having nominally different chemical or nechanical properties (as designated by Tab1e QW-422 of ASI,,IE Sec. IX) require :

63r88/0543E/10

ADCO Spec. No : Datre :

WS-L Rev. 2

Page Ll of 54

12.04.1990

(a) (b)

Separate welding procedure specification

(WpS)

Separate procedure qualification whenever a welding operation satisfactory for one base nater ial is, in the opinion of the company, unsatisfactory for another base material within the same p or Group nunber.

6.3.2

WeLdinq Process Any change in vrelding process, combinahion of welding processes. addition, deletion or

6.3.3

Joint Desisn a. b. A change fron a double sided weld to a single weld but not. vice versa. sided

An increase of more than 20o or a decrease of ncre than I0" in the included angle. Thickness shall be limited to t-wice

6.3.4

Base tlaterial

The naxirNnn thickness quatifieal lhe thickness of the lest pipe. 6.3.5 weldinq consrinEble 6.3.5.1 The following requalification : (a)

wiII

require

procedure

steels Change in r,tire chernistry for ferritic to another or to fron one AWSclassificalion not covered by AWs a chemical coqnsition fi11er metal specif icali"ons. A change in filler metal fron one specific type designaled under nake and Al'lS rG' to any other nanufacturer classification or nEnufaci:urer I s designation. A change in subnerged arc welaling flux from one manufacturer to another or from one grade grade to another nBnufacturerrs (equivalencry on the basis of AWS A5.17 or A5.23 is not accelaable ) .

(b)

(c)

6318E,/0543E,/rt

ADCOSpec. No : Date :

WS-1 Rev. 2

Page 12 of 54

12.04.1990

(d)

Changes in the chemical composition of the vreld deposit from one A number Lo any obher A nunber in ev{-442 of ASME Section IX including a change from A-l bo A-2 and vice versa.

6.3.5.2

Vthere impact tests are required, all low hydrogen type electrode sizes having no impact Lest requireflpnts according to the applicable AWS filler rptal specification must be certified by one of the following nethods : (a) the next largest size the of same fiBnufacturer's electrode grade meets the A!,lS impacL. requirements The specifi.c size of the same manufacturer's grade electrode the meets At'tS impacl: requireflFnts for t'he applicable eleclrode classification.

(b)

6.3.6

weldinq Posibion Any change in welding position in the 6G position or 2G plus for all positions. except that 5G positions qualification will qualify

6.3.7

weldinq PararTelers heat inpuh Any change in the pa.raneters affecting (currenl, speed) outside t I5g of voltage and welding-anal those qualified lor root, fill capping passes:

( Heac hput = current in ampsx volts x 60 ) ( (KJlcm) welding speed (ctn/nin) x 1000 )
6.3.8

For sour service applicaLions the following shaLI be treated as essential variables in addition to those stated from6.3.1 thru' 6.3.7. : a. b. c. Preheat. Any decrease in pre-heat tenperature below the specified value for a given thickness. Interpass lenperature. Any change in tenperature outside the specified range. Post inlerpass

Weld Heat treatlpnt. Decrease soaking or decrease in soaking tine for a given thickness.

63188/05438/12

ADCO Stac. No : Date :

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Page 13 of 54

12.04.1990

d.

Electro{e Bedrvinq and Storaqe before Welclinq. In the case or row hyclrogen electrodes, any appreciable change in the baking and storage practice lsuch as reduction in baking terq)erature and holding tinre at, baking lenperature ) that may cause an increase in hydrogen content in weldnent $riu call for requalification of the procedure. Tbsts

6.4

Qualification

6.4.r

Non-destruct ive Exanination 6.4.1.1 6.4.1.2 The lesb weld shall be 100? visually examined.

After satisfactory visual exarnination, butt welds shall be subjected to 100t radiographic exanination. Fillet welds shal.I be examined by particle nagnetic inspection for nagnetic materials and dye-penetrant exanination for non-magnelic nnterials. The acceptance criteria for 6.4.I.1 shall be ANSI 83I.3, Table 341-.3.2A. ancl 6.4.1.2

6.4.1.3 6.4.2

Mechanical Tests 6.4.2.1 specifies This section tesbing for rnechanical quali fi cation. requirements for procedure welding

6.4.2.2

The t)pe and nurber of q)ecinens required are The locat ion of test Exhibit 3. sho n in specinens to be removed fron the test weld shall be in accorclance with AS['!ESec. Ix. test spcified, specinen Unless otherwise procedure and evaluation of dinensions, lesling tests shall be in accordance rrrith ASME Sec. IX. A11 mechanical tests shall be conduci:ed after post weld trreatment where appl,icable. Carbon and low alloy steel test welds shall subjected lo the following testrs : be

6.4.2.3

6.4.2.4 6.4.2.5

a)

fhe ultjlnate Trangyersg Te.4silg ..Tesls lensile strengith of the test piece shall be greater than or equal to the niniinum specified ultinate tensile strength of the trDrent material.

63]'8E./O5438/r3

ADO Spec. N,o : Date :

WS-I Rev. 2

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12.04.1990

b) c)

Bend test.s. l.,lacro - Examinati on and Ltardness Survev TVo nacro sections shall be taken from the compleled joint near the 12 o'clock and 6 orclock positions. ltre specimens shall be polished, eLched and examined under a magnifying glass with a rnagnification upto 5X to ensure freedon from defects as per ANSI B31.3, Table 34I.3.2A. For carbon and low alIoy steels, a Vickers hardness survey sha11 be rnade on the macro (HvI0). specifiens using a I0 kg load flardness test lraverses shal1 be in accordance with Exhibit Ib. 4. Vickers hardness testing shal1 be as ASTl,l W2. the acceptance criteria hardness tests shall be as follows : per for

tuur Service (i) OiI Field Equisrnt (a) The rrErxinumhardness value carbon steel welds in as-+,re1ded condition, shal1 exceed 248 ltvlo (HRC 22) on Iocation. for the not any

(b)

For other naterials, bhe Bximun hardness value shall be as specif ied by I{ACE MR0175.

The maximumallowable hardness of welds of p number I carbon steel naterials including API 5L X-grade pipe in sweeh service and a1l other appli"cations shall not exceed 290 HVIo ( tiRC 29) with the Iimitation that the naxinurn hardness difference between parent metal, heat affected zone and weld deposit is less lhan 155 HV10.

63L8E,/.05438/14

ADCoSpec. Nr : Date :

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Page 15 of 54

12.04. L990

Heat Treated Welds The maximum allorable haralness of aII heat treated vrelds shall be as specified in Tabl"e 33I.3.1 of ANSI 831.3 exceptr as governed by NACE MR0I75 and this specification. The naxinun allov,able hardness of heat treated carbon steeL welds shall be 248 HV10 for al1 applications.
d)

Charpy V Notch ImpacL Tests Where the base nEterial has notch toughness requirements or where specified by the Cory)any (see Exhibit No. 3 for noLch locaLion and number of iry)act teshs).

e)

AIl weld trptal tensile test with production tlpe PhIHT to determi.ne ult rate sErength, yield strength, elongalion and reduction of area shall be conducLed whenever : (i) The velding consunnble does not fa1l within any of the At'lS fi11er metal specifications A 5.)(X series. Batch lest certificates or other satisfactory supplier cerbification are not available.

(ii)

7.0

PERFORT,IANCE \iIEIDER AND WELDING OPERATOR QUALIFICATIONS

7.1

Cneral Considerations
7.1.1 Welders and welding operators shall be qualified in accordance vrith ASME Section IX. and the requirements sLaLed hereunder.

7. I . 2 7.1.3

Autonatic MIG/MAG/AnAW welding operators qualified by radiography and guided bend tests.

shall

be

A11 welders and weltling operators who will be engaged on Company's work shall be qualified for all welding positions in which they will carry out production welding. lb unqualified welder shall be engaged on Companyrs work. A11 welds executed by unqualified \^relders shall be rejecled.

7.1.4

63l8E/05438/15

ADCO Spec. No : Date :

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Page L6 of 54

12.04.1990

7.I.5 7.I.6

ldc rrelder shall be qualified

on production welds.

A welder or wel.ding operator \^/ho fails the perforrnance qualification test of this specificaLion, may be granted an imnediate retrest in accorclancewith ASME Sec. IX ew-321 solely at the Corpany,s discretion. If the welder or welding operator fails in the retest, he nay be given only one further test in accordance hrith eW-321.3 but onlt after he has received adequate training to th; satisfaction of t'he Cornpany inspecLor.

7.2

Oualification Validitv 7,2.1 welder and welding operator qualifications are valid provided the Contractor can show to the indefinitely Companyrs satisfaction that the welder or lrelding operator has been continuously engagd on work of a similar nature vrith lhe specific welding process since successful qualification. A break in continuity of more rhan 3 months (90 days) shall require requalification. l,lhen a \^relder or welding operator ' s work is judged unsatisfactory by the ComtEny, that welder or vrelding operator shall ifi[rediately be renoved from the work. of Welders

7 .2.2

1.3

Identification 7.3.I

A11 welders and welding operators qualified for production welding shall be assigned a unique identification nunber or slmbol which shall be r$arkedby crayon adjacent to each of their production welds (narking crayons shall be free fron chloride and sulphur). ASMESeclion IX, Fonn QW-484atong with the welder's ptrotograph should be used for each performance (see Exhibit No. 6). Such records shovring certification the date and the results of qualification tests conpleted by each welder or welding operator \,rith the identification nwnlcers/synbols assi gned to them shall be avai lable for scrutiny by the Conpny at all times.

7.3.2

63L88/05 43F/ 16

AD@ Spec. No : Date :

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12.04.1990

8.0 8.1
General the Conlractor shalL carry out all production conlrol at his sole cost, in accordance with this specification. vrelding and quality the requirements of

8.2

Weldinq BruiplnenL 8.2.1 AII welding equignent shall be of sufficient capacity for lhe vrork to be perforned and shall be capable of producing welds of acceptabLe quality. A11 equipnent shall be naintained in good \.rorking condiLion by Lhe Contractor. Any equi[nFnL wtrich does not fieet these requirefients shatl be replaced. At1 welding nachines should be in a good working condition. They will be subject to inspection at any time by the Cofirpany inspector. AlI welding equipmenl and accessories shalL eeb the the safety regulations of relevant international (such as NEMA)and shall be safe to operate. speci.fications When using the GTAII process, a high frequency (ItF) arc unit, a controlled currenl delay device (lo initiaLion pre-and post-gas crater ) and suitable flow eliminate device (to eI iminate porosity and air enlrapnlenl ) shall be
,rea^

8.2.2

8.2.3

8.2.4

Welding Processes 8.3.1 8.3.2

8.4

Only welding processes approved under section 5.0 of this stEcification shall be used for producbion welding. the selection of welding processes shall be governed by SecEion 5.0 of this specification.

Wealher Protection 8.4.1 The Contractor shall provide adequate shelter satisfaction ot the Corq)any to prolect the envirorunent frorn inclenent weather and drafts. to the welding

8.4.2

All surfaces to be welded and the adjoining area of the malerial shall be warm and dry lo the touch with a minimum mehal ternperature as specified by the approved welding procedure specification (WPS).

63L8E/05438/r7

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8.4.3

vgherethe surfaces to be welded are and where there is no requirement appl icable WpS, bhe surfaces should and war Fal up by a hydrocarbon torch before starting to we1d.

covered by m)isture of preheat by the be conpletely dried using a soft flame

8.4.4

No welding shall be carried out whenthe xetd surfaces are wet. or when the work area i"s exposed to rain or strong winds.

I .5

Parent !,laberiaLs 8.5.I 8.5.2 A1l naterials used for the Conpanywork shall be stored in a proper mannerand protected fron weather conditions. The material storage areas shall be separateal by raterial tlpe such as carbon steel, stainless steel and non-ferrous materials. Material separation shall be fiBintained throughout the entire time of fabrication. Prior to fabrication, the ConLractor shall submit for Cofi[}anyapproval a proposed rnaterial storage and control procedure lo assure the setEration of prequalification areas as slat ed in 8.5.2. Material identification of al1 pipes and fittings shall be naintained on all components and sha1l be verified and fully docurnented Mill Test certificates which shall be by nade available to the Company. AIl spools shall be duly identified by painting or \.rr iting by crayon the Isonetric number, spool nunber, etcr. l,traterials vrhich do not have proper identification including valid mill lest cerbificates shall be rejected at ContracborI s sole cost.

8.5.3

8.5.4

8.5.5 8.5.6

8.6

Weldinq Consunables 8.6.1 Electrodes, filler wires and fluxes shall conform to the requirenenls of ASME Boiler and pressure Vessel Code Secti.on II Part C ( identical to AWSA5.XX specification series). the proposed brands should have been approved by Lloyd's Register of Shipping, DNV, Et\I, ABS or any internat ionally recognised controll ing,/inspect ing body. Gases, both combustible and inerl, shall requireflpnls of Arcrican Weldi.ng Society or standard acceptable to the Conpany. reet the any other

4.6.2

63188/0543E/18

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12.04.1990

8.6.3

Alt welding consurnables shall be subject to the approval and shal-L be selected such thah the weld netal exhibits nechanical protrnrties (yield tensi.Ie slrength and Loughness) equal Lo or in the minirrun specified values of the base n|aterial.

Companyrs deposited stiength, excesJ oi

8.6.4

Contractor shall prepare and sukxnit to the 6mpany, a 1ist. of vrelding consumables to be used on the project shovring typ, manufacturer, brand and the nEnufacturer'a recolffrended storage and drying procedure for each. Contractor shall prepare and submit to the Company a aletailed procedure for storage, inspecti.on, control and monitoring of welding consumables to assure adherence to job and manufacturer I s require pnts. The procedure when approved by the Cofipany sha1l be mandatory. Storage and control of welding accordance with the followinq : 8.6.6.1 consrmables shal1 be in

8.6.5

8.6.6

A11 electrodes shall be stored in fullv sealed packages and sbored in dry storage roo;ns. The elecLrodes should be properly identifiable upto hhe tine of usage. ALI elecLrodes \^rhi.ch are dannged, wet, rusty or otherwise contaminted with oi1, grease, dirt etc. shall be scrappeal. ELectrodes hrith visible stains as well as partLy used elecf,rodes shall not be used. Heating ovens with autonatic heat controls and tenperature read ouh equignent shall be provided to heah and slore the low hydrogen electrodes at the required ternperaLure. provide separabe ovens for Contractor shall baking and storing of low hydrogen welding consunables. SMAW electrrodes of differenL rield retal compositions or having different type flux covering shall not be stored or baked toge,ther in the sanF oven.

8.6.6.2

8.6.6.3

8.6.6.4

8.6.6.5

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8.6.6.6

tow hydrogen electrodes shall be baked at 300oC for at least one hour or as per manufacturerts recomrpndations so as to deposit v/e1d iletal with a hydrogen content of not greater than l0ml per f00gn. After this, the oven temperature should be brought down to 120"C. Thereafter Lhe electrodes may be transferred to an intermediate sLorage cabinet at 120-l50oC and mainhained at that te[perature before Ehey are issued for welding. Welders shall rernove from the ovens only enough rods that. will- be utilised \^rithin four (4) hours. These electrodes shalL be carried in quivers or portable heaters naintained at a ninimun temperature of 70oC and used wiLhin four hours. Welders shall ensure that their quivers are in working condition and thaL quiver lids are closed after removal of electrodes. Electrodes sha1l nol be baked more than once. Ele-ctrodes shall not be baked in layers greaher than 3 deep. Cellulose coated Sl.,lAW elecLrodes shall be kepl in a dry and dust free enclosure afLer opening of the factory container. These electrodes shall not be held at an oven lemperature above 65oC as the coating and weldability of these electrodes Cel1u1ose coated SMAI{ imSnired. may be electrodes thal have becolrp l.\tet, rusty or danaged shall be discarded.

8.6.6.7

8.6.7

Filler wires and bare electrodes shall be stored in sealed, dirt and moisture proof conbainers withi.n a dry, wires withdrawn from the dust-free enclosure. Filler container and not used sha1l be returned to their conlainer and the conlainer resealed. Filler vrires lhat have rusted or are contaninated vtilh oil, greasq, dirtl etc. shall be discarded. Fluxes shall be slored in sealed, dirt. and noisLure proof containers or bags within a dry, dust-free enclosure. Contarninated fluxes shall be rercved from the site and discarded. only fused tlT)e fluxes shall be used and they to should be dried according manufachurerrs If agglonerated fluxes are used, they recofimendab ion. shall be baked aL a tenperature of 250"c - 300oC for a niniRrm of two hours and kept in drying ovens at all times.

8.6.8

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8.6.9

wlres. 8.6.I0

For carbon steel materials, the SAW process shall not utilise an active (Mn-Si.) flux nor EHY\X (high manganese)
shall be used for the

Only low hydrogen electrodes following cases with SMAv'l :

(a) Welding and/or installing hot-tap connections on pipes containing flamable gas or combusiible liquids, naterials. (b) For the repair of welds fabricated welding process. (c) Fu1l pene-tration doublejroove with a low hydrogen

joints. for aII

(d) FilI and cap passes of all other applications carbon steels for all thicknesses.

I . 6. 1 1 With the excepEion of 8.6.10 (a) through (c),

cellulose coaced electrodes may be used onlv for the root passes of carbon steeLs with prior written [Ermission of the- Comtany.

8 . 6 . 1 2 Electrode size (a) The nBxinun electrode dianeter for all single sided welding using the SMAI{process shall be 3.2mn for the root pass and 5run for the fill and cap passes. (b) The maximumelectrode diameter for doubl-e sided welds using Sl,tAW shall be 4nm for the root pass and 5mn for the fill and cap passes.

8 . 6 . 1 3 Shieldinq C,ases
Shi.elding gases shall fieet the following requirements : grade and

(a) Carbon-dioxide (AoZ) shall be welding shall rrpet the following requirene-nts : @Z = 99.5E minimrm

Residuals = 0.58 maximum l.{oisture = 97 ppln naximun by wei.ght aE minus 34oC de$, point

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(b)

Argon (Ar) shall be welding grade and shall rneet the following requi remenbs: = 99.995* minimum Argon Moisture = 10.5 ppn naximum minus 60oCdevrpoint at

8.7.1

Preparation and cutting of carbon steels nay be done by machining, grinding, rachine guided gas torch or plasma arc cutt.ing. A11 cut surfaces shall be finally prepared by grinding or machi.ning to clean, bright netal. After the edqes have -examined been prepa.red for welding, they shall be visually to confirn that the preparations are smooth and uniforn anal free tears, gouges and fron cracks, ohher discontinuities which might affect the weld quality. Arc-air gouging shall only be used on carbon steels back-gouging doubte sided welds and defect excavation. for

8.1 .2

8.7.3 8.8

Cleaninq Requirements 8.8.1 A11 surfaces to be welded and the surrounding areas shall be clean and free of paint, oil, dirt, rust, oxides or any other foreign matter which could interfere vrith welding, prlor to the application of preheah or welding. Aliqrlrent Butt weld aligrunent shall satisfy the requirement of ANSI 831.3 and the condiEions stated below.

8.9

Joint 8.9.1

8.9.2

Internal misaligrunent of pipework shall not exceed l.6nm in order to facilitate welding of the root pass. !,lhen a cTAV'lroot pass is to be used the naxinum misalignment shall not exceed 0.8rm. Misaligrurent may be reduced by the use of hydraulic or screw tl4)e clamps. HamrEring or heating the pi.pe shal1 not be permitted, Excessive misaligrurent may be overcorne by buttering of the weld preparation, but only wi.th the prior approval of the Conpany.

8.9.3

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8.9.4

If rnisalignment upto 3.2mn exists, internal grinding or machining may be conducted to inprove root aligrunent, provided !h_e taper does not exceed I in 4 (14") fraximurn and the minimun required wall thickness is naintained. Correction of nisalignnent shall not be carrled ouL by cold working unless a subsequent heat treatflenh is appl ied prlor to vrelding. A11 correction of misaliqnrnent by cold working shalL be approved by Cofipany in writing prior Lo
the start of re-aligrunent.

8.9.5

8.9.6 8.9.7

Where internal pipe aligners are used, they shau not be rencved until the root pass has been conpleted. The longitudinal welds of staggered by at least lo0nrn. adjacent pipes shall be

8.10 Tack Welds 8.10.1 Al"1 tack welds shall be nade by qualified welders using al4)rovd electrodes a-nd pre-heat, as specified by the approved welding procedures. Tack welds to assist aI ignment shall have a minimurnlength of 25nun and shall be of sufficient size to naintain joint aligrunent until production welding begins.

8.10.2

possible, "bridge tacks' should be used. 8.10.3 Wherever 8.10.4 All tack welds \^rhichwill be part of the main welds shalL be cleaned, ground to a fealher edge at both ends and visually inspected prior to welding of the root pass. Any defective lack shall be conpletely renoved by grinding prior to welding of the root pass. v,lhentack welds are refioved, the Contractor shall ensure that the root preparation is correctly naintained for the subsequent pass. 8.10.5 Tack welds not incorporated in the finaL weld shall removedby grinding or other nechanical rneans. be

8.11 Joint Backinq RequirenFnts

8.Il.l 8.U.2 PernBnent backi.ng rings used. or backing plates shall not be

The use of cofipatible consunable inserts for root pass of single sided butt joints is permitted hrith prior approvaL of the Conpany.

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8.12

Preheat Requi renents

8.12.1 Preheat Tenperatures 8.12.I.1 Ttre minimwn pre-heat tenperature for weldi.ng, flame cuu ing and arc iuhting shall be ;; specified below. Where vlelding procedure specification (WpS) indicates thar j niqher pr*-heat te{perature is necessary, this shalf be used for production welding.
Material-s Carbon steeLs upto l9nrn thick Carbon steels above l9nrn thick

Minimum Preheat

2r"c
L000c

8.r2.t.2

the determination of pre-heat nininum tenperatures for carbon steel production weLds should be based upon BS 5135 (excega as ncdified by this section) after consideralion of specific heat input, joint thickness and consumablecombinations. Unless notified otherwise by the Cofipany, the following criteria should be usecl to determine preheat levels : (1) The relevant carbon equivalent (CE) should be calculated from the nnximum CE allowed by the material specificalion. The appropriate hydrogen scale shouLd be Scale B. Consideration should be given to joint restraint as in the case of branch (weldolets, connections sockolets and nippolets) . (Nole : Steels for sour service applications and micro alloyed steels will require higher preheat levels than those recomnended BS 5135 to by ensure freedon from hvdroqen cracking ) .

(2) (3)

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8.r2.1.3

When the base metal temperature is below 21oC for carbon seeels, the rnaterial shalL be preheatedto 50oCprjor to welding. Whenever malerial is wet or contains surface nl3isture or o)ndensate, it shal1 be dried by heating.
of preheat

8.12.1.4

8.12.2

Application

8.I2.2.I

Preheat shall be applied by electrical resistance methods. preheating methods hrith hydrocarbon gases shall only be used with prior written approval of the Conpany. fhe use of oxy-acetylene preheating is prohibited. torch for

8.L2.2.2 8.I2.2.3

Preheat shall be applied in a gradual and uniforn n ulner and sha11 be naintained bhroughout the welding operalion. the minimrm preheat tenperature shall be established on both sides of the joint preparation for a minimun distance of 75rmn or 3 tirnes the rnalerial thickness whichever possible, is greater. ff the preheat tremperature shall be [reasured on the opposite face to that being heated. Where access Lo only one face is possible, the heat source shall be turned off to allow for ternperature alualizaEion (one minute for each 25run of wall thickness) before measuring hhe preheat tenperature. The preheat tenperature shall be held for at Ieast 5 minutes before welding is comnenced and shaLl be checked before and during wel-ding by thermo-couples, contact pyrometer or by te$Erature indicating crayons.

8.12.2.4

lt

,) (

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8.13 Interpass Temperature 8 . 1 3 . 1 Interpass tenperature is the tenperature at which the weld area rmst be before the next liss is started. 8. 1 3 . 2 the maxinwl interpass temperature shall not exceeal the following limits unless stated i.n the Cory)anyapproved welding procedure speci fi cations (vtps) : (a) 8.13.3 Carbon steels
. ?qnoa

ltre minirmrminterpa.ss temperature shall be the mininum preheat temperature specified in the Cory)any approved weltling procedure specif ication. The interpass tenperature sha[ be measuredat a distance of about l2.5nrn from the bevel ends and shall be rneasured by contact. pyrometer, thermo-couples or t"*p.riiui" indicating crayons.

8.13.4

8. t4

Interruption of Weldi.nq
8.I4.I welding of each joint shall be a continuous operation. If, for any reason, vrelding is discontinued, the following criteria shall apply :

(a) lihere less than 252 of the groove has been deposited, then the weld shoulcl be cut out and shou]d be recomrpncedfron a new preparation. (b) !,llnere more than 252 of the groove has been deposited, the-n the welding operation may recomnence provided the following conditions (c) and (d) are met. The weld on interrutrtion shall be allowed to cool slowly fron welding temperatures co room (This nny be done by wrapping the \"reld terperature. vrith insulation and allowing the joint to cool in still air) . Before welding is resuned, the weld shall be prehealed to the specified tenperature, after a close visual or MpI as required by the Company Inspector .

(c)

(d)

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8.14.2

Root runs and second passes (hot passes) shall be made without interruption other than for changing electrodes or filler \.rires or Lo allow welalers to reposition the_mselves.

8.15

Weld Bead Sequence

8 . 1 5r.

WeId bead deposition shall be established aluring weLaling procedure qualification and shall be indicated on the joint design of the procedure eualification Record (PQn). Ihe specified welding sequence shall be adhered to during production welding. Mjacent. \.reld beads shall from the same location. Welding shall be carried mininize distortion. A1I welds shall following : be full be staggered and not started out in a sequence which will welds aparh from the

8.15.2 8.15.3 8.15.4

penetration

(a)

sockel welds which nEy be usecl on pipe of norninal size less than 5lnm as defined in the contract drawings and conpanyrnaterial specif ications. Pipe support attacturFnt rdelds.
Fillet weJ.ds, cont inuous. as specified, \thich shall be

(b)
(c)

8.15.5

Where access perrnits, pipework with noninal size over 6]0nm (24 inches) sha1l be \'relded from both sides. Double sided welds shall be back-gouged to sound metal and ground $noolh prior to welding from the second side. Al"l pressure containing \.relds shall have rnininum two passes with overlaps of starts and stops. Ttris includes seal welds of Ehreadedconnections and socket vrelals. longitudinal butt welded pipe fittings are not allowed without written approval of bhe Company.

8.15.6

8.15.7

8.16 Inlerpass Cleaninq 8.16.1 After each welding pass, the weld shall be cleaned of all f1ux, slag and spatter by power vrire brush, grinding or hand chippi.ng tools.

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8.t6.2

Every welding pass shall be visually examined by the ltelder to ensure that the weld is free fron slag, porosity and uneven conlour before the start of the next pass. Any defecls found shall be renpved or reoaired prior to the start of the next pass. Any cracks found shall be brought to Ehe Company Inspector's notice before renpval and restart of work.

8 . 1 6 . 3 Upon cory)letion of the weld, the adjacent surfaces shaLl be cleaned of all spatter, sIag, flux, soot and other foreign nnterials.

8.u

Sggilg
8.17.1 No weld peening of any sort shalt be perrnitted.

8.I8

Seal and Socket Weldinq 8 .I 8 . 1 8.18.2

Sealing compoundor Teflon tatF shall joints which are to be seal welded.

not be used on

Seal vrelding of threaaled connections shall cover all exposed threads. SeaL welds shall contain a minimumof lwo passes and shall extend fron the outer iliameter of snDothty to the nipple surface without any the fitting undercut .

8 . 1 8 . 3 Seal welding shall be carried out using a low heat-input process welali.ngprocess such as qIM or SMM. vlhen SMAI'I is used, the electrode size shall not exceed 3.2run in dianreler.
8 . 1 8. 4

During sockei welding, the inserLed enal of the pipe nipple sha1l not cone in contact with the bottom of lhe socket. A nininun clearance of l.6firn shall be given prior to wetding. Use of contraction rings to achieve rninirum clearance are not allowed vJithout wr itten approval of the Cornpany.

8.19 Attachrent Welds

8 . 1 9r .

Fillet welals used for attacfrnents shall be carried out by qualified welders using approved elecbrodes and pre-heat approved welding procedure. as specifi.ecl by the company Fillet welds shall have protEr fusion and penetration at the root of the joint. Filleh welds shall fuse gradually into the pipe and be free from narked irregularities, convexity/concaviby and undercut.

8.L9.2

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8.19.3

A11 temporary attachmenfs such as cleats, bridge pieces and tacking strips welded to pilEwork to facilitate fabrication shall be the sanF naterial or a Companv approved equivalent as hhe pj pework to which it wili be attached. During renNlval of tenporary attachrents, care shall be taken to avoid any parent metal ripping or dannge. Whereverpossible, temlDrary attachnents shall be rejnoved by grinding the aEtachment welds. !,lhere renpval is bv fIafiF cutting, the cut shall be nade clear of th; pipework such lhat at least 3nm of the tenporary attachfip-nt is left for final reroval by grinding. Any surface imperfecbions re-naining after their renoval shall be repaired by welcling in accordance with Conpany approved welding procedure. This shall be followed by grinding to a smooth finish, flush with the surface of the parent metal. The repaired area shall be subjected to rnagnetic particle or dye-penetrant examination. Removalof teflporary attachFnts is not permitted. by hamrlering or bending

8.19.4

8.19.5 8.19.6

be conpletely and temporary attachfients shall All carefully removedprior to any post weld heat treatnent.

8.20 qs$-@.!!s
8.20.1 8.2O.2 Distances between welds shall be neasured between lhe adjacent edges of the cap Passes. circwnferential butt welds (qirth welds) shall be flowever separated by the maximun possible distance. t short pipe lengths nay be required. In between fittings, Lhis case, butt welds shall not be within 75rrn of adjacent girth welds for nominal pipe sizes of 75rrn and above. For pipe sizes less than 75mn nominal, girth welds sha}l not be within the greater of 4 times the wall thickness or one pipe diameter of adiacenl girth we1ds. shall, require cirth welds closer than the above linits Coru)anyap'proval and rnay require post weld heat treatment solely at the discretion of the coq)any.

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a tn

Branch/nozzle and other pressure attachoent vrelds shall nol be closer lhan 75nun adjacent pressure rrrelds. to Cases which fail to neet this criteria shall be referred to lhe Coq)any for approval prior to the comnencement of fabrication.

8.20.4

Non-pressure containing attachfiL-nt welds, such as pipe support vrelds shaLl be a ninimum of 50nmnfrom anv pressure conlaining welds.

pup sections are to be inserted, the length of such 8 . 2 0 . 5 V'lhere inserE pup sections for boti new and existing fabrication shall not be less than three pipe diameters, or l5ftrun whichever is greater. 8 . 2 0 . 6 longitudinal butt vrelals of separated by at least loorun.
8.21 WorknBnship and Weld Finish

adjacent

pipes

shall

be

8 . 2 1I .

Ttre welding arc shall be struck inside lhe joint groove or where the weld is to be nade. Arc strikes, gouges and other indications of careless workrranship outside the weld arc shall be carefully refiDved by grinding and the ground area shall be exanined by t'lPI or Dlze-penetrant test. If grinding of the base netal reduces the thickness to less than the minimumdesign thicknessr the ground area shall, vribh prior approval of the Coryany Inspector ' be rewelaled, ground flush with the parent metal surface and exanined by MPI or rye-penetrant test. Coated surfaces shall be protecEed fron the weldi.ng arc and the associated weld spalter.
v,leld reinforcenent and inlernal vreld protrusion shall be as required by ANsr 831.3 but in no case shall the height exceed 3runat the weld crown.

8.2L.2

?t

8.2L.4

In npigged' lines, shall be L.6rrn.

the maximuninternal

weld protrusion

8 . 2 1 . 5 Excessive internal weJ.dprotrusions on accessible joints welds having excessive shalt be renrcved by grinding. joints shall be cut and protrusions on inaccessible re'welded.

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f2.04.f990

8 . 2 r . 6 Welds which are to be examinedby non-destructive testing

shall be appropriately surface finished easy interpretation of results. to facilitate

8.2t.7

External weld undercutting shall not be permitted.

8 . 2 1 . 8 The accelAabiLity of fille-t welds shall be established by suitable gauges or tenplates. Ttre minimun required size of each fillet vreld shall be as specified in the applicable alrawing. vthere leg Iength is specified, the throat lhickness for a 1x I fillet weld sha1l be from 0.7 to I times lhe required Leg length. The throat thickness for a 1x 2 fillet weld shall be 0.7 to 1.2 tines the size of the shorter leq.
8.22 Weldinq Technique

8 . 2 2 . 1 Vlhere-verpossible, welding should be carried out wi.th mininun weaving. The width of vave during production vrelding shall be hrithin acceptable limits of the conpany approvd and qualifiecl welding procedure (See Section 6.3.7). In no case shall the width of weaving exceecl three tines the core wire dianeter or l2fim whichever is Iess for SMAW. 8 . 2 2 . 2 For SAW process, welding shaLl be alone without weaving (oscillaEion). 8 . 2 2 . 3 A1I pressure containing welds shall have at least passes vrith overlapping starts anal stops. any tvJo

8 . 2 2 . 4 only single electrode processes shall be used. Use of flultiple eleclrodes shall require prior Company approval.
8.22.5 Welding of all pressure containing welals shall with direct currenl unless otherwise previously by the Cory)any. be done approved

o.zz.0

All vertical welding shall be done uphill. Downhill (rstove-pi.pe') welding of pressure containing welds shall nol be permilEed.

8.23 Weldinq Requirerrnls f-or Carbon Steels 8 . 2 3 . 1 the weld melal conposition
parent nBterial. shall be cory)atible wibh the

8.23.2

When welding pipoatork by the submerged arc \^relding process, the electrode,/wire shall have a cou)atible chenical conposilion as the parent naterial.

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8.23.3

Wtten SI,IAW used, only basic 1ow hydrogen electrodes is shall be used, except that single sided root pass welds of butt joints of pipes nay be madewith cellulose coated electrodes with prior written approval of the Company subjecE to the limitations of Section 9.6.10. Ttre second pass (hot pass) of carbon steel pipe welds shall be deposited imnediately after the root pass in order to prevent 'cold crackingi in the root area due to shrinkage stresses and joint restraint. The following requirernents are applicable service (aqueousIt2S) applications : for sour

8.23.4

8.23.5

(a) Filler wires conforming to Al[S A5.18 m 70S-6, ER 705-7 and ER 70S-G shall not be useal for GTAW process. m. 705-2 filler wire maybe used. (b) Produclion welds shalI have a maxirnum content of I.6 per cent Manganese and I.0 per cent Silicon as per A-I analysis of Table qt-442 of ASME Section IX.

8.24 Posl Weld Heat Treatment 8.24.I Post WeId Heat Treatnent shall follovring conditions : (a) (b) be required under the

A11 carbon steel pipework when the b.hicker naterial thickness through a butt vreld joint exceeds 19.05nun. Carbon steeL pipework subject to vibration, such as conpressor piping, \^/hen the material thickness through the butt weld joint exceeds 12.7nm. Carbon sleel branch connections when the thickness in any plane through the branch weld exceeds 38.1nun, or 25.4fim for compressor piping (Refer ANSI 831.3 para 331.1.3). Wherever specified on the Coru)anyapproved contract clrawings.

(c)

(d) 8.24.2

Post weld heat creatflpnt shall be carried out as soon as possible after conpletion of welding and shall be conducted in accordance with AI.ISI 831.3 excepl as nodified by this specification. The tenlErature co-ntrols during heating and cooling shall nFet the requirenents of A.SME Sec. VIII Division 1.

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8.24.3

A post weld heat treatnent (phfitT procedure shall be ) subrnitted for Cory)anyapproval prior to any phHT being conducted. only Companyapproved procedures sha1l be used for PI/{HT. The procedure shall include but not li.mited to the temperature at which the part is loaded inlo the furnace (for furnace heating), rate of heating upto the holding temperature, holding temperature, holding tine at maximum temperature, rate of cooling from the maxinun temperature, the nufiber, Iocation and method of attachfient of thernocouples to the part heat treabed. Wherever possible fi,ntT shall be conducted in an enclosed furnace. For site or field welals, local pklHT by elecbrical resistance ehhod shall be conducted. The use of nanually operated gas torches or gas rings or proprietory exothernic kits shall not be permitted. Wilere local PviHTis done, the weld being post-ireld heat treated shall be in the centre of the heateal band. The heated band shall be sufficiently wide such that a band at least 25mnon each side of the weld edges reaches the specified temperature range. there shall be sufficient insulation to avoid any undesirable temperature gradient. During furnace or local postrvreld heat Ereatment, there shall be a minimumof 4 thernocouples (or as otherwise alproved by the CorTrpany) used to ensure that lhernal gradients outside the requirerrnts of this specification alo not occur during the heat treatment cycle. Thernocouples shall be positioned at a mininun of two locations (top and bohtom) at a distance of 2tnm from lhe weld edges on each side of the weld. The ninimu:n number of thernccouples requireal nay be decreased only with prior Colpany approval. A ti.roe tenperature chart recording the thennal history of the part treated shall be provicled by the Contractor. The chart shall be clearly the identified with drawing,/Iso nunber, pa.rt and weld number and signed by the Cont.ractor and certifying author ity \^rhere applicable. The chart shall be includeal in the 'As{uilt' docrxnentation.

8.24.4

8.24.5 8.24.6

8.24.1

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8.24.8

Thenrocouples shall, if possibJ.e, be placed on the inside for objects being heated from the outside, and vrce-versa if internally heated. The method and placement of thermocouple attachnFnt to pipework is subject to Cornpany approval.

8.24.9

For local ptilHT, only one butt weld joint shaU be recorded on any one chart. More than one chart rnav be used on any joint.
Thernncouples and temperature recording equigrnt prior be calibrated to use and shall have a certification by a reputed cartifying authority. shall valid

8.24.10

8.24.II

Welding should be avoided on any post-weld heat, treated maberial. If required, ANSI 831.3 para 331.1.3 (b) irens I and 3 along with the requirercnts of para 8.20 of this specification shal1 be used for guidance. If any welding is to be carried out on any post weld heat treateal naterial, this shall be referred to the Cory)any. No welding on post weld heat treated material shall 6e conducted withouh Company. prior s written approval. Failure to do so will calt for repeating heat treatfiFnt. All machined surfaces such as pipe ends, flange faces and threads shaLL be suitably protected during the p!'lHTcycte. NffI of welds, where applicable, PWIiTfor final acceptance. shall be conducted after

8.24.L2

8.24.13 8.24.14 8.25

Weld Identification pach weld shall be uniquely identified vJith a weld nurber and ISO/drawing nwrber anal the sane must be represented on the \.re1d identif ication/MT drawings. Mter the cornpletion of each vreld b,o ihs visual and prior examination, the weld and welder identifications sha1l be nrarked ailjacent to the wel-al at a distance of aboul 50run from the weld using paint or indelible crayons. Ttris identification shall remain on the pipe trill the conpletrion of all NDT for any verification by the ConrpahyInspector.

63t8F,/05438/34

ADCO Spec. I,l,o : DaLe :

WS-1 Rev. 2

Page 35 of 54

12.04.1990

a n

NON.DESTRUCTIVE EXMINATION 9.1 General 9.I.I

Ihe Contractor shall submit detailed non-destructive examination (NDE) procedures for Cornpany approval. All NDE shall be carried out in accordance with the procedures approved by Company. the Contractor shall provide easy access to the jobs for inspection and NDE and shall provi.de full co-operation and all assistance that the Cofipanynny request. Prior lo the @mnencenentof work, hhe Contrachor shall establish an identification system such that each assenbly, each component and each weld can be uniquely and fuuy identified with welder/welding operator, welding procedure specification (VIPS),NDEprocedure/ technique, extent of NDEand NDEresults. Procedures for radiography, ultrasonic, nngnetic particle anal dye-penetrant exanination shall al1 be conducted in accordancewith ASm Section V. Weltling inspection shaLl be to Al{Sor CSWIP. certifid perforlrpd by personne]

9.L.2

9.1.3

9 .r . 4

All personnel perfonning NDEshall have A.SNIIvel II or (CSWIP' ERS and shall be equivalent certification ) of approved by the conpany prior to the comnencement work. 9.L.'t ReducedPercentage Examination For any exarnination frequency less than 100t, say 'X' percent exanination (X nay be 5' 10 or 252\, the following rules shall apply : (a) At least 'xr percent of the total nwnber of welds within the specified line class shalL be examined for l00t of hheir length (circunference) . At least 'x' percent of the total numberof welds on each isonetric shalL be exanined and shall not be less then one weld per isornetric. At least 'X' percent of hhe tolal nunber of welds rade by each welder shall be exanined for 100t of their length. At least one cornplele weld shall be examinedfor each welder. Exaninations shall be representative of the entire range of pipe sizes and joints that have been welded.

(b)

(c)

(d)

63L88/05438/35

ADCI)Spec. No : Date :

WS-l Rev. 2

Page 36 of 54

L2.04.1990

(e) Where reducealpercentage exanination is required and the resulting test shows defects, then additional exanination as required by ANSI 831.3 para 341.3.4 shall apply regardless of the examination process used. (f) Defect acce[aance criteria percentage examinations shall 1008 exanination. for all reduced be the same as for

(S)

rXr percent shall be determined by the cory)any.

The Contractor nust subnit an liDE drawing system for Cor[>anyreview and written Cory)anyap6rroval is required prior to lhe comnencefiFnt fabr icat ion. of
q ,

Visual Examinalion

9.2.r

Prior to visual examinalion, welds and the adjoining areas shall be thoroughly cleaneal free of all slag, mill scale,. dir-t, weld spatter, paint, oil, flux, stub ends and oener toretgn nBtcer. The Contractor sha1l provi.de e-asy access to the pipework for inspect ion. this vrill include the provisions of Iadders and scaffolding when required. the workmanshipanil weld finish this specification. shaU be as per 8.21 of

9.2.2

9.2.3 9.2.4

Weld acceptance criteria for visual exanination shall be as per NiISI 831.3, Tab1e 341.3.2A except as rcdif ied by Sechion 8.2L.4, 8.21.5, 8.2L.'7 and 8.21.8 of this specifi-cation. Where specified on the contract drawings, the root passes on certain welds in process gas service shall be either internally ground or depositecl using GTAW.

9.3

Radioqraphic Exanination
o ? 1

Radiographic procedures shall be in accordance with the methods describetl in ASMESeclion V Article 2 except as nodified by this section. Radiographs should be evaluated in accordance with ANSI 831.3, Table 341.3.2A. only fine grain, high contrast filrn or ultra fine grain high contrast film shall be used. T1rpe I film (AGFA, structurix D4 or equivalent ) of ASTM E94 sha1l be used for gamm ray radiography of pipes with wall thicknesses below l0mn.

o 2 ,

63r8E/O543F/35

ADC0Spec. No : Date :

WS-1 Rev. 2

Page 37 of 54

12.04.1990

9.3.3

Wtrerever possible, DIN penetrameters (wire t)pe Image padiographic Indicators) Quality shall be used. sensitivity shall be 2t or better. Where film side IeI's are used, correlation of sensitivity with source side lelrs sha11 be establishecl before proceeding with inspection. OnIy le,ad intensifying screens shal1 be used.

9 . 3. 4

The raaliographic density in the diagnostic area shall be between2.0 and 3.5.
Y.5.1

Unrepaired 'burn-throughn areas that are detected shall be evaluated as lack of pnehration or internal concavity ah the cliscretion of Che Coq)any Inspector and evaluated in accordance with ANSI831.3 Tab1e34I.3.2A. Radiography shall be conducted after for final acceptance. any required p{iHT

o ? o

Reportinq ltre radiography inforrnation : report shall i.ncluale the following

contract nw ler Project title Nane of the component Source lype (x-rayllr-192) Source strength (mA/curies ) Foca1 spoc size Technique (S:I^ISI,/DhIDI,/DV{SIIPANAROMIC) FiIm type and size Penetraneter tlr[)e and nunber Exposure tine Developing line and tenperature Density Sensitivity Iad screens (front and back) Specification (ANSI831.3) Weld identifications Pipe diameter and $ra1l thickness Welder Identification Interpretation Rernarks(Acceph/Reject) Raaliographerrsnameand signature Date of exposure

6318E,/05438/37

Attco Spec. No : Date :

WS-l Rev. 2

Page 38 of 54

12.04.1990

9.4

Ultrasonic ExaninaLion 9.4.1 the ContracEor shall submit an ultrasonic examination procedure for a1l fu1l penetration butt and branch welds for Coru)any approval prior to ehe comnencement of examination of production vJelds. Ultrasonic examination shaU be carried out in accordance with Asl',tE Sect,ion v Article 5, except as rnodified by this section and the results shaU be evaluated in accoidance i.rith ANSI B31.3 Table 341.3.2A and suprplemented by section336.4.6(b). The ultrasonic equignent shall be checked for linearity, db atlenuation etc. and a valicl calibration certificate duly approved by TPI shall be submitted for Cornpany review. As a minimun requirefpnt, ullrasonic examination shall be conducted using a minirnun of three transducers, one slraight bean and tvJo angle beam transducers with a frequency of I to 5 MHZ. I'lhere access permits, ultrasonic examination shall be conducted from both sides of the joint. Prior to conducting ultrasonic exanination, the Contractor shall ensure that the vrelal and the surrounding area are sufficiently snooth to avoid false or misleading indicalions. Transfer correction should be applied to accomncdate surface curvature and roughness. Branch connections that include a reinforcing pad plate shall be examined after welding the branch to the header and again afler \rrelding on the reinforcing plate. Ttre test report should oultine the technique enployed, tlpe and size and frequency of probes used, and defects discovered and shall contain the foLlowinq infornntion as a minimum:
Weld identj.ficaLion and welder nunber Weld procedure used size of reportable
(d)

9.4.2

9.4.3

9. 4 . 4

9.4.5

9.4.6

9. 4 . 7

(b)

defect defect of reportable defect (with

Depth of reportable

location and orientation a sketch) weld acce,ptable/not

accetaable.

63188/0543E,/38

ADCO Spec. lio : Date :

WS-l Rev. 2

Page 39 of 54

12.04.1990

9.4.8

Ultrasonic exmination of welals shall be conducted after that may be required for final acceptance. P1^[1T

It{agnetic particle exanination shall be carried out on magnetic materials. Dye-penetrant examinaLion shall be carried out on non-magne-tic naterials (stainless steels anal non-ferrous rnalerials) . 9.5.2

Weld areas to be examinedby rnagnetic particle/ dye-penetrant examination shall be sufficiently srooth lo avoid spurious indications that may result from irregular weld surfaces. AII magne,ticparticle exaninaLion shaLl be carried out by alternating current yoke method with a white backqround and black magnetic ink.
t{agnetic particle examination shall be carried out in accordance vrith ASMESection V ArticLe 7. Dve-peneLrant exanination shall be carried out in accordancie iirn asm Section V Article 6. The acceptance criteria shall be as per ANSI 831.3 Table 341.3.2A. Vlhere PI,{HT is required, magnetic particle,,/dye-penetranL exarnination shall be conducted afber plfttT for final acceptance. Exanination should be conducted before PWHT for any repair/rectification chat may be required before P1^lttT.

9.5.3

9 .s . 4

9.5.5

9.6

Ultrasonic Ttrickness Measurenents Ultrasonic thickness measurenents, where required by the Conpany, sha1l be done wilh Ultrasonic Fla\.r Deteceors. The use of D-Meters is not permitted for thickness measurenents. 9.6.2 Where specified by the Company, ultrasonic thickness neasurenEnls shall be nade on both sides of welds at a distance of 25mnfron the vreld edges. the thi.ckness readings shall drawings. be recorded on NDE spool

9.6.3

63L8E/O543E/39

ADCoSpec. No : Date :

WS-l Rev. 2

Page 40 of 54

12.04.1990

9.7

Brinell 9 . 7. L

Hardness Testinq

Where required by the Cornpany, Brinell hardness testing of production wel&nents shaLl be carried out in accordancevrith ASTM 8110. A hardness test other than Brinell hardness test may be used if the values obtained can be correlated with Brinell or Vickers hardness nunbers. Al1 results shal1 be reported in equivalent Brinetl or Vickers hardness nwnlcers. Any equipnent and hardness test procedure other than BrineII hardness testing as in 9.7.I shall require prior Coq)any approval. Hardness tests on a produchion weld shall incLude a reading on the centre of the weld and the heat-affected zones on both sides of the weld. The hardness test of the heat-affecteal zone shaU be rade at a poi.nc as near to the edge of the weld as practi cabJ-e. To facililate hardness testing, the weld reinforcernent nay be ground smooth, if necessary, but not less Lhan flush with Lhe parent metal surface. Due care shall be taken cluring hardness tests on production welds of especially thin walled pipes lo avoid damage due to excessive indentation.

o'1

.>

4 7 1

9 . 7. 4

9 . ' t. 6

Iocation of lest Points (a) For butl welds on pipes of noninal size upto and incluiling 254mn(10"), one set of readings shall be taken on the 12 orclock position. For butt welds on pipes of noninal size above 25rhmn, three se-ts of reaalings 120o apart, with one set on the 12 orclock position, shall be taken. welds on pipes of For branch connections and fillet all dianeters, lwo sets of readings 1800 aparl shall be taken. shall be

(b)

(c)

o 1 1

The acceptance criteria for hardness tests Section 6.4.2.5(c) of this specification.

9.8

Extent of Non-Destructive Examination The mininun requirenents of nondestructive exanination of v,'elds shall be as per Table 1. More stringent NDEnay be specified based upon materials of construction, service severity and/or testing linitations.

63]"8E,/05438/40

ADCO Spec. No : Date :

WS-l Rev. 2

Page 41 of 54

12.04.1990

t .o.z

AIl welds lrhere the pipe wau thickness exceecls 32nrn sha1l be 100t ultrasonically examined in addition to radiography. For pipe waII thicknesses less than 32run, ultrasonic exanination shall be as specified by the company. Brinnel HardnessTeseinq (a) 100* hardness testing of weL&nentsshal1 be required when all of the following conditions are present at the sametime : (i) (ii) (iii) Sour service the v,reldsare locally stress relieved Welds of air harde-nable steels or sheels with nininum specified yielal strengths above 358 Mpa (52,000 psi) or minimurnspecified tensile slrengths above 485 Mpa (70,000 psi).

(b)

Furnaceheat treated welds of steels of type 9.8.3a (iii) above in sour service shall- be 10? hardness tesled in each batch.

(c) welds other rhan 9.9.3 (a) and (b) shaLI be subjected to random hardness test ing at the discreEion of the Cofipany Inspector to assure conformancewith the sgncif ication. 9.9 NDE PersonnelOualifications
o o 1

Welding inspectors shall hrecertified

to AWS CSrWIp. or

9.9.2

Al,I personnel carrying out non-deshructive examination (radiography, pareicle ultrasonic. nagnetic and dye-penelrant examination) shal1 be ASNI Ivel II certified or equivalent such as qsWIPor m.S. lihere the NDEtechnician is cerhified by the Contractor hinself, the qualification shall be in accordance with Contractorrs writlen procedures which shall use As}{trs recomrenaledpractice No. SNI-TIC-IA, as a guide. This written procedure shall be made available to the Coq)any whenever required and sha1l be subject to Conpany approval.

q o

Newqualification tests nay be required if a technicianrs perfonEnce indicates deficiencies. The Contractor shall bear all costs for gralifying technicians. the Coru)any Inspector will to have the option witness any qualification tests.

6318E/05438/4r

ADCO Spec. No : Dahe :

WS-1 Rev. 2

Page 42 of 54

12.04.1990

9.9.4

The Contractor shall have records of qualifications and certificates for each technician available for review bv the Conpany prior to the conrrxsncenentof !,rork by the technician. Any -technician. may be disqualified by the Conpany upon proof of unehhicaL practices, negligence, non-cbmpliairce \4tith procedures or poor perfornance.

9.9.s

10.O REPAIROF DEFECTS

10.1 General
1 n 1 r

Pri.or lo carrying out any repa.irs involving $relding, the Conlraclor shalI suhrdt a written repair welalinq procedure to the Cornpanyfor approval. This shali include details of lhe tlT)e and extent of defects, methoal of renDval, preparation of area to be welded, method of application of preheat, reference welding procedure specification and NDEprocedures. all repair \,/ork to the only proceed with Conpany

1 0 . 1 . 2 The Contraclor shal1 report Companyand repair work shall author isat ion .

1 0 . 1 . 3 Acceptance of al1 repair vrork shall be subject to Conpany approva.r.. 10.2 Minor Surface Remirs 1 0 . 2 . 1 Minor surface inperfections may be renpved by grinding provided lhat the wal1 thickness is not reduced locally by nnre than 12.5t of the noninal- value specified or the mininun design thickness whichever is greater and the ninimun wall thickness is naintained.

r o . 2 . 2 The ground area shall be dressed to a uni"form and slrrf,oth

profile with no sharp corners or notches. 1 0 . 2 . 3 The ground area shall be exanined by MpI or dye-penetrant exarnination to ensure that the alefects have been conpletely removed.

63L88/O5438/42

ADCoSpec. No : Date :

WS-I Rev. 2

Page 43 of 54

12.04.1990

I0.3

Repairs Involving Weldinq 10.3.1 10.3.2 /vry defect that cannot be removedby surface grinding as per section I0.2 shaLl be repaired be welding. Any defect exceeding acceptance criteria of this specification shalt be carefully rem)ved by grinding, chipping or arc-air gouging. The excavation shail extend at least 25rm beyond both extremities of the defect without substantial removal of the base mehal and shalL be done in such a manner that the rernaining weld or base fletal is not nickeal or undercut. fhe grooves shall be free from scale, have a snr)oth contoui to facilitate welding. Arc-air gouged or thermal cut netal surface should be grounclto a s[Doth, br ight netal surface. ltre ground area shall be carefuLly exarninedvisually and lhen by MpI or dye-penetrant examination prioi to corunencefr*-nt re-vlelding to ensure that the defect has of been cofipletely rejrcved. The area to be repaired sha1l be pre-heated to at least 50"C above the terperature specified in the corresponding welding procdure but shall not exceed the initial rnaximum interpass terq)erature. Repair welding shall be $relding procedure carried oub using the initial specification in accordance with section 10.1. the Contractor shall take ap'propriate care such as proper veld sequencing, control of interpass temperature etc. to minimize residual slresses. A11 repair welders. welding shall be carried out by qualified

10.3.3

10.3.4

t0.3.5 I0.3.6

If any repairs are carried out after post weld heat lre-alfpnt test, lhe or hydrostatic PI.{HT and/or hydrostatic tesl shal1 be repeated. If planar defects such as cracks etc. are to be repaired, every effort shall be nnde lo prevent propagation of the defect dur ing its removal. MPI shall be carried out ho ensure conq)lete renoval of bhe alefect.

10.3.7

631S8/0543E/43

ADCOSpec. Nc : Date :

WS-L Rev. 2

Page 44 of 54

12.04.1990

I0.4

NDEof Repair Welds 10.4.1 AII areas_repaired by vlelding shall be thoroughly cleaned free of slag, spatter etc. and ground to a smootf, contour with the parent naterial and existing wefd taking ciie that over-grindi.ng does not occur. be subject to IOO* visual exanination and then NDEby the same techniques used for the original exanination. The acceptance ciiheria shall be the sameas for the original we1ds.

ro.4.2 The repaired welcl shall

1 0 . 4 . 3 A weld with defects may be only repaired tvrice. If the repair is not acceptable after the second repair, the conplete weld shall be renoved, rebevelled, re-w:elded and re-examined.
1I.O DOCUMENTAIION

Il.1

The as-built
td,

eC dossier shall incluile the follovrinq :

reports the for each

tr{aterial identification/t.raceability ilen in the contract drawings.

(b)

MiIl certificates of all materials giving conposition and mechanical properties.

chemical (WpS )

Company approved welding proceilure specifications (See Exhibit No. I for sarnple forms).
(d)

Company approved Procedure eualification Records (pB') (See Exhibit t{o. 5) along with back-up NDE and nechanical tesl reports. List of Welders and Qualified Certificates (See Exhibit lb. 6). NDT reports. As-built drawings. on drawings. Welder perforrance

(e)
(f)

(s)
(h) (i)

Weld identificati

NDT sulffnary control sheets which show weld nunbers, type and exlent of NDT for each weld, report nunbers for each weld identif ication drawinq.

63188/05438/44

ADO Spec. No : Date :

WS-l Rev. 2

Page 45 of 54

12.04.1990

(j) (k)

Heat treatnent reports and charts. Dinensional inspecEion reports. Hydrotest reports. Blasting and painting reports.

(1) (m)

11.2 The Contractor shall have the various inspection stages witnessed nAcceptance' by and reporls revielred by the Co$)any inspector. the Colru)anyinspector does not relieve the Contractor of hi! responsibility to fulfill his conrractual obtigations.

63L88/05438/45

H(HIBIT NO. 1

Page 46 of 54

(ADCO) OIL OPERATIONS FOR ABU DHABI COMPANY ONSHOPA

Conpany
W.P. No. S Revision No. DaLe

Date --

By suppo code lYpe(s)

Welding Process(es )

(AuLomatic, Manual, Machine or Serni-Aubo) DETAIIS,/SKETCH JOn{IS Joint Design Backing (Yes) _
NO

Backing l,taterial (lYpe)

BASE I''IETALS P-No. _ Group No. type and grade

to P-No.

GroupNo.

OR Specification

to specification

tsypeand grade

Chem. Analysis and Mech. ProP. bo Chem. Analysis & l,lech. Prop. Thickness Range : Groove Dianeter Range : Groove

! rIlec
Fi I1al-

FILI,IIR METAI"S F-NO. A-NO.

Ohher OLher

spec No. ( SFA) AviSNo. (Class) meLals Size of filler

F'IUX TT dE NATIB Consumable Inse

Electrode-Flux (CIass)

Sht. I of 2

63r8F,/0543E/46

EISIBIT NO. I

Page 47 of 54

Position(s) of Groove welding Progression: Up _ Position(s) of FilLet: Preheat TenP. Min. Interpass Teirp. Preheat Maintenance where applicable shoulal be recorded)
TECHNIQUE

Dxswn

Range TemperaLure Tine Range

GAS Shielding cas(es) _

p"i ".ni conrpo; i o;Tnimtit

Gas Backing Trailing Shielding

( Continuous or sPecial heating

Gas

Composition

Str lng or WeaveBead _ orifice or Gas Cup Size

^^-:11^!:^\JDU!ItaLtvtr

Contact $rbe to Work Di.sbance

Multiple or single ElecErodes Travel speed rnge

ELESIPJCAL CHARACTERISTICS

Current AC or Dc Tungsten Electroale Size and T1rpe Modeof Metal" Transfer for GI{AW
Electrode Wire Speed Range er Mebal

Polarity

TraveI I speed ipill T'ype-T- Anp lvolt I Range I weld I I | Iaver(s) lProcessl Class l(mm) lPolarl RangelRanqe L(crnlmin) Current

other

I I
I I

Sht. 2 of 2

63t88/0543E,/47

D(HIBIT llo. 2
llPS No.

Page 49 of 54

No. : PQX. e Test (QW-I50)

I road nr-eaitolar, I unit^stress ti:::f?": lsp."i*niwia*,ittictcnessi

(Qvr-r70 )

No """' Result - Satisfactory : Yes ... No " " " ' penetration into ParenbMeEal : Yes ... Macro-Results fyp" *a Character of Results other Tests Tvpe of Test ... ol-posiu AnalYsis oEher .

N . W e l d e r r s a m e. . . . . . . tests conaucted by :

N Stamp o. ...... C l o c kN o TesL N'o " " " Iaboratory

that the We cerLify bhat the statements in Lhis record are correct and the wiLh test rrreldswere prepared, welded and tesLed in accordance o requirenents f .......... Manufacturer BY".'"""

D a t e. . .

63188/0543E,/49

r'

H(HIBIT NO. 2

Page 48 of 54

(PQR) RECORD QUALIFICATION Q!{-483 PROCEDURE

JOrMS (0W-402)

Groove Design Used

(OW-403) BASEMRTATS Material Spec. .

B p e o r c r a d e. . . . . . .
P. No.

to P No. ...

POST{i HEATTREATMEI'II IELD ) 1qW-407 TemperaLure T i m e. . . . Other ..

GAs (0v{-408) 1!pe of Gas or c.ases Coru)osition GasMixture .......... of O t h e r. . . . . . .

FII,LER METAIS (QW-404) Weld Metal Analysis A }lo' Size of Electrode Filler Metal F No. ... S F AS p e c i f i c a t i o n . . . . . . . . . . . AI^IClassificalion .......... S Other ... CS ELECTFJCAT CHARACTERISTT (QW-409 )

current
PoLariby Amps. . OLher . v o l t s s. . . . . . . .

POSrrroN (Qv{-405) Position of Groove v'IeldProgression (UPhiII, Dovrnhill ) . Ohher......

(QW-410) TECHNTQUE Travel Speed Str ing or Weave Bead oscillahion Multipass or Single Pass (Per side) single or MultipLe Elecbrodes Other .......

(q'{-406) PREHEAT PreheatSemp...... T Interpass emp............. O b h e. . . . . . . r

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EKH IBIT No. 4

Vickers ltar&ress Testing as per ASII{ Et2 wi th l0kq load

Indntations shall be aco:rately and as detailed Lrelcn :

located

as shcprn on tie

aPpropriate

figures

(I )

krent t{aterial :

Indents shall be on 2m cntres with 3 each side of weld for each har&tess traverse. The first indent. shall b ar[n from apparent HAz.

(2)

indent adjacent to the vteld . Heat Af,fec|ed zone (HAz) : The first shall be 0.5mn naxitnum from ehe fusion the fusion line. but not dl line, shall be on Subsequent indentations with a minimum of 3 each 0.5rl[n centres, side of weld per hardness traverse, until tie unaffected parent raterial- is reached . vJeld : ltrree egually spaced indentations hardness traverse. across t}te weld for each Fiq)re B

(3)

Fiqn:re A Double v and Double bevel uelds

Single v welds

Fiqure c T-Joints and Fi llet welds

Figure D (This applies Eo Fig. A' B and C)

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(r,y7)

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563@"1046 48

--

H(HIBIT NO. 5

Page 53 of 54

TESTS QUALIETCATION OR OF S RECORD WELDE|R IIEI,DING OPE8AIOR Vessel Code) MANUFACANRER' Boiler and Pressure (See OVF3OI' Section Ix' ASME

FOR

ONLY

Filler I.leLaI Diafileter and Trade Narne " ' Subnerqed Arc FIux Trade Narne cas tteEal Arc welding Shietd Gas Tra'le Na le gw-462.2(a), {Fl-462.3(a)r Ql^l-462'3(b) TEgr REsuLTS GJIDEDBEND

For Radiograohic

FracEure

63188/05438/s3

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eS

SUPPLEMENTTO ADCO SPECIFICATIONWS-l REV.2

REQUIREMENTSFORWELDING & NON-DESTRUCTIVE TESTING OF DUPLEX & SUPERDUPLEX STAINLESSSTEEL WELDS

REVISION RECORI)
Rev.

Date

Originator

Reviewed

1 2

13tlt 199

6trU0l

LE(M&W) LE(M&W)

SCrE SCrE

Approved ESM ESM

Description full updateof the spec. gas Shieid/purge & PRE reqts

CONTENTS

1.0

Scope

2.0

Welding Processes

3.0

Welding ProcedureAnd Welder Qualifications

4.0

ElectrodesAnd Filler Metals

5.0

GasesFor ShieldingAnd Backing

6.0

Preparation Of BaseMaterial

7.0

Initial And InterpassCleaning

8.0

Inert Gas Purging And Backing

9.0

PreheatAnd lnterpass Temperatures

10.0 Heat Input

I 1.0

Atmospheric Protection

12.0

Post Weld Cleaning

13.0 Non-Dest ructiveTestin g

1.0

SCOPE This specification prescribes minimum technicalrequirements welding, inspection the for ancl non-destructive exanrination of ferritrc-austenitic (<luplex and super <luplex) stainless stecl piping systems.

2.0

WELDING PROCESSES 2.1 GTAW (TIG) and SMAW (MMA) processes approvedfor use on duplex and super are duplexstainless steelpipe work with the limitationsof clause 2.4 and2.5. Other processes may be usedonly upon specil'rcapprovalby the Company. The TIG welding equrpment shall have a high frequency (HF) arc initiation umt, a controlled currenl delay device and suitablepre-andpost-gasflow devicc.
1,1

2.2

For all single sidedbutt welds,the root zmdhot passes shall be deposited with CTAW processregardless pipe diameterand wall thickness. Subsequent of passes may be deposited with SMAW process with the limitationof clause 2.5. Pipes of nominal sizeslessthan or equalto 51mm (2 inches) and/ or wall thicknessless than6.4mm shallbe fully weldcdwith GTAW process. AutogenousGTA welding i.e. GTAW welding without the addition of fillcr metal shall not be nermitted

2.5

t.6

3.C)

WELDING PROCEDURB, AND WELDER QUALIFICATIONS 3.1 WeldingProcedureOualification

3.1.1 Welding proceduresshall be qualified as per ASME Section IX ald this specification and approved by the Company prior to the commencemenlof work. 3.1.2 Mill certificatesof the basematerial and batch test cefiificates of electrodesand filler wires for welding shall be submitted along with ProcedureQualification Record (PQR) for Companyreview and approval. 3.i.3 Welding procedures previouslyqualtfiedby other clientsshall not be accepted. Welding procedure qualificationtests shall be witnessedby ADCO or ADCO anoorntedTPI. The lollowing variablesshall be considered variablesin addition to essential thosespecified ASME Section : in IX a) b) c) A changein the LINS number of the alloy designation. A changein filler wire size for the root passand hot pass. A change in electrode or filler wire manufacturer or brand name or AWS DN 8550 classification.

3.L4

d)

Addition, deletion or a change in the nominal composition of consumable insert. Al increasein the maximum interpasstemperature beyondthat qualified.

e)

1) A changein the heat inpr.rtby more than 10% of the nomrnal value qualified for eachlayersubject the limitattonsin Section10.0below. to g) Ary change the composition the shieldinggasor the backinggas. in of h) Deletion or any change in the method of post cleaning of weld root lollowing weld completion. 3.1.5 The test weld shall be qualifiedin the most dilficult test position(suchas 6G) envisaged production in welding. 3.1.6 The completed test weld shall be subjected 100%radiography butt welds to for and 100%dye-penetrant for fillet welds. test 3.1.7 The testbutt welds shallbe subjected the following tests: to i) Chemical analysisof the weld metal taken from the weld root layer. For double sided welds, analysis shall be from the weld metal layer on thc process side. Ferite content measurementof the weld and heat-aflfected zones using metallographicdetermination,and by plotting the chernicalanalysisfront WRC-92Dragranr (for weld metal only) Micro examinationof weld cross sectionsaI 12 and 3 0' clocJ< pipe posrtions. Transverse tensile testsas per ASME SectionlX. Transverse bend tests with a plunger diameter equal to 4 times the specimen thickness per ASTM A370 and ASME Section as IX. Charpy Vee notch impact tests with notches centered in the weld metal and heat-atTected zone at the minimum design temperature. Vickers (HV10) hardness survey of weld cross sections from macro samplestaken at 12 o'clock and 3 o'clock pipe positions at 2mm lrom the outer surface & inner surface and at mid wall. The spacing and location of rndentations shall be as per WS- I Specification. Conosion tests as per ASTM G48 Method C to detemine Critical Pitting Temperature(CPT) of the weldment in the "as-welded" condition i.e. without any post cleaningof the weld root. A detailedlaboratory procedure for the corosion test shall be submitted to the Company for review and approvalprior to the test. Other corrosiontests such as ASTM G- 150 may be requested the by Companywhen appropnate.

ir)

iii)

rv)
v)

vr)

vii)

viii)

ix)

3.1.8 Acceotance Criteriafor Tests 3.1.8.1The chemicalanalysisof the weld metal for carbon, sulphur,silicon, manganese, chromium, nickel, molybdenum,nitrogen and copper shall be

determined.Where tungstenis intentionally added in the filler wire, then tungstenshall also be anaiysedand reporled. The chemtcaicompositionshall comply with the filler wire specification asper DIN 8556classification. b. The Pitting Resistance Equivalent (PRE) as defined bythe fonnula : pRE - o/oCr 3.3.%Mo + 0.5 %W + 16%N shallbe at + least40 for both duplex and superduplex stainlesssteelwelds. The Nickel Equivalent(: %Ni + 35 %C + 20 %N+ 0.25 %Cu) and Chromium Equivalent(: %Cr + oAMo+ 0.7 %Nb) shall be calculatetj from the chemical compositionof the weld metal and plotted on the WRC-92 diagram. The Ferrite number shall be betueen 40 and g5. Failre to comply with this requirement shall be cause rejectionof lhe for procedure.

c.

3.1.8.2Ferrite content measurementon weld metal and heat-affected zones by metallographicdeterminationon the macro sample shall be carried out. Ferritecontentshall be between30 and 60%. 3.1.8.3The macro examination shall show completefusionand penetration, and freedomfrom any cracks. 3.1.8.4During transverse tensiletest,the ultimatestrength yietd strength (0.2% , offsel) and elongation shall be detemined. The tensile and leld strength shall meet the requirements of the base metal and welding consumable specifrcation. Minimum elongation shallbe 25%. 3.1.8.5 During bendtests,thereshallbe no visible crackon bending. 3.1.8.6The acceptance criteria for Charpy impact tests shall comply with the requircments the base metal specificatron. In the absence thrs of of requirement, the weld metal and heat-affected zone shall have a minrmum absorbedenergy value of 100 Joules (Average of thrcc specimens) and 75 Joules(individual minimum) at +20.C. 3.1.8.7The maximum hardness reading at any point during HV10 hudness surwey shallnot exceed 334 HV10. 3.1.8.8The Critical Pitting Tenrperature(CPT) of weldments shall be determinedusing ASTM G 48 Method C. Test specimensshall be takcn lrom the weld root in the "as-welded" condition. ( i.e. the inside surface of the root weld shall not be wire bmshed or ground or treated after welding and prior to the corrosion test). The duration of exposureofthc test specimento the test solution shall be 24 hours . The minimum CPT for duplex s^tainless steelpiping welded with superduplex filler material shall be 30"C. The minimum CPT for super duplex piping weldment shallbe 450C.

4.0

ELECTRODES AND FILLER METALS 4.1 Filler metals for GTAW processshall conform to DIN8556. Electrodes for SMAW shall conlorm to AWS A5.4 or DIN 8556. Super duplex filler wire conforming to DIN 8556 SGX2 CrNiMoN 25 l0 havinga nominalchemistryof 25% Crl 10%Ni/ 4% Mo/ 0.25%N shallbe usedto weld both duplex(UNS No. S 31803) and superduplexpiping (tlNS No. S 32750)with GTAW process. Electrodes SMAW process for shallconform to DIN 8556 E 25 10 4 LN B 20+. The Pitting Resjstance (PRE)of the allEqurvalent weld chemistry of the proposedwelding consumablefrom the batch cerlificatesshall be at least 40 for both duplex and superduplex stainlesssteelsto meet the requirementof

3.1.8.1(b) above for the welcl rnetal. The detatls of orooosed filler/ electrode specification, manufacturerand brand name shall be submitted for Company review prior to qualification. Storage and drlng of electrodes shall be in accordance with the electrode manulacturer'srecommendations. For SMAW process, synthetic electrodes with mild steercorewire shal not be used. 1.4 Electrodes and filler wires of suitablecompositionshall be selected such that fenrle content in the weld metal shall be between 30%o and 60%.The Ferrite Number (FN) on WRC-92 diagram shall be betr,,'een and 85. 40

Tungstenelectrodes GTAW processshall conform to AWS A5.12 E Th_2 (2% for thoriated type) specifi cation.

5.0

GASES FOR SHIELDING AND BACKING For GTAW process,Argon with 2%o Nitrogen shall be used for inert gas shielding.pure Argon or a gas composition containing 90't/onitogetl 10% hydrogen shall be used for inefi gas backing.Argon gasshallbe of welding gradeand shallbe at least99.995% pure. Dew point of Argon shall be minus 57"c (minus 70 'F) or lower. ( Note: The use of 2% Nitrogenin the Argon shielding gas and the use of 90% nitrogen/ 10% hydrogen as backrnggas during GTAW process rs known to enhancethe critical pitting temperaturc of duplex and super duplex weldments)

6.0

PREPAR{TION

OF BASE MATERIAL

The edgesand surfacesof parts to be joined shall be preparedby machining, or grinding usrng Aluminum oxide grindingdiscs.

7.0

INITIAL

AND INTERPASS CLEANING

7.1

Prior to welding, the edgesto be welded and a circumferential band of 25mm on both sidesof the bevel edgesshall be clean,dry and free of foreign materialsand defects. Stainlesssteel wire bmshesnot previously used on any other materials shall be usedfor brushing and Aluminum oxrde grinding discs for grinding. The useof carbonsteelwire brushesand carbidegrinding discs are prohibited.

1.2

8.0

INERT GAS PURGING AND BACKING 8.1

The inside bore of the pipe shall be suitably purged with Argon ( or 90% nitrogen/ 107o hydrogcn) prior to and during the root pass. The inert gas backing shall be maintained for a minimum of two additional layersto avoid oxidation of the root. For welding pipes with wall thicknessup to 6.4 mm, inert gas backing shall be maintainedfor full welding of thejoint. Whereverpossible,baffles or dams of proper design should be usedto conserue the backing gas and to provide effective protection of the weld root. The purge dams should be typically located about three inches on both sides of the weld. The backing gas inlet on the dam should be locatednear the bottom of the pipe and the outlet should be locatednearthe top ofthe pipe for effective gasbacking.

8.2

8.3

Preliminary stepsto a pre-purgingevacuationcycle shall be as follows : a) b) c) All weld joints of the assembly must be sealed with high temperature tape. The endsof all branch connections must be ventedto eliminate air entrapment. In order to ensureadequate purging before starting to weld, the purge shall be allowed to flow long enough to provide at least twenty volume &anges within the cheunber.

8.4

8.5

Upon completion of pre-weld purging, vents in a| branch with connectionsmusl be closedwith verrtingthrough main headeror pipe run only. The gasventing orihce must have a flow capacityequal to or greaterthan that of the input side to prevJnt a build-up ofgas pressure. (The outlethole must equalor exceed Argon inlet hole). the No welding shall start until the oxygen content in the gas inside the pipe has dropped below 100 ml/ ml.. During the ,ooi ,-,rn,there may bI a surgewhen the weraing is startedand welding shall be stoppedif this surgegoeshigher than 500 ml/ ml.. This shall be measuredwith an oxygen analysercapableof measuringoxygen contents between0 and 1000ml/ ml3 ( Note: presence oxide depositon the insidewclcl root of surlace due to inadequategas backing is known to reduce the cpr values of weld significantly. Also, the backing gas flow rate may have to be increasedto around 20 litAnin during welding to keep the oxygen level inside the pipe within acceptable limits).

8.5

Durins Welding : a.) b) Seal-tape mustbe left on alljoints exceptthe one to be welded. For the joint to be welded, the tape must be removedjust in advanceof welding progressionaroundthe joint. Purge gasflow ntust be adjustedto maintain zero interior gagepressure.

c) 8.6

Weldingofjoints shallprogress downstream from the point of Argon entry.

9.0

PREHEAT AND INTERPASS TEMPERATURES

9.1

Preheatis not normally required, except when the ambient temperatureis below 10"C, thenpreheat 50'C. to When moisture may be present,the basematerial shall be heatedwam-to-hand or until all indications moistureareremoved. of Intetpasstemperature shall not exceed 150'C. For welding super duplex stainless steels,the interpasstemperatue betweenthe root and the secondpassshould be below 100"C to ensureoptimum pitting resistance a:rdto minimize secondary phases.

9.2

9.3

IO.O HEAT INPUT Welding shall be carried out with low heat input and minimum joint restraint. The heat input shallbe controlled between - I .5 KJ/mm. 0.5 I1.O ATMOSPHERIC PROTECTION

l , i

All welding whether in the field or shop, shall be carried out in a draught-freearea. In majorrty ofcases,the welding areashallrequirethe useofshields to give proteclionfrom air disturbance and contamination. For field welds with GTAW process,welding shall be performed in an enclosedspacefor adequate protection from wind, dust. moisture etc.

12.0 POSTWELD CLEANING

12.1 Following completion of welding, wherever the inside surfaceof the pipe bore is accessible, root side of all productionwelds shall be subiected visualinsnection the to to determinethe level of oxjdation.Welds shall have no bum marks (which can be caused improperback purgingwhen using GTAW). The weld appearance by shourd be shinybut a smalldegree ofgrey oxidationon or nearthe weld is acceotable. Whereveraccess petmits,the insideroot surface the weld shall be ihorouehlvcleaned of by suitable methodssuchas wire brushing, grinding,glassbeadbrastcreaning. pickring or acid cleaning with nitric-hydroflouric acid of appropriate composition. (Note : cleaning of the weld root to remove the oxide rayer is known to improve the pitting reslstance duplexstainless of steelweldments)

12 2

13.0
I 3.1 All butt welds shall be 100% radiographetl using X-ray and all fillet / attachment / branchwelds shall be 100% examinedby dye_penetrant test. ASTM E94 Type I (AGFA Structurix D4 or equivarent) firm shall be used for radtography ofpipes with wall thickness below l0mrn. Wire type IQI's (penetrameters) be used. shall Radiographic sensitivity shallbe 2% or better. Acceptancecriteria for welds shall be ANSI E|31 for utility and processpiping. .3 NDT Technicians shall be qualified to ASNT Level-II or equivalentsuch as pcN Level-IL

r3-2

13.3 13.4 13.5 13.6

1 . 1

SUPPLEMENTTO ADCO SPECIFICATIONWS-l REV.2

REQUIREMENTSFOR WELDING & NON-DESTRUCTIVE TESTING OF DUPLEX & SUPERDUPLEX STAINLESSSTEEL WELDS

RJVISION RECORD
Rev.
'I

Date

Originator

Reviewed

13l11799 LE(M&W) LE(M&W) 6t11/Ol

SCrE SCrE

Approved ESM ESM

Description fulI updateof the spec. Shield/pursesas & PRE reqts

CONTENTS

1.0 2.0

Scope

Welding Processes

3.0 4.0

Welding ProcedureAnd Welder Qualifications

ElectrodesAnd Filler Metals

5.0

GasesFor ShieldingAnd Backing

6.0 7.0

Preparation Of BaseMaterial

Initial And InterpassCleaning

8.0

Inert Gas PurgingAnd Backing

9.0

Preheat And InterpassTemperatures

10.0

Heat lnput

I 1.0

Atmospheric Protection

12.0

Post Weld Cleaning

13.0 Non-DestructiveTesling

1.0

SCOPE This specification prescribes minimum technical requirementsfor welding, inspection amd the non-destructive examination of feiritic-austenitic (duplex and super duplex) stainless steel piping systems.

t.0

WELDING PROCESSES 2.1 GTAW (TlG) and SMAW (MMA) processes approvedfor use on duplex and super are duplexstainless steelpipe work with the limitationsof clause 2.4 and2.5. Other processes may be usedonly upon specihc approvalby the Company. The TIG welding equipment shall have a high frequency (HF) arc initiation unit, a controlled current delay device and suitablepre-andpost-gasflow device. For all single sidedbutt welds,the root and hot passes shall be deposited with GTAW process regardlessof pipe diameter and wall thickness. Subsequentpassesmay be deposrted with SMAW processwith the limitation of clause2.5. Pipesof nominalsizeslessthanor equalto 51mm (2 inches)and/or wall thickness less than 6.4mm shall be fullv welded with GTAW orocess. AutogenousGTA welding i.e. GTAW welding wrthout the addition of filler metal shall not be permitted

2.2 2.3

2.4

2.5

2.6 1.0

WELDTNGPROCEDURE AND WELDER OUALIFICATIONS 3.1 WeldinsProcedure Oualification

3.1.1 Welding procedures shall be qualified as per ASME Section IX and this specification and approved by the Company prior to the commencementof work. 3-1.2 Mill ceftihcatesof the basematerial and batch test cedificates of electrodes and filler wires for welding shall be submitted along with ProcedureQualification Record (PQR) for Companyreview and approval. 3.1.3 Welding procedures previouslyqualifiedby other clientsshall not be accepted. Welding procedurequalification tests shall be witnessed by ADCO or ADCO anoointed TPI. 3.1.4 The following variablesshall be considered variablesin addition essential thosesoecified ASME SectionIX : in a) b) c) A changein the UNS number of the alloy designation. A changein filler wire size for the root passand hot pass. A change in electrode or filler wire manufacturer or brand name AWS/DIN 8550 c Iassificat ion. Addition, deletion or a change in the nominal composition of consumable insert.

d)

An increasein the maximum interpasstemperature beyondthat qualified. A changein the heat input by more than 10% of the nominal value qualified for eachlayer subjectto the limitations in Section 10.0below. Any changein the compositionof the shielding gas or the backing gas. h) Deletion or any change in the method of post clealing of wel<1root following weld completion. 3.1.5 The test weld shall be qualifiedin the most difficult test position(suchas 6G) envisagedin production welding. 3.1.6 The completed test weld shall be subjected l0O% radiography butt welds to for and 100% dye-penetrant for frllet we1ds. test 3.1.7 The testbutt weldsshallbe subjected the following tests: to i) Chemical analysisof the weld metal taken from the weld root layer. For double sided welds, analysis shall be from the weld metal layer on the process side. Ferrite content measurementof the weld and heafaffected zones using metallographicdetermination,and by plotting the chemicalanalysisfrom WRC-92 Diagram (for weld metal only) Micro examination of weld cross sections at 12 and 3 0' clock oine posltlons. Transverse tensiletestsasper ASME SectionlX. Transversebend tests with a plunger diameter equal to 4 times the specimenthicknessas per ASTM .4370 and ASME SectionIX. Charpy Vee notch impact tests with notches centered in the weld metal and heat-affected zone at the minimum desisn temoerature. Vickers (HV10) hardness survey of weld cross sections from macro samples taken at 12 o'clock and 3 o'clock pipe positionsat 2mm from the outer surface & imer surface and at mid wall. The spacing and location of indentationsshall be as per WS-l Specification. Corrosion tests as per ASTM G48 Method C to determine Critical Pitting Temperature(CPT) of the weldment in the "as-welded" condition i.e. without any post cleaning of the weld root. A detailed laboratory procedurefor the corrosion test shall be submitted to the Company lor revrew and approvalprior to the test. Other conosion tests such as ASTM G-150 may be requested the by u Company henappropriate.

ii)

iii)

rv)
v)

vl)

vri)

viii)

ix)

3.1.8 Accentance Criteriafor Tests 3.1.8.1The chemicalanalysisof the weld metal for car'bon, sulphur,silicon, manganose, chromium, nickel, molybdenum, nitrogen and coppershall be determined.Where tungstenis intentionally added in the filler wire, then tungstenshall also be analysedand reporled. The chemical composition shall comply with the filler wire specification as ocrDTN8556classification.

b.

The Pitting Resistance Equivalent (PRE) as defined by the formula : pRE = o/oCr 3.3.%"Mo+ 0.5 %W + 16%N shallbe at least40 + for both duolex and superduplexstainless steelwelds. The Nickel Equivalent (: %Ni + 35 %C + 20 %N+ 0.25 %Cu) and Chromium Equivalent (: %,Cr + yoMo + 0.1 %Nb) shall be calculated from the chemical composition of the weld metal and plotted on the WRC-92 diagram. The Ferrite number shall be between 40 and g5. Failure to comply with this requirementshall be causefor rejection of the procedure.

3.1.8.2Ferritecontentmeasurement weld metal and heat-affected on zonesby metallographicdeterminationon the macro sample shall be carried out. Fenite contentshall be between30 and 60%. 3.1.8.3The macroexamination shall show completefusion and penetration, and freedomfronr any cracks. 3.1.8.4During bansverse tensiletest,the ultimalestrength yield strength (0.2% , offset) and elongation shall be detemined. The tensile and yield strength shall meet the requirements of the base metal and welding consumablespecification. Minimum elongation shallbe 25%o. 3.1.8.5During bendtests, thereshallbe no visible crackon bending. 3.1.8.6The acceptance criteria for Charpy impact tests shall comply with the requirementsof the base metal specification. In the absenceof this requirement, the weld metal and heat-affected zone shall have a minimum absorbed energy value of 100 Joules (Average of three specimens) 75 Joules and (individualminimum) at +20'C. 3.1.8.7The maximum hardness reading at any point during HV10 hardness surveyshallnot exceed 334 HV10. 3.1.8.8The Critical Pitting Temperature (CPT) of weldments shall be determinedusing ASTM G 48 Method C. Test specimensshall be taken from the weld root in the "as-welded" condjtion. ( i.e. the inside surface of the root weld shall not be wire brushed or ground or treated after welding and prior to the conosion test). The duration of exposureof the test speclmento the test solution shali be 24 hours . The minimum CPT for duplex stainlesssteelpiping welded with super duplex filler material shall be 30"C. The minimum CPT for super duplex piping weldment shallbe 45'C.

4.0

ELECTRODES AND FILLER METALS 4.1 Filler metals for GTAW processshall conform to DIN8556. Electrodes for SMAW shall conform to AWS A5.4 or DIN 8556. Super duplex frller wire conforming to DIN 8556 SGX2 CrNiMoN 25 10 having a nominal chemistryof 25%o 10%Nil 4o/o Ct/ Mol 0.25% N shall be usedto weld both duplex (I-INSNo. S 31803) and superduplex piping (LNS No. S 32750) with GTAW process.Electrodesfor SMAW processshall conform to DIN 8556 E 25 l0 4 LN B 20+. The Pitting Resistance Equivalent (PRE) of the allweld chemistry of the proposedwelding consumablefrom the batch cerlificatesshall be at least 40 for both duplex and super duplex stainlesssteelsto meet the requirementof 3.1.8.1(b) above for the weld metal. The details of proposed filler/ electrode specification, r:nanufacturer and brand name shall be submitted lor Company review prior to qualification. Storage and drying of electrodes shall be in accordance with the electrode manufacturer' recommendations. s

/1 't

4.3
4.4

For SMAW process,syntheticelectrodes with mild steel core wire shall not be used. Electrodes and filler wires of suitable composition shall be selectedsuch that feirite content in thc weld metal shall be between 30% and 60yo.TheFerite Number (FN) on WRC-92 dragramshall be between40 and 85.

Tungsten electrodesfor GTAW process shall conform to AWS A5.12 E Th_2 (2% t horiated typel spec ificar ion.

5.0

GASES FOR SHIELDING AND BACKING For GTAW process,Argon with 2% Nitrogen shall be used for inert gas shielding. pure Argon or a gas composition containing 90To nitrogenl 10% hydrogen shall be used for inen gas backrng.Argon gas shall be of welding gradeand shall be at least 99.995%pure. Dew point of Argon shall be minus 57'c (minus 70 'F) or lower. ( Note: The we of 2,'/oNitrogen in the Argon shielding gas and the use of 90% nitrogen/ I 0% hydrogen as backing gas during GTAW process is known to enhancethe critical pitting temperature of duplex and super duplex weldments)

6.0

PREPARATTON OF BASE MATERIAL The edgesand surfacesofparts to be joined shall be preparedby machining, or grinding using Aluminum oxide gnnding discs.

7.0

INITIAL AND INTERPASS CLEANING

1.1

Prior to welding, the edgesto be welded and a circumferential band of 25mm on both sidesof the bevel edgesshall be clean,dry and free of foreign materialsand defects. Stainlesssteel wire brushesnot previously usedon any other materials shall be used for brushing and Aluminum oxide grinding discs for grinding. The use of carbonsteelwire brushesand carbidegrinding discs are prohibited.

7.2

8.0

INERT GAS PURGING AND BACKING 8. I The inside bore of the pipe shall be suitably purged with Argon ( or 90o/o nitrogenl I}"h hydrogen) prior to and during the root pass. The iner-tgas backing shal1be maintained for a minimum of two additional layers to avoid oxidation of the root. For welding pipes with wall thicknessup to 6.4 mm, inert gas backing shall be maintained for full weldine of the ioint. Wherever possible, baffles or dams of proper design should be used to conservethe backing gas and tb provide effective protection of the weld root. The purge dams should be typically located about three inches on both sides of the weld. The backing gas inlet on the dam should be locatednear the bottom of the pipe and the outlet should be locatednearthe top ofthe pipe for effective gasbacking. Preliminary stepsto a pre-purgingevacuationcycle shall be as follows : a) b) All weld joints of the assemblymust be sealedwith high temperature tape. The endsofall branchconnectionsmust be vented to eliminate air entrapment.

8.2

6.J

c)

ln order to ensureadequatepurging before starting to weld, the purge shall be allowed to flow long enoughto provide at least twenty volume changeswithin the chamber.

8.4

8.5

Upon completion of pre-weld purging, vents in a1l branch with connectionsmust be closedwith venting through main headeror pipe run on1y. The gas venting orifice must have a flow capacity equal to or greaterthan that of the input side to prevent a build-up ofgas pressure.(The outlethole must equalor exceed Argon inlet hole). the No welding shall starl until the oxygen content in the gas inside the pipe has dropped below 100 ml/ mlt. During the root run, there may be a surge when the welding is stafiedand welding shall bc stoppedif this surgegoeshigher than 500 ml/ ml'. Thrs shall be measured with an oxygen analyser capable of measuring oxygen contents between0 and 1000ml/ ml' ( Note: Presence oxide depositon the insideweld root of surface due to inadequategas backing is known to reduce the CPT values of weld significantly. Also, the backing gas flow rate may have to be increasedto around 20 lit/min during welding to keep the oxygen level inside the prpe within acceptable limits).

E.5

During Weldins : a) b) joints exceptthe one to be welded. Seal{apemustbe left on a1l For the joint to be welded, the tape must be removedjust in advanceof welding progressionaroundthe joint. Purge gas flow must be adjustedto maintain zero interior gagepressure.

c) 8.6

Welding of joints shall progressdownstreamfrom the point of Argon entry.

9.0

PREHEAT AND INTERPASS TEMPERATURES

9.1

Preheatis not normally required, except when the ambient temperatue is below 10"C, thenpreheat 50'C. to When moisture may be present,the basematerial shall be heatedwarm{o-hand or until all indicationsof moisture areremoved. shall not exceed 150"C. For welding super duplex stainless Interpass temperature steels,the interpasstemperature betweenthe root and the secondpassshould be below phases. and to minimize secondary 100'C to ensureoptimum pitting resistance

9.2
9.3

1O.O HEAT INPUT

Wclding shall be carried out with low heat input and minimum joint restraint. The heat input shallbe controlled between - 1.5IJ/mm. 0.5 11.0 ATMOSPHERICPROTECTION All welding whether in the field or shop,shall be carried out in a draught-freearea. In majortty ofcases, the welding areashall require the use ofshields to give protection liom air disturbance and contamination. For field welds with GTAW process,welding shall be performed in an protectronfrom wind, dust, moisture etc. enclosedspacefor adequate

I2.OPOST WELD CI,EANING I2'lFollowrngcompletionofwelding,wherevertheinsidesurfaceofthepipeborets to visual inspection the accessible, root side of a1lproduction welds shall be subjected marks (which can be to determine the level of oxidation Welds shall have no bum appeala:ceshould be causedby improper back purging when using GTAW) The weld acceptable' shury but a ,-ali deg,eeoi grey oxidation on or near the weld is inside root surfaceofthe weld shall be thoroughly cleaned r2.2 Wher"ue, ucc".s p"ioitr, th"e blast ctlltns' pickling by suitablemethodssuch as wire bmshing, grinding' glassbead composition. (Note : or acid cleaninj with nitric_hydroflouric acid of appropriate to improve the pitting cleaning of the inreld root to remove the oxide layer is known of resistance duplex stainlesssteelweldments) 13.0 NON-DESTRUCTIVETESTING

l3.1Allbuttweldsshallbe100%radiographedusingX-rayandallfrllet/attachment/ branchwelds shall be 100% examinedby dye-penefant test' 1'3,2ASTME94Typel(AGFAStructurixD4orequivalent)filmshallbeusedfor radiographyof pipes with wall thicknessbelow 10mm' 13.3 13.4 13.5 shall Wire type IQI's (penetrameters) be used' be sha11 2% or better' sensitivity Radiographic processpiping' Acceptancecritena for welds shall be ANSI 831 .3 for utility and

13.6NDTTechniciansshallbequalifredtoASNTLevel.[orequivalentsuchasPCN Level-Il.

,-\
.tG ..

' t
1

',

ABU DHABI

COUpary

FoR ONSHORE OIL

oPERATTONS

(ADCO)

SUPPLEUENT

TO ADCO SPECIFICATION

WS-1

REV.2

REQUIREUENTS AUSTENITIC

FOR WELDING STEEL

AND

NDT

OF

STAINLESS

PIPING

SYSTEI.{S.

Prepar Name designaETon Signature Revision M. Muthuraman Insp. Engineer (w) D.G. Thomas sr , rnsp. .Ejnltr.
ABBAS A. KHOORI

HQA&C

rl
No: 0 Date:14-08-1-991-

ABU DMBI

@UPAITY FOR OITSHORB OIL

OPERATIOIIS RBV.2 SSBET 2 OF 5

SI'PPI.EHENT TO ED@ SPBCTFIC,ATTOTI XO. rS-1

REOI'IREI,IETTS TOR NBIDITG END TDT OF EI'STtsI|ITIC STAIIII,ESS STBEL PIPIXG STSTEI{S

1..0

Weldino 1.1-

Procedure

and WeLder oualifications be gualified aE per prior company to ASME the

Welding procedureE and Weldera shall Sectj.on IX and approved by the connencement of work.

I.2

l.til-l- certificates of the baEe material and batch certificates of electtodeE and filler wires for welding be submitted along with procedure Record eualification f,or company review and approval. Process:

test shalt (pgR)

2.O

Weldino 2.1

GTAVI (?IG) and SMAII (Ml.lA processes ) pipework austenitic stainleas steel clause 2.4 and 2.5. Other processes may be used the company QA&c Department. only

are approved for use with the limitations

on of

2.2

upon

specific

approval

by

2.3

The TIG welding equj.pment shal-l have a high frequency arc inj,tiation unit, a controlled current delay device pre-and post-gas suitabl-e flow device. For al-1, single shall be laid deposited with 2.5. sided butt welds, with cTA!{ process. suAw process with the root and hot passes Subsequent the of limitation

(HF) and

2.4

passes may be cl-ause

2.5

Pipes of nominal sizes l-ess than or equal to 51mn (2 inches) and waII thicknesses less than 5.4mm Ehall be fullv welded with GTAW process. and Filler Metals conform to SFA 5.9 and SFA 5.4 of Asl'lE section

3.O

Electrodee 3.1

Filler metals for CTAW process shall electrodes for SUAW shall- conform to II Part C.

3.2

storage and drying of electrodeE Ehall be in the electlode manufacturer's recotnmendations. For SMAW proceEE. Eynthetic wire Ehall not be used. electrodes with

accordance

vrj"th

3.3

mild

steel

core

ABU DBBI SI,PPL&{BNT

@I{PAITI

FOR OITSEORB OIL IO.

OPENATIOI{S rNS-1 REV.2 SERET 3 OF 5

[O ADOO SPECIFIC.ATIOII

REOUIRBI{BISIS FOR IiIETI)I!{G Af,D TDr OP AUSTETTITTC STAITTIJBSS STEEf,, PIPIIIG SYSTEITI;

3.4

The chemical composition parent of the material bearing electrodeg for Titanium parent bearing stainleaa steel).

of

the weld .depoEit shatl match that except that columbium (Niobium) SMAW may be ueed for equivalent material (e.9. 8347 for Type 321

3.5

For type 316 and 316L stainleEE steel-s, 316L grade welding consumables shal-l be used. while welding 3L6 grade, the welding consumable shall meet the minimum strenqth requirements of the parent material. Tungsten electrodes for A5.L2 E Ah-2 (22 thoriated GTAVI process sttall type) specification. conform to AWS

3.5

4.O

Argon gas ueed for Ehielding and backlng 6hall be of welding grade pure. and shall be at least 99.995t Dew point of Argon shal-l be minus 57oc (minua ?ooF) or lower. Preparation of Base Material-; The edger and Eurfaces of parts to be joined machining, or grinding using Aluminium oxide Initial 6.1 and fnterDass cleanino

5.0

shal-l be prepared grindi.ng discs.

by

6.0

Prior to wel,ding,the edges to be welded and a circumferential band of 25mm on both sides of the bevel edgeE shall be clean, dry and f,ree of forelgn materials and defectE. Stainless steel wire brushes not previouEly used on any other materials shallbe used for brushing and al-uminium oxide grinding grinding. discs for The use of carbon steel wire gri,nding brusheE and qarbide discs are prohibited. eas Purqinq and Backinq

6.2

7.O

Inert 7.1,

The inside bore of the pipe purged with shall be auitably plior Argon to and during paga. gas the root The inert backing 6hall be maintained for a minimum of two additional layers to avoid oxidation of the root. Use of nitrogen for gas backing is not pernitted.

7.2

Bafflee or argon gas.

dams of

proper

design

may be used to

conserve

7.3

P r e l i m i n a r y steps as follows : (a)

to

a prepurging

evacuation

cycle

shal-l be

AII weld joints of temperature tape.

the

assembly

must be aealed

r,rith

high

ABI' DEABT @UPNII SI'PPI.EI{EXI TO AI)@

FOR OITSSONB OIL

OPERATIOI|S REV.2 SNEET 4 OF 5

SPBCTPICATIONT TTO. IIS-1

RBd'IRBI{EXAS FOR NBLDITTC N|I TrDT OF AUSTEIIrTIC STAII|I,BSS STBIL PIPIITG SIST S

(b)

The endg eliminate

of all branch air entraDment.

connectionE

mugt

be

vented

to

(c)

In order to ensure adequate purging before starting to weld, the purge Ehall be al-lowed to flow long enough to provide at leagt six volume changea within the chamber.

7.4

Upon completj,on prer,reld purging, of vents in al-l branch connectionE rnust be closed r.rith ventlng through main header or pipe run only. The gas venting orifice must have a fl,ow capacity equal- to or greater than that of the input side to prevent a build-up of gas preBsure. (The outlet hole must equal or exceed the Argon inlet hole). During (a) Welding !be left on all joints except the one to

7.5

Seal-tape must be welded.

(b)

For the joint to be welded, the tape must be removed juEt in advance of welding progression around the joint. gas Purge flow ctu6t gage preEgure. interior shall be adjusted to maintain

(c)

7.6

Welding of joints Argon entry. and Interpass

progresE

downstream

from

the

point

of

8.O

Preheat 8.1

Temperature6 required. except then preheat to when the arnbient

Preheat is temperature

not normalIJ is below lo-c,

sooc.
be are

4.2

when moiEture may be heated hrarm-to-hand or removed. Interpass temperature be carried

present, the base material shall until all indicationE of, moisture

8.3 9.O

shatl out

not with

exceed low

15OoC. heat input and minimum

welding should joint restraint.

1O.O AlL welding whether in the fj-eld or shop, shall be canied out in a draught-free area. In majority of cases, the welding area ehal-l require the use of shiel-ds to give protection from air disturbance and contamination.

'

ABU DMBI $'PPI;BUEtrT

@XPENY FOR OITSEORE OII' TO AD@ SPECIFICATIOIT

OPERATIONS REIr' 2 SEEBT 5 OT 5

TTO. WS-I

NEOUIRBI{BI{TS FOR NEII)ITTG II{D TrDT OF AI'STE|IITTC STAItrI,ESS STEEL PIPIIIG SYSTEIII|

11,.O Non-destructive 1L.1

TeEtinq

be as per shall exami-nation of, non-destructive The extent Dye-penetrant Ws-1 Rev-2' ADco specification Tabl-e 1 of austenitic for UPI of !-n place apply will examinatlon stainIeEE gteel branch connect iona ' fil-m D4 or equivalent) ASTM E94 TyPe 1 (AGFA structurix of PiPeE with wall thicknesses be used for radiograPhy 1omm. type penetrameters sensitivity shal-l shall be used. be 2* or better' shall beloi^'

11.2

11-.3 wire 11.4

Radiographic

be ANSI 831.3 for uti-Iity for welds shall criteria 1-l-.5 Acceptance reduced alI for criteria pi.pfng. Acceptance and procesE l-00* as for same be the shall percentage examlnationE examinatioo. l-1.6 shall be qualified NDT technicians Euch as CSWIP' ERS. equivalent to ASNT Level II or

Loc / L-L.I lrMln

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tol

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dp 0J c.,

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(.)
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'&',

r,

'

Higher purge flow rates will decrcasethe time required for preweld purging, but increasethe amount of gas required. ln geoeral, reasonablepreweld flow rdtes and times can be arri\d at ftom simple calculations of the slstem volume and by applying a time factor. The time for one volume change of the system is found by dividing the volurne by the purge gas flow rate. For the .-.example, prepurgetime for one volumechangein a 20 ft (6 m) length of 18 in. (0.46 m) diameter pipe prepurged at 50 cftt (24 l/min) would be: Volume = 0.785 X (pipediamelsl): x lengrh 0J85 x (t.5 ft)r x 20 ft = 35.3 ft' 35.3 ftr : 0J0 hour or 42 minutes 50 cth

the timefor one In SI unitsat 24 liten per minute, Purge pipewould be: volumechange the same of 0J85 x (0.46m)r x (6m; : 9.93*'

qrc+i#Pd=

42minutes

A general mle is to prcwldpurgeat flow ratesandtimes that will prcduce5 to 6 volumechanges. the example In above,one volume.change occursapproximately evury42 minuaes. changes Six would require252 minutesor about 4 hours. Figure2 shows minimumpreweldpurgetime in minutes per 12in. (300mm) of pipfor varyingpipediameters at preweld 50 cfh (24 liten per minute)flow mte. Suggested purge . timescanbefoundquicklyandeasilyf.om thisgraph

. =
z

i n .

1 2 3 4 5 6 25 5t 76 1U2 121 tA2

8 1 0 2d] 254

1 2 305
PIPESIZE

1 4 356

1 6 406

1 8 457

2 0 548

24 610

Poplrgo lim6 fof 12 i.. (3OO mrnlor pip aia tlow rar. of 50 CFH 124lit.r. P.r hinut.l To c.lculata rh prplrg. tim. to..ny tcngth of pip, mlltiply th valu. obtaind l.orn tne chan by rha tnqth of pip.

Errrrrirj Fi.d tim requird fo. p.epurging of 2OOtt {60 ml ol 5 in. {127.nml pipa From ch..t ar 5 in. {!27 mml pip siz6, g.t on! ftin 9. l? in. {0.3 m) ot pip.; h.nc.,2001t {0 m)-200 minur$ or 3 hoort 20 mi.ut3.

Figure 2-Preweld purge evacuationof air

ABUDHABICOIiIPANY 0tl|sH0RE 0pERATrONs FoR oIL (ADC0)

SUPPLEI,IINTADCO T0 SPECIFICATI0N REV.2 fS-t

REQUIRE}IENTS IdELDII{G FOR ANDIIDT OF NICKEL ALLOYS PIPING FOR SYSTE}IS.

Name

-n-fr[inuraman

De-SignaTion Insp. Engineerlt'[

Signature

---ntr-mtmas- -TT-or5es ----EFaEEo*-Sr. Insp.Tngrr.

MM"/{*-'"Date:25-08-1990

R e v i s i o nN o : 0

SHEET OF 4 2

u a li f i c a ti o n s
I-l s l l e l d i n g p r o c e d u r e a n d l , J e l d e rs h a l l b e q u a l i f i e d s a s p e r ASME Section IX and a by the conbany prior to the comnencement norfl.ou.d or

1.2 MiII.-certificates of the base material a c e r t i f i c a t e s o f f i l l e r w i r e f o r * . l J l n q - r n u fn c l batch test procedure iricai'ton-ir.ii'"a" f b e s u b m i t t e d along with quat tpqnt for company reviewandapproval . 2 . 0 l^leldjng Process:
2.1 0TA!{-(TlG) and SMAI{ (Ml4A) proce-sses are s n i c k e l a l l o y p i p e w o, r k i t h ' t h e ' l - i ; i t a i ' i i napproved for use on w o f c l a u s e2 . 4 a n d

2'2
2.3

onlv speciric approvar bv 3ll"i.,fJ.',ii1if,i, $Xtr.!;rJir': upon

shail , (HF) ]l: l;frifJf;Xsuf.q.uipTent haveeljsl^J-i:ql:ncy' a n i r c u * n t d e l a vd e v i t e suitable re-and p
oltt S.rttittlllIed
ro _ nd hot p s h a l l b e l a i d w i t h .e r n w - p r o c e i -t.hie r . q o"tn ap a s s e s a s s e s s ,' l l . m a vb e deposited with SMAt^l procsss ;iti ;;;"j'i_it'atio-i-i,i'.l,uulE 2 .5 . sinqle sided_butt welds,

2.4 For ali

2 . 5 P i p e so f n o n i n a l s i z e s .l e s s . t h a n o r e q u a . l t o 5 l m m( 2 i n c h e s )

; ;d;;i to o'cmm' -bl shiiJ ilf',1L1r:l';Tt;';?ir';;;..',11;

2 n

2.6 Tungsten erectrodesfor GTA process conformto AHS A 5 . t Zt l h - z { Z % h o r i a t e dv p " i i p e i i r i sharl n . T t caiio F i l . l e r l ' l e t a l s f o r G T A l , l . p r o c es h a l l c o n f o"of -ss -iJ'irn rmo sFA5.I4 and t electrodesfor sr4AW shail'coniornr i.'rr Asr4E Section II Plil .c..Storageand drying of eie;ir;;;;-rr,.fr o. in accordance with the electrodemanuiacfurer,, i"iorr.naiiion, . I n e e d g e s n ds u r f a c e s f . p a r t s t o b e j o i n e d s h a l l a o "oiiO. be preparedv "" b "' machiing, or grinding usi rig Alumi um n j ni g;:inOns-a! l.!l'

4 . 0 P r e p a r a t i oo f B a s e | a t e r a l : n | i

SHEET OF 4 3 TO ADCO SPECIFICATION US-I REV.2 NO. SUPPLE},IENT

5 . 0 I n i t i a l a n d I n t e r p a s sC l e a n i n q t 5 . 1 P r i o r t o w e l d i n g , t h ee d g e s o b e w e l d e da n d a c i r c u m f e r e n t i a l on band of 25rnm both sides of the bevel edges sha11 be solvent. by thoroughly degreased a suitabie non-flammable n 5 , 2 S t a i n l e s s s t e e l t , r i r eb r u s h e s o t p r e v i o u s l yu s e do n a n y o t h e r m a t e r i a l s s h a l l b e u s e d f o r b r u s h i n g a n d a l u m i n i u mo x i d e grinding discs for grinding. The use of carbonsteel wire b r u s h e s n d c a r b i d eg r i n d i n g d i s c s a r e p r o h i b i t e d . a from pickup of iron and sulphur from items such 5.3 Contamination a s g r i n d i n g w h e e l so r c r a y o n ss h a l l b e a v o i d e d . ng 6 . 0 GasBacki w Theinside boreof the pipe shall be suitably purged ith an inert g a s l i k e A r g o np r i o r t o a n d d u r i n g t h e r o o t p a s s . T h e i n e r t g a s f o b a c k i n gs h a i l b e m a i n t a i n e d o r a m i n i m u m f o n e a d d i t j o n a l p a s s t o a v o i d o x j d a t i o n o f t h e r o o t . U s eo f n i t r o g e n f o r g a s b a c k i n gi s not pemi tted. 7 . 0 Preheatand Interpass Temoeratures 7 . 1 P r e h e a t i s n o t n o r m a ly r e q u i r e d , e x c e p t w h e n t h e a m b ' i e n t 1 t e m p e r a t u r es b e l o w1 0 " C ,t h e n p r e h e a tt o 5 0 " C . i 7.2 l,0hen noisture may be present, the base material should be h e a t e dw a r m - t o - h a n d u n t i l a l l i n d i c a t i o n s o f m o i s t u r ea r e or removed . 1 7 , 3 I n t e r p a s st e m B e r a t u rs h a l l n o t e x c e e d 5 0 o C . e 7.4 Temperature sensitive crayonsshould be applied at a distance of 25mmfrom the bevel edges to determine the interpass using crayons, care must be taken to avoid temperatur.(lllhen c o n t a m i n a t i oo f t h e w e l d a r e a ) . n 8 , 0 | . l e l d i n gs h o u l d b e c a r r i e d o u t w i t h l o w h e a t i n p u t a n d m i n i m u m joint restraint to avoid 'hot cracking' in the weld and HAZduning welding. 9 . 0 A l 1 w e l d i n gw h e t h e ri n t h e f i e l d o r s h o p , s h a l l b e c a r r i e d o u t i n a draught-free area. In majority of cases, the welding area shali r e q u i r e t h e u s e o f s h i e l d s t o g i v e p r o t e c t i o nf r o m a i r d i s t u r b a n c e and contami i on. nat

SHEET OF4 4

l0.l Butt welds shali be subjectedLo l0A%v i s u a l e x a m i n a t i o n 1 0 0 % , r a d i o g r a p h y .i 1 l e 1 w e l d s s h a l I be subjected to a n d F 100% visual followed by 1002, dye penetrant e x a m ia t i o n . n 1 0 . 2 A S T M 9 4T y p e1 . . ( A G F A . S t r u _ c t D r i o r e q u i v a l e n t )f i l n E u4x be used for radiographyof pipes lrith vrail *ricririessei s h a l l [eiow 1Omm. 10.3 llire type penetrameters shall be used. 1 0 . 4 R a d i o g r a p h is e n s i i l v i t y s h a l I b e Z %o r b e t t e r . c 1 0 . 5 A c c e p t a n cc r i t e r i a f o r w e r d ss h a i l b e A N s I8 3 1 . 3 f o r u t i r i r . v e and process piping. Acceptance riteria for alI i"Ou."i c percentage examjnations shall be the same as for lOOr" exami nati on. 10.6 NDT technicians sh-a-'!l_, qualified be e q u i v a l e n ts u c ha s C S h l I pE R S . , to ASNT Level II or

10c/1-r.1/tm/n

SHEETOF2 I

u a li f i c a t i o n s

t . 1 ltle di ng procedures l and Ueiders shall be qualified as per ASIiIE -- -- '-' Secti on IX prior to the commencenent
of iort.

t . 2 llel d i ng procalure quali fi cati on shali

1.3 llill c e r t i f i c a t e s . _o f

i ncl ude chemi 'p-,cal ys anal i s of we'ldmetal for Cu, Ni, Fe, Mn, S A the base material

review and approval .

a c t c e r t i f i c a t e s f f i l l e r w - i r e o r w e l d i n g t a in du b aitu h mei sitl i o f s i -ir;-;ffi;;; i J- 6 alongwith procedure ification neii'"o iiqit Qual

2 . 0 trlel i nq Process d :
(TI:G)processshall be used. The weldjng equipment GTAl'l shall have . .eItj a y d e r e c e e n c y( H F ) a r c i n i t i a t i o n u r i i ; ' a c o n t r o i l e d c u r r e n t Sh, f vi qu d a n d s u i t a b l e p r e _ a n d o s t _ g a sl o w d e v i c e . p f

3 . 0 F i l l e r M e t a l s h a ll c o n f o r m o s F A 5 . 7 E R c u N i o f A S M E e c t i o n t S II Part
C.

4 . 0 Preparationof Basel.lateri : al

The edgesand surfaces of parts to- be jo.ined shall be prepared -" m a c h i n i n g r g r i n d i n g u s i n d A l u m i n i u m - x i O J g r i n d i nd i i c s l - - - by o O g

5 . 0 I n i t i a l a n d I n t e r n a s sC l e a n i n q
5.1 Prior t^owelding'the edgesto be werdedand a circumferentiar 'riali-'il band of 25mmon both sides of the bevel "agJ thoroughly degreased a suitable non fl ammabl solvent. _ by e5.2 Stainless steel wire brushe:s not previously used on any other m a t e r i a l s s h a l l b e u s e d f o r b r l s h i n g a i a a t u m i n i u mo i i O e g r i n d i n g d i s c s f o r g r i n d i n g . T h e u s e -o f c a r b o n s t e e l wiie brushesand carbide grinding discs are prohibited. 5.3 contamination from pickup of iron and surphur from items such a s g r i n d i n g w h e e l so r c r a y o n s h a i l b e a v b i d e d . s 6 . 0 GasEacki nq T h e i n s i d e -b o r e o f t h e p i p e . s h a l l b e s u i t a b l y p u r g e d i t h a n i n e r t w gas.like Ar_g_on prior to.and duringc o m piooi* iisi. ffre tnert qas - the l e l i " ; f - ; . i J i n g . ' ' U i . ' o i b a c k i n gs h a l l b e m a i n t a i n e d n t i l u n i t r o g e n f o r g a s b a c k i n gi s n o t p e r m i t t e d .

7 . 0 lrghelt lnd, Intero

t.t

atures rreheat is not nomally required, except when the ambient temperature below 10"C, then pr6heat to SOoC. is

SHEET OF 2 2

7 .2 I'lhenmo sture may be prese_nt,the base material i should heatedwarm-to-hand u n t i l a l i i n d i c a t i o n s o f m o i s t u r e be or aie removed . 7.3 Interpass temperature shall not exceedl50oC.

7.4 Temp-erature sensitive crayonsshould be applied at a of 25mmfrom the bevel edges io- OeteHtne ttre di stance i nterpass temperature.(l,lhen. using cratons, care musl be taken t o a v o i d c o n t a m i n a t i oo f t h e w e l d a r i l a ) . ' n 8 . 0 t l e l d i n g s h o u l d b e c a r r i e d o u t w i t h l o iw 'h e,a t i n p u t and minjmun j o i n t r e s t r a i n t t o a v o i d ' h o t c r a c k i n g- n 1 f . ; w"il-inA'ifnZ"'il;;;; welding. 9 . 0 Non-destructi Testinq ve 9.1 Shop welded butt welds sha.l'l be subjcted to 100% -ft2 -radiogr;pht. visual , 'iiii;i 100%dye penetrant.examinationand w e l d s s h a l l b e s u b J e c t e do I O O Z l s u a i i o t t o i e d ' O " ur o d ' a r . t v

penetrant examination. .Fierdwerdsshari be suuieiteui-."r06i. visual followedby 100% penetrant dye examinati6n.

9 . 2 X - r a d i a t i o na n d A S T _ M . ET y p e I ( A G F A t r u c - u r"i x D 4 94 S -- t -' or e q u i v a l e n t f i l m s h a l l b e u s e d ' f o rr a i i o g r a p t r y . ) 9.3 llire type penetrameters shall be used. 9 . 4 R a d i o g r a p hs c n s i t i v i t y s h a l i b e 2 %o r b e t t e r . ie 9 . 5 A c c e p t a n c ei t e r i a f o r w e r d s h a i l b e A N S 8 3 r .-aii r u t i r i t v r s I 3f o and process piping. Acceptance criterii foi ;;;;;;; percentage exami ons shalI be the sarne as for nati lOOy, exami i on. nat 9 . 6 N D Tt e c h n i c i a n ss h a l l b e q u ailf i e d t o A S N T e v e l I I L equivalentsuchas CSlilIp, ERS. or

Tufiuiaman u .u . I n o m a s I.S. Forbes-lnsp. "';------=DesTgnaIIon TngineerlT'- r r . l n s p . L n g r . ---TIF0A&T'

Signature

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