GS 118-10 Welding of Transmission Pipelines: Supplementary To BS 4515: 1996 December 1998 (Amended February 2000)

GS 118-10
WELDING OF TRANSMISSION
PIPELINES
Supplementary to BS 4515: 1996
December 1998
(Amended February 2000)
Copyright The British Petroleum Company p.l.c.
Copyright The British Petroleum Company p.l.c.

All rights reserved. The information contained in this document is subject to the terms and
conditions of the agreement or contract under which the document was supplied to the
recipient's organisation. None of the information contained in this document shall be
disclosed outside the recipient's own organisation without the prior written permission of
Manager, Standards, BP International Limited, unless the terms of such agreement or
contract expressly allow.
BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING
Doc. No.
GS 118-10
Issue Date
December 1998
Latest Amendment Date
February 2000
SUPPLEMENTARY TO BS 4515: 1996

(Replaces BP Engineering Std 192 Part 1 and BP GS 118-10 April 1986)
APPLICABILITY
Regional Applicability:
International
SCOPE AND PURPOSE

This BP Group
AMENDMENTS
Amd
Date
Page(s)
Description
___________________________________________________________________
01
01 Feb 2000
19-20 Reference BS EN 1435 replacing BS 2910
23-24 Amendment to Table 8(j)
29-30 Amendment to list of referenced standards.
Approved for issue:December 1998
.
John Hammond
DOCUMENT CUSTODIAN
CUSTODIAN (See Current Status List for Contact)
Welding
Issued by:-
Engineering Practices Group, BP International Limited, Research & Engineering Centre

Chertsey Road, Sunbury-on-Thames, Middlesex, TW16 7LN, UNITED KINGDOM
Tel: +44 1932 76 4067
Fax: +44 1932 76 4077
Telex: 296041
CONTENTS
Section
Page
FOREWORD ..................................................................................................................... iii

1. GENERAL .......................................................................................................................1
1.1 Scope and General Applicability .................................................................................1
1.3 Definitions .................................................................................................................1
1.4 Information to be supplied, items to be approved and requirements to be
agreed and documented ..............................................................................................2
1.5 Equipment .................................................................................................................4
1.6 Welding Processes......................................................................................................4
1.7 Welding Consumables.................................................................................................5
1.8 General Requirements.................................................................................................6
2. TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES....................................................................................................................7
2.1 General
.................................................................................................................7
2.3 Welding Procedure .....................................................................................................7
2.4 Changes Affecting Qualification and Approval (Essential Variables)............................7
2.5 Testing of Butt Joints for Procedure Qualification.....................................................10
2.6 Testing of Fillet Welds for Procedure Approval ........................................................12
2.7 Testing of Repair Welds for Procedure Qualification.................................................12
3. TESTING, QUALIFICATION AND APPROVAL OF WELDER..............................13
3.1 General
...............................................................................................................13
3.5 Changes Affecting Qualification and Approval (Essential Variables)..........................13
3.6 Non-destructive Testing............................................................................................13
3.7 Destructive Testing...................................................................................................13
3.8. Retests
...............................................................................................................13
3.9 Records ...............................................................................................................13
3.10. Mechanized Welding..............................................................................................13
4. PRODUCTION WELDING ..........................................................................................14
4.1. Proximity of Welds ..................................................................................................14
4.2 Pipe End Preparation................................................................................................14
4.3. Fusion Faces............................................................................................................14
4.4 Alignment ...............................................................................................................15
4.5 Line-up Clamps and Pipe Supports ...........................................................................15
4.6 Tack Welds ..............................................................................................................15
4.8 Stray Arcs ...............................................................................................................15
4.9 Weather Conditions ..................................................................................................16
4.10 Preheating and Post-weld Heat Treatment...............................................................16
4.11 Branches ...............................................................................................................16
4.12 Inter-run Cleaning...................................................................................................17
DRAFT
GS 118-10
WELDING OF TRANSMISSION PIPELINES
PART 1 - SUPPLEMENTARY TO BS 4515
PAGE i
4.13 Partially Completed Joints.......................................................................................17

5. INSPECTION AND TESTING .....................................................................................18
5.1 Inspection and Testing ..............................................................................................18
5.1 General
...............................................................................................................18
5.2 Personnel Qualification.............................................................................................18
5.4 Radiographic Testing................................................................................................18
5.5. Manual Ultrasonic Testing .......................................................................................21
5.6. Automatic Ultrasonic testing....................................................................................21
5.7 Magnetic Particle Testing .........................................................................................21
5.8 Destructive Testing...................................................................................................22
6. ACCEPTANCE AND RECTIFICATION OF WELDS ...............................................23
6.1 Non-Destructive Testing Acceptance Criteria ...........................................................23
6.2 Rectification of Welds...............................................................................................24
There are no requirements additional to BS 4515:1996.......................................................
ANNEX C TO BS 4515 (INFORMATIVE).
PROPOSED WELDING PROCEDURE SPECIFICATION..........................................25
ANNEX D TO BS 4515 (INFORMATIVE)
EXAMPLE OF A RECORD FORM FOR WELDER QUALIFICATION TEST. .........26
ANNEX E TO BS 4515 (INFORMATIVE) .
GUIDANCE FOR ESTABLISHING PREHEATING REQUIREMENTS .....................26
ANNEX F TO BS 4515 (INFORMATIVE).
EXAMPLE OF A RADIOGRAPHIC SPECIFICATION................................................26
APPENDIX A.....................................................................................................................27
DEFINITIONS AND ABBREVIATIONS ........................................................................27
APPENDIX B.....................................................................................................................29
LIST OF REFERENCED DOCUMENTS ..................................................................29
APPENDIX C.....................................................................................................................32
ALTERNATIVE TECHNIQUE FOR BATCH TESTING OF WELDING
CONSUMABLES.........................................................................................................32
FIGURE C1........................................................................................................................33
PROCEDURE FOR ESTABLISHING BATCH TEST REQUIREMENT......................33
DRAFT
GS 118-10
PAGE ii
FOREWORD
Introduction to BP Group Recommended Practices and Specifications for Engineering
The Introductory Volume contains a series of documents that provide and introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular,
the General Foreword sets out the philosophy of the RPSEs. Other documents in the
Introductory Volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.
Value of this Guidance for Specification
This Guidance for Specification specifies all BP general requirements for welding of
transmission pipelines that are within its stated scope, and for use with a supplementary
specification to adapt it for each specific application.
This Guidance for Specification is based upon an industry specification.
The value of this Guidance for Specification to its users will be significantly enhanced by their
regular participation in its improvement and updating. For this reason, users are urged to
inform BP of their experiences in all aspects of its application.
Application
This Guidance for Specification is intended to guide the purchaser in the use or creation of fitfor-purpose specification for enquiry or purchasing activity.
This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.
Previous Changes from Previous Editions
This document completely supersedes the earlier BP Standard 192 Part 1 (April 1986) which
was later reformatted into BP GS 118-10 (1986), both former documents being based on BS
4515:1984. This document is based on BS 4515:1996 and reflects the extensive revision of the
base document.
DRAFT
GS 118-10
PAGE iii
Feedback and Further Information

Users are invited to feed back any comments and to detail experiences in the application of BP
RPSEs, to assist in the process of their continuous improvement.
For feedback and further information, please contact Standards Group, BP International or the
Custodian. See Current Status List for contacts.
DRAFT
GS 118-10
PAGE iv
1.
GENERAL
1.1
Scope and General Applicability
1.1.1
This BP Group RPSE specifies general BP requirements for the welding

of transmission pipelines in accordance with BS 4515: 1996.
To apply this BP Group RPSE, supplementary specification and
approval actions by BP are required to adapt it to each specific project
application.
The titles and numbering of the text of this BP Group RPSE follow
those of BS 4515:1996 for the convenience of the user. As a result of
this, gaps in the numbering sequence may occur. Text either qualifies,
substitutes, modifies or adds to its requirements those of BS 4515:
1996. Where additional text is to be read as an extension of the text of
BS 4515:1996, the text numbering of BS 4515:1996 has been extended
accordingly.
1.1.2
BP Group GS 118-10 is applicable where statutory regulations require

that the pipeline is welded in accordance with BS4515:1996, as in the
UK, or other areas where BS 4515:1996 may have been adopted by a
statutory authority or by choice as the pipeline welding code. Its
alternative companion GS, BP Group GS 118-9 is applicable where
statutory regulations or similar adoption of API standards require that
the pipeline is welded in accordance with API Standard 1104.
1.3
Definitions
In this standard, the following definitions shall apply in addition to or
modifying or supplementing those of Section 1.3 of BS 4515:1996.
Any specific application of the terms and responsibilities for the parties
defined as follows is a matter for the Conditions of Contract on a
project.
1.3.1
(a) employer:
(b) BP
BP, acting directly or through an authorised

representative.
The British Petroleum Company p.l.c, an
associate or subsidiary, or other organisation as
defined in the conditions of contract.
1.3.2
contractor:
a contractor responsible BP for the welding of the

pipeline
1.3.22
inspector:
an employee of the contractor with overall
DRAFT
GS 118-10
PAGE 1
responsibility for ensuring that all construction,

inspection and testing are undertaken in accordance
with the requirements of this GS
1.3.23
batch:
a single cast of filler wire, a single blend of flux, or, for

covered electrodes , the combination of a single cast of
core wire with a single dry blend of covering.
1.3.24
duty:
pipeline service which is to be defined by BP as

normal or severe. Welds in severe duty pipelines will
(may) be subject to more onerous requirements than
those in normal duty pipelines.
1.3.25
service:
to be defined by BP as either sour or non-sour (see

1.3.13 of BS 4515:1996).
1.3.26
quality assurance (QA):

all those planned and systematic actions necessary to
ensure quality and technical compliance. (i.e. to provide
adequate confidence that a product will be fit for its
intended service).
1.3.27
quality manual
a document setting out the general quality policies,
procedures and practices of an organisation
1.3.28
quality plan (QP)

a document prepared by the contractor, setting out the
specific quality practices, resources and sequence of
activities relevant to the particular pipeline welding
contract.
1.4
Information to be supplied, items to be approved and

requirements to be agreed and documented
1.4.1
Information to be Supplied by the Employer

Where possible, the information to be supplied is provided below under
the appropriate clause numbers. However, in addition to the items
identified by BS 4515: 1996, the following information will be supplied
by the employer:-
DRAFT
(i)
Test pressure for pipeline field hydrostatic test
(ii)
The pipeline duty and service.
(iii)
Requirement for Charpy testing of welding consumables on

severe duty pipelines.
GS 118-10
PAGE 2
1.4.2
(iv)
Whether any change in heat input is considered significant.

(See 2.4, Table 1 j5.)
(v)
Whether additional hardness surveys on macro-sections are

required.
(vi)
Alternative Charpy test temperatures.
(vii)
Use of fluorometallic screens.
(viii)
Sensitivity levels for gamma radiography.
(ix)
Welds and areas requiring ultrasonic testing
(x)
Further limitations on root undercut and shrinkage groove for

sour service pipelines.
Items to be Approved by the Employer

Where BP have specific requirements, these are stated below under the
appropriate clause numbers. However, in addition to the items
identified by BS 4515: 1996 the following additional approvals are
required:-
DRAFT
(i)
Use of automatic and semi-automatic welding systems (See 1.6)
(ii)
Quality plan prior to production welding. (See 1.8.3)
(iii)
Acceptance of batch testing failure before re-tests are allowed.

(See 1.7.1)
(iv)
Acceptance of re-welding in procedure qualification tests (See

3.8)
(v)
Acceptance of material grouping. (See 3.5)
(vi)
Acceptance of diameter and thickness group combination.

(See 3.5c)
(vii)
Acceptance of Charpy V-notch impact test results.

(See 2.5.2.5)
(viii)
Acceptance of pipe diameter or wall thickness changes.

(See 3.5)
(ix)
Welder re-training programme. (See 3.8).
GS 118-10
PAGE 3
(x)
Alternative 'pup' piece length. (See 4.1)
(xi)
Angle of field bevel if different from mill bevel. (See 4.2)
(xii)
Alternative method for pipe end cleaning. ( See 4.3)
(xiii)
Corrective action for misalignment. (See 4.4)
(xiv)
Use of fabricated fittings. (See 4.11).
(xv)
Use of Iridium 192. (See 5.4.1)
(xvi)
Use of gamma-radiography. (See 5.4.2)
(xvii) Use of permanent magnets or prods. (See 5.7)

(xviii) Limits on size and location of weld repair excavations.
(See 6.2.4)
1.4.3 Requirements to be Agreed
Where appropriate, the requirements of BP are stated under the
appropriate clause numbers. However, in addition to the items
identified by BS 4515: 1996 the following requirements shall be subject
to specific agreement between BP and the contractor.
(i)
1.5
Use of wall thickness and pipe diameter grouping for welder

qualification on severe duty pipelines. (See 3.5)
Equipment
The contractor shall supply all necessary equipment for welding, heat
treatment, mechanical handling, testing and radiographic processing.
1.6
Welding Processes
The contractor shall specify in his tender the welding process, or
processes or combination of processes proposed for the pipelay welding
operation. Manual processes, semi-automatic or automatic welding
systems may be offered. Where a process or system is proposed of
which BP has no previous experience BP will specify welding and NDT
trials which are to be undertaken by the contractor and completed
successfully before the proposed technique can be approved for
qualification testing. Separate qualification of a manual metal arc
procedure may also be required, for possible use in the event of failure
of semi-automatic or automatic equipment in production welding.
DRAFT
GS 118-10
PAGE 4
1.7
Welding Consumables
The contractor shall supply all necessary welding electrodes, filler
wires, fluxes, shielding and backing gases and all other consumable
items required for the work.
1.7.1
General
Where the duty of the pipeline is specified by BP as severe, each batch
of welding consumables shall pass the Charpy V-notch impact test
required for welding procedure qualification. This requirement will be
waived if further tests from the qualification weld still meet the
specified values when tested 20C below the specified test temperature.
All batch testing shall be completed prior to the start of field welding.
No re-tests are permitted unless a satisfactory explanation for the failure
can be given and is accepted by BP.
1.7.2
Storage and handling.
1.7.2.1
General
Each coil of filler wire, bag of flux and tin or packet of electrodes shall
be clearly marked with its batch number (and shall be stored completely
separated). The storage and handling of welding consumables shall be
generally in accordance with BP Group GS 118-4. The contractor's
detailed proposals shall form part of the quality plan.
1.7.2.1
Shielding Gases - General

Where appropriate, gases or gas mixtures complying with BS EN 439
shall be used:(a)
(b)
(c)
argon,
carbon dioxide
gas mixtures that have been proved to be satisfactory as a result
of procedure approval tests.
When a gas mixture is used which has specified additions e.g. 2% O2,
5% CO2, the variation of such addition shall not exceed 10% of that
stated.
1.7.2.2
Shielding Gases - Storage and Handling

Shielding gases shall be stored away from extremes of temperature. In
the field, only gases specified in 1.7.2.1, as supplied by the
manufacturers, in specially marked containers, shall be used. Gases that
are of questionable purity and those in containers which show signs of
damage shall not be used.
1.7.3
DRAFT
Welding Consumables for Fillet Welds
GS 118-10
PAGE 5
Basic coated low hydrogen electrodes or other approved low hydrogen

process shall be used for any fillet welding directly on to the pipeline,
but rutile coated electrodes may be used for fillet welds between nonpressure bearing parts such as structural supports.
1.8
General Requirements
1.8.1
Supervision of the Work

The contractor shall employ competent supervisors to ensure that both
the standard of workmanship, and the quality of materials used, comply
with the requirements of this BP Group RPSE.
1.8.2
Field Hydrostatic Test

The completed pipeline shall be hydrostatically tested for a minimum
period of 24 hours. The test pressure, which will be defined by BP,
shall not normally exceed that required to produce a hoop stress equal
to 95% of the specified minimum yield strength in a pipe with the
specified minimum wall thickness.
The completed pipeline shall be proved free from internal obstructions
by the passing of a pig fitted with a gauging plate, of dimension 96% of
nominal bore.
1.8.3
Quality Assurance
1.8.3.1
Responsibility for quality assurance shall rest with the contractor. The
contractor shall devise and implement a quality plan for the systematic
control of the construction, inspection and testing required by the
particular contract. This quality plan, which shall be based on ISO
9002/9003 shall be submitted to BP for approval prior to production
welding, and shall include evidence that the inspector and his team are
independent of production management.
1.8.3.2
The inspector shall ensure that all documentation required by this

Standard is gathered, collated, indexed, stored and subsequently
presented to BP. He shall compile a log identifying by number each
pipe and fitting, and indicating the weld numbers joining them to other
items. Each circumferential weld (whether a field joint or a shop-made
weld) shall be allocated a unique number, which shall be used for
reference to the weld in all reports, radiographs and NDT documents.
DRAFT
GS 118-10
PAGE 6
2.
TESTING, QUALIFICATION
PROCEDURES
2.1
2.3
AND
APPROVAL
OF
WELDING
General
(a)
All welding procedure qualification tests shall be conducted in

the presence of a BP representative.
(c)
A test shall be allowed to cool for a minimum of 24 hours in

simulated site conditions. After this 24 hour period, the
procedure qualification test welds shall be fully radiographed,
ultrasonic tested and magnetic particle tested prior to
conducting destructive tests.
(h)
For pipelines designated as severe duty, BP will require welding

procedures to be specifically qualified on the actual material for
construction. Previous weld qualification test results will not be
acceptable for such applications.
Welding Procedure
Procedure approval tests shall be carried out on pipe, made from the
same material, from the same source and in the same supply condition
that is to be used for pipeline construction.
2.4
Changes Affecting
Variables)
Qualification
Table 1.
Welding Procedure
Changes Affecting Approval.
and
Approval
Specification
(Essential
Details
and
The following additional restrictions or changes apply to all welding

procedure specifications:Item
Relevant Change or Restriction
(a) Welding process
The gas tungsten arc process (GTAW)

shall be used for welding on all pipe
diameters less than 60 mm.
(b) Material Specification
Pipe, valves, flanges and fittings from

different sources, or made from
material from different sources, or in
different supply conditions shall be
treated separately and shall require
separate
procedure
qualification,
unless some form of material grouping
is approved by BP
.
Different wall thicknesses and
(c/d) Diameter /Thickness
DRAFT
GS 118-10
PAGE 7
diameters shall be qualified separately,

unless approved otherwise approved
by BP.
(e5) Joint configuration
The use of permanent backing rings is

not permitted.
(f) Filler metal
Basic coated low hydrogen electrodes

or approved low hydrogen process
shall be used for all fillet welds to the
pipeline
(g) Number of runs
The number and position of weld beads

shall be selected to give the finished
weld a substantially uniform crosssection.
No two weld beads shall start
at the same point, unless the area is
dressed clean and sound before the
second bead is started. Single pass
welds are not permitted
(i) Electrical
For Manual Shielded Metal Arc

Welding characteristics of pipe
diameters above 300 mm welded d.c.
electrode positive (d.c.e.p) polarity
shall be used.
An increasing tendency towards use
of d.c electrode negative (d.c.e.n) for
polarity for root runs of pipe of all
diameters is noted. Where a
contractor proposes use of d.c.e.n the
welding procedure qualification test
shall include this feature. Arbitrary
change from d.c.e.p to d.c.e.n. or vice
versa is not permissable.
(j5)
Any change in heat input outwith the

limiting values calculated from values
of arc voltage (j2), wire feed speed (j3)
and travel speed (j4) or considered
significant by BP.
Heat input
(l) Direction of welding
DRAFT
For all tie-ins (closing welds), all welds

where external line-up clamps are
used, and for all repair welds, verticalup welding shall be used for the root
runs. For pipe diameters less than 150
mm and for all welds to valves, flanges
or fittings including fillet welds, the
GS 118-10
PAGE 8
complete weld shall be vertical-up.
(o) Time lapse
When vertical-down welding is

employed between runs the second run
(hot pass) shall be deposited
immediately after completion of the
root run (stringer bead), and the time
lapse shall not be greater than that
used in the welding procedure
qualification test.
(p) Partially completed joint
Welds shall not be cooled below

preheat temperature before:For pipe to pipe welds onshore
4 runs minimum completed.
For welds offshore.
completed.
All
runs
For welds on fittings, tie-in welds and

repair welds. All runs completed.
(q) Type of line-up clamp if used
For pipe over 150 mm diameter an

clamp, internal line-up clamp shall be
used.
Where the use of an internal clamp is
impracticable, an external line-up
clamp shall be used.
(r) Lowering-off or barge move-up as The pipe shall not be lowered-off

applicable
until both the root pass and the
second pass are complete, unless the
contractor can demonstrate to the
satisfaction of BP that the root run
alone is adequate to resist deformation
and cracking. For offshore pipelay,
barge move-up shall not occur until the
hot pass is complete
(t6) Interpass temperature
DRAFT
Interpass temperature in construction

shall not exceed the maximum value
achieved in the welding procedure
qualification test, which in any case
shall not exceed 250C.
GS 118-10
PAGE 9
(t7) Ambient temperature
Minimum ambient temperature below

which preheating is to be applied.
(u) Post weld heat-treatment
The temperature range of any PWHT

shall be selected, taking into account
the
steel
composition
and
manufacturing route.
The PWHT
temperature, time and method of
application
used
in
pipeline
construction shall fall within the range
used in the welding procedure
qualification test.
2.5
Testing of Butt Joints for Procedure Qualification.
2.5.1
Non-destructive Testing
All test joints shall be examined visually followed by:(i)
Radiography in accordance with clause 5.4.
(ii)
Ultrasonic examination in accordance with clause 5.5.
(iii)
A magnetic particle test in accordance with clause 5.7 at

external and internal weld surfaces.
The acceptance criteria for non-destructive testing shall be in

accordance with clause 6.1.
2.5.2
Destructive Testing
The following additional tests are required:-
2.5.2.1
Test Specimens
For pipe outside diameters up to and including 114.3 mm, two
transverse weld tensile test specimens shall be taken.
For pipe outside diameters up to and including 114.3 mm, two sets of
three Charpy impact specimens shall be taken at the 9 o'clock position.
For pipe outside diameters over 114.3 mm, two additional sets of three
specimens shall be taken at the 6 o'clock position.
When specified (separately) for severe duty pipelines, two sets of three
CTOD specimens shall be taken. An all weld tensile test to BS 709 :
DRAFT
GS 118-10
PAGE 10
1983 is also required on each weld from which CTOD tests are taken,
on material from a location as close as possible to the CTOD tests.
2.5.2.2
Transverse Tensile Test
2.5.2.2.1
Requirements
If any specimen breaks outside the weld at a tensile strength below the
specified minimum tensile strength, the material shall be considered
suspect and its physical properties shall be investigated before any
additional tests are made.
2.5.2.2.2
Method
The test specimens shall not be flattened before testing.
2.5.2.4
Hardness Survey
2.5.2.4.1
Requirements
In addition to the requirements of Table 4, where the pipeline service is
defined as sour, no individual hardness value shall exceed 248 HV10
(see BP Group RPSE GS 136-1).
2.5.2.4.2
Method
BP may require additional hardness surveys on macro-sections taken
from different locations.
A macro-photograph shall be supplied to show the location of all
hardness indents.
2.5.2.5
Charpy V-Notch Impact Test
2.5.2.5.1
Requirements
Unless otherwise specified by BP, the impact test temperature shall be
the minimum design temperature and energy requirements for the weld
shall be 40 J minimum average of three specimens and 30 J minimum
individual value.
2.5.2.5.2
Method
For pipe diameters up to and including 114.3 mm, one set of Charpy Vnotch test specimens shall be notched in the weld metal and the other in
the heat affected zone.
For pipe diameters over 114.3 mm, the additional sets of Charpy tests
at the 6 o'clock position shall be notched and tested as the other
samples.
DRAFT
GS 118-10
PAGE 11
For pipe wall thickness over 20 mm, both sets of test specimens at the 3
o'clock position shall be positioned at the weld root. One set of test
specimens shall be notched in the weld metal and the others in the heataffected zone. For weld metals, the percentage of shear area of each
fracture surface shall be estimated and reported. If the results are
inconsistent with the measured energy, BP may require further
investigation before approving the test results.
2.5.2.6
Crack Tip Opening Displacement (CTOD) Testing

Detailed CTOD testing was removed from BS 4515 when the 1996
edition was prepared, leaving only a minor note (3) to clause 2.5.2.5.1.
Exact CTOD requirements are not specified in this GS as these will be
dependent on each individual application. Where an Engineering
Criticality Assessment (ECA) approach is required as part of pipeline
design for installation or operation, it is the responsibility of each
project to define the ECA philosophy and specify the methodology for
CTOD testing and acceptance values according to its own needs.
It is suggested that use should be made of BS PD 6493 for any ECA philosophy. The
selection of material and sampling of each respective zone for CTOD testing shall
take into account the importance of identifying the zone of potentially lowest
fracture toughness. All CTOD tests shall be conducted in accordance with BS
7448: Part 2: 1998 at the minimum design temperature.
Where possible the specimens shall be full wall thickness, preferred geometry and
the pipe curvature shall not be machined from the sample. The exact notch
positions and geometry in the CTOD test samples should be subject to agreement
but should include the weld metal and the heat affected zone.
2.6
Testing of Fillet Welds for Procedure Approval
2.6.2.4
Hardness Survey
2.6.2.4.1
Requirements
In addition to the requirements of Table 4, where the pipeline service is
defined as sour, no individual hardness value shall exceed 248 HV10
(see BP Group GS 136-1).
2.6.2.4.2
A macro-photograph (or sketch) shall be supplied which shows the

locations of all hardness indents.
2.7
Testing of Repair Welds for Procedure Qualification

Section 2.7 of the new 1996 edition of BS 4515 deals with the testing of repair welds
for procedure qualification and is deemed to meet BPs general requirements
without a supplement.
DRAFT
GS 118-10
PAGE 12
3.
TESTING, QUALIFICATION AND APPROVAL OF WELDER

3.1
General
Welders qualification tests shall be witnessed by a BP representative.
3.5
Changes Affecting
Variables)
Qualification
and
Approval
(Essential
If the following additional item is changed, the welder using the new
procedure shall require re-approval:(f)
3.6
For manual metal-arc welding a change in electrode trade name.
Non-destructive Testing
For manual metal-arc, tungsten inert gas (TIG) and submerged-arc
welding the test weld shall be assessed by X-radiography as specified in
clause 5.4. For metal inert gas (MIG)/metal active gas (MAG), CO2
and non-shielded welding, the weld shall be assessed by X-radiography
to clause 5.4 and ultrasonic examination as specified in clause 5.5.
3.7
Destructive Testing
In addition to NDT, destructive testing shall be used for examination of
welds made by any process other than manual metal arc, TIG and
submerged arc.
3.8.
Retests
If, in the opinion of BP, An individual welder is responsible for a high
level of repairs in production, he/she shall be removed from the work
and shall undergo a re-training programme approved by BP before
being retested.
3.9
Records
The details of each welders approval test and test results shall be
recorded by the contractor and be available for inspection by BP. The
contractor shall submit all documentation relating to welder approval
tests to BP for approval prior to the welder commencing production
work. BP will specify the period for which records shall be maintained.
(The content and requirement for this may vary from project to project
and will be individually specified).
3.10.
Mechanized Welding
Welders for mechanised welding shall be approved for all parts of the
operation. The inspection, testing and re-testing of welds for approval
purposes and records shall be in accordance with the following:-
DRAFT
GS 118-10
PAGE 13
(i)
Visual examination to clause 3.6.
(ii)
X-radiography to clause 5.4.
(iii)
Ultrasonic examination to clause 5.5
(iv)
Destructive testing to clause 3.7.
(v)
Retests to clause 3.8.
(vi)
Records to clause 3.9.
The acceptance criteria for NDT shall be in accordance with 6.1.2.

4.
PRODUCTION WELDING
4.1.
Proximity of Welds
Branches, fittings and attachments shall be sited away from other welds
(including longitudinal and circumferential welds) on the pipeline. The
minimum separation between any two welds shall be the largest of the
diameter of the branch or fitting, six times the wall thickness of the
thicker component, or 150 mm.
No two circumferential welds shall be closer than the diameter of the
pipe, but if a pup piece is used to replace a defective section, its length
shall not be less than twice its diameter, unless otherwise approved.
4.2
Pipe End Preparation

The pipe end bevel may be specified by the contractor and shall be
suitable for the welding process to be used. In general, the API 5L
standard bevel will be considered suitable for manual welding
processes, but for thick-wall pipe or for certain types of GMAW
mechanised welding, an alternative compound bevel may be proposed.
The bevel design shall be subject to agreement by BP.
Manual cutting shall not be used for bevelling.
If the blending of burns, small score marks, indentations or other minor
imperfections within the joint area is agreed, then it shall be confirmed
by ultrasonic measurement that the remaining wall thickness is above
the allowable minimum.
Weld repairs to pipe ends shall not be permitted.
4.3.
Fusion Faces
Before welding, the pipe shall be cleaned inside and out using power
driven wire brushes, grinding or other method approved by BP, for a
minimum distance of 40 mm from the edge of the weld bevel.
DRAFT
GS 118-10
PAGE 14
4.4
Alignment
Where misalignment exceeds 1.5 mm, corrective action shall be subject
to the approval of the BP representative in each case. Hammering of the
pipe to obtain correct alignment should be kept to a minimum and shall
be carried out using only a bronze headed hammer. The mass of the
bronze headed hammer shall not exceed 5 kg. Any surface
contamination of the pipe surface from the hammering shall be
removed. Heat shall not be used for corrective purposes.
4.5
Line-up Clamps and Pipe Supports
4.5.1
Power operated internal clamps shall be used for pipe of over 150 mm
diameter, and they shall be demonstrated as capable of reducing the
maximum permitted out-of-roundness of the as-manufactured pipe
sufficiently to meet the alignment requirements of clause 4.4. External
clamps shall be used only when the root run is deposited by the verticalup technique.
4.5.2
For on-land pipelines, at least the root run and the second run shall be
completed before the pipe is lowered on to skids or, in the case of
fittings, the support is removed, unless the contractor is able to
demonstrate to the satisfaction of BP that the root run alone is adequate
to resist deformation and cracking.
4.6
Tack Welds
Tack welds are allowed for vertical up welding only. All tack welds
shall be deposited by approved welders and in accordance with the
welding procedure specification. Where pre-heat is required for the
root run, this shall be applied prior to tack welding and maintained until
the joint is completed.
4.8
Stray Arcs
Repair of stray arcs in sour service pipelines may be restricted by BP.
When repair is allowed this shall be bt grinding only. Repairs by
welding are not allowed.
If grinding to remove the effects of stray arcs reduces the wall thickness
below the minimum specified in the data sheet, the defective pipe
section shall be cut out and the pipe re-bevelled and re-welded. If a
pup piece has to be used to replace the defective section, its length
shall not be less than twice its diameter. Note that stray arcs are also
possible between the pipe and the return cable and shall be avoided by
good electrical connections.
DRAFT
GS 118-10
PAGE 15
4.9
Weather Conditions
When necessary, the end of the pipe shall be covered to prevent water
being channelled into the weld root. Windshields shall be used when
necessary.
4.10
Preheating and Post-weld Heat Treatment
4.10.2
Preheating
Except as permitted under clause 4.13, preheating shall be maintained
throughout the entire welding of the joint.
4.10.3
Post-weld Heat Treatment Temperatures

Thermocouples shall be used for recording post-weld heat treatment
temperature. As a minimum, thermocouples shall be placed at the 6 and
12 o'clock positions. For pipe sizes above 600 mm outside diameter,
thermocouples shall also be placed at the 3 and 9 o'clock positions. The
pipe shall be heated for a minimum distance of 2.5 Rt (where R is the
external radius and t is the wall thickness) on either side of the joint.
The temperature at the edge of this heated band shall not be less than
half the peak temperature at the centre (in C).
4.10.4
Thermocouple Attachment and Junctions

Thermocouples shall be attached by the capacitance discharge method.
After use, thermocouples shall be removed by grinding and the area
shall be examined by magnetic particle inspection as for a stray arc.
4.11
Branches
Unless otherwise approved by BP, forged fittings shall be used for
branches and other pressure containing attachments. To simplify the
welding of some large fittings such as tees or elbows into the line, a
'pup' piece may be welded to the fitting and the length of such pup
pieces should be sufficient to accommodate the line-up clamp to be
used. Other large fittings may be girth welded directly into the pipeline
provide that wall thickness of the fitting and pipe are reasonably
matched and that suitable clamping can be accommodated.
Items such as weld-o-lets may be welded directly on to the pipeline,
using the appropriate qualified procedures. Large weld-o-lets and heavy
fittings may require special support, particularly when welded on to thin
section pipelines.
Where accessible, all welds to valves, flanges and fittings shall be
ground back smooth internally prior to radiography.
DRAFT
GS 118-10
PAGE 16
4.12
Inter-run Cleaning
Each run shall be thoroughly cleaned by power tools.
4.13
Partially Completed Joints

(i)
Land Pipelines
The welding of fittings, tie-ins and repairs shall be completed in
one cycle. When production conditions are such that pipe-topipe joints have to be left partially completed, at least four weld
runs shall be completed prior to cooling unless a procedure
qualification test involving fewer runs has been carried out.
(ii)
Submarine Pipelines and land pipelines in construction on steep

gradients.
All welds shall be completed in one cycle.
DRAFT
GS 118-10
PAGE 17
5.
INSPECTION AND TESTING

5.1
Inspection and Testing
5.1
General
The frequency of non-destructive testing shall be as specified under the
separate clauses 5.4, 5.5 and 5.7.
Prior to examination of the weld, each joint shall be thoroughly cleaned
using power driven wire brushes. All spatter, bonding media and any
inks or dyes used for crack detection, shall be removed. The completed
weld shall be examined visually prior to being examined by radiography.
Ultrasonic and magnetic particle flaw detection testing equipment shall
be available to supplement radiography on any area nominated by BP.
When automatic and semi-automatic welding systems have been
approved by BP, ultrasonic testing shall be required to supplement
radiography. The extent of this testing will be specified by BP.
5.2
Personnel Qualification
All inspection personnel shall be experienced in the appropriate
inspection and control and control techniques and shall hold current,
valid certificates demonstrating approval to either BGAS Transco,
CSWIP or PCN systems.
Note that the BGAS Transco and CSWIP examinations are run by TWI Training &
Examinations Dept. The Certification body for CSWIP is TWI Certification Ltd,
Granta Park, Great Abington, Cambridge, UK. PCN is administered by the British
Institute of Non-Destructive Testing (BINDT) at Northampton, UK).
Both Institutes are able to verify the validity of individual certificates. Certificates
are issued for specific periods only and an out-of-date certificate is invalid. Care
should be taken to ensure that the certificate and approval category covers
competence in the required skills for the job. e.g. BGAS Transco Senior Pipeline
Inspector covers welding inspection and radiographic interpretation, but CSWIP
welding inspector and radiographic interpreter are discrete and different
categories.
5.4
Radiographic Testing
5.4.1
General
100% radiographic testing is required in the following cases:-
DRAFT
(a)
All welds in severe duty pipelines.
(b)
All welds between pipes of different nominal bore.
GS 118-10
PAGE 18
(c)
All welds to valves, flanges and fittings.
(d)
All tie-ins (closing welds).
(e)
All welds in river and other crossings.
On a pipe-lay barge, the weld shall not be moved past the weld repair
station until the interpretation of the radiograph is complete and the
weld is judged satisfactory. Unless otherwise approved by BP, coating
and wrapping of the joint shall not begin until the weld is judged
satisfactory.
For normal duty pipelines, the first five welds of each thickness and
diameter made by each welder shall be 100% radiographically tested. If
any of these welds requires a repair, all subsequent welds by the same
welder shall be 100% radiographically tested until five consecutively
produced welds are judged to be satisfactory. Thereafter, BP will select
at least one weld from every ten welds, and radiograph this 100%. If
any of these one-in-ten welds should require repair, BP will require
some or all of the other nine to be radiographed 100%.
BP may specify 100% radiography for some normal duty pipelines.
Radiography shall be conducted using X-rays.
Under certain
circumstances BP may approve the use of Iridium 192, but other
sources of gamma rays are not permitted.
As exposure of any part of the human body to X-rays or gamma rays
can be injurious, it is essential that whenever X-ray equipment or
radioactive sources are in use, adequate precautions are taken to
protect the radiographer and all other personnel in the vicinity.
Note 1. The use of X-ray machines and gamma-radiography sealed sources in
factories and certain other premises and works coming within the scope of the
Factories Act is controlled by the Ionising Radiations (Sealed Sources) Regulations
1969 and th Radioactive Substances Act (1960).
Note 2. Attention I is drawn to the Code of Practice for Site Radiography prepared
by the Oil and Chemical Plant Contractors Association and published by KluwerHarrap Handbooks, Brentford. Attention is also drawn to the need for audible and
visual warning arrangements and for regular monitoring of radiation levels.
The above paragraph and two notes formed section 37.2 Protection of BS 4515:
1984 - but were not included in BS 4515:1996. The proposal of WEE/21/7 was that
the warning should be covered in separate regulations, rather than in the base
standard for pipeline welding but, as it is uncertain where such warnings are
covered elsewhere, it is deliberately included in this BP GS.
5.4.2
Approved Radiographic Procedures

The following details shall be included in the radiographic procedure.
(The following items were additional to section 37.3 of BS 4515: 1984 but the
format of the whole section - now 5.4.2 of BS 4515: 1996 has changed, the list has
DRAFT
GS 118-10
PAGE 19
been dropped and reference has been made to BS 2910. In 1997, BS 2910 was
superseded by BS EN 1435. Amendment No 1 of this GS draws on BS EN 1435 in
respect of the following details of radiographic technique and assessment of
radiogrpahic sensitivity. .
5.4.3
(a)
technique
Radiographic techniques shall be in accordance

with BS EN 1435 Class B (Improved
techinques). The preferred technique for
radiographic examination of pipeline girth welds
is film outside with the source of radiation inside
the pipe.(BS EN 1435 Para 6.1.4 and Figure 5).
Exceptionally, where the preferred technique is
not practicable, a double wall single image (BS
EN 1435 Para 6.1.8 and Fig 13) may be
considered
(b)
type of film
Fine grain, high contrast, direct type BS EN 5841 Class C3 or better.
(c)
intensifying
screens
Lead screens shall be used, unless fluorometallic

screens have been approved by BP Amoco.
(d)
limit of film
The limit of diagnostic film coverage length for

pipes over 1 metre in diameter shall not exceed
one third of the pipe circumference. (BS EN
1435 Para 5.6)
(e)
Image quality A wire-type image quality indicator* (IQI)

indicator
conforming to BS EN quality 462-1: 1994 shall
be used. (* Also termed penetrameter). The IQI
shall be used in accordance with placement
directions in Para 5 of BS EN 462-1: 1994.
(f)
Processing
All radiographic film shall be dried thoroughly

prior to viewing and shall be processed to allow
storage of the film without deterioration for a
period of at least five years.
Acceptable Radiographic Sensitivity Levels

Radiographic sensitivity is expressed as a percentage, and is defined by
the ratio of the diameter of the smallest IQI wire clearly visible on the
radiograph to the material thickness. The radiographic sensitivity
achieved for the single wall single image (SWSI) techniques shall be as
defined by Table B3 of BS EN 1435 and for the double wall single
image (DWSI) technique, as defined by Table B11.
Gamma-radiography is not normally acceptable where the pipewall
DRAFT
GS 118-10
PAGE 20
thickness is below 12 mm and its use shall be subject to approval by

BP.. If approved, sensitivity levels will be specified by BP.
The radiographic procedure shall be repeated at the discretion of BP
whenever any change is made to the operating techniques, or whenever
production films differ appreciably from the detail, contrast, or density
of the qualifying radiographs.
5.5.
Manual Ultrasonic Testing
5.5.1
General
BP will require ultrasonic testing of the following areas:-
5.5.4
(a)
Following field cut back of pipe, a zone extending 100 mm back

from the new field bevel shall be ultrasonically tested for
laminations.
(b)
A zone 100 mm wide around the planned cut-outs of nozzles for

laminations.
(c)
To verify minimum wall thickness.
(d)
To verify defects found by radiography.
(e)
Additional welds and areas as requested by BP, including welds

involving the use of automatic and semiautomatic welding
systems.
Reporting and Evaluation - Testing of Pipe Material

The acceptance criteria for ultrasonic examination within the pipe ends
and at the planned cut-outs for nozzles shall be to quality grade B4
given in Table 1 of BS 5996, unless an alternative quality has been
agreed with BP.
5.6.
Automatic Ultrasonic testing.

The use of automatic ultrasonic testing shall be subject to the approval
of BP in each instance.
5.7
Magnetic Particle Testing

The following welds shall be tested using the magnetic particle flaw
detection method:
DRAFT
(a)
All repair welds.
(b)
All welds to fittings.
GS 118-10
PAGE 21
(c)
All fillet welds.
(d)
In severe duty pipelines, the finished weld bevel shall be

magnetic particle flaw detected following field cut back of pipe.
Electromagnetic (a.c.) yoke and/or adjacent cable techniques are

preferred. Permanent magnets or prods shall not be used without prior
BP approval.
5.8
Destructive Testing
BP will require completed welds to be removed for testing if there is
any suspicion that they have not been produced strictly in accordance
with the approved procedure. The contractor may attempt to guard
against this eventuality by qualifying welding procedures at the extreme
parameters which the welders may consider using.
The above requirement which related to 36.3 of BS 4515: 1984 was not included in
BS 4515: 1996 but is retained in this BP GS as the qualification of a welding
parameter range is routinely carried out.
DRAFT
GS 118-10
PAGE 22
6.
ACCEPTANCE AND RECTIFICATION OF WELDS

6.1
Non-Destructive Testing Acceptance Criteria
6.1.1
General
The acceptance criteria for non destructive testing shall be in
accordance with 6.1.2.
Acceptance criteria based on engineering critical assessment to clause
6.1.3 of BS 4515:1996 do not apply to this Standard except in specific
instances, where the design of the pipeline specifies ECA in accordance
with PD 6493.
6.1.2
Acceptance Criteria Based on Quality Control

In areas of weld preparation such as pipe ends, fusion faces and
branches, planar defects are not acceptable.
TABLE 8. Acceptance Criteria for Welds
The following limits on acceptance modify those given in BS
4515:1996:Flaw type
DRAFT
Acceptance Criteria
(c) Root penetration
Not to exceed 1.5 mm for pipe

diameters less than 60 mm.
(d) Root concavity
At no point shall the weld be thinner

than the calculated design thickness of
the pipe.
(e) Root undercut
BP may specify further limitations for

root undercut and shrinkage groove for
pipelines in sour service.
(f) Incomplete root
These defects are unacceptable in sourpenetration service pipelines.
(h) Cap undercut
Undercut exceeding 0.5 mm in depth is

unacceptable in severe duty and shall
be blended out by light grinding prior
to radiography.If this reduces the pipe
wall thickness below the specified
minimum, the entire circumferential
weld shall be cut out and bevelled and
re-welded.
GS 118-10
PAGE 23
(j) Porosity (other than elongated Not to exceed a total area, when
porosity in the root run)
projected radially through the weld of
1% of any 600 mm2 of projected weld
area. An isolated pore greater than
20% of the pipe thickness or 1.5 mm,
whichever is the smaller, in any
direction,
shall
be
considered
unacceptable.
(k) Tungsten inclusions
6.1.3
Tungsten inclusions shall not exceed

two per weld and shall be separated by
a minimum of 50 mm
Acceptance Criteria Based on Engineering Critical Assessment

Not applicable to this BP Group GS unless the design of the pipeline
specifies ECA in accordance with BS PD 6493.
6.2
Rectification of Welds
6.2.2
Preparation for Re-welding
6.2.2.1
Partial Removal of Weld

Defects shall be removed by grinding and the repair excavation checked
by magnetic particle inspection to ensure complete removal of the
defect. Cracked welds shall be cut out and the weld re-made
6.2.3
Re-welding
Root sealing or single run repairs shall not be practised. There shall be
no internal welding on sour service pipelines. For severe duty pipelines
a repair shall only be attempted once, thereafter the weld shall be
completely removed. For normal duty pipeline a second repair may be
made. If this second repair fails to meet the requirements of clause 6.1
the entire circumferential weld shall be cut out and re-bevelled.
For offshore pipe-lay of submarine pipelines, the limits on size and
location of proposed weld repair excavations beyond the final tensioner
shall be submitted to BP for approval, supported with calculations and
appropriate diagrams.
NOTE: Stresses imposed by construction techniques existing at the time of making a
repair such as at a lay-barge repair station, may be such that to remove 20% of the
weld length may render this operation unsafe. In such cases, the permitted length of
a repair should be reduced to ensure that the stress applied to the weld under repair
does not exceed 80% of the specified yield stress of the pipe.
A full record of all repairs shall be maintained by the contractor. The

record shall be made as each defect is discovered, and shall include the
following:
DRAFT
GS 118-10
PAGE 24
DRAFT
(i)
The weld number.
(ii)
The type and size of defect.
(iii)
The circumferential location (defined to an approved system).
(iv)
An estimate of the depth (assessed by ultrasonic test where

possible).
(v)
Name and/or number of the welder who produced the defect.
(vi)
Repair welding procedure number.
(vii)
Name and/or number of repair welder.
(viii)
Copy of the inspection report for the repair.
(ix)
Date of repair.
GS 118-10
PAGE 25
ANNEX C TO BS 4515 (INFORMATIVE).

PROPOSED WELDING PROCEDURE SPECIFICATION
There are no requirements additional to BS 4515:1996. The contractor may propose
alternative format welding procedure specification forms to those shown in Annex C of
BS 4515:1996 but any alternative shall be subject to approval by BP.
ANNEX D TO BS 4515. (INFORMATIVE)

EXAMPLE OF A RECORD FORM FOR WELDER QUALIFICATION TEST.
There are no requirements additional to BS 4515:1996. The contractor may propose
alternative format welding procedure specification forms to those shown in Annex D of
BS 4515:1996 but any alternative shall be subject to approval by BP.
ANNEX E TO BS4515. (INFORMATIVE) GUIDANCE FOR ESTABLISHING

PREHEATING REQUIREMENTS
This informative annex is for guidance only. Where necessary the contractor shall
undertake trials to establish an adequate level of preheat to ensure compliance with the
requirements of this standard. The precise preheat level shall be as proven satisfactory
by the welding procedure qualification test. A minimum preheat of 150C shall apply to
the welding of fittings, repair welds and tie in welds.
ANNEX F TO BS 4515. EXAMPLE OF A RADIOGRAPHIC SPECIFICATION

There are no requirements additional to BS 4515. Any specification of alternative
format shall be subject to approval by BP.
DRAFT
GS 118-10
PAGE 26
APPENDIX A
DEFINITIONS AND ABBREVIATIONS
Definitions
Standardised definitions may be found in the BP Group RPSEs Introductory Volume.
Other definition which supersede, qualify or are an addition to Section 1.3 of BS 4515:1996
are found in the corresponding section of this standard
Abbreviations
API
American Petroleum Institute
BGAS Transco
A qualification and certification system, formerly known as ERS, for

pipeline inspection personnel, originally instituted and run by the former
British Gas Engineering Research Station, Killingworth, UK. Now
known as BG Approval Scheme and managed by TWI Certification Ltd
for Transco
BS
British Standard
CSWIP
Certification Scheme for Welding and Inspection Personnel managed by

TWI Certification Ltd Granta Park, Great Abington, Cambridge, UK
CTOD
Crack Tip Opening Displacement
DIN
Deutsches Institut fur Normung
GMAW
Gas Metal Arc Welding
HV
Vickers hardness
MAG
Metal Active Gas
MDT
Minimum design temperature
MIG
Metal Inert Gas
NACE
National Association of Corrosion Engineers
NDT
Non-Destructive testing
PCN
Personal Certification in Non-Destructive Testing ( a scheme for the

qualification of non-destructive testing and inspection personnel
DRAFT
GS 118-10
PAGE 27
managed by The British Institute of Non-Destructive Testing (BINDT)

Northampton, UK
PWHT
Post Weld Heat Treatment
SI
Systeme International d'Unites
TIG
Tungsten Inert Gas
TWI
The Welding Institute, Granta Park, Great Abington,

Cambridge CB1 6AL, UK
.
UNITS
This Standard employs SI metric units.
WEE/21/7
British Standards Sub-Committee responsible for BS 4515
DRAFT
GS 118-10
PAGE 28
APPENDIX B
LIST OF REFERENCED DOCUMENTS
A reference invokes the latest published issue or amendment unless stated otherwise.
Reference standards may be replaced by equivalent standards that are internationally or
otherwise recognised provided that it can be shown to the satisfaction of the purchaser'
professional engineer that they meet or exceed the requirements of the referenced standards.
American Standards
API Standard 1104
Standard for welding pipelines and related facilities
British Standards
BS 709:1983
Methods of destructive testing fusion welded joints and weld metal in

steel.
BS 3971:1980/(1985) Specification for image quality indicators for industrial

radiography(including guidance on their use)
* Partly replaced by BS EN 462-2:1994
BS 639: 1986
Covered carbon and carbon manganese steel electrodes

for manual metal-arc welding (The former standard BS 639 has been
withdrawn and is superseded by BS EN 499:1995. However, reference
to the former BS 639 is retained here for the method of testing specified
in Appendix C)
PD 6493:1991
Guidance on methods for accessing the acceptability of flaws in fusion

welded structures.
BS 4515: 1996
Specification for process of welding of steel pipelines on land and

offshore
BS 5996: 1993
Specification for acceptance levels for internal imperfections in steel

plate, strip and wide flats, based on ultrasonic testing.
BS 7448 Part 1: 1991: Fracture mechanics toughness tests. Part 1 Method for determination
of K1c, critical CTOD and critical J values of metallic materials
BS 7448 Part 2: 1998 Fracture mechanics toughness tests. Part 2 Method for determination
of fracture toughness of weldments in metallic materials.
BS EN 439: 1994
DRAFT
Welding Consumables - Shielding Gases for Arc Welding and Cutting
GS 118-10
PAGE 29
BS EN 462-1: 1994
Image quality indicators (wire type). Determination of image quality

value. * Partly replaces BS3971: 1980 (1985)
BS EN 462-2: 1994
Image quality indicators (step/hole type). Determination of image

quality value. * Partly replaces BS3971: 1980 (1985)
BS EN 499: 1995
Welding consumables. Covered electrodes for manual metal arc welding

of non-alloy and fine grained steels. Classification.
BS EN 584-1: 1995
Non-destructive testing - Industrial radiographic film. Part 1.

Classification of film systems for industrial radiography.
BS EN 1435:1997
Non-destructive examination of welds. Radiographic examination of

welded joints
BS EN ISO 9002: 1994 Quality systems. Model for quality assurance in production,
installation and servicing.
BS EN ISO 9003: 1994 Quality systems. Model for quality assurance in final inspection and
test.
BP Group RPSE
GS 136-1
Materials for sour service to NACE Standard MR-01-75 (1990

Revision)
Note latest NACE MR-01-75 is 1998 Revision
GS 118-4
Storage and control of welding consumables
GS 118-9
Welding of transmission pipelines. Part 2.

Supplementary to API Standard 1104
DRAFT
GS 118-10
PAGE 30
German Standard
DIN 54 109 : Part 1 Nondestructive testing; image quality of radiographs of metallic
materials; definitions, image quality indicators, determination of image
quality index
Note:
1.
The definitions for employer and inspector replace those given in BS 4515:1996.
DRAFT
GS 118-10
PAGE 31
APPENDIX C
Alternative Technique for Batch Testing of Welding Consumables
Batch tests of welding consumables are not intended to undertaken as a routine measure for all
pipelines, but may be required by BP for certain offshore pipelay operations and land-based
pipelines designed for certain categories of critical service. When batch testing is specified by
BP it shall be carried out in accordance with this Appendix by the consumable manufacturer
rather than by the pipe-welding contractor. All batch test welds shall be made as all-weldmetal deposits as defined in former standard BS 639: 1986. In the following list of steps, the
illustrative results (given in parenthesis) refer to this Addendum, Figure C1 :(i)
BP will define the Charpy test requirements for the welding procedure qualification
test (Average 50 J at -10C).
(ii)
The contractor shall obtain acceptable results from the welding procedure qualification
test at mid-wall thickness (Average 80 J at -10C).
(iii)
The consumable supplier shall prepare an all-weld-metal deposit using the same batch
of consumables that was used in the welding procedure qualification test. Where more
than one size of consumable is used, a separate deposit should be made for each size.
Consumables used for the root run only do not require batch testing.
(iv)
The consumable supplier shall test a set of three Charpy test pieces, of the same size as
those taken from the welding procedure qualification test, at the temperature of the
welding procedure qualification test (Average 160 J at -10C).
(v)
The consumable supplier shall test further sets of three Charpy test pieces, decreasing
temperature by -10C per set, until the average falls below that specified for the
welding procedure qualification test:150 J at -20C
140 J at -30C
90 J at -40C
40 J at -50C
(vi)
By interpolation, the temperature will be found, at which the all-weld-metal deposit

gives the same energy as that measured in the welding procedure qualification test
(-42C).
(vii)
All batch tests shall be carried out at this temperature, against the same energy
requirement as that specified for the welding procedure qualification test (50 J).
DRAFT
GS 118-10
PAGE 32
FIGURE C1
Procedure for Establishing Batch Test Requirement
DRAFT
GS 118-10
PAGE 33

GS 118-10 Welding of Transmission Pipelines: Supplementary To BS 4515: 1996 December 1998 (Amended February 2000)

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GS 118-10 Welding of Transmission Pipelines: Supplementary To BS 4515: 1996 December 1998 (Amended February 2000)

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GS 118-10

Copyright The British Petroleum Company p.l.c.

Copyright The British Petroleum Company p.l.c.

BP GROUP RECOMMENDED PRACTICES AND SPECIFICATIONS FOR ENGINEERING

Latest Amendment Date

SUPPLEMENTARY TO BS 4515: 1996

SCOPE AND PURPOSE

Approved for issue:December 1998

CUSTODIAN (See Current Status List for Contact)

Engineering Practices Group, BP International Limited, Research & Engineering Centre

FOREWORD ..................................................................................................................... iii

4.13 Partially Completed Joints.......................................................................................17

Feedback and Further Information

Scope and General Applicability

This BP Group RPSE specifies general BP requirements for the welding

BP Group GS 118-10 is applicable where statutory regulations require

BP, acting directly or through an authorised

a contractor responsible BP for the welding of the

an employee of the contractor with overall

responsibility for ensuring that all construction,

a single cast of filler wire, a single blend of flux, or, for

pipeline service which is to be defined by BP as

to be defined by BP as either sour or non-sour (see

quality assurance (QA):

quality plan (QP)

Information to be supplied, items to be approved and

Information to be Supplied by the Employer

Test pressure for pipeline field hydrostatic test

The pipeline duty and service.

Requirement for Charpy testing of welding consumables on

Whether any change in heat input is considered significant.

Whether additional hardness surveys on macro-sections are

Alternative Charpy test temperatures.

Use of fluorometallic screens.

Sensitivity levels for gamma radiography.

Welds and areas requiring ultrasonic testing

Further limitations on root undercut and shrinkage groove for

Items to be Approved by the Employer

Use of automatic and semi-automatic welding systems (See 1.6)

Quality plan prior to production welding. (See 1.8.3)

Acceptance of batch testing failure before re-tests are allowed.

Acceptance of re-welding in procedure qualification tests (See

Acceptance of material grouping. (See 3.5)

Acceptance of diameter and thickness group combination.

Acceptance of Charpy V-notch impact test results.

Acceptance of pipe diameter or wall thickness changes.

Welder re-training programme. (See 3.8).

Alternative 'pup' piece length. (See 4.1)

Angle of field bevel if different from mill bevel. (See 4.2)

Alternative method for pipe end cleaning. ( See 4.3)

Corrective action for misalignment. (See 4.4)

Use of fabricated fittings. (See 4.11).

Use of Iridium 192. (See 5.4.1)

Use of gamma-radiography. (See 5.4.2)

(xvii) Use of permanent magnets or prods. (See 5.7)

Use of wall thickness and pipe diameter grouping for welder

Storage and handling.

Shielding Gases - General

Shielding Gases - Storage and Handling

Welding Consumables for Fillet Welds

Basic coated low hydrogen electrodes or other approved low hydrogen

Supervision of the Work

Field Hydrostatic Test