Welding and NDT

Specification
Experience that Delivers
Prepared for: TAQA
Welding and NDT of 22%Cr Duplex Stainless

Steel Pipelines, Flanges and Fittings
November / 2010
Experience that Delivers
TAQA
FALCON DEVELOPMENT
WELDING AND NDT OF 22%CR DUPLEX
STAINLESS STEEL PIPELINES,
FLANGES AND FITTINGS
06-2915-U-1013
Specification
FAL-W-ST-0006
51
J P Kenny Caledonia Limited

Caledonian House
234 Union Street
Aberdeen
AB10 1TN
Tel: +44 (0) 1224 347300
Fax: +44 (0) 1224 347301
http://www.jpkenny.com
01
08/11/2010
ISSUED FOR COMMENT
CF
JM
SR
CBN
COMMENTS SHEET
REVISION
01
DATE
08/11/2010
COMMENTS
ISSUED FOR COMMENT
JPK Doc.No. 06-2915-08-U-1-013 Rev 01

Client Doc. No. FAL-W-ST-0006
TAQA
Falcon Development
Welding and NDT of 22%Cr Duplex Stainless Steel
Pipelines, Flanges and Fittings
Table of Contents
1.0
INTRODUCTION ...................................................................................................... 5
1.1
General ......................................................................................................................... 5
1.2
Development Overview ................................................................................................ 5
1.3
Scope............................................................................................................................ 6
1.4
Safety............................................................................................................................ 6
1.5
Definitions ..................................................................................................................... 6
1.6
Abbreviations ................................................................................................................ 6
1.7
HSEQ for Pipeline Welding Operations........................................................................ 8
1.8
Pre- Production Consultation........................................................................................ 8
1.9
Duties of the Contractor................................................................................................ 9
1.10
Quality Conformance .................................................................................................... 9
1.11
Records......................................................................................................................... 9
1.12
Contractors Personnel .................................................................................................. 9
2.0
APPLICABLE CODES AND STANDARDS........................................................... 11
2.1
Revisions .................................................................................................................... 11
2.2
Conflict of Information................................................................................................. 11
2.3
Referenced Documents.............................................................................................. 11
2.4
Codes and Standards ................................................................................................. 11
2.5
Referenced Standards................................................................................................ 11
3.0
MATERIALS........................................................................................................... 14
3.1
Materials ..................................................................................................................... 14
3.2
Materials Storage........................................................................................................ 14
4.0
WELDING PROCESSES ....................................................................................... 16
4.1
General ....................................................................................................................... 16
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4.2
Welding Consumables................................................................................................ 16
5.0
TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES

FOR BUTT AND FILLET WELDS.......................................................................... 18
5.1
General ....................................................................................................................... 18
5.2
Records....................................................................................................................... 18
5.3
Welding Procedure Qualification Testing ................................................................... 19
5.4
Changes Affecting Qualification and Approval (Essential Variables)......................... 19
5.5
Testing of Butt Joints for Procedure Qualification ...................................................... 23
5.6
Testing of Fillet Welds for Procedure Qualification .................................................... 29
5.7
Testing of Repair Welds for Procedure Qualification Destuctive Testing ............... 30
5.8
Dissimilar Welds ......................................................................................................... 30
6.0
TESTING QUALIFICATION AND APPROVAL OF WELDERS............................. 31
6.1
General ....................................................................................................................... 31
6.2
Butt Joints ................................................................................................................... 31
6.3
Changes Affecting Qualification and Approval (Essential Variables)......................... 31
6.4
Non-Destructive Testing ............................................................................................. 32
6.5
Destructive Testing ..................................................................................................... 32
7.0
PRODUCTION WELDING ..................................................................................... 35
7.1
Proximity of Welds ...................................................................................................... 35
7.2
Pipe End Preparation.................................................................................................. 35
7.3
Fusion Faces .............................................................................................................. 35
7.4
Alignment .................................................................................................................... 35
7.5
Tack Welds ................................................................................................................. 35
7.6
Stray Arcs and Earthing.............................................................................................. 36
7.7
Weather Conditions .................................................................................................... 36

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7.8
Preheating, Inter-Pass Temperature and Post Weld Heat Treatment ....................... 36
7.9
Branches..................................................................................................................... 37
7.10
Inter-run Cleaning ....................................................................................................... 37
7.11
Partially Completed Joints .......................................................................................... 38
7.12
Purge Gas Monitoring................................................................................................. 38
7.13
Temporary Attachments ............................................................................................. 38
7.14
Records....................................................................................................................... 38
8.0
INSPECTION AND TESTING OF PRODUCTION WELDS................................... 40
8.1
General ....................................................................................................................... 40
8.2
Personnel Qualification............................................................................................... 40
8.3
Visual Inspection......................................................................................................... 40
8.4
Radiographic Testing.................................................................................................. 41
8.5
Ultrasonic testing ........................................................................................................ 43
8.6
Liquid Penetrant Examination..................................................................................... 45
9.0
ACCEPTANCE AND RECTIFICATION OF WELDS ............................................. 46
9.1
Non-Destructive Testing Acceptance Criteria ............................................................ 46
9.2
Rectification of Welds ................................................................................................. 46
10.0
DOCUMENTATION................................................................................................ 48
10.1
General ....................................................................................................................... 48
10.2
Documentation to be Provided with Tender ............................................................... 48
10.3
Documentation Required Prior to Commencement of Work...................................... 48
10.4
Documentation Required on Completion of WORK ................................................... 48
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Index of Figures
Figure 1.1 Northern North Sea Assets........................................................................................... 5
Figure 5.1 Location of Test Specimens ....................................................................................... 25
Index of Tables
Table 5.1 Welding Procedure Specification Details and Changes affecting Approval ................. 20
Table 5.2 Number of Specimens for Procedure Qualification Tests on Butt Joints ..................... 24
Table 5.3 Impact test Requirements (10mm x 10mm sample) ..................................................... 27
Table 5.4 Energy Reduction Factors for Reduced Size CVN Specimens ................................... 27
Table 6.1 Acceptance criteria for Welds ...................................................................................... 32
Table 8.1- Acceptable Radiographic Sensitivity Levels (Using Wire Type IQI to ASTM E747 or BS
EN 462-1) ................................................................................................................................ 44
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1.0
INTRODUCTION
1.1
General
The Taqa owned Northern North Sea assets comprise various subsea field developments
and surface facilities situated 100 to 150km North East of the Shetland Islands in a water
depth of approximately 160m.
The Falcon Field (Block 210/25a) is located within the Northern North Sea assets,
approximately 8km north east of the Tern platform. Falcon comprises two reservoir blocks
(south & north), where one appraisal well (210/25a-9) was drilled in 2000 on the South
block, whilst a second well (210/25a-10z) was drilled in April 2010 on the North block.
It is proposed that Falcon be developed as a subsea system, where the suspended well
210/25a-10z, will be completed as production well FA-P1. Production from this single well
will be routed via Kestrel to the Tern platform process systems. Lift gas from Tern will be
supplied to the production well through the Kestrel gas lift system. Control of the new
production well and provision of injection chemicals will be through an extension to the
existing Kestrel control and injection systems.
Water injection is not planned for this initial development phase, but may be implemented
as part of a second phase.
Figure 1.1 Northern North Sea Assets

1.2
Development Overview
The development plan for Falcon requires drilling and completion of 1 production well
(210/25a-10) at the Falcon drill centre, tied back approximately 4km to the Kestrel P2
production well via flexible production and gas lift flowlines. Controls and chemical
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injection for Falcon well 210/25a-10 will also be tied back approximately 4km to the existing
Kestrel controls system via a dedicated electro-hydraulic control umbilical. There is no
capacity in the existing Kestrel EHC to deliver corrosion inhibitor, therefore none will be
delivered to Falcon well 210/25a-10.
1.3
Scope
This specification when read in conjunction with the referenced standards, specifications,
other listed documents and relevant data sheets, defines the minimum technical
requirements for the welding and NDT of Duplex linepipe, spools, flanges and fittings
(Bulkheads) in accordance with BS 4515-2: 1999.
Items are designated for sour service and shall hence meet the requirements of BS EN ISO
15156.
This document shall be read hereafter in conjunction with BS 4515-2; 1999 as clarified,
amended or supplemented below.
1.4
Safety
All risks to personnel and the environment resulting from the Taqa Falcon Development
should be As Low As Reasonably Practicable (ALARP). Safety is the primary consideration
during design and all risks associated with the design shall be minimised by adhering to the
relevant governing design codes, and COMPANY procedural requirements.
1.5
1.6
Definitions
COMPANY
TAQA Bratani Ltd or any of its subsidiaries or representative agents.
CONTRACTOR
The Party contracted by COMPANY to carry out welding operations

on 22% Cr Duplex.
MANUFACTURER
The Material Supplier to the CONTRACTOR or vendor of material,

his representative or agent.
Shall
Indicates mandatory requirements.
Approval
Consent given in writing, on behalf of COMPANY, in advance of an

event, by a person with appropriate authority. Approval by
COMPANY relieves CONTRACTOR neither from any of its
contractual obligations nor from having to make good any part of the
item to be delivered found to be defective subsequent to Companys
Approval.
Abbreviations
ACCP
ASNT Central certification Programme
ALARP
As Low as Reasonably Practicable
ANSI
American National Standards Institute
ASME
American Society of Mechanical Engineers
ASNT
American Society of Non-Destructive Testing
ASTM
American Society of Testing & Materials
AUT
Automated Ultrasonic Testing
AWS
American Welding Society

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BAM
Federal Institute for Materials Research and Testing (Germany)
BGAS CSWIP
British Gas Approval Scheme Certification Scheme for Welding and

Inspection Personnel
BS
British Standard
CEng
Chartered Engineer
Cr
Chromium
CRA
Corrosion Resistant Alloy
CSWIP
Certification Scheme for Welding and Inspection Personnel
CVN
Charpy V Notch
CWI
Certified Welding Inspector
DWE
Double Wall Examination
DWDI
Double Wall Double Image
DWSI
Double Wall Single Image
DN
Diameter Nominal
DPE
Dye Penetrant Examination
EN
European Norm
EWE
European Welding Engineer
FCAW
Flux Cored Arc Welding
GMAW
Gas Metal Arc Welding
GTAW
Gas Tungsten Arc Welding
HAZ
Heat Affected Zone
HSE
Health and Safety Executive
HSEQ
Health, Safety, Environmental and Quality
HV10
Vickers Hardness (10kg load)
ID
Internal Diameter
IQI
Internal Quality Indicator
ISO
International Standards Organisation
IWE
International Welding Engineer
LPE
Liquid Penetrant Examination
NB
Nominal Bore
MDT
Miniumum Design Temperature
MUT
Manual Ultrasonic Testing
MPQ
Manufacturing Procedure Qualification
NDT
Non Destructive Testing
NDE
Non Destructive Examination

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1.7
NIST
National Institute of Standards and Technology
NPS
Nominal Pipe Size
NDT
Non Destructive Testing
PCN
Personnel Certification in Non- Destructive Testing
PE
Professional Engineer
PQR
Procedure Qualification Record
PREn
Pitting Resistance Number
pWPS
Preliminary Weld Procedure Specification
OD
Outside Diameter
QA
Quality Assurance
QC
Quality Control
RT
Radiographic Testing
SAW
Submerged Arc Welding
SCWI
Senior Certified Welding Inspector
SI
Statutory Instrument
SMAW
Shielded Metal Arc Welding
SMYS
Specified Minimum Yield Strength
UTS
Ultimate Tensile Strength
UT
Ultrasonic Testing
VE
Visual Examination
HSEQ for Pipeline Welding Operations

Welding, cutting, NDT and associated operations shall be undertaken in a safe manner and
with due regard to individual health and safety, and the minimization of environmental
impact consistent with COMPANY requirements. Welding, Cutting and NDT activities, and
associated operations shall feature in CONTRACTORs operational safety planning and in
the safety audit schedule ANSI Z49.1 or similar codes shall be followed.
Measures shall be taken to ensure adequate ventilation and control the quality of breathing
air during welding operations.
As a minimum, radiography operations shall conform to the Ionising Radiation Regulations
1999 (SI 1999 No.3232) and the Approved Code of practice and Guidance- Working with
Ionising Radiation 1999.
Environmental guidance shall be taken from EN14717 when undertaking welding and its
associated processes.
1.8
Pre- Production Consultation

Pre-production meetings shall be held with COMPANY and any appropriate third-party
inspection personnel in order to ensure that all parties fully understand the requirements of
this specification. These meetings shall be held before welding procedure qualification
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testing and before commencement of fabrication. The COMPANY welding engineer shall
be consulted at the following stages:
1. During bid evaluation to agree the basic welding and NDT methods proposed and to
advise on acceptability.
2. Before weld Procedure qualification for approval of the proposed welding procedures
(pWPS).
3. Before production welding for approval of the final WPS.
1.9
Duties of the Contractor

Construction, welding and pipe- lay shall be carried out by a workforce who has proven
experience in similar projects.
Unless advised otherwise by COMPANY, welding and associated equipment, including but
not limited to heating equipment, fluxes, gases, filler metals, welding units, mechanical
handling, testing equipment, and NDT equipment shall be supplied and appropriately
calibrated.
CONTRACTOR shall be responsible for the compliance of subcontractors with this
specification.
1.10
Quality Conformance
The CONTRACTOR shall demonstrate to the satisfaction of the COMPANY that his
activities within the scope of this document comply with ISO 3834 parts 1 & 2 and the
relevant sections of BS EN ISO 9001.
Prior to the commencement of work, the CONTRACTOR shall submit to the COMPANY for
review and Approval, a Quality Plan and procedural specifications, which shall include
procedures for storage and control of materials and welding consumables, welding and
non- destructive testing and supporting qualification records. The Quality Plan shall define
all sub-contractors involvement with the work.
Names of individual welding engineers/ welding inspectors responsible for implementation
of quality assurance and quality control functions shall be included, along with their CVs.
1.11
Records
Documents required by this specification shall be gathered, collated, indexed, stored and
finally presented to COMPANY for secure long term storage.
A log identifying, by number, each pipe or fitting and identifying the weld numbers joining
them to other items shall be compiled.
Each circumferential weld (whether field joint or shop-made weld) shall be allocated a
unique number, which shall be used for reference to the weld reports and in test
documents.
All documents shall be available in a format agreed by COMPANY.
1.12
Contractors Personnel
1.12.1 General
Personnel associated with welding including engineers, welders, welding operators,
welding inspectors and non destructive testing technicians shall be properly trained and
qualified to recognized standards by examination and/or by individual test.
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1.12.2 Welding Engineers
A competent and suitably qualified welding engineer shall be employed. The welding
engineer shall be responsible for the technical aspects of all welding operations including
the following:
Selection of welding processes, equipment and consumables;
Preparation and qualification of welding procedures;
Qualification of welders;
Providing technical oversight of the production welding;
Liaison with the COMPANY and the NDT sub contractors.
The welding engineer shall have at least 10 years in a similar role who has specialist
training and experience in welding technology and be subject to COMPANY approval prior
to commencing any work.
1.12.3 Welding Inspectors
Competent and certificated welding inspection personnel shall be employed in sufficient
numbers to ensure that all welding related activities are adequately inspected.
Welding inspectors shall have a sound knowledge of welding processes and their
application to pipeline welding, and possess the knowledge and skills to carry out the tasks
given in the accepted Quality Plan, including those necessary for the following:
Conduct of routine inspections and checks on site or at suppliers in a systematic

manner;
Production of accurate records and reports.
Welding inspectors shall as a minimum hold current certification from a recognized

certifying authority, namely:
CSWIP (TWI, UK)- Welding Inspector
BGAS-CSWIP (TWI , UK)- Welding Inspector
PCN (BINDT, UK) Weld inspection Level 2.
AWS QC1 Certified Welding inspector.
Alternative welding inspector certification is subject to COMPANY approval.

A senior welding inspector maybe employed to supervise the work of the welding inspector.
The role of a senior welding inspector requires at least 10 years relevant experience and
sound knowledge of welding processes and their application. Formal engineering training
through apprenticeship and technical college education are required.
Senior welding inspectors shall, as a minimum hold current certification to any of the
following standards:
CSWIP (TWI , UK) - Senior Welding Inspector
BGAS-CSWIP (TWI, UK) - Senior Welding Inspector (SWI) or Senior

Pipeline Inspector.
PCN (BINDT, UK) - Weld inspection Level 3.
AWS QC1 Senior Certified Welding inspector.

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2.0
APPLICABLE CODES AND STANDARDS
2.1
Revisions
The latest issues for the relevant standards, codes, statutory regulations and specifications
referenced herein shall be applied to the work, unless otherwise noted.
2.2
Conflict of Information
In the event of any conflict, inconsistency or ambiguity between the contract documents,
this, or any other, specification, associated data sheets, or any of the applicable codes,
standards or regulations, CONTRACTOR shall immediately inform COMPANY in writing
and receive written clarification from COMPANY before proceeding with the work.
2.3
Referenced Documents
It is the responsibility of CONTRACTOR to ensure that he has received from COMPANY all
specifications, etc which are referenced within applicable specifications to enable him to
understand and comply with all aspects of the work to be performed for COMPANY.
2.3.1
Project Documents
The following documents pertaining to the Taqa Falcon Project are related or applicable to
this Specification:
2.4
06-2915-08-U-1-0008
Specification for 22%Cr Duplex Stainless Steel Linepipe
06-2915-08-U-1-0009
Specification for 22%Cr Duplex Stainless Steel Flanges and

Fittings
06-2915-08-U-1-0010
Specification for Field Joint Coating
06-2915-08-U-1-0011
Specification for Insulation and Corrosion Coating
Codes and Standards

CONTRACTOR is responsible for the quality of the work and compliance with the
requirements of the applicable International Codes, Statutory Regulations and Specifications
as listed. The following Codes, Standards and Specifications with their latest published
amendments shall apply:
2.5
Referenced Standards
2.5.1
American Society for Testing Materials

ASTM A370
Standard Test Methods and Definitions for Mechanical Testing of

Steel products
ASTM A380
Recommended practice for Cleaning and De-Scaling Stainless

Steel Parts, Equipment and Systems.
ASTM A923
Standard Test Methods for Detecting Detrimental Intermetallic

Phase in Duplex Austenitic/Ferritic Stainless Steel
ASTM E92
Standard Test Method for Vickers Hardness of Metallic Materials.
ASTM E407
Standard Practice for Microetching Metals and Alloys

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2.5.2
2.5.3
2.5.4
ASTM E562
Standard Test Method for Determining volume Fraction by

Systematic Manual Point Count
ASTM G48
Standard Test Methods for Pitting and Crevice Corrosion

Resistance of Stainless Steels and Related Alloys with the Use
of Ferric Chloride Solution
ASTM E1815
Standard Test Method for classification of Film systems for

Industrial Radiography
American National Standards Institute (ANSI)

ANSI/AWS A5.32
Specification for Welding Shielding Gases
ANSI /AWS B5.16
Specification for the Qualification of Welding Engineers
ANSI /AWS C5.3
Recommended Practice for air carbon arc gouging and cutting
ANSI/AWS Z49.1
Safety in Welding, Cutting and Allied Processes.
American Welding Society (AWS)

AWS A5.4/A5.4M
Specification for Stainless Steel Electrodes for Metal Arc

Welding.
AWS A5.9/A5.9
Specifcation for Bare Stainless steel Welding Electrodes and

Rods.
British Standards
BS 4515-2
Specification on Welding of Steel Pipelines on Land and

Offshore: Duplex Stainless Steel Pipelines
BS EN 473
Non Destructive Testing Qualification and Certification of NDT

Personnel General Principles
BS EN 719
Welding Co-Ordination. Tasks and Responsibilities
BS 7448-1
Fracture Mechanics Toughness Tests. Method for Determination

of CTOD and Critical J Values of Metallic Materials.
BS 7910:2005
Guide to Methods for Assessing the Acceptability of Flaws in

Metallic Structures
BS EN 10204
Metallic Products Types of Inspection Documents
BS EN 12074
Welding Consumables. Quality Requirements for Manufacture,

Supply and Distribution of Consumables for Welding and Allied
Processes.
BS EN ISO 14175
Welding Consumables. Gases and Gas Mixtures for fusion

Welding and Allied Processes
BS EN ISO 15156
Petroleum and Natural Gas Industries Materials for Use in H2S

Containing Environment in Oil and Gas Production
SI 1999 No.3232
The Ionising Radiations Regulations 1999.
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2.5.5
International Standards Organisation

ISO 148
Metallic Materials Charpy Pendulum Impact Test (V notch)
ISO 2504
Radiography of Welds and Viewing Conditions for Films

Utilisation of Recommended Patterns of Image Quality Indicators
(IQIs)
ISO 3452
Non-Destructive Testing Penetrant Inspection - General

Principles.
ISO 3834
Quality Requirements for Welding. Fusion Welding of Metallic

Materials, Parts 1-2
ISO 4136
Destructive Tests on Welds in Metallic Materials - Transverse

Tensile Tests
ISO 5173
Destructive Tests on Welds in Metallic Materials Bend Tests
ISO 5580
Non-Destructive Testing Industrial Radiographic Illuminators

Minimum Requirements
ISO 6507-1
Metallic Materials - Vickers Hardness Test - Test Method
ISO 9001
Quality Management Systems Requirements
ISO 11699-1
Non-Destructive Testing Industrial Radiographic Films Part 1:

Classification of Film Systems for Industrial Radiography
ISO 15156
Petroleum and National Gas Industries Materials for Use in

H2S Containing Environments in Oil and Gas Production
ISO 17636
Non-Destructive Testing of Welds - Radiographic Testing of

Fusion Welded Joints
ISO 17637
Non-Destructive Testing of Welds - Visual Testing of Fusion

Welded Joints
ISO 17640
Non-Destructive Testing of Welds - Ultrasonic Testing of Welded

Joints
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3.0
MATERIALS
3.1
Materials
The CONTRACTOR shall supply all necessary equipment for welding, mechanical handling
and testing.
The CONTRACTOR shall maintain all welding equipment in good working order and shall
maintain a system of calibration that ensures the production of welded joints consistently
meet the quality requirements of this Specification. All welding machines shall be properly
grounded to minimise the occurrence of stray arcing.
The CONTRACTOR shall provide independent means for accurate monitoring of the
welding parameters, such as current, voltage, welding speed, preheat and interpass
temperatures, defined in the agreed welding procedures specification, during production.
The monitoring system shall incorporate the use of portable arc monitoring and recording
equipment.
In the case of semi-automatic and mechanised / automatic welding, the welding power
supplies used for procedure qualification shall be of the same type, model and software
version as those used in production. The manufacturers model and type of equipment and
software shall be identified in the procedure qualification record.
Gauges for measuring the weld preparation, weld bead profile and the profile of weld repair
excavations shall also be provided by the CONTRACTOR.
All items of equipment including hand tools shall be selected, stored and operated in order
to avoid contamination of CRA materials with carbon steel. Hand tools shall be colour
coded to prevent inadvertent use of carbon steel tools on 22%Cr duplex material.
Pipe handling equipment and pipe end preparation machines shall not damage or
contaminate the CRA materials. Pipe handling equipment, pipe-stands, vices, work bench,
etc., shall be lined with non-carbon steel material or CRA material.
Particular care shall be taken to ensure that low melting point metals or their alloys do not
come into contact with the 22% Cr material.
Shop equipment shall be subject to COMPANY approval.
3.2
Materials Storage
Piping materials shall comply with the grade, dimensions, material quality, and end
preparations as defined by the applicable specifications and standards.
Materials shall be securely stored above ground using non metallic dunnage.
Dissimilar materials shall be kept segregated from the rest and marked properly in order to
allow easy traceability.
Solid 22%Cr materials shall be stored under cover on a prepared surface to minimise
external contamination.
End caps shall remain in place until the materials are required for fabrication.
If end caps are removed during storage and internal surface contamination is suspected by
the COMPANY, the Ferroxyl test shall be applied to each open end and any contamination
removed to an agreed technique. If end caps are removed from fittings, the COMPANY will
require the entire internal surface to be tested.
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If a material is not properly identified it shall be quarantined until its source is confirmed.
The COMPANY shall agree on the selected method for identifying the material prior to
welding.
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4.0
WELDING PROCESSES
4.1
General
The welding process used shall be GTAW, SMAW, SAW or a combination of these
processes.
4.2
Welding Consumables
4.2.1
Filler Metal
Electrodes, filler wires and shielding gases and wire /flux combinations shall produce weld
metal that has 0.2% proof strength and tensile strength at least equal to the minimum
specified for the parent metal. The selection of electrodes, filler materials and wire/flux
combinations shall be approved by the COMPANY. The filler metal shall be supplied with
certification in accordance to EN 10204 3.1 which shall contain all the relevant mechanical,
chemical and metallurgical information.
Each batch/lot of welding consumables shall be purchased from manufacturers operating a
quality system based upon ISO 9001 or EN 12074. The PRE of consumables shall be
equal to or greater than 34.0 for 22% Cr. The ferrite level shall be 35% - 65% in all regions
of weld metal. The use of consumable inserts shall require COMPANY approval.
4.2.2
Shielding Gas
Shielding gases shall be 99.99% pure argon. The gas must be free of hydrogen and be
supplied with a MANUFACTURERs certificate.
Shielding gases shall meet the requirements of BS EN 14175 or AWS 5.32. Gases shall be
pre-mixed and bottled by the CONTRACTOR and shall have certificates of compliance. The
certificates shall show the composition and dew point. Gases shall be held in the containers
in which they are supplied and stored with adequate support, in a secured area.
4.2.3
Backing Gas
99.99% pure argon shall be employed for back purge.
Positive flow of backing gas shall be maintained during tacking and welding, including
capping passes if pipe wall thickness is less than 10 mm.
If pipe wall thickness is greater than 10 mm, positive flow may be terminated and bore
sealed once more than 10 mm of the weld has been completed.
4.2.4
Storage and Handling

Welding consumables shall be individually marked, stored and handled in accordance with
the manufacturers recommendations. The CONTRACTOR shall maintain and implement a
consumable storage and handling procedure, which shall be submitted to the COMPANY
for approval.
GTAW filler wires shall be degreased prior to use and shall subsequently be handled with
clean gloves.
Degreasing agents shall leave no chloride or sulphide containing residues on the surface.
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4.2.5
Additional Batch Testing by Contractor

Only the batches of consumables mechanically tested during qualification of the weld
procedure shall be used for production welding. Each batch of consumables shall be used
sequentially with the new batches being opened only after consumption of all electrodes
from the preceding batch.
Each cast and batch/lot of consumables for production welding shall be subjected to the
batch tests during qualification of weld procedures. A butt weld test shall be performed and
be subjected to the following testing:
All-weld metal tensile test at room temperature and 100C;
Weld metal Charpy impact test;
Corrosion tests to BS 4515-2 Annexe C that ensure adequate corrosion resistance

to the process fluids under the design operating conditions;
Macro-examination and hardness at 3 oclock position.
The as-deposited weld metal composition shall be such that the weld metal:
Matches the minimum 0.2% proof stress and tensile strength of the parent material
at both ambient and maximum design temperature of 100oC;
Matches the minimum 0.2% proof stress and tensile properties of the stronger
material when welding dissimilar materials;
Provides adequate toughness at both the maximum and minimum design

temperature;
Ensures adequate corrosion resistance to the process fluids under the design
operating conditions. Corrosion tests to BS 4515-2 Annexe C.
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5.0
TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES FOR BUTT

AND FILLET WELDS
5.1
General
Welding procedure qualification shall be carried out specifically for pipe, valve, connector,
flange and fitting materials using contract materials or COMPANY approved equivalent
materials. The WPQT shall simulate the production welding and shall be undertaken under
site ambient conditions at each fabrication site, where the work will be carried out.
Pre-qualified WPSs previously accepted by COMPANY for 22%Cr materials may be
submitted to the COMPANY for review. Requirements for any supplementary qualification
data and/or production testing to support previously qualified procedures shall be agreed
with COMPANY in advance.
5.1.1
Protocol for Testing

Prior to WPQT and production welding, meetings shall be held between the COMPANY,
the CONTRACTOR and any third party inspection personnel in order to ensure that all
parties fully understand the specified project requirements.
All welding procedures, including repair procedures, shall be qualified in accordance with
this specification.
Welding, NDT and mechanical testing of the WPQT welds shall be witnessed by the
COMPANY or an approved third party. The witnessing of mechanical tests should include
the positioning of the notches for Charpy tests.
5.2
Records
5.2.1
Welding Procedure Specification Information

The information detailed in Table 1 of BS 4515-2:1999 as modified in Table 5.1 of this
Specification shall be detailed on the WPS using the CONTRACTORS standard format:
The PQR documentation package for each WPS shall comprise of:
As-run records- including sketches of the weld runs;
NDT results;
Mechanical, chemical, and corrosion test results and macrographs;
Consumable certification;
Parent material certification.
The following data shall also be available, if requested by the COMPANY Welding
Engineer:
Calibration certificates for equipment and measuring devices;
Welding Inspector and NDT personnel certification;
NDT procedure qualification records;
Test house approval certificates.
The approved WPS and PQR packages shall also be available in a good quality electronic
format.
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5.3
Welding Procedure Qualification Testing
5.3.1
Welding Procedure Parameters

Sufficient information shall be recorded to allow full replication of the procedure
qualification welds. A record of the data shall be kept for the purpose of aiding production
and to assist with the diagnosis of problems, but need not be formally entered on to the
PQR.
The methods of measuring the welding parameters and the records to be kept shall be
agreed with the COMPANY Welding Engineer.
Following WPQT the pWPS shall be revised to reflect the parameters recorded during
qualification. The revised WPS values for current, voltage and travel speed shall be either:
Within the range recorded during WPQT, noting that transient and anomalous
values should not be used to establish the parameter range, or;
The mean value 10%.
A WPS written with more than one supporting Procedure Qualification Record (PQR) shall
not permit optional processes, but shall specify the process for each pass.
All welding procedures, including repair procedures, shall be qualified by visual
examination, NDT, mechanical and corrosion testing as detailed in BS 4515-2 and this
Specification.
The final WPS shall be approved by the COMPANY before being used for production
welding.
5.3.2
Arc Energy
The arc energy for each pass shall be calculated using the recorded values of current,
voltage and travel speed from the PQR without the addition of a percentage.
For 22%Cr duplex the arc energy shall be restricted to 0.8 2.0kJ/mm.
Calculation of arc energy assumes each welding process has an efficiency of 1.
5.3.3
Re-tests
Re-testing is permitted subject to COMPANY approval, provided the CONTRACTOR can
demonstrate that the test failure was due to error in test procedure, specimen preparation
or defect in the mechanical test specimen. Otherwise no re-tests shall be permitted in the
event of any tensile, Charpy impact or corrosion test failures and also for adverse
metallographic test observations including the presence of harmful intermetallic phases.
5.4
Changes Affecting Qualification and Approval (Essential Variables)

Changes affecting qualification and approval are a modified version Table 1 of BS 45152:1999. These are listed in Table 5.1.
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Table 5.1 Welding Procedure Specification Details and Changes affecting Approval
ITEM
WPS DETAIL
ESSENTIAL VARIABLE
a1
The specific arc welding process

(or combination)
A change from one arc welding

process to another
a2
Whether manual, semi-automatic

or mechanized
Any change between manual,

semi-automatic and
mechanized
a3
Whether pulsed arc welding is

used
Any change between pulsed

and non-pulsed welding
b1
Specified standard and Unified

Numbering System (UNS)
number
Any change
b2
Composition
Any Change
Diameter
Nominal outside diameter D of

pipe
A Change outside the range

0.5D to 2D.
Thickness
Nominal pipe wall thickness t
For t > 5mm, a change outside

the range 0.75t to 1.5t but not
<5mm. For t is less than
5mm, a change outside the
range t to 1.5t.
Joint configuration
Pipe end preparation including the following:
with a sketch
e1
Type of bevel
Any Change
e2
Angle(s) of Bevel
Any change beyond 2
e3
Size of Root Face
0.5mm of WPQR value.
e4
Width of Root Gap
-0, +2mm of WPQR value
e5
Any use of backing rings
Any addition or deletion, or

change of material
The following information is needed for each run:
f1
Nominal diameter of
filler/electrode core
wire
Any change for the capping

layer or the first two layers.
f2
Trade name
Any change
f3
Classification
Any change
f4
Any drying or pre-treatment for

hydrogen-controlled electrodes
Any change outside the

manufacturer's
recommendations
f5
Number of wires for each run
Any change
g1
For both butt and fillet welds, the

number of runs from each side
A change from single to multirun or vice versa
g2
Sides welded first and last
Any change
Welding process
Base material
Specification
Electrode
Metal
or
Filler
Number of Runs and

number of sides
welded
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Any increase for other runs
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ITEM
Shielding gas or
flux or backing
gas
Electrical
Characteristics
Welding
parameters
WPS DETAIL
ESSENTIAL VARIABLE
h1
(double-sided welds only)

Shielding gas
h2
Backing gas
Any change in the nominal

composition
h3
Shielding gas flow rate
Any change exceeding 10%
h4
Trade name and type of flux
Any change
h5
Method of monitoring the backing

gas oxygen content in the pipe
bore
Any change
h6
Maximum oxygen content of the

backing gas in the pipe bore
during welding
Any increase
h7
Number of runs before cessation

of backing gas supply
Any reduction
i1
GTAW power supply
Change from normal use to

pulsed or vice versa
i2
Pulse Parameters
Any change in frequency, wave

form or peak and background
current.
i3
Polarity
Any change in polarity
The following information is needed for each wire size. [Different

values may be used for different runs]:
j1
Electrical stick-out (SAW, MAG,

FCAW
Any change exceeding 5 mm
j2
Arc voltage
Any change exceeding 10 %
j3
Welding current or wire feed

speed (SAW, MAG, FCAW)
j4
Background current in any

pulsed welding
j5
Peak current in any pulsed

welding
j6
Pulse duration
j7
Travel speed

If run out length is adopted, a
variable (10% ) shall be
applied
j8
Calculated value of arc energy
To be agreed between the

contracting parties
j9
Calculated heat input
Changes to any parameters

which result in a variation in
calculated heat input > 10%
Page 21 of 48
Any change in the nominal

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ITEM
WPS DETAIL
ESSENTIAL VARIABLE
Welding Position
Angle of pipe axis to the

horizontal
Any change exceeding 25,

except that qualification in both
the PC and PF positions covers
all other welding positions
Direction of welding
Vertical up, vertical down, or

horizontal
Any change
Welding Technique
The following information is needed for each wire size [Different

values may be used for different runs]:
m1
Maximum amplitude of any

mechanized weave

contracting parties
m2
Frequency of any mechanized

weave

contracting parties
m3
Dwell time at the side of any

mechanized weave

contracting parties
n1
Internal, external, or alternative

method (give details)
A change from internal to

external, or from clamp to
alternative
n2
Number of runs before release of

clamp
Any reduction
Lowering-off
(on land), or
barge move-up
(offshore)
Number of runs before this

activity commences
Any reduction
Preheating
p1
Preheat and miniumum interpass

temperature
Any Change
p2
Maximum interpass temperature
Any Change
p3
Method of accelerating weld

cooling
Any Change
q1
Repair welding procedure details
Any of the items in this table

affecting approval
q2
Welding procedure details for the

weld requiring repair
Any change affecting the

approval of the procedure for
the weld on which the repair
welding procedure was
qualified
q3
Surface from which repair takes

place
Any change from external to

internal, or vice versa
q4
Number of attempts at a repair
Any increase
q5
Number of runs in repair
A change from single run to

multi-run or vice versa
q6
Amount of original weld

remaining
A change from complete

removal of the original weld
metal to partial removal, or vice
versa
Line Up Clamp
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5.5
Testing of Butt Joints for Procedure Qualification
5.5.1
Non-Destructive Testing
The NDT procedures for WPQT welds shall be qualified and subject to approval by the
COMPANY. WPQT welds shall be visually examined as soon as possible after completion
of welding with 100% coverage of all weld surfaces. WPQT welds shall meet the same
requirements for VE and weld profiles as those specified for production welds. The full
circumference of the WPQT welds shall be examined by RT or UT and by LPE.
Technique and acceptance criteria shall be in accordance with this Specification.
Acceptance by the COMPANY Welding Engineer/ COMPANY representative shall be
required prior to sectioning of WPQT welds for mechanical testing.
5.5.2
Destructive Testing
Mechanical testing shall be conducted as specified in Table 5.2. Samples shall be removed
from the locations shown in Figure 5.1.
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Table 5.2 Number of Specimens for Procedure Qualification Tests on Butt Joints
TEST
NUMBER OF SPECIMENS
Transverse tensile
Macro Examination
All Weld Metal Tensile
1*
Hardness Survey (on Macro)
Micro Examination
Weld Root Charpy Sets
Fusion Line Root Charpy Sets
Weld Cap Charpy Sets(For Wall Thickness

>20mm)
Fusion Line Cap Charpy Sets (For Wall

Thickness >20mm)
Weld Mid Thickness Charpy Set (For Wall

Thickness 35mm)
Fusion Line mid-thickness Charpy set (For

Wall Thickness 35mm)
Face Bend test less than 114.3mm OD.
Side Bend test equal to or greater than

114.3mm OD.
Root bend Tests less than 114.3mm OD.
Corrosion tests to BS4515-2 Annexe C
* for OD greater than 114.3mm.
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Figure 5.1 Location of Test Specimens
Transverse weld metal tensile specimens shall be in accordance with ISO 4136, have a
rectangular cross section and sample the full material thickness. Specimens shall not be
flattened; the weld reinforcement and the internal weld bead surface shall be machined or
ground flush with the parent material surface.
Transverse tensile tests shall be carried out at both ambient temperature and the maximum
design temperature. The results of all transverse weld tensile tests shall meet or exceed
the specified minimum requirements for the base material with respect to the specified
tensile strength. Transverse weld tensile specimens shall fail at a location within the HAZ
or base metal. The position of failure shall be recorded, i.e. weld metal, HAZ or base
metal. For acceptance, transverse weld tensile specimens shall fail at a location within the
HAZ or base metal.
If base metals of different strength levels are used, then acceptance criteria shall be based
on the lower strength base metal.
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5.5.3
Macro-Examination
Three macro-examination test pieces shall be taken from each WPQ. The locations shall
correspond to those shown in Figure 5.1. All macro-examination specimens shall be
polished to a metallographic (1m) finish and etched in a suitable COMPANY approved
etchant. When examined at 10 times magnification the macro-section shall reveal:
No cracks;
Thorough fusion between adjacent layers of weld metal and between weld metal
and base metal;
Full fusion at the root;
Undercut within acceptance criteria of Table 6.1;
There shall be no excess penetration >1.5mm and reinforcement >3mm;
At no point shall the weld surface, ID or OD, lie below the adjacent base metal;
Both the internal root profile and the external weld reinforcement shall blend
smoothly into the adjacent base metal.
Original photo-macrographs of macro-examination specimens (highlighting hardness

indents) at 3 to 5 times magnification shall be included in the PQR documentation.
5.5.4
Hardness Testing
The hardness testing technique shall be the Vickers method with an applied load of 10 kg
in accordance with ISO 6507-1 or ASTM E92.
The hardness surveys shall be undertaken on each of the macro-examination

specimens specified in Figure 5.1
Each survey shall consist of three rows of indents. One traverse shall be located
below the cap, one above the root (or internal surface) and one at mid-thickness.
The positions are shown in Figure 8.2 of this Specification. The mid-thickness
traverse may be waived for single sided welds below 12.7 mm. The COMPANY
Welding Engineer may require additional hardness indent positions, e.g. when a
consumable type has not been sampled by the three specified traverses;
A tabulation or diagram showing the result and location of each indent, identifying
the maximum and minimum values, shall be included in the PQR documentation;
A photo-macrograph shall be taken showing the whole macro section, illustrating

the location of all hardness indents.
Individual HAZ and weld metal hardness values shall not exceed 290 HV10 for 22%Cr
duplex. The parent material hardness values shall not exceed 290 HV10.
5.5.5
Micro-Examination
5.5.5.1 % Ferrite Content
A microstructural assessment shall be undertaken to determine the austenite / ferrite

balance in the HAZ and the weld metal at the root, cap and mid thickness positions in
accordance with BS 4515-2 Annex B and ASTM E562. The micro-examination shall show
a ferrite content of 35-65% in both regions.
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5.5.5.2 Microstructure Evaluation
Microstructure evaluation shall be conducted in accordance with ASTM A923 Method A, to

determine the presence of undesirable inter-metallic phases, which may affect toughness
or corrosion resistance. A reference sample showing an affected microstructure shall be
used to calibrate the etching method.
The microstructure at X400 magnification shall show no signs of sigma phase, nitrides or
other deleterious phases and shall be classified in accordance with ASTM A923
Unaffected Structures or otherwise. Annotated photographs of the weld/HAZ shall be
referenced and included within the WPQ package.
5.5.6
Charpy Impact Testing

The test pieces shall be prepared and tested in accordance with ISO 148 and EN 10045-1.
Three sets of Charpy specimens shall be taken. One set shall be notched at the weld
centreline, one set at the fusion line and the final set at the fusion line +2mm as detailed in
Figure 4 (BS 4515-2);
All specimens shall be notched with the axis of the notch perpendicular to the pipe surface.
Acceptance criteria shall meet requirements stated in Table 5.3.
Table 5.3 Impact test Requirements (10mm x 10mm sample)
LOCATION
TEST TEMPERATURE C
MINIUMUM AVERAGE (J)
MINIMUM
SINGLE (J)
Parent metal
-46
60
45
Weld Metal
-46
60
45
Heat affected Zone
-46
60
45
If sub size Charpy specimens are to be used, they energy reduction factors shall be as
stated as in Table 5.4.
Table 5.4 Energy Reduction Factors for Reduced Size CVN Specimens
CHARPY SPECIMEN SIZE (MM)
ENERGY REDUCTION FACTOR (ERF)
7.5 x 10
0.80
6.6 x 10
0.75
5.0 x 10
0.66
For wall thicknesses greater than 20mm, additional sets of weld metal, fusion line and
fusion line + 2mm Charpy specimens shall be tested at the external surface;
Additional sets of Charpy Impacts may be required by the COMPANY Welding Engineer.
Partial penetration repair weld procedures shall be impact tested with notches located at:
The repair centreline;
The fusion line between repair weld metal and parent material;
The fusion line between repair weld metal and original weld metal.
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Individual samples may be replaced if there is evidence of a weld defect on the fracture
surface;
Re-testing may be allowed following discussion with the COMPANY Welding Engineer.
5.5.7
Corrosion Testing
22%Cr welded materials shall be required to pass the ferric chloride corrosion test as
detailed in BS 4515 Annex C at the appropriate temperature highlighted; the maximum
weight loss shall be 4g/m2 with no visible pits under a magnification of 20X permitted.
Probing with a sharpened steel pin shall be applied to clarify the location of any pitting.
Only one re-test shall be permitted.
Corrosion testing shall not proceed until a detailed testing procedure has been prepared by
the CONTRACTOR and approved by the COMPANY.
5.5.8
Weld Metal Tensile Testing

The Weld metal tensile testing shall utilise round bar specimens in accordance with
ASTM A370:
5.5.9
For narrow gap welds where the width of the weld bead is insufficient to permit a
conventional all-weld metal tensile test piece to be prepared, the geometry of the
test piece shall be agreed with COMPANY;
The tensile specimen shall be prepared by machining, and its size and location
shall be such that the gauge length consists only of weld metal;
The longitudinal axis of the tensile test specimen shall coincide with the procedure
qualification test-weld axis;
Weld metal tensile testing shall be undertaken at ambient and at the maximum
design temperature;
The weld metal tensile strengths shall not be less than the minimum tensile strength
of the parent materials. If base metals of different strength levels are used, then
acceptance criteria shall be based on the lower strength base metal.
The weld metal yield strength shall not be less than the SMYS of the parent material;
Weld metal overmatching of the typical pipe yield strength shall be achieved at the
above maximum design temperatures.
Bend Testing
Transverse root bends, face bends, and side bend specimens where applicable shall be
prepared and tested in accordance with ISO 5173:
Specimens shall be of full material thickness and the root samples shall be
nominally 25mm in width while the side bend specimens shall be nominally 10mm
in thickness.
Bending shall employ a former having a minimum diameter of 4x and a maximum

diameter of 6x the full pipe wall thickness.
Testing shall not reveal any open weld defects greater than 3mm in length.
Defects shall not be acceptable in the root or hot pass location.

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Tearing from the specimen edges up to a maximum length of 3mm shall be

acceptable provided that it is not associated with any weld defects.
5.6
Testing of Fillet Welds for Procedure Qualification
5.6.1
General
Welding consumables proposed for fillet welds shall be tested in a butt weld configuration.
Details of this test and the scope of mechanical evaluation shall be agreed with
COMPANY. The fillet weld WPQT shall simulate production welding conditions and shall
be undertaken in the 1F, 2F, 3F, or 4F position as appropriate.
The weld bead deposition sequence for multi-pass fillet welds shall ensure that the final
weld bead is not deposited in the pipe wall.
Fillet welds shall not be used for pressure containing welds.
5.6.2
Non Destructive Testing of WPQT

The NDT procedures for WPQT welds shall be qualified and subject to COMPANY
approval. WPQT welds shall be subject to VE as soon as possible after the completion of
welding with 100% coverage of the weld surface. The full length of the WPQT shall be
subject to LPE. COMPANY acceptance shall be required before sectioning of the WPQT
welds for macro examination and hardness testing.
5.6.3
Micro Examination and Hardness Indents

Macro sections shall be taken from the WPQT at the 1/4, 1/2, and 3/4 weld length positions
and prepared for examination and macro photography. When examined at 10 times
magnification the macro-section shall reveal:
No cracks;
Thorough fusion between adjacent layers of weld metal and between weld metal
and base metal;
Full fusion at the root;
No undercut;
At no point shall the weld surface lie below the adjacent base metal;
Original photo-macrographs of macro-examination specimens (highlighting hardness

indents) at 3 to 5 times magnification shall be included in the PQR documentation. The
hardness testing technique shall be the Vickers method with an applied load of 10 kg in
accordance with ISO 6507-1 or ASTM E92. Three hardness traverses shall be carried out,
two 1.5mm from the abutting surfaces and one mid- thickness of the weld from OD to ID.
The hardness surveys shall be undertaken on each of the macro-examination

specimens;
A tabulation or diagram showing the result and location of each indent, identifying
the maximum and minimum values, shall be included in the PQR documentation;
A photo-macrograph shall be taken showing the whole macro section, illustrating

the location of all hardness indents.
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Individual HAZ ,weld metal and parent metal hardness values shall not exceed 290 HV10
for 22%Cr duplex.
5.7
Testing of Repair Welds for Procedure Qualification Destuctive Testing

All repair weld procedure shall be qualified and submitted to the COMPANY for approval:
5.8
The limits of the length of weld repairs for partial penetration shall be limited to 30%
of the weld length;
Only one attempt at a repair shall be permitted.
Hardness testing shall be conducted;
Micro-examination shall be conducted;
Corrosion testing shall be conducted;
For multipass external repairs CVN impact test for weld metal, FL and FL+2mm
shall be performed.
Dissimilar Welds
If applicable, CONTRACTOR shall submit dissimilar welding procedures for welding to
duplex material.
When welding duplex material to carbon steels, the same or higher alloyed filler metal as
used for welding the CRA material to itself shall be used.
Welding procedure qualification shall be carried out in accordance with the requirements of
this Specification. Pre-qualified WPSs previously accepted by COMPANY may be
submitted to the COMPANY for review.
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6.0
TESTING QUALIFICATION AND APPROVAL OF WELDERS
6.1
General
Welders shall be qualified prior to production welding. Qualification for positional welding in
6G position is required at maximum root gap specified by relevant welding procedure.
Welders shall not be qualified on production welds.
Previous welder qualification tests may be accepted by the COMPANY provided they are
fully documented, supported by production records demonstrating satisfactory welder
performance, and are less than 6 months old. These tests shall have been conducted
utilizing a WPS substantially the same as that for the current work and for mechanised or
semi-automatic welding procedures, utilizing the same type, manufacturer, software
version and model number of welding unit and power supply. Additionally, these tests shall
have been conducted by the same fabrication CONTRACTOR and witnessed by the
COMPANY, or have been conducted by a COMPANY approved independent testing
laboratory.
Welder qualifications test (using manual and semi-automatic welding processes) on duplex
materials shall be subject to corrosion testing as per BS 4515-2 Annex C.
Any welder who, in the opinion of the COMPANY is either consistently ignoring good
welding practice or specification requirements or is responsible for a high level of repairs
during production shall be removed from the work, and shall undergo a re-training
programme approved by the COMPANY before a retest may be considered.
6.2
Butt Joints
Welder qualification tests shall be carried out on full diameter project pipe. Welders shall
weld 100% of the circumference of the test pipe. All qualification welding shall be carried
out in the presence of a COMPANY representative. The COMPANYs decision on
acceptance is final. Welders shall not be qualified by production testing.
6.3
Changes Affecting Qualification and Approval (Essential Variables)

A welder who has successfully completed a qualification test shall be qualified for the type
and position of weld concerned within limits of the following items. If any of the following
occur the welder using the new procedure shall be re-qualified.
a) A change from one welding process to another welding process or combination of
welding processes.
b) A change in direction of welding from vertical-up to vertical -down or vice versa.
c) For butt joints and branch connections, a change on pipe diameter or thickness outside
the ranges given in Table 4 (for branches the diameter of the branch is the applicable
dimension).
d) For a branch connection, a change in branch orientation exceeding 20 from that
approved, except that approval on a connection with the branch and main pipe axes both
horizontal gives approval fro all welding positions.
e) A change on joint design, e.g. backing ring to no backing ring, or single U to single V
preparation.
f) For manual metal-arc welding to a change form one electrode covering type to another.
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g) For continuous tubular electrodes: a change from metal cored to flux cored or vice
versa; a change from one flux type to another; a change from gas shielded to non
shielded or vice versa.
h) Any change on the nominal composition of the shielding gas.
i) Any other change in the welding procedure or equipment which, in the opinion of the
COMPANY, will make production of a sound weld more difficult for the welder.
6.4
Non-Destructive Testing
Shall be as per the PQR testing.
6.5
Destructive Testing
For butt welds, macro-examination shall be undertaken.
Fillet welds shall be examined visually in accordance with BS EN 870 and shall undergo
dye penetrant examination.
The results form visual examination and non destructive testing shall be assessed
according to table 6.1.
Table 6.1 Acceptance criteria for Welds
FLAW TYPE
ACCEPTANCE CRITERIA
a)External Profile
Excess weld metal (reinforcement) shall be

uniform and shall merge smoothly with the
parent metal and shall extend beyond the
original joint preparation by not more than
3mm on each side. In no area shall the
weld surface be lower than the adjacent
pipe surface. Fillet welds shall not be less
than the specified dimensions, regular in
form and without undercut as given in h).
b)Internal Profile
The root bead or any concavity shall merge

smoothly into the adjacent surfaces.
c)Root Penetration
Shall not exceed 3mm. If service conditions

necessitate a more stringent limit, this shall
be specified by the employer.
d)Root Concavity
Length shall not exceed 25% of total length

of weld. Depth shall not exceed 10% of
pipe thickness, or 1.5mm whichever is the
smaller , but at no point shall the weld
including the cap reinforcement, be thinner
than pipe thickness.
e)Root undercut
Length shall not exceed 25mm in any

continuous weld length of 300mm, or 1/12 of
the total weld length where this is less than
300mm. Depth shall not exceed 10% of
pipe thickness, or 1.5mm, whichever is the
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smaller. For branch welds this flaw is not

permitted.
f)Incomplete Root penetration ( Single side Length shall not exceed 25mm in any
welds only) Lack of root fusion(single side continuous weld length of 300mm, or 1/12 of
welds only)
the total weld length where this is less than
300mm. Depth shall not exceed 10% of
pipe thickness, or 1.5mm, whichever is the
smaller. For branch welds this flaw is not
permitted
g)Cracks
Not permitted.
h)Cap Undercut
The toes of welds shall blend smoothly and

gradually into the parent metal. Length not
to exceed 50mm in any continuous weld
length of 300mm, or 1/6 of the total length
of weld where this is less than 300mm.
depth not to exceed 10% of pipe thickness
or 15mm, whichever is the smaller. For
branch
welds the length of the weld
affected not to
exceed 25mm in any
continuous weld length of 300mm, or 1/12 of
the total length of the weld where this is
less than 300mm..
i) Shrinkage cavity lack of interrun fusion,

lack of sidewall fusion. Elongated inclusions
incomplete root penetration (double sided
welds only).
Length of weld affected shall not exceed

50mm in any continuous weld length of
300mm. Depth not to exceed 10% of pipe
thickness or 1.5mm, whichever is the
smaller. For branch welds the length of
weld affected not to exceed 25mm in any
continuous weld length of 300mm, or 1/12
of the total length of the weld where this is
less than 300mm.
j) Porosity
Shall not exceed a total area, when

projected radially through the weld, of 1% of
projected weld area in the radiograph
(consisting of the length of weld affected by
the porosity , with a minimum length of
150mm, multiplied by the maximum width of
the weld. An isolated pore greater than
25% of the pipe thickness, or 3mm,
whichever is the smaller, in any direction
Shall be considered unacceptable.
k) Isolated inclusions ( tungsten or non Width of inclusion shall not exceed 12mm in
elongated slag)
any continuous weld length of 300mm, and
not more than four inclusions of maximum
width in this 300mm length. Adjacent
inclusions shall eb
separated
by a
miniumum distance of 50mm.
l)Copper inclusions
Not permitted.
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m) Burn -Through
Not permitted.
n) Wormhole
Shall not exceed 6mm in length or 1.5mm

in diameter for thicknesses not exceeding
25mm, or a total length of 25% of the
thickness or 12mm, whichever is the
smaller, or 3mm in diameter for thicknesses
over 25mm.
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7.0
PRODUCTION WELDING
7.1
Proximity of Welds
For pipe sizes of DN 300 (NPS 12) and below, minimum acceptable separation of welds
shall be 50 mm from weld toe to weld toe. For pipe sizes greater than DN 300 (NPS 12),
minimum acceptable separation shall be 100 mm. Branch and non pressure part
attachment welds shall not cross longitudinal seams or circumferential butt welds and shall
be subject to toe to toe separation distance specified for circumferential butt welds. If such
intersections are unavoidable, the main weld shall be subject to non-destructive
examination prior to making attachment weld. Joints involving intersection of more than
two welds shall be avoided.
7.2
Pipe End Preparation

Pipe ends shall be bevelled to the dimensions specified in the WPS.
7.3
Fusion Faces
Prior to fit up and welding fusion faces and the adjacent base material shall be cleaned
utilising solvent. Degreasing of base metal shall extend at least 50 mm from the edge of
the fusion faces on both ID and OD surfaces. All cleaning solvents shall be used from a
suitable container, shall have all necessary documentation available and be approved by
the COMPANY as HSE compliant.
Note: All pipe end caps shall remain in place until the pipes are required for fabrication. If
iron contamination of the CRA surface is suspected, then a Ferroxyl test shall be performed
and any contamination removed by an agreed technique.
7.4
Alignment
Only rotation of the pipes shall be used for the obtaining minimum misalignment. Maximum
misalignment shall be 1.0mm for < 6diameter pipe and 2.0mm for 6 pipe and greater.
Any misalignment in pipe to fitting girth weld set-ups that exceed 2.0mm at any point on the
internal surface shall be subject to corrective action agreed with the COMPANY.
Hammering is not allowed.
7.5
Tack Welds
All tack welds (if used) shall be deposited by qualified welders using uphill welding in
accordance with an approved WPS.
Alignment by tacking for fabrication welds, e.g. for pipe to flange joints, shall be subject to
the approval of the COMPANY. The following shall apply when tacking is used:
The joints to be tacked will be adequately supported;
The preferred method is bullet tacking. The bullets shall be made from 22%Cr or
25%Cr using the same consumable material as specified on the WPS;
A minimum of four tacks shall be used for diameters >100mm. More tacks may be
required for diameters > 300mm;
All welding shall be confined to the weld preparation and not impinge on the root
area;
Tacks shall be removed by grinding as root welding progresses around the butt;
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Tacking shall be incorporated in the WPQT if it is to be used in production.
The COMPANY may agree to waive LPE of the ground area following tack removal.
7.6
Stray Arcs and Earthing

The COMPANY shall have the option to require removal of weldments with more than one
arc burn from the pipe. Welding arc strikes or arc burns outside the weld preparation shall
be removed by careful grinding, and subsequently checked by LPE. The wall thickness at
each ground area shall be checked for compliance with the specified minimum wall
thickness. Repairs by welding of under thickness areas after grinding shall not be
permitted.
All earthing connections shall be securely attached to avoid stray arcing. Copper earth
clamps shall be protected by CRA material to prevent copper contamination to the material
being welded.
If blending to remove the effects of arc burns reduces the wall thickness below the specified
minimum, the defective pipe section shall be cut out and the pipe re-bevelled and re-welded.
Welding shall not be used to repair arc burns.
7.7
Weather Conditions
The COMPANY shall decide if the protection given from the weather is adequate and that it
will not affect the quality of the completed weld.
7.8
Preheating, Inter-Pass Temperature and Post Weld Heat Treatment
7.8.1
General
Preheat is not usually required for welding, but it is essential that the weld zone is dry and
free from moisture.
The minimum metal temperature for welding shall be 20C.
Inter-pass temperatures for parent pipe materials and weld metals shall be closely
monitored and shall not exceed the lesser of either the temperature measured during the
WPQT or the following requirements:
150C for 22%Cr;
In order to facilitate production welding, accelerated cooling between weld passes can be
achieved by forced air or the application of water jackets.
When used in production, any of the aforementioned cooling processes shall be qualified
by the WPQT.
Direct water cooling shall not be used.
7.8.2
Temperature Measurement
Where used, pre-heat temperature shall be measured at a distance of between 10mm20mm from each edge of the weld bevel at a minimum of four circumferential locations,
each approximately 90 apart.
Temperature measurement shall be made on the heated face of the pipe after a time
interval following the removal of the heat source to allow for temperature equalisation.
The time interval shall be 1 minute per 12.7 mm of wall thickness, e.g. 2 minutes for 25 mm
thick material.
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The metal temperature should be confirmed immediately before the commencement of
welding and around the whole joint whilst welding is taking place.
Inter-pass temperature shall be measured on the weld metal immediately before the
passage of the arc.
The maximum specified inter-pass temperature shall not be exceeded.
Inter-pass temperature checks shall be made during welding.
For continuous welding, inter-pass temperature shall be measured at the commencement
of welding.
Suitably attached or contact (and calibrated) thermocouples, or calibrated contact or optical
pyrometers, or Tempilsticks shall be used to check preheat and interpass temperatures.
7.8.3
Post Weld Heat-Treatment

Post weld heat treatment is prohibited.
7.9
Branches
Procedures for cutting, joint preparation, setting-up, welding and NDT shall be subject to
COMPANY approval.
7.9.1
Welding
Set-in fitting welds shall be inspected as follows:
Where accessible and following completion of the full weld, the root bead shall be
ground flush on the inside of the pipe, its location clearly marked with indelible pen
and inspected by visual and LPE. Weld caps to be subjected to visual and LPE;
The full welds shall be examined with radiography using the SWE/SWV technique
with the film inside and radiation source outside, using a minimum source to film
distance of 600mm. A minimum of four equidistantly spaced separate exposures
shall be used for branches 150mm nominal bore. The DWE/SWV technique may
only be used if approved by the COMPANY. In each event the centre radiation
beam shall pass through each weld region being tested at normal incidence to the
weld face.
Set on fitting welds shall be inspected as follows:
7.10
The root bead and weld cap shall be examined by visual examination. Visual
examination of the root bore shall be undertaken through the bore of the fitting from
the outside of the pipe;
Weld caps shall be examined by LPE. Where access and geometry allows UT shall
be undertaken from the inside surface of the fitting.
Inter-run Cleaning
The method of weld cleaning shall be specified in the WPS.
Excessive mechanical working of the weld bead surface that may mask surface defects or
otherwise inhibit a proper visual inspection is prohibited.
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7.11
Partially Completed Joints

A procedure shall be in place to ensure that in the event of an unavoidable interruption,
welding is restarted in a controlled manner. This procedure shall, as a minimum, cover the
application of any necessary NDT, removal of condensation from the joint, and the reinitiation of purge gas flow.
Root welds shall be completed without interruption other than to allow the welder to take a
new length of filler wire or to reposition himself.
Welds shall not be left incomplete at the end of shift.
7.12
Purge Gas Monitoring

The internal surface of the pipe and weld shall be adequately purged by a continuous gas
flow during deposition of the weld to ensure that minimal oxidation occurs.
7.13
The gas escaping from the purge gas chamber shall be continuously monitored for
oxygen content using a COMPANY approved calibrated oxygen monitoring device;
Welding shall not commence until the oxygen content of the purging gas has
equalized within the butt and shows a maximum of 0.5% using a COMPANY
approved monitoring device;
Internal purging shall continue until a weld throat thickness of 10mm has been
established.
Temporary Attachments
The use of temporary attachments is only permitted with the prior approval of the
COMPANY.
7.14
All temporary attachments shall be made by qualified welders according to an

approved WPS;
Temporary attachments shall be removed by careful grinding and the finally ground
surface shall be subject to LPE;
The wall thickness of the pipe shall be checked by UT.
Records
All documentation required by this Specification and BS 4515-2 shall be collated, indexed,
stored safely and presented to the COMPANY.
A log identifying, by number, each pipe or fitting and identifying the weld numbers joining
them to other items shall be compiled. Each circumferential weld (whether a field joint or
shop-made weld) shall be allocated a unique number, which shall be used for reference to
the weld in all reports, radiographs and test documents.
Quality records shall include the following:
Record of contract/design review;
Material certificates;
Consumable certificates;
WPSs;
Name and / or number of welder;

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Welding procedure approval test records;
Welder or welder operator approval certificates;
Non-destructive testing personnel certificates;
Non-destructive testing and destructive testing procedures and reports, including

production hardness tests;
Dimensional reports;
Records of repair and other non-conformity reports;
Site or technical queries pertaining to welding and NDT.
The above documentation shall be traceable back to individual weld numbers, where
applicable.
All records shall be supplied in hard copy and electronic format.
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8.0
INSPECTION AND TESTING OF PRODUCTION WELDS
8.1
General
Each production butt weld shall be subjected to a visual, LPE and RT or UT examination.
Prior to NDT testing, each joint shall be thoroughly cleaned of spatter and other extraneous
material. However, care shall be taken to ensure that when LPE is to be employed, surface
breaking defects are not sealed.
All duplex welds shall be subjected to 100% RT. The use of UT will not be permitted in
place of radiography, unless it is a time of flight diffraction technique with a permanent
record which is available to COMPANY.
NDT of dissimilar butt welds between clad components to CRA pipe shall include 100% RT
to specifically qualified procedures as well as UT to the maximum achievable extent to
confirm absence of lack of fusion or other planar defects.
Proposed NDT procedures shall be submitted in writing to the COMPANY for approval. All
procedures shall be qualified and approved by the COMPANY before use.
The COMPANY shall have the right to inspect individual welds and NDT operations. This
inspection may be made during the welding or after the weld has been completed. The
right of inspection may include NDT undertaken by COMPANY personnel in addition to any
NDT undertaken by the CONTRACTOR. For example, the COMPANY may choose to
inspect welds by UT.
Completed welds may be ground when required to facilitate NDT provided the wall thickness
complies with the minimum specified limit. Grinding shall ensure no stress raisers and a
smooth transition exists.
8.2
Personnel Qualification
NDT personnel shall hold current Level 2 certification (or equivalent), specific to weld
testing, for the appropriate NDT methods to any of the following standards as a minimum:
CSWIP (TWI, UK);
BGAS-CSWIP (TWI, UK);
PCN (BINDT, UK);
ACCP (ASNT);
SNT-TC-1A (ASNT).
NDT personnel certificated to the requirements of a Written Practice under the rules of
SNT-TC-1A shall not be used, unless the Written Practice and the personnel certification
has been reviewed and accepted by the COMPANY for the specific work.
8.3
Visual Inspection
8.3.1
General
All completed welds shall be fully examined by VE in accordance with ISO 17637 or BS
EN 970 immediately upon completion of welding.
Adequate lighting (500 lux min) shall be provided for this examination which shall be
both external and internal;
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8.3.2
Internal examination shall be facilitated by remote camera viewing.
The remote viewing technique and the associated calibration procedure shall be
demonstrated to the satisfaction of the COMPANY before the commencement of
the WPQT program.
A VE procedure including the detail of the remote viewing system and its calibration
shall be submitted for COMPANY approval prior to commencement of the WPQT
program;
The initial internal VE shall be performed following completion of the root and hot
pass in order to eliminate the need for through thickness repairs.
Acceptance Criteria
Visual inspection of all welds shall meet the requirements of Table 5 (BS 4515-2) and as
detailed below. Welds not meeting these requirements shall be removed from the pipeline.
8.3.2.1 Internal Surface
The root pass shall be of regular width and shall blend smoothly with the pipe wall;
Full penetration shall be achieved over the entire length of the weld with no missed
edge or burn through being present;
No surface breaking defects shall be visible; and, when an internal backing bar is
employed, cold lapping of the weld metal over the internal pipe wall internal shall
not be acceptable;
The maximum depth of root concavity shall be the lesser of 10% of the wall thickness
or 1.5mm, the total length of root concavity shall not exceed more than 10% of the
weld length;
The maximum bore protrusion shall be 1.5mm;
Welds showing heavy oxidation shall be removed from the pipeline.
8.3.2.2 External Surface
The weld preparation shall be completely filled;
The weld bead shall be of regular shape and the weld metal shall blend smoothly
with the parent material around the full circumference of the joint;
Overlap of the weld cap onto the parent material shall be minimal and not exceed
2mm on either side of the joint;
No surface breaking defects shall be visible and cap undercutting exceeding 0.5mm
shall be unacceptable and shall be blended out by light burr grinding or filing prior to
NDE;
If blending reduces the pipe wall thickness below the specified minimum the entire
weld shall be cut out and the pipe ends re-bevelled and re-welded.
8.4
Radiographic Testing
8.4.1
General
Radiographic testing shall be conducted using X-ray equipment. Where the use of X-ray
equipment is impracticable, Iridium 192, Ytterbium 169 or Selenium 75 may be used
subject to approval by the COMPANY. The single wall exposure for single wall viewing
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(SWE/SWV) technique with the radiation source located inside the pipe/ fitting shall be the
preferred technique for RT of girth welds, and the minimum standard of radiography
produced shall be in accordance with Class B.
Radiographic practice shall be in accordance with this specification and ISO 17636.
8.4.2
Radiographic Procedures
As part of the radiographic procedure qualification, three test radiographs shall be
produced using each radiographic procedure planned for use; these shall be made on the
welding procedure qualification welds or welds made with the production WPS. The full
circumference of each test weld shall be radiographed.
The procedure test radiographs shall be submitted to the COMPANY for approval prior to
the start of production. New procedure test radiographs may be requested at the discretion
of the COMPANY whenever any change is made in operating technique or whenever
production radiographs differ appreciably from the detail, contrast, definition or density of
the qualifying radiographs.
Procedure test radiographs shall be readily available for comparison purposes in each
darkroom used for radiographic viewing.
Film type shall be ISO 11699-1 Class T2 or ASTM E1815-96 Class I, e.g., Agfa Structurix
D5 or Kodak Industrex T200, or finer grain (slower) film. Where it is shown that exposure
times would exceed 2 minutes using X-ray equipment with this film, the use of ISO 11699-1
Class T3 or ASTM E1815-96 Class II may be permitted at the discretion of the COMPANY.
Lead (Pb) intensifying screens shall be used. The COMPANY may approve the use of
fluorometallic screens, as an alternative, where the CONTRACTOR is able to demonstrate
that test procedures and results are of a standard acceptable to the COMPANY.
8.4.2.1 Procedure Specification
Specifications of radiographic procedures shall, where relevant, define the following:
Pipe diameter and wall thickness;
Radiation and source;
X-ray equipment manufacturer, model name and number;
Technique (equipment rating, in voltage, external or internal equipment);
Geometric relationships (source focal-size, film focus distance, object-film distance,

radiation angle with respect to weld and film);
Penumbra or geometric unsharpness;
Film type (trade name, designation and dimensions);
Intensifying screens (front and/or back, material thickness, filters);
Exposure conditions (voltage,

Gigabecquerel-minutes);
Processing (developing time/temperature, stop-bath, fixation, washing, drying,

manual or automatic processing, manufacturer and type of equipment);
IQI type and sensitivities, in percent of wall thickness, based on source-and filmside indicators, respectively);
Film density;
current
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and
duration,
Curie-minutes
and
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8.4.2.2
Film overlap;
Reference to actual WPS;
Temperature of welds during inspection;
Archival life;
Initial source strength.

Exposure Geometry
Source-weld-film arrangements shall comply with ISO 17636 except that the elliptical
technique shall be used on all girth welds on pipe 88.9 mm diameter. The perpendicular
technique (straight through) exposures shall not be used unless approved by the
COMPANY.
8.4.2.3
Selection of Image Quality Indicators
Only wire type IQIs (ISO 2504 or COMPANY approved equivalent) shall be used.
For radiographic procedure qualification, wire type IQIs shall be placed across the weld on
both the source side and the film side of the area being examined. The sensitivity level,
obtained using the film side IQI, shall be no worse than that given in Table 8.1 The
corresponding sensitivity for the source side IQI shall be recorded. If any test radiograph
shows one visible wire more on the film side IQI, compared to the source side IQI, the
COMPANY has the option to reject the radiographic procedure.
8.5
Ultrasonic testing
If UT is selected a TOFD method shall be used with permanent data storage method. The
record shall be available to COMPANY for review.
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Table 8.1- Acceptable Radiographic Sensitivity Levels (Using Wire Type IQI to ASTM E747
or BS EN 462-1)
THICKNESS 1
X-RADIOGRAPHY
GAMMA RADIOGRAPHY
mm
SWSI
DWSI
DWDI
SWSI
DWSI
DWDI
4.5
Note 3
Note 3
Note 3
Note 3
Note 3
Note 3
4.5 6.0
2.0%
2.5%
3.2%
2.6%
2.7%
3.5%
6.0 9.0
1.7%
2.0%
3.0%
2.4%
2.5%
3.2%
9.0 14.0
1.5%
1.8%
Note 3
2.4%
2.5%
Note 3
14.0 18.5
1.4%
1.7%
NA
2.0%
2.2%
NA
18.5 26.0
1.3%
1.7%
NA
1.7%
2.0%
NA
26.0 40.0
1.1%
1.7%
NA
1.5%
1.8%
NA
>40.0
Note 3
Note 3
Note 3
Note 3
Note 3
Note 3
NOTES;
1
Thickness for SWSI and DWSI is estimated single weld thickness. Thickness for DWDI is one wall
thickness plus one estimated weld thickness.
2
Sensitivity shall be no worse than the values given in this Table. Sensitivity values are based on IQI
placed on film side for SWSI and DWSI exposures and IQI on source side for DWDI exposures. Sensitivity shall
be calculated using the formula:
Sensitivity =
3
Thickness of thinnest wire visible in weld area

Thickness1
Sensitivity requirement to be agreed with COMPANY following production of test radiographs.
8.5.1.1 Film Density
Except for small localized areas caused by weld weave or discontinuities, the radiographic
density shall be between 2.0 and 3.2 in the weld area. If this density range cannot be
achieved within the full weld width in a single exposure, then the above density range shall
be achieved by producing two radiographs of the weld area at different exposures or by
using the sandwich technique, unless otherwise agreed by the COMPANY.
Densitometers shall be used for measuring density and shall be calibrated using a density
strip (density reference scale) of known densities. A density strip certified within the last 3
years to a recognized standard, e.g., NIST or BAM, shall be present on site. To save wear
and tear on the calibrated density strip, a working density strip may be used for checking
and calibrating densitometers; this shall be checked against the certified density strip at no
more than 3 monthly intervals.
8.5.1.2 Film Viewing Equipment
The viewing facilities shall provide subdued lighting of an intensity that will not cause
troublesome reflections, shadows or glare on the radiograph. The viewing equipment shall
produce sufficient brightness for the illuminated radiograph to be satisfactorily interpreted
and shall meet the requirements of ISO 5580. The image shall be free from fog and
processing irregularities that could mask the image of actual imperfections.
All
radiographic film shall be dried thoroughly prior to viewing.
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8.5.1.3 Storage of Film and Other Imaging Media
All radiographic film shall be dried thoroughly prior to viewing and shall be processed to
allow storage of the film without deterioration for a minimum period of 5 years.
At the discretion of the COMPANY, the radiographic contractor shall satisfactorily
demonstrate that the film can be processed, using the site facilities, to have a fog level not
greater than 0.3.
One radiograph in every 100 shall be subjected to a residual thiosulphate test, to ensure
that the film has been suitably processed for 5 years storage. The procedure for this test
shall form part of the radiographic procedure package for COMPANY approval.
Radiographs shall be stored in an environment that will not detrimentally affect the
radiographs. Boxes shall be used to store radiographs in multiples of 25, 50 or 100 welds.
The weld numbers that apply to the stored radiographs that each box contains shall be
clearly visible on each box.
8.6
Liquid Penetrant Examination
8.6.1
General
When required, LPE shall be applied as described in ISO 3452 / BS EN 571-1.
An examination procedure shall be submitted for the COMPANY approval prior to
commencement of the WPQT program and shall be qualified during this test program.
During examination, the surface temperature shall be in the range 15C - 35C.
8.6.2
Acceptance Criteria
Indications that cannot be removed by light burr grinding to a maximum depth of 0.5mm
shall be cause for rejection of the weld and shall be subject to an agreed weld repair
technique.
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9.0
ACCEPTANCE AND RECTIFICATION OF WELDS
9.1
Non-Destructive Testing Acceptance Criteria
9.1.1
General
The acceptance standards defined in section 9.1.2 shall be the minimum requirement in
which radiography is the primary NDT method.
When unacceptable flaws occur in more than five consecutive welds or when, in the
opinion of the COMPANY, a particular flaw type becomes repetitive in terms of its size
and/or location, the cause of the flaws will be investigated by the Welding Engineers
working on behalf of the CONTRACTOR and the COMPANY. If necessary, welding will be
terminated until the cause of unacceptable flaws has been established and satisfactorily
resolved.
9.1.2
Acceptance Criteria Based on Quality Control

The acceptance criteria shall be assessed in accordance with this specification and meet
acceptance criteria stated in Table 6.1 of this specification.
9.1.3
Suspect Welds
Any weld suspected of not having been produced in accordance with the approved welding
procedure shall be cut out, and may be subject to investigation at the discretion of the
COMPANY.
9.2
Rectification of Welds
9.2.1
Removal of Flaws
A WPS for repair welding shall be approved in accordance with Section 7.
Defects shall not be repaired in any part of the weld without prior approval by the
COMPANY. All repairs shall be witnessed by the COMPANY, and the relevant NDT
records shall be made available to the COMPANY at that time.
For completed welds, full penetration repairs are not permitted. Partial penetration repairs
are permitted to within 6mm from the pipe internal surface; however the internal purge gas
shall be reinstated for repairs within 10mm of the internal surface. This is subject to
COMPANY approval and a suitably qualified procedure. Only one attempt at a weld repair
shall be permitted. If unsuccessful, complete removal of the weld is required.
No more than one separate repair is allowed in any single weld.
Small crater cracks shall be removed by local grinding and repaired.
Excavations shall be made to simulate those expected during production using the
appropriate profile and depth. The excavation shall be mimicked and a drawing included
within the WPQ documentation package.
No internal root repairs are allowed.
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9.2.2
Preparation for Re-Welding

The minimum allowable repair length shall not to be less than 50 mm. The limits of the
length of weld repairs are specified in clause 12.2.1 of BS 4515-2 i.e. 30% of the weld
length maximum partial penetration repair. Full penetration repairs are not permitted.
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:
The weld number;
The type and size of defect;
The circumferential location (defined to an approved system);
An estimate of the depth (assessed by ultrasonic test where possible);
Name and/or number of the welder who produced the defect;
Repair welding procedure number;
Name and/or number of repair welder;
Copy of the inspection report for the repair;
Date of repair.
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10.0
DOCUMENTATION
10.1
General
All documentation shall be in the English language.
CONTRACTOR shall propose a document list for APPROVAL by COMPANY, which should
include but not be limited to the following.
10.2
Documentation to be Provided with Tender

CONTRACTOR shall submit the following with tender:
10.3
Quality plan;
Quality documentation (ISO 9001).
Documentation Required Prior to Commencement of Work

All documents to be presented for APPROVAL before commencement of production or
production qualification, whichever is earliest:
10.4
Quality plan (including inspection and test plan);
Weld maps including unique identification numbers;
Welding procedure specifications (WPSs) and welding procedure qualification

records (WPQRs);
Welder qualification certificates;
Welding consumable control;
Inspection, NDE and testing procedures;
PMI procedures;
NDE operator qualification certificates;
Key personnel CVs E.g. Welding Engineer, Senior Inspector, Senior NDE
Technician.
Documentation Required on Completion of WORK

The following documentation is required with the supplied items:
APPROVED copies of documents cited in Sections 10.2 and 10.3;
Signed-off quality plan (including inspection and test plan);
Welding consumable batch test certificates.
Page 48 of 48
JPK Doc.No.06-2915-08-U-1-013 Rev 01


Welding and NDT

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Specification

Experience that Delivers

Prepared for: TAQA

Welding and NDT of 22%Cr Duplex Stainless

Experience that Delivers

J P Kenny Caledonia Limited

ISSUED FOR COMMENT

JPK Doc.No. 06-2915-08-U-1-013 Rev 01

Development Overview ................................................................................................ 5

HSEQ for Pipeline Welding Operations........................................................................ 8

Pre- Production Consultation........................................................................................ 8

Duties of the Contractor................................................................................................ 9

Quality Conformance .................................................................................................... 9

Contractors Personnel .................................................................................................. 9

APPLICABLE CODES AND STANDARDS........................................................... 11

Codes and Standards ................................................................................................. 11

WELDING PROCESSES ....................................................................................... 16

JPK Doc.No.06-2915-08-U-1-013 Rev 01

TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES

Welding Procedure Qualification Testing ................................................................... 19

Changes Affecting Qualification and Approval (Essential Variables)......................... 19

Testing of Butt Joints for Procedure Qualification ...................................................... 23

Testing of Fillet Welds for Procedure Qualification .................................................... 29

Testing of Repair Welds for Procedure Qualification Destuctive Testing ............... 30

Dissimilar Welds ......................................................................................................... 30

TESTING QUALIFICATION AND APPROVAL OF WELDERS............................. 31

Butt Joints ................................................................................................................... 31

Changes Affecting Qualification and Approval (Essential Variables)......................... 31

Non-Destructive Testing ............................................................................................. 32

Destructive Testing ..................................................................................................... 32

PRODUCTION WELDING ..................................................................................... 35

Proximity of Welds ...................................................................................................... 35

Pipe End Preparation.................................................................................................. 35

Fusion Faces .............................................................................................................. 35

Tack Welds ................................................................................................................. 35

Stray Arcs and Earthing.............................................................................................. 36

Weather Conditions .................................................................................................... 36

JPK Doc.No.06-2915-08-U-1-013 Rev 01

Preheating, Inter-Pass Temperature and Post Weld Heat Treatment ....................... 36

Inter-run Cleaning ....................................................................................................... 37

Partially Completed Joints .......................................................................................... 38

Purge Gas Monitoring................................................................................................. 38

Temporary Attachments ............................................................................................. 38

INSPECTION AND TESTING OF PRODUCTION WELDS................................... 40

Ultrasonic testing ........................................................................................................ 43

Liquid Penetrant Examination..................................................................................... 45

ACCEPTANCE AND RECTIFICATION OF WELDS ............................................. 46

Non-Destructive Testing Acceptance Criteria ............................................................ 46

Rectification of Welds ................................................................................................. 46

Documentation to be Provided with Tender ............................................................... 48

Documentation Required Prior to Commencement of Work...................................... 48

Documentation Required on Completion of WORK ................................................... 48

JPK Doc.No.06-2915-08-U-1-013 Rev 01

JPK Doc.No.06-2915-08-U-1-013 Rev 01

Figure 1.1 Northern North Sea Assets

JPK Doc.No.06-2915-08-U-1-013 Rev 01

TAQA Bratani Ltd or any of its subsidiaries or representative agents.

The Party contracted by COMPANY to carry out welding operations

The Material Supplier to the CONTRACTOR or vendor of material,

Indicates mandatory requirements.

Consent given in writing, on behalf of COMPANY, in advance of an

ASNT Central certification Programme

As Low as Reasonably Practicable

American National Standards Institute