05-3300-01-W-01-009 Pipeline Welding and NDT Spec (Onshore) Rev P2

cobra
ACS COBRA CASTOR UTE
P KENNY
CASTOR UNDERGROUND GAS STORAGE

DEVELOPMENT
SPECIFICATION
PROJECT No.
053300
REF
PIPELINE WELDING AND NDT SPECIFICATION

(ONSHORE)
W-01-009
No OF SHEETS
17
DOCUMENT No
OFFICE CODE
PROJECT No
3300
05
COBRA No.
AREA
TYPE
01
DISC
W
01
NUMBER
009
CAS-3000-JP-EG-SPE-005
r1
- %IP
KiLt---
P2
05/11/09
Re-Issued for Client comment
'
P1
13/07/09
Issued for Client comment
RCP
OLA
RCP
AFB
REV
DATE
BY
CFIK
ENG
PM
DESCRIPTION
"'
CLIENT
PIPELINE WELDING AND NDT

SPECIFICATION (ONSHORE)
TABLE OF CONTENTS
1
INTRODUCTION............................................................................................................................. 3
1.1
1.2
1.3
1.4
1.5
General ............................................................................................................................... 3
Purpose of Document ....................................................................................................... 3
Definitions .......................................................................................................................... 3
Abbreviations..................................................................................................................... 3
Units.................................................................................................................................... 4
REFERENCES, CODES AND STANDARDS ................................................................................ 5

2.1
2.2
2.3
Codes and Standards........................................................................................................ 5

Project Specifications and Data Sheets.......................................................................... 5
Order of Precedence ......................................................................................................... 5
SCOPE............................................................................................................................................ 6
MODIFICATIONS OF ISO 13847: 2000 CLAUSES ...................................................................... 7
05-3300-01-W-01-009 Pipeline Welding and NDT Spec (Onshore) Rev P2.doc
Page 2 of 17

INTRODUCTION
1.1
General
The 30 gas pipeline has an offshore section approximately 22km long and an onshore
section approximately 8.5km long. It will be used to transport natural gas from the Spanish
gas pipeline system to the offshore platform and return dehydrated gas from the offshore
platform complex to the onshore gas treatment plant. The offshore section will be connected
by a 31km Fibre Optic Cable (FOC) to the Onshore Operations Plant (OOP). All pipelines will
be buried.
1.2
Purpose of Document
This Specification defines the minimum technical requirements for welding and nondestructive testing of the onshore section of the pipeline during installation. It includes butt
welding of linepipe and butt welding of fittings to linepipe.
Welding shall be suitable for sour service according to NACE MR10175/ISO 15156-2.
1.3
Definitions
For a comprehensive list of definitions refer to the Contract Agreement to which this
Specification applies.
For the purpose of this Specification:
ACS COBRA CASTOR
ACS COBRA CASTOR UTE or its appointed representatives.
Contractor
The ACS COBRA CASTOR selected contractor for the

provision of the services.
Specifications
Those Specifications contained in the Contract Agreement.
Other defined terms used in this Specification and elsewhere in the Contract Agreement shall
have the meaning assigned to them as defined within the General Terms and Conditions.
Within the Contract Agreement, defined terms are denoted by means of words with an initial
capital.
1.4
Abbreviations
EN
European Standard
ISO
International Standard Organisation
MPS
Manufacturing Procedure Specification
MUE
Manual Ultrasonic Examination
PQR
Procedure Qualification Record
QA
Quality Assurance
QC
Quality Control
QP
Quality Plan
Page 3 of 17

SI
1.5
System of International units
Units
System of International (SI) units shall be used throughout the design. In accordance with
standard industry practice, other units may be used as follows:
Nominal pipe size
inches []
Pressure
bar gauge [barg]
Temperature
Celsius degree [C]
Contractor shall take full responsibility for the use of any pre-treatment chemicals and shall
take full responsibility for compliance with HSE requirements regarding use and disposal of
pre-treatment chemical residues.
Page 4 of 17

REFERENCES, CODES AND STANDARDS

The latest revision of the following Codes, Standards and Specifications shall apply unless
otherwise indicated.
2.1
2.2
2.3
Codes and Standards

EN 1011-2
Welding Recommendations for welding of metallic

materials Part 2: Arc welding of ferritic steels
EN 10204
Metallic Products Types of Inspection Documents
EN 26847 (ISO 6847)
Covered electrodes for manual metal arc welding.

Deposition of a weld metal pad for chemical analysis
ISO 13847: 2000
Petroleum and natural gas industries

transportation systems Welding of pipelines
NACE MR0175/ISO 15156-2
Petroleum and natural gas industries Materials for use in

H2S-containing environments in oil and gas production
Part 2: Cracking-resistant carbon and low alloy steels, and
the use of cast irons
Pipeline
Project Specifications and Data Sheets

05-3235-7100-1-001
Specification for Linepipe
05-3235-7100-7-004
Data Sheet for Linepipe
Order of Precedence
Contractor shall notify ACS COBRA CASTOR of conflict between this Specification, the
related Data Sheets, the Codes, Specifications and Standards and any other Specifications
noted herein.
Resolution and/or interpretation of precedence shall be obtained from ACS COBRA CASTOR
in writing before proceeding with the design or manufacture.
All written responses to Contractor from ACS COBRA CASTOR shall be binding. However
any such response shall not relieve Contractor of his contractual obligations unless
specifically stated.
In case of conflict, the order of precedence shall be:
1) This Specification
2) Industry Codes and Standards
3) Approved application procedure
Page 5 of 17

SCOPE
Field welding shall be in accordance with ISO 13847: 2000 (hereafter referred to as ISO
13847) together with the additional and requirements and amendments detailed in this
specification. All sections of ISO 13847 shall apply, unless otherwise modified by this
Specification.
Welding shall be suitable for sour service in accordance with NACE MR0175/ISO 15156-2.
Page 6 of 17

MODIFICATIONS OF ISO 13847: 2000 CLAUSES

The following sections of this Specification present the modified clauses of ISO 13847. Their
numbering and headings are the same as those in ISO 13847.
Where modifications are made to an existing clause of ISO 13847, its reference is quoted.
Where a clause is added to ISO 13847, the text Additional to ISO 13847. is indicated in the
section heading.
Normative References
Delete the following:

ISO 9956-2:1995 Specification and approval of welding procedures for metallic materials.
Part 2: Welding procedure specification for arc welding.
ISO 9956-3:1995 Specification and approval of welding procedures for metallic materials.
Part 3: Welding procedure tests for arc welding steels.
Replace with the following:
EN ISO 15609-1:2004. Specification and qualification of welding procedures for metallic
materials- Welding procedure specification -Part 1: Arc Welding.
EN ISO 15614-1: 2004. Specification and qualification of welding procedures for metallic
materials- Welding procedure test-Part 1: Arc and gas welding of steels and arc welding of
nickel and nickel alloys.
Terms and definitions
3.5
by agreement
Replace existing text as follows:

agreed between ACS COBRA CASTOR and Contractor.
Specification].
3.6
[Note: see Clause 1.3 of this
company
References to company in ISO 13847 shall be read as ACS COBRA CASTOR. [Note: see
Clause 1.3 of this Specification].
3.7
contractor
References to contractor in ISO 13847 shall be read as Contractor. [Note: see Clause 1.3
of this Specification].
Add the following Section:
3.20
approved
Where relevant, approved shall have the meaning qualified and approved by ASC COBRA
CASTOR.
Page 7 of 17

Welding procedure specification testing and approval
5.1
General
Delete reference to ISO 9956-3 in the first paragraph and replace with EN ISO 15614-1
Add the following:
Contractor shall specify in his tender the welding process, processes or combination of
processes proposed for pipelay or shop welding operations. Manual, semi-automatic or
automatic welding processes may be offered.
Welding by the Self-Shielded Flux Cored Arc Welding (SSFCAW) process, the oxyacetylene
welding process and any process not covered by ISO 13847 shall not be permitted.
Preliminary welding procedure specifications (pWPS) shall be submitted to ACS COBRA
CASTOR for approval prior to approval qualification testing.
Qualification of each agreed pWPS shall be carried-out by non-destructive and mechanical
testing of a test weld in accordance with this Specification. A procedure qualification record
(PQR) shall be prepared based on the welding variables recorded during test welding and
submitted to ACS COBRA CASTOR for approval. As a minimum, the PQR shall include the
following documents:
The preliminary WPS approved by ACS COBRA CASTOR for qualification;
A record of actual welding details/variables of the qualification test, including all the
details required in Section 5.2 for the WPS;
Material certificates and consumable data sheets;
PAMS printout of the welding parameters;
Summary of welding parameters recorded, including heat input calculation;
Pre-heat treatment records (as applicable);
Visual Inspection Report;
NDT Reports;
Laboratory Test Report for mechanical and metallurgical tests from a laboratory
approved by ACS COBRA CASTOR.
All welding procedure qualification tests shall be carried-out in the presence of a

Representative of ACS COBRA CASTOR
Following satisfactory completion of WPQ, a final WPS shall be produced and submitted to
ACS COBRA CASTOR for approval for production welding. This shall be based on the
pWPS, which shall be modified to reflect any changes that were recorded during the
qualification tests.
Previously qualified welding procedure specifications shall not be permitted.
Page 8 of 17

5.2
Welding Procedure Specification
Delete reference to ISO 9956-2 in first and last paragraph and replace with EN ISO 156091.
Add the following to the list of requirements of WPS:
-
5.3
For mechanised GMAW , GSFCAW or FCAW, the number of welding heads for each
pass, contact tip to work distance, inductance setting, mode of transfer, pulse details (if
applicable), oscillation frequency and width, dwell time on side wall..
Welding of test piece
5.3.5.1 Girth welds

Modify existing text as follows:
Test pieces for test welding shall be made by joining pipe pup pieces 1 m in length or 1.5
times the pipe diameter, whichever is greater.
When an internal line-up clamp is used in production welding, the length of the pup pieces
used in qualification testing shall be sufficient to accommodate the full length of the clamp.
The minimum length of test rings for the qualification testing of fittings shall be subject to
agreement with ACS COBRA CASTOR.
5.3.5.2 Branch connections and fillet welds
Delete reference to ISO 9956-3 in clause 5.3.5.2 and replace with EN ISO 15614-1.
5.4
Inspection and testing of test pieces
5.4.1
Scope of Inspection and testing
Add the following to Table 1 (Inspection and testing of the test pieces for girth welding):
-
100% Magnetic particle examination (MPE)
100% Manual ultrasonic examination (MUE)
Add the following clarifications:

Visual examination shall cover internal and external surfaces.
All-weld tensile testing shall be mandatory (One specimen for each test weld).
5.4.2
Non-destructive examination
Delete 2nd paragraph and replace with the following:

Non-destructive examination shall be carried-out no sooner than 48-hours after completion of
welding.
Page 9 of 17

5.4.3
Destructive testing - Girth welding
5.4.3.4 Transverse tensile testing

Delete 4th and 5th paragraph and replace as follows:
The minimum tensile strength of the transverse tensile test specimens shall not be less than
the minimum tensile strength of the linepipe parent material specified in the Data Sheet for
Linepipe 05-3235-7100-7-004.
5.4.3.5 Impact testing
Delete 5th paragraph and replace as follows:
The Charpy V-notch impact testing temperature and acceptance criteria shall be as specified
in the Data Sheet for Linepipe 05-3235-7100-7-004.
5.4.3.7 Hardness testing
Add the following clarification:
The results of hardness testing shall meet the requirements of Table 2 for sour service.
The parent metal hardness values shall not exceed those permitted in the Data Sheet for
Linepipe 05-3235-7100-7-004.
5.4.3.8
All-weld-metal tensile testing
Delete existing text and replace with the following:

All-weld tensile testing shall be required according to Table 1. The test specimens shall be
prepared and tested in accordance with EN 876 or alternative method agreed with ACS
COBRA CASTOR.
The measured yield strength shall not be less than the SMYS of the parent pipe metal as
specified in the Data Sheet for Linepipe 05-3235-7100-7-004.
5.5
Re-testing
5.5.2
Re-testing for approval of WPS
Add the following:

Should a welding procedure qualification test fail to meet the minimum requirements of nondestructive and destructive tests, or permitted retests, the welding procedure specification
shall be regarded as not complying with the requirements of this specification. The cause of
the failure shall be established, rectified and the welding procedure revised to the satisfaction
of ACS COBRA CASTOR, before the qualification test is repeated.
5.6
Essential variables and range of approval
5.6.2
related to the contractor
Modify the second paragraph as follows:

Approved and qualified welding procedures shall not be transferred from one contractor to
another.
Page 10 of 17

5.6.3
Related to the material
5.6.3.1
Steel grade

Qualification of welding procedures for linepipe shall be carried out on linepipe supplied to the
project in accordance with Specification for Linepipe 05-3235-7100-1-001 and Data Sheet for
Linepipe 05-3235-7100-7-004.
Qualification of welding procedures to connect line pipe directly to components such as
fittings, flanges, tee or bends shall be carried out using representative test material. These
shall be test rings or actual components produced by the manufacturer of the component to
be welded using the same MPS.
5.6.3.2
Chemical composition

Based on product analysis, a change in the CE value greater than +0.01 or -0.03 or greater
than +0.01 or -0.02 Pcm shall require requalification.
CE shall be calculated as follows:
CE = %C +
%Mn
6
(%Cr + %Mo + %V)

5
(%Cu + %Ni)
15
Pcm shall be calculated as follows:

Pcm = %C +
%Si
30
%Mn
20
%Cu
20
%Ni
60
%Cr
20
%Mo
15
%V
10
+ %B x 5
5.6.3.3 Supply condition

Add the following:
Any change in the linepipe supplier shall require requalification of the WPS.
5.6.3.4 Thickness
Delete 1st paragraph and replace as follows:
For girth welding, the approved pipe thickness range shall be as follows:
5.6.4
5.6.4.7
t 30 mm: 0.75 to 1.5 times the wall thickness of the test piece.
t > 30 mm: 0.75 to 1.25 times the wall thickness of the test piece.
Related to all welding processes

Arc energy
Modify the existing text as follows:
Any change in arc energy for each pass outside the range in the approved WPS shall
constitute an essential variable.
Page 11 of 17

The qualifying heat input range for the root pass, hot pass, fill pass and cap pass shall be
considered separately.
When Contractor opts to carry-out separate qualification tests at the proposed maximum and
minimum heat input, in order to extend the heat input qualification range, the heat input
tolerance shall not exceed the maximum and minimum recorded in all qualification tests.
5.6.4.15
Time interval
The approved time lapse between root and hot pass for any welding consumable type shall
not exceed that recorded during qualification.
5.6.5
Related to specific welding processes
5.6.5.1 Shielded metal arc welding and self-shielded flux-cored arc welding
Add the following:
Self-shielded flux cored arc welding shall not be permitted (See Clause 5.1).
5.6.5.3 Gas metal arc welding and gas-shielded flux-cored arc welding
Add the following:
For GMAW and GSFCAW the approved electrical characteristics and transfer mode shall be
the same as that used for welding of the test piece.
Approval and testing of welders and welding operators
Add the following general clarification:
Welders shall be qualified by CENIM (Centro Nacional de Investigaciones Metalurgicas) or

third party authorized to check compliance according to Reglamento de Gases Combustibles.
6.5
Inspection and testing of test welds
6.5.1
Non destructive examination of welder test pieces shall include visual examination of external
and internal surfaces and radiography. In the case of welds carried out by the GMAW and
GSFCAW processes, manual ultrasonic examination shall be carried-out in addition.
6.7
Range of approval
Add the following to g):
Same electrode manufacturer and brand name.

Delete j) and replace as follows:
j) welding equipment and system: same make and model of welding equipment or system.
Page 12 of 17

6.8
Records
Add the following:
For details on the procedure qualification record (PQR) reference is made to Section 5.1.
6.9
Period of validity
Delete 2nd paragraph, 1st sentence and replace as follows:
The qualification and ACS COBRA CASTOR approval of a welder or welding operator shall
remain valid for a period of one year provided that:
Production Welding
7.1
General
Add the following:
Contractor shall provide independent means for accurate monitoring of the welding
parameters defined in the agreed welding procedure specifications.
7.2
Equipment
Add the following:
Automatic welding equipment shall be the same make and model as used in production.
7.10
Electrodes and filler materials
Add the following:
Filler metals and fluxes shall conform to the appropriate American Welding Society (AWS)
and/or British Standard and shall be subject to approval by ACS COBRA CASTOR before
starting work.
The use of cellulosic electrodes for welding butt joints in pipe and fittings shall be restricted to
welding of the root and hot pass only.
Repair welding and welding of fittings shall be carried out using low hydrogen consumables.
Additional requirements for handling and control of consumables are as follows:
Records of consumable usage shall be maintained such that source, type and batch of
welding consumables used for each weld can be identified.
Consumables shall be supplied in sealed, dirt and moisture-resistant packages. Damaged
packages and any consumables showing any signs of damage, deterioration, corrosion or
any other contamination shall not be used.
Each coil of filler wire, bag of flux and tin or packet of electrodes shall be clearly marked with
its batch number and shall be stored completely separated.
Consumables shall be stored and handled at all times in such a way as to avoid damage and
contamination to them or their containers. Any consumables in open containers shall be
protected from excessive moisture changes.
Page 13 of 17

Special care shall be taken by Contractor to ensure that basic coated low hydrogen
electrodes are stored in sealed containers in a warm, dry environment. Prior to use, low
hydrogen electrodes shall be baked in accordance with the manufacturers instructions to give
a diffusible hydrogen content of less than 5ml/100g of deposited weld metal. After baking, the
electrodes shall be transferred to a holding oven operating at 150C minimum, where they
may be stored for a period of up to 7 days and after which they shall be re-baked. Electrodes
shall not be re-baked more than two times.
A procedure for marking and tracking electrodes on their baking route shall be proposed by
Contractor for ACS COBRA CASTOR approval.
Low hydrogen electrodes shall be issued for use from the holding ovens into heated quivers
held at 70C minimum. Any low hydrogen electrode remaining unused after 4 hours in a
quiver shall be returned to the baking oven and re-dried for 2 hours at 350C before being
returned to the holding oven.
Vacuum packed, low hydrogen electrodes may be used without prior baking, provided they
are used within the consumable manufacturers guidelines.
Add the following mandatory requirements for batch testing of welding consumables:
Batch testing of welding consumables is required as detailed below:

The purpose of batch testing is to verify that the consumables used for girth welds remain
nominally equivalent to that used for welding procedure qualification, with respect to
chemistry and mechanical properties.
A batch is defined as the volume of product identified by the consumable manufacturer under
one unique batch number, manufactured in one continuous run from batch controlled raw
materials.
Each individual product (brand name and dimensions) shall be tested once per batch, except
for solid wire originating from the same heat, where one diameter may represent all.
SAW fluxes do not require individual testing, however, SAW wires shall be tested in
combination with a selected, nominal batch of flux.
The testing shall be performed on samples taken from girth welds welded according to the
welding procedure specification to be used in production. Three samples shall be removed
from the 12 and 6 o'clock position and from the 3 or 9 o'clock position.
The testing of each sample shall include:
a)
1 all-weld metal tensile test. Hardness testing (HV10) of the centre at the end of each
grip;
b)
1 macro section taken adjacent to the all-weld metal tensile test. The macro section
shall be hardness tested (HV10) vertically through the weld centre line with
indentations spaced 1.5mm apart;
c)
1 set of Charpy V-notch test at weld centre line in half thickness.

temperature shall be as specified in clause 5.4.3.5;
d)
Chemical analysis. For solid wire and metal powders, the analysis shall represent the
product itself. For coated electrodes and cored wires, the analysis shall represent the
weld metal deposited according to EN 26847 (ISO 6847). The analysis shall include
all elements specified in the relevant classification standard and the relevant data
sheet.
The test
Page 14 of 17

The mechanical properties shall meet the specified requirements for the welding procedure
specification.
Batch tests shall be documented by an inspection certificate to EN 10204 3.1 with reference
to a recognised product qualification standard and contain all specified results.
7.12
Preheating
Add the following:
The minimum preheat shall comply with EN 1011-2.

Preheat shall be applied when required by the qualified WPS. In all cases, preheat shall be
required when the ambient temperature measured on the pipe is below 10C and to ensure
that the weld area is dry.
A minimum preheat temperature of 150C shall be used for welding fittings and for repair
welds.
The use of hand held torches for the application of preheat is not permitted.
7.18
Partially completed welds
Delete the existing text of the 5th paragraph as follows:
Partially completed welds should be rejected when welding has been interrupted before
completion of three passes. Additional inspection may be specified in case completion of such
welds is permitted
Replace with the following:
Welding shall not be interrupted before the joint has sufficient strength to avoid plastic yielding
and cracking during handling. Prior to restart after an interruption, preheating to the minimum
inter-pass temperature of the pass in question shall be applied.
7.19
Post-weld heat treatment
Post weld heat treatment shall not normally be required.
Page 15 of 17

8.1
General
Add the following:
All production welds shall be subjected to the following visual and NDE:
a)
100% radiography.
b)
100% external visual.
Manual UE may be used as an aid in interpretation of radiography.

8.6
Ultrasonic examination
8.6.4
Manual ultrasonic examination
Add the following:
Manual UE shall not be used as the primary NDE method, without the prior approval of ACS
COBRA CASTOR.
8.6.5
Mechanised examination
Not applicable.
Acceptance criteria for non destructive examination
9.3
Visual examination
Add the following:
External surface breaking lack of fusion or lack of penetration is unacceptable.

9.6
Surface testing
9.6.2
Acceptance criteria
Add the following:
External surface breaking lack of fusion or lack of penetration is unacceptable.
Page 16 of 17

9.8
Acceptance criteria - ECA
Not applicable.
10
Repair and removal of defects
10.1
General
The extent of testing to qualify welding repair procedure specifications shall be as follows:
a)
Full penetration repairs.
Testing and inspection requirements are the same as

normal production welds.
b)
Partial penetration repairs.
Any relaxation of testing requirements, compared to

normal production welds, shall be subject to approval of
ACS COBRA CASTOR.
c)
Single pass repairs.
In the case of single pass repairs, mechanical

qualification testing shall comprise one macro/hardness
examination.
10.4
Defect removal and preparation for repair
Add the following:
In the event that cracks are detected in a weld, the complete weld shall be cut out of the
pipeline.
The cause of the cracking shall be determined by Contractor and precautions against a
reoccurrence of the cracking justified to ACS COBRA CASTOR.
Annex A
Hyperbaric welding
Not applicable.
Annex B
Special requirements for welding of CRA-clad steel and CRA pipelines
Not applicable
Annex C
Recommendations for brazing and aluminothermic welding of anode

leads
Not applicable.
Page 17 of 17

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ACS COBRA CASTOR UTE

CASTOR UNDERGROUND GAS STORAGE

PIPELINE WELDING AND NDT SPECIFICATION

Re-Issued for Client comment

Issued for Client comment

PIPELINE WELDING AND NDT

REFERENCES, CODES AND STANDARDS ................................................................................ 5

Codes and Standards........................................................................................................ 5

MODIFICATIONS OF ISO 13847: 2000 CLAUSES ...................................................................... 7