KG-DWN-98/2 PRE-FEED

General Requirements for Welding and Non-Destructive

Testing - SURF & SPS

Level 18, Menara AIA Cap Square

No. 10 Jalan Munshi Abdullah
Kuala Lumpur 50100
Malaysia

Document No. : 402020-01391-01-SY-CRT-0001

Revision : Revision 0A
Date : 08 Sept 2016

www.intecsea.com
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HOLDS List

HOLDS to be inserted in following table.

HOLDS closed during following revision of document to be deleted from the table.

Section No.
HOLD
& Revision Description of HOLD
No.
Inserted

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Table of Contents
1 SCOPE ....................................................................................................................................... 8
1.1 Project Overview ..................................................................................................... 8

1.2 Purpose of Document .......................................................................................... 8

1.3 General Requirement ............................................................................................ 8

1.4 Scope of Work ......................................................................................................... 8

1.5 Project References ................................................................................................. 9

1.5.1 General ...................................................................................................................... 9

1.5.2 Referenced Project Documents ....................................................................... 9

1.6 Codes and Standards .......................................................................................... 10

1.6.1 Table of Codes / Standards .............................................................................10

1.7 Definitions ............................................................................................................... 13

1.7.1 Table of Definitions ............................................................................................13

1.8 Abbreviations and Acronyms ........................................................................... 14

1.9 Key Assumptions .................................................................................................. 15

2 DESIGN DATA ...................................................................................................................... 16

2.1 General Design Data ........................................................................................... 16

2.2 Welding and NDT Design Data ....................................................................... 16

2.2.1 Welding ...................................................................................................................16

2.3 Non-Destructive Testing.................................................................................... 16

3 DESCRIPTION OF WORK ................................................................................................. 17

3.1 Overview .................................................................................................................. 17

4 DESIGN AND MANUFACTURE....................................................................................... 18

4.1 General ..................................................................................................................... 18

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5 WELDING & NON DESTRUCTIVE TESTING ............................................................... 19

5.1 General ..................................................................................................................... 19

5.1.1 Welding ...................................................................................................................19

5.1.2 Non Destructive Testing (NDT) ......................................................................19

5.2 Welding Procedure Specification (WPS) ...................................................... 20

5.3 Procedure Qualification Record (PQR) ......................................................... 21

5.4 Mechanical Testing .............................................................................................. 23

5.5 Welder Qualification ........................................................................................... 24

5.6 Production Welding ............................................................................................ 24

5.6.1 General ....................................................................................................................24

5.7 Welding Consumables-General ...................................................................... 25

5.8 Welding Equipment............................................................................................. 26

5.9 Pre-Heat................................................................................................................... 26

5.10 Interpass Temperature ....................................................................................... 27

5.11 Post Weld Heat Treatment ............................................................................... 27

5.12 XMT, Tubing Hanger and Associated Equipment .................................... 28

5.12.1 Welding Requirements .....................................................................................28

5.12.2 NDT Requirements. ............................................................................................28

5.13 Pipeline / Flowline Welding Applications .................................................... 29

5.13.1 Design Code ..........................................................................................................29

5.13.2 Welding Requirements .....................................................................................29

5.13.3 Welding Consumables for Pipeline / Flowline .........................................29

5.13.4 Weld Traceability .................................................................................................30

5.13.5 Pipeline / Flowline Weld Repairs ...................................................................30

5.13.6 NDT of Pipelines / Flowlines ...........................................................................30

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5.14 Duplex Stainless Steel Welding Requirements .......................................... 31

5.15 Welding of Duplex Stainless Steels ............................................................... 31

5.16 Welds on Clad Material ...................................................................................... 32

5.17 Repair Welding...................................................................................................... 32

5.18 Welding Requirements for Flexible Flowlines ............................................ 33

5.18.1 NDT Requirements for Flowlines...................................................................33

5.19 Welding of Jumpers ............................................................................................ 33

5.19.1 NDT of Jumpers ...................................................................................................34

5.20 Welding of Subsea Valves ................................................................................. 34

5.20.1 NDT of Subsea Valves .......................................................................................34

5.21 Overlay Welding ................................................................................................... 35

5.21.1 NDT of Overlay Welding ..................................................................................35

5.22 Welding of Piping, Fittings and Flanges ...................................................... 35

5.22.1 NDT of Piping, Fittings and Flanges Welds ...............................................35

5.23 Welding of Piping within Structures, PLETs/PLEMS, Manifolds and

ILS............................................................................................................................... 35

5.23.1 NDT of Piping within Structures ....................................................................36

5.24 Welding of Umbilical Components ............................................................... 36

5.25 Testing Requirements Duplex Material ........................................................ 37

5.25.1 Ferrite Testing (Umbilicals) ..............................................................................37

5.25.2 Chemical Composition (Umbilical) ...............................................................38

5.25.3 Production Welding (Umbilical).....................................................................38

5.25.4 Tube Repair (Umbilical).....................................................................................39

5.25.5 NDT of Umbilicals ...............................................................................................39

5.26 Welding of Subsea Distribution Units (SDU).............................................. 40

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5.26.1 NDT Requirement for SDU ..............................................................................40

5.27 Welding of Diverless Connectors ................................................................... 40

5.27.1 NDT requirements for Subsea Diverless Connectors ............................40

6 WELDING AND NDT DOCUMENTATION .................................................................. 41

6.1 General ..................................................................................................................... 41

6.2 Documentation ..................................................................................................... 41

7 ENGINEERING CRITIAL ASSESSMENT (ECA)............................................................. 42

7.1 General ..................................................................................................................... 42

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1 SCOPE

1.1 Project Overview

ONGC intends to develop the New Exploration Licensing Policy (NELP) Block KG-DWN-98/2, in
deep waters off the east coast of India. The discovery areas in the block have been categorized as
Northern Discovery Area (NDA) and Southern Discovery Area (SDA). The scope of this present
development is limited to Cluster 2 of NDA only.

A more detailed project description is provided in the 402020-01391-01-SY-BOD-0001, Overall

Design Basis.

1.2 Purpose of Document

The purpose of this document is to define the General Requirements for Welding and Non-
Destructive Testing (NDT) for the Subsea Umbilicals, Rigid Jumpers, Risers and Flowlines (SURF)
and Subsea Production Systems (SPS) components of the Project that will comply with ONGC's
practices for safe and responsible operations. These general requirements are applicable to all
phases of the CONSTRUCTION, however more specific and defined requirements shall be
developed for each CONSTRUCTION package.

1.3 General Requirement

The Welding and NDT requirements for all aspects of the CONSTRUCTION shall be established
based on Contractual and applicable regulatory requirements.

1.4 Scope of Work

This specification is applicable to the following applications

 Pipeline and Flowline Welding (rigid and flexible) and shall apply to all onshore and offshore
pipelines as well as Risers, PLEMs, PLETs Manifolds, ILS, ILT, rigid Jumpers and Tie ins for the
automatic and manual welding of girth welds and attachments.
 XMT, Tubing Hangers and associated equipment
 Pressure Retaining Components Welding (piping, fittings, flanges etc.)
 Structural Welding including Subsea Structures
 Tubing Welding including, but not limited to, Umbilicals and Flying Leads

All welding and inspection shall be carried out using welding processes and techniques permitted
by the Project referenced Codes and Standards and as listed in COMPANY project specifications.

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CONTRACTOR shall obtain COMPANY written approval for any deviations from the requirements
of this document or specifications, standards and drawings referenced herein or elsewhere in the
Contract.

This document and the codes, specifications and referenced documents listed in section 1.4 and
1.5 below are not intended to be all-inclusive. The requirements set forth do not relieve
CONTRACTOR of his responsibility to perform all services in a safe manner, to meet applicable
codes and standards, to comply with government regulations or to supply a product capable of
performing its intended service.

In addition to the requirements of referenced documents listed below the supplemental

requirements of this specification shall apply and take precedence.

1.5 Project References

1.5.1 General

The latest editions of all applicable codes, specifications and references shall define the minimum
requirements applicable to the subject work and no statement contained in this General
Requirements document shall be construed as limiting the work to such minimum requirements.

Wherever conflicts or omissions between codes, specifications and contract occur, the most
onerous condition shall apply. CONTRACTOR is responsible for reviewing the list below and
informing the COMPANY of any omissions. All conflicts shall be formally brought to the attention
of COMPANY.

1.5.2 Referenced Project Documents

Ref No. Document Number Document Title

1 402020-01391-01-SY-BOD-0001
2 402020-01391-01-QA-CRT-0001
3 402020-01391-01-SY-CRT-0001
4 402020-01391-01-SY-DEG-0001
Overall Design Basis
General Requirements for QA/QC – SURF & SPS
General Requirements for Welding and NDT –
SURF & SPS (This document)
Corrosion Design Basis Memorandum – SURF &
SPS

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1.6 Codes and Standards

1.6.1 Table of Codes / Standards

Item Code / Standard Number Description

No.
International Standards Organization (ISO)
Design and Operation of Subsea Production Systems –
1 ISO 13628-1
General Requirements and Recommendations
Design and Operation of Subsea Production Systems –
2 ISO-13628-5
Subsea Umbilicals
Design and Operation of Subsea Production Systems –
3 ISO-13628-6
Subsea Production Control Systems
Design and Operation of Subsea Production Systems –
4 ISO 13628-8
ROV Interfaces on Subsea Production Systems

5 ISO 9001 Quality management systems requirement

6 ISO 14001 Environmental management systems
7 ISO 10204 Metallic products – Types of inspection documents
Non-Destructive Testing –Qualification and Certification
8 ISO 9712
of NDT Personnel-General Principles.
Drilling and Production Equipment- Wellhead and
9 ISO 10423
Christmas Tree Equipment
American Society of Mechanical Engineers (ASME)
10 Section II-Part C Welding Rods, Electrodes and Filler Metals
11 Section V Non-Destructive Testing
12 Section VIII Rules for Construction of Pressure Vessels
13 Section 1X Welding and Brazing Qualification
14 ASME B16.5 Pipe Flanges and Flanged Fittings
15 ASME B16.10 Face-to-face and end-to-end dimensions of valves
16 ASME 16.25 Butt welded ends for pipe, valves, flanges and fittings
17 ASME 16.34 Valves flanged, threaded and welding end
18 ASME 31.3 Process Piping
19 ASME 36.10 Welded and seamless wrought steel pipe
20 ASME 31.8 Gas Transmission and Distribution Piping Systems.

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Item Code / Standard Number Description

No.
Pipeline Transportation Systems for Liquid Hydrocarbons
21 ASME 31.4
and Other Liquids
American Society for Testing and Materials (ASTM)
Standard Test Methods for Detecting Susceptibility to
22 ASTM G28 Intergranular Corrosion in Wrought, Nickel-Rich,
Chromium-Bearing Alloys
Standard Test Methods and Definitions for Mechanical
23 ASTM A370
Testing of Steel Products
Standard Specification for Straight Beam Ultrasonic
24 ASTM A578
Examination of Plain and Clad Steel Plates.
Practice for Determining Volume Fraction by Systematic
25 ASTM E562
Point Count.
Standard Specification for seamless and welded ferritic
26 ASTM A789
steel tubing for general use.
Standard Specification for general requirements for
27 ASTM A 450
carbon, ferritic alloy and austenitic alloy steel tubes
Standard Specification for Carbon and Alloy Steel
28 ASTM A694 Forgings for pipe flanges, fittings, valves and parts of high
pressure transmission services.
29 ASTM A 165 Standard Test Method for Liquid Penetrant Testing
30 ASTM G46 Examination and Evaluation of Pitting Corrosion
Standard Practice for ECT examination of seamless and
31 ASTM E426 welded tubular products, austenitic stainless steel and
other similar alloys.
Standard Test Method for Vickers Hardness Testing of
32 ASTM E23
Metallic Minerals
Standard Practice for Contact Ultrasonic Examination of
33 ASTM E164
Weldments.
34 ASTM E709 Standard Practice for Magnetic Particle Examination.
American Petroleum Institute(API)
Design Construction, Operation and Maintenance of
35 API RP 1111
Offshore Hydrocarbon Pipelines ( Limit State Design)

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Item Code / Standard Number Description

No.
Recommended Practice for Planning, Designing and
36 API RP 2A Constructing Fixed Offshore Platforms Working Stress
Design
Welding Guidelines for the Chemical, Oil and Gas
37 API RP 582
Industries
Recommended Practice for Subsea Production Reliability
38 API RP 17N
and Technical Risk Management,
Recommended Practice and Supplementary Welding
39 API RP 14E
Guidelines for the Chemical, Oil and Gas Industries
40 API 6A Specification for Wellhead and XMT equipment.
41 API 17J Specification for Un-bonded Flexible Pipe
42 API 14E Specification for Subsurface Safety Valve Equipment
43 API 6D SS Specification for Subsea Pipeline Valves.
American National Standards Institute/National Association of Corrosion
Engineers(ANSI/NACE)
ANSI/NACE MR 0175 ISO Materials for use in H2S containing environments in oil
44
15156 Pts 1,2 & 3 and gas production.
British Standards (BS)
45 BS EN ISO 9001 Quality Management Systems Requirements
Welding Consumables. Gases and Gas Mixtures for Fusion
46 BS EN ISO 14175
Welding and Allied Processes
47 BS EN ISO 6507-1 Metallic Materials Vickers Hardness Test. Testing Method.
Metallic Materials. Method of Test for the determination
48 BS EN ISO 15653
of Quasistatic Fracture Toughness of Welds.
49 BS EN 10204 Metallic Products –Types of Inspection Documents.
Det Norske Veritas(DNV)
50 DNV-OS-F101 Submarine Pipeline Systems
51 DNV RP B401 Recommended Practice for Cathodic Protection Systems.
52 DNV RP C101 Design of Offshore Structures (LRFD-method)
53 DNV RP C203 Fatigue Strength analysis of Offshore Structural Steel.
54 DNV OS C401 Fabrication and Testing of Offshore Structures.
55 DNV RP F204 Riser Fatigue

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Item Code / Standard Number Description

No.
Design of Duplex Stainless Steel Subsea Equipment
56 DNV RP F112
Exposed to Cathodic Protection.
Fracture Control for Pipeline Installation Methods
57 DNV RP F108
introducing Cyclic Strain.
Pipe Girth Weld AUT System Qualification and Project
58 DNV RP F118
Specific Procedure Validation.
59 DNVGL RP 0034 Steel Forgings for Subsea Applications.
American Welding Society (AWS)
60 AWS D1.1 Structural Welding Code-Steel
61 AWS A3.0 Standard Welding Terms and Definitions.
American Society of Non-destructive Testing (ASNT)

Recommended Practice –Personnel Qualification and

62 ASNT-SNT-TC-1A
Testing in Non-Destructive Testing.

1.7 Definitions
For the purpose of this document, the following definitions shall apply:

1.7.1 Table of Definitions

Term Definition
COMPANY or “Owner” shall mean ONGC, its affiliated companies,
COMPANY partners, co-lessees, co-owners, joint ventures, and their agents, third
party inspectors, officers, and employees.
Where referenced shall mean COMPANY’S written and executed
CONTRACT
contract with the CONTRACTOR.
Also referred to as “Vendor”, “Seller” or “Supplier” shall mean the party
CONTRACTOR to whom COMPANY’S Purchase Order, CONSTRUCTION Order, or other
written CONTRACT is awarded.
Where referenced, shall mean those processes that produce the
CONSTRUCTION
equipment, including manufacture, fabrication, assembly, and testing.
MAY Indicates possible course of action.
Any assembly or sub-assembly deemed to be critical to the safety,
Safety Critical Element
integrity and performance of the subsea production system.

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Term Definition
SHALL Indicates mandatory requirement.
SHOULD Indicates preferred course of action.
The person, group or organization who may be employed by
CONTRACTOR (or sub-CONTRACTOR in reference to a supply chain) to
Sub-CONTRACTOR provide services for the design, manufacture, testing and load-out /
shipping of the equipment, or, to provide materials, sub- components
and sub-assemblies for incorporation in the specified equipment.
WILL Indicates an intention of action.
WORK The scope of CONSTRUCTION to be performed per the CONTRACT.

1.8 Abbreviations and Acronyms

Term Definition
AUT Automatic Ultrasonic Testing
CE Carbon Equivalent
CO2 Carbon Dioxide
CRA Corrosion Resistant Alloy
CVN Charpy V Notch
ECA Engineering Critical Assessment
ECT Eddy Current Testing
FPSO Floating Production Storage and Offloading
GTAW Gas Tungsten Arc Welding
H2S Hydrogen Sulfide
HAZ Heat Affected Zone
HE Hydrogen Embrittlement
HISCC Hydrogen Induced Stress Corrosion Cracking
ILS / ILT Inline Sled / Inline Tee
KOH Potassium Hydroxide
MPI Magnetic Particle Inspection
NDA Northern Discovery Area
NDT Non Destructive Testing

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Term Definition
Pcm Critical Metal Parameter
PLEM Pipeline End Manifold
PLET Pipeline End Termination
ppmV Parts per Million by Volume
PQR Procedure Qualification Record
PWHT Post Weld Heat Treatment
QA Quality Assurance
QC Quality Control
RBM Riser Base Manifold
ROL Run Out Length
RPQR Repair Procedure Qualification Record
RT Radiographic Testing
RWPS Repair Welding Procedure Specification
SDA Southern Discovery Area
SDU Subsea Distribution Unit
SPS Subsea Production System
SURF Subsea Umbilicals, Risers and Flowlines
UT Ultrasonic Testing
WPS Welding Procedure Specification
XMT Christmas Tree.

1.9 Key Assumptions

1) CO2 content: 0.5% mol

2) H2S content 50 ppmV for gas only systems

3) H2S content 250 ppmV for oil systems.

4) Hg content Nil

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2 DESIGN DATA

2.1 General Design Data

Key design data for overall field development is defined within the Overall Design Basis (Document
Number: 402020-01391-01-SY-BOD-0001).

2.2 Welding and NDT Design Data

2.2.1 Welding

The governing standard for welding on the KG-DWN-98/2 project shall be as follows.

1) Structural Welding: API RP 2A/AWS D1.1

2) XMT, Tubing Hanger and associated equipment ASME IX/DNVGL RP-0034

3) Pipeline and Riser Welds DNV OS F101

4) Welds in Pipe within ILS/Manifolds/PLET DNV OS F101/ASME IX

5) Any supplementary requirements of welding within the CONTRACT referenced documents,

including this document.

2.3 Non-Destructive Testing

The governing standard for NDT on the KG-DWN-98/2 project shall be as follows:

1) Structural Welding AWS D1.1/ASME V

2) XMT, Tubing Hanger and associated equipment ASME V /DNVGL RP 0034

3) Pipeline and Riser Welds DNV OS F101

4) Welds in Pipe within ILS/Manifolds/PLET etc. DNV OS F101/ASME V

5) Any supplementary requirements of NDT within the CONTRACT referenced documents,

including this document.

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3 DESCRIPTION OF WORK

3.1 Overview
The KG-DWN-98/2 CONSTRUCTION CONTRACTOR is responsible for the Scope of Work under the
CONTRACT in accordance with this specification, including the provision of all labor, materials,
tools, facilities and services required to design, manufacture, test, deliver and load out the specified
equipment. All work shall be performed in accordance with the requirements and provisions of this
specification and CONTRACTOR supplied Project Execution and Quality Plan which shall be
reviewed by COMPANY prior to the start of work.

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4 DESIGN AND MANUFACTURE

4.1 General
The Design Requirements are included in the core specifications, statutory design codes
/regulations and basis of design.

A separate overall and documented philosophy for the prevention of HE and HISSC shall be
established, planned and implemented covering all phases from conceptual development through
to abandonment.

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5 WELDING & NON DESTRUCTIVE TESTING

5.1 General

5.1.1 Welding

All welding on the CONSTRUCTION shall be carried out using a process or combination of
processes that has been fully qualified according to the requirements, referenced codes and
standards and Project specifications.

Within the CONTRACT specified deliverables period, after award, CONTRACTOR shall submit a
matrix showing all welding procedures and procedure qualification records proposed for their
scope of work.

5.1.2 Non Destructive Testing (NDT)

CONTRACTOR shall submit and demonstrate the required examination procedures for COMPANY
review before any welding or procedure qualification welding takes place.

Non-destructive testing shall comply with the specified Codes, Standards and Specifications as
defined in the applicable codes and project specific requirements stated in section 1.6.1 and
relevant to NDT.

RT testing is not allowed for narrow gap configuration welds. Approved AUT methods shall be
used on narrow gap configurations welds.

All NDT technicians shall be qualified as a minimum to ASNT Level NDT II.

QC inspection personnel utilized on the project shall be qualified to CSWIP 3.1.

All NDT procedures shall be reviewed and endorsed by ASNT NDT Level 3 qualified personnel.

The qualifications of intended NDT personnel shall be submitted to COMPANY for review prior to
the commencement of NDT activities.

CONTRACTOR shall provide an NDT matrix to be reviewed by COMPANY prior to start of

manufacture.

CONTRACTOR shall provide a NDT personnel matrix to be reviewed by COMPANY prior to start of
manufacture

Extent of NDT shall be 100% of external surface and volume of weld and their components.

Due to the complexity of flaw assessment and inspection methods of CRA clad materials
considering the dissimilar nature of the materials abutting at any welded joint, CONTRACTOR shall

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develop a reliable inspection technique which allows full assessment of the integrity of any CRA
clad materials following deposition of root and subsequent weld depositions. The inspection shall
demonstrate an absence of root defects and deleterious volumetric defects, and weld shall have a
satisfactory internal root profile. The inspection technique shall be reviewed by COMPANY prior to
any production.

COMPANY reserves the right to proficiency test at no additional cost to COMPANY, any NDT
operative working at any of CONTRACTORs fabrication yards/barges or sub-contractors facilities
irrespective of their current NDT Qualifications. The test will comprise of a practical demonstration
of the NDT operatives abilities on a sample test piece or NDT report relative to the work they will
be carrying out on the project.

5.2 Welding Procedure Specification (WPS)

Weld Procedure Specifications (WPS) shall be based on the allowable weld processes and material
grade to be joined that establishes a detailed method by which sound welds with suitable
properties can be produced. These WPS shall be developed by CONTRACTOR and issued to
COMPANY for review. The WPS shall conform to the requirements of the relevant referenced
specifications and guidelines in section 1.6.1 of this document.

Qualifications shall be conducted on production pipe or plate materials unless otherwise agreed by
COMPANY.

Special care to be taken on carbon steel welds to ensure weld metal is not anodic to parent metal.
Preferential weld corrosion shall be avoided by careful choice of consumables with respect to the
parent metal by the CONTRACTOR in conformance with the relevant referenced specifications and
guidelines in section 1.6.1 of this document. CONTRACTOR to demonstrate compliance to this
requirement for pressure containing welds.

If accelerated cooling is to be used during production welding, then this will be qualified during
procedure qualification using identical conditions as the production welds, including cooling
medium, cooling pressure and minimum coolant temperature.

Position and Welding parameters shall be as qualified in the Procedure Qualification Record (PQR)
for pressure containing welds.

The proposed Welding Procedure Specifications shall include, but not be limited to, the following
information:

 Material type and grade, thickness range and diameter range

 Welding position
 Welding process(es)
 Welding consumables - manufacturer, brand name, type, classification, and size
 Welding travel speed or run-out length (ROL)

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 Welding direction and progression

 Welding amperage and voltage for each pass
 Type of current and polarity for each pass
 Gas shielding - flow rate and composition
 Groove design and preparation method including a sketch with dimensions and tolerances
 Sketch of number and order of passes
 Preheat and interpass temperatures
 Post weld heat treatment

Pre-qualified welding procedures for pressure retaining and primary structural components shall
not be permitted. If permitted previously qualified PQR shall be endorsed by a third party and a
new project specific WPS generated. This WPS shall reflect applicable Project Specifications and
latest codes and standards.

Structural procedures previously qualified by CONTRACTOR and meeting all the requirements
specified for the Project may be submitted for evaluation by COMPANY.

The qualification testing of the WPS shall be documented in a Procedure Qualification Record
(PQR) with testing performed at a COMPANY agreed laboratory.

CONTRACTOR shall provide sufficient advance notice of PQR testing to allow COMPANY to witness
all of the testing.

Only welding procedures reviewed by COMPANY shall be used for production welding

The allowable range of heat input rates to be applied by the welding process for each bead shall
be clearly specified. The units used shall be kilojoules per mm (kJ/mm).

5.3 Procedure Qualification Record (PQR)

Procedure Qualification Record (PQR) of each qualified weld procedure shall contain a record of all
non-essential and essential welding variable values actually used during procedure qualification
welding and the essential variable of heat input shall be logged for each weld pass.

During weld procedure qualification, weld data logging equipment shall be used that allows
recording of voltage, amperage and travel speed for each weld pass, to enable the heat input to be
calculated. This same equipment, or agreed equivalent, shall also be used during production
welding.

Weld data logging equipment shall have valid calibration at the time of checking/measurement.

The PQR shall also contain a weld map detailing the location of each welding pass placed. PQR
shall contain a record of all examination and test results and shall include copies of all examination
and test reports.

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Procedure qualification including mechanical testing shall be witnessed by COMPANY or their

appointed Third Party and if applicable a Classification Society.

When Automatic Ultrasonic Testing (AUT) is to be utilized, CONTRACTOR shall provide the AUT
inspection company with the joint designs details for weld procedure qualification and production
welding for use in the manufacture of the calibration blocks for AUT made from project material
specific to the pipeline.

Test pieces for procedure qualification of carbon steel shall be selected from the higher range of
carbon equivalents (CE) and/or Pcm based on the steel purchased for the Project.

For carbon steel an increase in Pcm of more than 0.02, CE of more than 0.03 or C content more
than 0.02% shall require requalification. Pcm and CE are defined as follows;

𝑆𝑆𝑆𝑆 𝑀𝑀𝑀𝑀+𝐶𝐶𝑢𝑢+𝐶𝐶𝐶𝐶 𝑁𝑁𝑁𝑁 𝑀𝑀𝑀𝑀 𝑉𝑉

Pcm = C + 30 + 20
+ 60 + 15
+ 10 + 5𝐵𝐵

𝑀𝑀𝑀𝑀 𝐶𝐶𝐶𝐶+𝑀𝑀𝑀𝑀+𝑉𝑉 𝑁𝑁𝑁𝑁+𝐶𝐶𝐶𝐶

CE = C + 6
+ 5
+ 15

Any CONTRACTOR proposed Autogenous welding process shall be subject to review by

COMPANY.

Autogenous welding of Duplex Stainless Steel is prohibited.

The Heat Number of the material used for Qualification shall be recorded on the PQR including the
CE and/or Pcm value.

PQR shall record the application of preheat, which may be by electrical resistance method or oxy-
propane torches.

Coupons used on Pipeline/Flowline PQR shall be of representative length and a minimum of 2m

for each coupon (4m for test piece) shall be used

Separate qualification testing is required for repair welding and these repair procedures shall be
subject to COMPANY review cycle and shall be carried out in representative conditions and shall
include a description of defect removal and groove preparation. The RPQR should be similar to a
Procedure Qualification Record and reflect anticipated welding parameters and conditions.
Material test certificates and typical welding consumable test certificates or other background
information shall be provided.

The welding consumables used shall be of a grade which will yield a weld equivalent to or higher
than that of the base metal. Sufficient quantities of welding consumables shall be available for the
entire production program.

Cellulosic electrodes shall not be used for installation welding in deep water (>500m). For other
applications, (e.g. onshore welding and shallow water), use of cellulosic electrodes shall only be
allowed with written consent from COMPANY.

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Welding consumables supplied from a different batch than those used in the qualification program
shall be subject to batch testing.

All NDT for welding procedure’s qualifications shall be carried out 48 hours after the completion of
the weld.

Batch testing of consumables shall be performed using COMPANY reviewed WPS (s).

For any sour service environment, the chemical composition of welding consumables shall comply
with ISO 15156 relevant section

For any sour service environment, the WPS/PQR and production welding shall conform to ISO
15156 relevant section.

All non-sour services for the SURF and SPS shall comply to DNV-OS-F101.

The heat number, material number and other tracking identification shall be transferred and
recorded in the PQR test record.

Weld procedure qualifications shall be performed on coupons of suitable length to accommodate

NDT inspection and to facilitate removal of mechanical test specimens.

5.4 Mechanical Testing

Mechanical testing shall be carried out in accordance with Code requirements, as referenced in the
relevant specifications of section 1.6.1 of this document, by a COMPANY agreed test house, and
witnessed by COMPANY or their appointed Third Party and if applicable a Classification Society.

All mechanical testing and examination shall be conducted after any post weld heat treatment that
may be required.

The review of welding procedure qualifications will be based on satisfactory mechanical testing and
non-destructive examination in accordance with the applicable welding Code.

Qualification Certificates shall include the actual results of the tests required by this Specification.
The term 'satisfactory' for tensile, CVN, hardness and corrosion tests is not acceptable

Acceptance criteria for tests relating to weld performance (tensile, hardness, CVN, corrosion tests,
etc.) shall be included with the reported results (as per construction or welding codes, whichever is
the most stringent).

Additional tests required for corrosion resistant alloys (CRA) shall be reported with mechanical
testing. These shall include acceptance criteria (e.g. ASTM G48 – duration, test temperature and
maximum weight loss) with the results of the test. No evidence of pitting at x20 magnification will
be considered as acceptable. In the event of disputed pits, namely occluded or non-occluded, the
ASTM G46 recommendations shall be used to define the morphology of the pit.

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5.5 Welder Qualification

Only qualified welders/operators shall be employed. Welders shall be qualified in accordance with
applicable project codes using the NDT and destructive testing techniques specified.

COMPANY reserves the right to witness welder and welding operator qualification testing
including any mechanical testing of qualification test coupons.

Grouping weld procedures for welder qualification purposes shall be per the applicable code,
specification or standard referenced for the project.

Welders / welding operator’s qualification tests shall be subject to the same NDT method and
technique as used for production welding.

Welder qualifications remain valid providing there are no gaps greater than 6 months during which
welding using same process, materials and consumables has not been performed.

Pre-qualified welders/welding operators shall be subject to COMPANY review. Welders/Welding

operator’s continuity record shall be reviewed and endorsed by a recognized Third Party.

Each welder’s defect rate shall be monitored by CONTRACTOR.

Any welder/operator responsible for a disproportionate number of defective welds during

construction may be disqualified from further welding on the project or be required to be re-
qualified. Disqualified welders shall only be allowed one re-test. Failing this test, the
welder/welding operator will be required to undergo training before being allowed to take a
second re-test.

Automatic welding equipment used for welder qualification shall be the same type as that
proposed by CONTRACTOR for pipeline/flowline welding.

A list of qualified welders or operators and the procedures they are qualified to use shall be
maintained and posted on the work site. Welder qualification certificates shall include a
photograph of the welder for identification purposes.

5.6 Production Welding

5.6.1 General

Production welding shall be carried out in accordance with COMPANY reviewed welding
procedures.

The qualified WPS shall be located in the vicinity of production welding and shall be available to
welders or automatic welding operators.

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Welding surfaces shall be thoroughly cleaned so as to be dry and free from paint, oil, rust, scale,
and any other material detrimental to weld quality.

Each bead shall be cleaned of scale, oxides, dirt, slag, silicates, and other impurities before any
succeeding weld passes are made.

Welding and heat treatment of weldments must be protected from weather conditions that would
impair weld quality.

Welds carried out on socket welds or threaded seal welds will have a minimum of two runs
showing, on completion of the final pass.

5.7 Welding Consumables-General

Handling and storage of all consumables shall be according to the manufacturer’s
recommendations.

Any consumables unmarked or showing signs of damage degradation or deterioration shall be

discarded. This applies to electrodes, wire and flux.

Low hydrogen electrodes must be adequately stored to limit diffusible hydrogen to a maximum 4.0
ml/100 g deposited metal.

Electrode storage must comply with that used during weld procedure qualification.

Re-baking of low hydrogen electrodes shall be in accordance with manufacturer’s

recommendations for re-baking and if applicable, the requirements specified in COMPANY
specifications or Project Codes.

Only one re-baking shall be allowed.

Flux for submerged arc welding shall be free from any active weld metal alloying additions.

Consumables shall deposit weld metal having a minimum yield and ultimate tensile strength at
least equal to that specified for the parent material.

For piping weld procedure qualifications, the batches of electrodes used for qualifications shall be
used for production.

Should different batches from those used in qualifications be proposed for production, such
consumables will be subject to individual batch tests using COMPANY reviewed WPS (s).

Vacuum packed Low Hydrogen electrodes shall be protected from damage and be accompanied
by the hydrogen classification certificates.

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Low Hydrogen welding consumables capable of depositing weld metal containing less than 4 ml of
hydrogen per 100 grams of deposited weld metal shall be used for carbon steel structures and
pipe work unless specified otherwise in CONTRACT or Project Documentation.

5.8 Welding Equipment

All welding equipment shall be in good working order, in a safe condition and capable of
producing acceptable welds that meet the requirements of the Project specifications.

All equipment used for monitoring or measures welding parameters shall be calibrated to ensure
compliance with the variables listed in the approved welding procedures.

Welding machines shall be operated within the approximate voltage and current ranges
recommended for each type of electrode used. Welding Machines shall not be operated beyond
their rated capacity and shall be maintained in good working order.

Welding machines shall be promptly repaired or replaced if found defective. Welding

instrumentation shall be calibrated every six (6) months.

Welding machine ground leads shall be fastened securely using clamps or other mechanical means
(not welded). Connections shall prevent damage and arcing.

Welding cables with damaged insulation that exposes wire shall be replaced.

Flow meters shall be used for accurate flow rate measurement when shielding gases are used. Gas
analyzers shall be available for checking compositions of gases.

For Non Ferrous Metals, only stainless steel tools or grinding disks dedicated to stainless steel shall
be used. Material supports, internal purge dams, alignment clamps, and other tools may be coated
with a compatible material reviewed by COMPANY.

5.9 Pre-Heat
The minimum preheat temperature for welding shall be in accordance with the temperature
specified in the qualified welding procedure.

Temperature monitoring shall assure the required preheating temperature is obtained before
welding and maintained during the welding operation.

Temperature indicating crayons shall not be marked on weld bevels, weld beads or surfaces to be
welded.

Preheat shall be applied by electrical resistance method or oxy-propane torches.

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Under no circumstances shall the use of oxy-acetylene welding or cutting torches be permitted for
preheating weld joints.

Preheat shall be supplied in a gradual and uniform manner and shall be maintained throughout the
welding operation.

The minimum preheat temperature shall be established on both sides of the joint preparation for a
minimum distance of 75 mm or three times the material thickness, whichever is greater.

If possible, the preheat temperature shall be measured on the opposite face to that being heated.

Unless specified otherwise, the preheat minimum temperature shall be held for a minimum of one
minute for each 25 mm of material thickness before welding is commenced.

The preheat temperature shall be checked before and during welding by temperature indicating
crayons or contact pyrometers.

5.10 Interpass Temperature

The minimum interpass temperature shall be the specified preheat temperature for the material.
The maximum interpass temperature shall be as specified in the reviewed welding procedure.

Maximum interpass temperature shall be measured within 25 mm of the weld bevel by contact
pyrometer or any method of temperature measurement reviewed by COMPANY.

5.11 Post Weld Heat Treatment

Post weld heat treatment shall be required when specified on the reviewed welding procedure.

Heat treatment shall precede any hydro testing requirement.

Weldments which require post weld heat treated shall be indicated by CONTRACTOR on the
fabrication drawings and submitted to COMPANY for review prior to start of fabrication.

For PWHT and/or stress relief procedures, if required, shall be according to the requirements of
applicable code. CONTRACTOR shall submit a PWHT procedure in compliance for COMPANY
review prior to any PWHT being conducted. Only COMPANY reviewed procedures shall be used for
PWHT. These shall include, but not be limited to, the number, location, and method of attachment
of thermocouples to the pipe or location within a furnace.

Any threaded connections shall be gauge checked after heat treatment.

Exposed machined and threaded surfaces shall be protected from oxidation during heat treatment.

Cleaning of piping after fabrication and heat treatment shall be performed externally and internally
to remove all loose scale, weld spatter, sand and other foreign material.

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Final acceptance NDT must be performed after heat treatment.

The use of manually operated gas torches or gas rings shall not be permitted for post weld heat
treatment.

Wherever possible, post weld heat treatment shall be carried out in an enclosed furnace with a
neutral furnace atmosphere. For site or field welds, particularly "in situ" welds, local post weld heat
treatment shall be conducted.

Local post weld heat treatment shall be conducted in accordance with an approved procedure.

During furnace or local post weld heat treatment a minimum of four (4) thermocouples shall be
used to ensure that a uniform temperature is achieved, and no harmful gradients occur during the
heat treatment cycle.

No welding shall be permitted on any material that has been post weld heat treated.

Pipe ends, flange faces, threads and any other machined surfaces shall be suitably protected
against oxidation during the post weld heat treatment cycle.

Multiple post weld heat treatments shall be subject to agreement with COMPANY.

5.12 XMT, Tubing Hanger and Associated Equipment

5.12.1 Welding Requirements

WPS for XMT, Tubing Hanger and associated components shall meet or exceed the requirements
of relevant specifications, ASME IX, NACE MR 0175/ISO 15156 and any additional requirements of
this specification.

5.12.2 NDT Requirements.

All aspects of the XMT, Tubing Hanger and associated components shall be NDT tested utilising a
COMPANY reviewed procedure as per DNV/ASME/BPVC Section V for Non Destructive Testing.

CONTRACTOR shall implement the requirements of DNVGL RP-0034 –Steel Forgings for subsea
applications.

Additional requirements for all major forgings such as tree spools, blocks and valves shall as a
minimum be NDT tested at the thickest section and the highest utilisation section of the forgings
to ensure minimum mechanical properties required for the CONSTRUCTION are achieved
throughout the forging.

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5.13 Pipeline / Flowline Welding Applications

5.13.1 Design Code

The Design Code for KG-DWN-98/2 pipelines and flowlines shall be DNV-OS-F101. Welding shall
follow the requirements of Appendix C of DNV-OS-F101 and any other supplementary
requirements of this general welding and NDT document.

5.13.2 Welding Requirements

Automatic welding processes nominated by CONTRACTOR shall have a proven track record or
have a test program to prove the process capabilities.

CONTRACTOR shall demonstrate that acceptable welds can be reproduced joint to joint utilizing
the process to be used in production.

CONTRACTOR shall establish the production heat input range for each welding pass by completing
a full weld at the Low Heat Input (LHI) and High Heat Input (HHI) values. The maximum/minimum
or range of average for heat inputs for each weld pass shall be measured and documented.

Use of grinders is limited to interpass cleaning only and shall not be used to remove slag or
spatter. Flapper wheels can be used to remove surface slag or spatter.

5.13.3 Welding Consumables for Pipeline / Flowline

Low Hydrogen welding consumables capable of depositing weld metal containing less than 4 ml of
hydrogen per 100 grams of deposited weld metal shall be used for carbon steel pipelines/flowlines
unless specified otherwise in CONTRACT or Project Documentation.

Cellulosic electrodes shall not be used for installation welding in deep water (>500m). For other
applications, (e.g. onshore welding and shallow water), use of cellulosic electrodes shall only be
allowed with written consent from Company.

The yield strength of the weld metal should be selected to ensure that the yield strength of the
deposited girth welds overmatches the actual yield strength of the parent pipe material at both
ambient and maximum design temperature.

Consumables shall provide adequate toughness at both the maximum and minimum design
temperatures. Fracture mechanics testing shall as a minimum, but not limited to, be compliant with
the requirements defined in Appendix A, Subsection D (Girth welds under Strain-based Loading
Assessed According to ECA Static – Full) of DNV-OS-F101.

Each batch/lot of welding consumables shall, be purchased from manufacturers operating a quality
system based upon ISO 9001 and shall have a manufacturer’s certificate conforming to the relevant
EN, ISO or AWS filler metal specification.

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All welding consumables shall be individually marked and supplied with an inspection certificate
type 3.1 according to EN 10204.

All welding consumables shall be delivered in accordance with Manufacturer's data sheets, which
shall state the minimum and maximum levels of C, Mn, Si, P, S, micro-alloying elements and any
other intentionally added elements including trace elements.

The use of consumable inserts shall require COMPANY approval.

Filler metals and fluxes classifications shall conform to the appropriate American Welding Society
(AWS) and/or British Standard (BS).

5.13.4 Weld Traceability

On Pipeline/Flowline welding all welds, weld identification numbers shall be painted on the pipe
using contrasting colors.

A reference between weld numbers and pipe numbers shall be maintained. Each weld number shall
be located on either side of the pipe between clock positions 1:00 and 5:00 and 7:00 to 11:00
adjacent to the weld.

The width of each letter or number shall not be less than 19 mm (3/4 in.).

Weld identification must be legible using sequential numbers and/or combination of English block
letters and numbers.

5.13.5 Pipeline / Flowline Weld Repairs

Procedure qualifications shall be prepared and qualified for each repair procedure that is
proposed. Such specifications shall include a description of defect removal and groove
preparation and NDT method to inspect the excavated area to ensure removal of flaw.

Only one attempt at repair is permitted.

Unacceptable defects shall be removed by gouging, grinding or machining of entire removal of

weld.

Repairs to Cracks are not permitted. Welds containing cracks shall be cut out.

5.13.6 NDT of Pipelines / Flowlines

NDT of Pipelines/Flowlines constructed to the requirements of DNV-OS-F101 shall conform to the

NDT requirements of DNV-OS-F101 Appendix D and other relevant clauses.

For Automatic Ultrasonic Testing of Girth Welds CONTRACTOR shall conform to the requirements
of DNV-OS-F101 Appendix E.

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5.14 Duplex Stainless Steel Welding Requirements

Each electrode lot shall require a separate procedure qualification(s). A lot includes changes within
the manufacturers brand and type of consumable. Such changes include material heat, flux batch,
etc.

Welding Procedures for DSS welding shall conform to the relevant welding specification defined in
section 1.6.1 of this document.

Welding procedures shall be qualified by separate test coupons welded at the lowest and highest
heat input to be used in production.

Welding procedures shall be on representative size specimens. Small diameter test pieces will not
qualify larger diameters. Diameter range for procedure tests shall be reviewed by COMPANY.

The ferrite/austenite phase balance of the weld metal shall be measured by the point count
method ASTM E562 for the root, fill and cap area of the weld cross section. The ferrite content shall
be 30% to 55% in the weld metal. A magnetic ferrite gauge shall be used to measure the ferrite
percentage on the cap of the weld metal and be reported on the PQR for reference.

The heat input shall be between 0.5 – 2.5kJ/mm

5.15 Welding of Duplex Stainless Steels

The maximum interpass temperature shall not exceed 150°C. Measurements shall be taken on the
parent metal surface, directly adjacent to the weld groove, using a contact thermometer with an
instant digital display. Temperature indicating crayons or “Tempilstik” shall not be used.

All single sided welds shall be made with a GTAW root pass and back purged until at least 6mm of
the weld metal thickness has been deposited. Backing gas shall be welding grade 100% argon with
a purity of at least 99.95% argon. The oxygen content of the back-purged volume shall be less than
0.5% (5000ppm). CONTRACTOR shall submit details of the method and equipment to be used for
monitoring oxygen content as part of the welding procedure specification.

All duplex stainless steel welding shall be monitored 100% and heat inputs and welding sequence
agreed with COMPANY prior to welding.

Production welds shall be checked on the cap along the weld with a calibrated ferrite gauge and
shall not exceed 55% ferrite. The measurement spacing along the weld length shall be the lesser of
three equidistant locations or 300mm (12”). A minimum of five measurements shall be taken at
each location. The surface shall be prepared as recommended by the manufacturer of the testing
instrument. Acceptance shall be based on the average of the measurements at each location. Of
the five local measurements, the highest and lowest values may be discarded and the average of
the remaining three reported as the final value.

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5.16 Welds on Clad Material

Selection of Welding Procedures for CRA clad material shall consider reliability, corrosion
resistance, weldability, weld profile, all positional welding capability and susceptibility to welding
defects.

Selection of filler wire material shall be reviewed by COMPANY and all WPS/PQR qualifications
shall be carried out in representative simulated fabrication/installation conditions and joint
geometries. Fit up, backing gas and welding consumables shall be agreed with COMPANY.

All other relevant welding requirements of this specification will apply.

5.17 Repair Welding

Minimum acceptability standards for weld defects shall be in accordance with applicable Codes
and Project specific requirements.

COMPANY shall be notified prior to any repair activities being conducted.

Weld repairs shall only be performed in accordance with the qualified/reviewed repair WPS and
only one attempt at repairing a defect is permitted. Re-repairs shall require Company review and
will only be permitted if a re-repair WPS has been qualified.

Unacceptable defects shall be removed by gouging, grinding or machining, or entire removal of

the weld if necessary. Excavated area shall be examined by suitable NDT method to ensure defect
has been completely removed.

Repaired areas shall be examined with the same NDT method used for original weld.

Repairs to cracks are not permitted. Welds containing cracks shall be cut out.

Arc strikes shall be repaired by grinding and examined by MPI.

Only low hydrogen processes and consumables may be used for repair welding.

For procedures based on carbon steel groove welding procedures, work piece temperature shall be
a minimum of 50°C higher than the minimum preheat temperature required for the original
reviewed welding procedures.

Grinding shall not reduce the remaining wall thickness to less than the minimum thickness
specified by the applicable design code. UT thickness checks to be used to verify compliance.

Repairs of forgings by welding shall not be permitted.

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5.18 Welding Requirements for Flexible Flowlines

WPS for flexible flowline components shall meet or exceed the requirements of relevant
specifications, NACE MR 0175/ISO 15156 and any additional requirements of this specification.

5.18.1 NDT Requirements for Flowlines

Extent of NDT shall be 100% of volume of welds and 100% of exposed surface of welds and
components.

All aspects of the flexible flowline components shall be NDT tested utilising a COMPANY reviewed
procedure as per DNV/ASME/BPVC Section V for Non Destructive Testing.

End Fittings:

CONTRACTOR shall implement the requirements of DNVGL RP-0034 –Steel Forgings for subsea
applications. Additional requirements for all end fitting forged components shall as a minimum be
NDT tested at the thickest section and the highest utilisation section of the forgings to ensure
minimum mechanical properties required for the CONSTRUCTION are achieved throughout the
forging

5.19 Welding of Jumpers

WPS and all welding for rigid well jumpers shall meet or exceed the requirements of DNV-OS-F101
NACE MR 0175/ISO 15156 and any additional requirements of this specification.

Automatic welding shall be held within the minimum and maximum parameters recorded in the
PQR.

Production heat input range shall be as qualified in the WPS. The maximum/minimum or range of
average heat inputs for each weld pass shall be measured and recorded.

Only groove full penetration welds shall be used in pressure containing envelopes. Fillet welds only
allowed with agreement of COMPANY.

Circumferential girth welds shall be separated by the maximum possible distance and at least one
diameter of pipe utilized.

All welds shall be fully traceable between the structure location, weld number and adjoining pipe
or fitting.

Pipe with seam welds shall have their longitudinal seams offset by at least 150mm, preferably
located in the top half of pipe section.

COMPANY shall be notified prior to any repair activities being carried out on jumper spools. Repair
welding shall only be performed in accordance with a qualified and reviewed repair WPS. Only one

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attempt at repairing a defect is allowed. Repairs are not allowed on welds containing cracks. Welds
containing cracks shall be cut out.

The full section of pipe shall be removed if laminations, split ends or longitudinal seam defects are
discovered in any jumper pipe material.

Arc burns shall be prevented. If COMPANY does allow repair, then arc strike shall be removed by
grinding and ground area subject to MPI and UT thickness check. Remedial work shall not reduce
the wall thickness to less than the minimum thickness stipulated in the applicable design
requirements.

Electrical continuity straps shall be attached in accordance with COMPANY reviewed drawings.
Prior to applying surface coating, electrical continuity shall be checked across the interfaces of
structural frames and piping as well as any clamps for piping, top and bottom halves.

Anodes shall not be directly welded to the jumper pipework but shall be attached by doubler plate
connections welded to the pipe utilising a reviewed procedure and connected to the jumper pipe
with continuity straps. Electrical impedance shall not be greater than 0.1 ohm.

Weld overlay where required shall conform to ASME IX/NACE MR0175/ISO 15156 and
requirements of this specification.

5.19.1 NDT of Jumpers

Extent of NDT shall be 100% of volume of welds and 100% of exposed surface of welds and
components.

All aspects of the flexible flowline components shall be NDT tested utilising a COMPANY reviewed
procedure as per DNV/ASME/BPVC Section V for Non Destructive Testing.

5.20 Welding of Subsea Valves

WPS and all welding for Sub-Sea Valves shall meet or exceed the requirements of ASME IX/API 6D
SS, NACE MR 0175/ISO 15156 and any additional requirements of this specification.

5.20.1 NDT of Subsea Valves

Extent of NDT shall be 100% of volume of welds and 100% of exposed surface of welds and
components.

Sub-Sea Valves shall be NDT tested utilising a COMPANY reviewed procedure as per ASME/BPVC
Section V for Non Destructive Testing.

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5.21 Overlay Welding

Overlay welding shall only be performed within the minimum and maximum parameters qualified
in the Procedure Qualification Record (PQR). All overlays shall be such that the resulting overlay
weld will be equal in corrosion resistance and similar in composition to the alloy applied. All
overlays shall have a minimum of 2 overlapping runs and a minimum thickness of 3mm.

5.21.1 NDT of Overlay Welding

The NDT of overlay welding shall conform to the relevant requirements of API 6A and API 5LC and
include:

 Weld Overlay Ultrasonic Testing to ASTM A578/ASTM B499

 Weld Overlay Thickness Report –minimum 3mm.
 Dye Penetrant Inspection of all overlay surfaces in the final machined condition to ASTM A165
 Ferrite Count to ASTM E562 with a maximum of 5% Ferrite content.

5.22 Welding of Piping, Fittings and Flanges

Welding of piping, fittings and flanges will have the same requirements as the connected
pipework.

5.22.1 NDT of Piping, Fittings and Flanges Welds

Extent of NDT shall be 100% of volume of welds and 100% of exposed surface of welds and
components.

Flanges to connecting pipework shall be NDT tested utilising a COMPANY reviewed procedure as
per DNV/ASME/BPVC Section V for Non Destructive Testing.

5.23 Welding of Piping within Structures, PLETs/PLEMS,

Manifolds and ILS.
WPS and all welding for Piping within subsea structures shall meet or exceed the requirements of
ASME IX, NACE MR 0175/ISO 15156 and any additional requirements of this specification.

Structural Welding shall conform to AWS D1.1 as well as additional requirements of this
specification.

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5.23.1 NDT of Piping within Structures

Extent of NDT shall be 100% of volume of welds and 100% of exposed surface of welds and
components.

Components shall be NDT tested utilising a COMPANY reviewed procedure as per

DNV/ASME/BPVC Section V for Non Destructive Testing.

5.24 Welding of Umbilical Components

CONTRACTOR shall include detailed and comprehensive documentation within the proposal that
the procedures of welding, inspection and testing of individual tubes are in accordance with the
relevant ASTM, ASME and BS EN Codes listed in this specification.

Each consumable lot shall require a separate procedure qualification(s). A lot includes changes
within the manufacturer’s brand and type of consumable. Such changes shall include material heat,
and batch etc.

Welding procedures shall be qualified by separate test coupons welded at the lowest and highest
heat input to be used in production.

Autogenous welding is not allowed on CRA material without COMPANY written approval.
Autogenous welding may be permitted on some classes of Stainless Steels. Autogenous welding
on Duplex Stainless Steel is prohibited.

Welding procedures shall be on representative size specimens. Small diameter test pieces shall not
qualify larger diameters and vice versa. Diameter range for procedure test shall be reviewed by
COMPANY.

The ferrite/austenite phase balance of the weld metal shall be measured by the point count
method ASTM E 562 for the root, fill, and cap area of the weld cross section. The ferrite content
shall be 30 to 55% in the weld metal. A magnetic ferrite gauge shall be used to measure the
percent ferrite on the cap of weld metal and be reported on the PQR for reference.

The minimum number of mechanical test specimens required for a welding procedure qualification
test weld shall be in accordance with ASME Section IX, with the addition of requirements in Section
5.25.

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5.25 Testing Requirements Duplex Material

Test Quantity
Charpy V- Notch at -40°C
Weld Centreline 3
Fusion Line 3
Fusion Line +2.3mm 3
Fusion Line +4.5mm 3
Cross Section for macro-examination, photomicrographs and 1
ferrite measurements.

Charpy impact testing shall be in accordance with ASME Section VIII, UG-84.

Acceptance standards for welding procedure qualification tests shall be as follows:

Charpy Tests

Lateral expansion measurements shall be reported for information. In the event of failure of Charpy
tests, re-test requirements shall be agreed with COMPANY.

5.25.1 Ferrite Testing (Umbilicals)

For ferrite assessment during procedure qualification tests, metallurgical sections shall be polished
and electrolytically etched at 7-8 V in 40% KOH to clearly reveal the two-phase austenite/ferrite
microstructure. The area being point counted, either parent material, weld metal or HAZ, should be
examined and photographed under a microscope at a sufficient magnification to fill the field of
view and to be able to clearly discriminate between the constituent phases. A magnification of
400X minimum is required.

The photographs shall be overlaid with a grid of at least 100 points and the percentage ferrite shall
be calculated from the number of points that fall on the ferrite phase and the total number of
points used.

The ferrite content shall be measured on one of the metallurgical sections using the point counting
technique at the following locations:

In the parent metal, one measurement on each side of the weld at mid thickness (total of 2).

In the heat affected zone on each side of the weld, in the region of the root pass (total of 2).

In the weld metal, 3 measurements near to the vertical centre line of the weld, one in the cap, one
in the root, and one at mid thickness (total of 3).

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Photomicrographs and Macro-examination

Photomicrographs at 400X minimum shall be provided to the COMPANY for each of the locations
where a phase balance assessment is performed.

Photomicrographs shall show a typical austenite/ferrite micro-structure.

The macro-examination shall provide evidence that the weld is sound and free from cracks and
other defects with full penetration and fusion between weld passes and parent metal.

5.25.2 Chemical Composition (Umbilical)

A full chemical composition shall be performed on the weld deposit and the following elements
shall be measured and reported: C-Cr-Ni-Mo-Si-Ti-Al-Mg-N-Cu-Nb.

5.25.3 Production Welding (Umbilical)

The maximum interpass temperature shall not exceed that of the PQR. Measurements shall be
taken on the parent metal surface, directly adjacent to the weld groove, using a contact
thermometer with an instant digital display. Temperature indicating crayons shall not be used.

Backing gas shall be welding grade 100% argon with a purity of at least 99.95% argon. The oxygen
content of the back-purged volume shall be less than 0.5% (5000 ppm). CONTRACTOR shall
submit details of the method and equipment to be used for monitoring oxygen content as part of
the welding procedure specification. Where mixed gases are used these will be agreed with
COMPANY.

Production welds shall be checked on the cap along the weld with a calibrated ferrite gauge or
other reviewed method and shall not exceed 55% ferrite. A minimum of three (3) measurements
shall be taken at each location. The surface shall be prepared as recommended by the
manufacturer of the testing instrument. Acceptance shall be based on the average of the
measurements at each location. Of the five (5) local measurements, the highest and lowest values
may be discarded and the average of the remaining three reported as the final value.

The welding of tubes shall be completed in accordance with COMPANY reviewed procedures and
shall only be conducted by qualified personnel certified by an approved third party inspection
body.

Each production butt weld made on all tubes shall be uniquely identified to allow for full
traceability. This may be done by numbering the welds and recording the tube numbers on each
side of the weld. In addition, each weld shall be NDT inspected in accordance with the latest
edition of the relevant ASTM and ASME codes. X-ray sensitivity shall allow for close scrutiny of
welds such that any indication from a radiograph of a weld defect that exceeds the acceptable
allowable shall be cause for rejection.

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5.25.4 Tube Repair (Umbilical)

Tube repair on individual tube sections or welds is not acceptable. The section of damaged tube
or unacceptable weld shall be cut out and a new section of tubing welded in. All damaged,
rejected or unacceptable tube shall be destroyed.

5.25.5 NDT of Umbilicals

Radiographic testing of welds shall be performed on 100% of the welds in accordance with the
requirements of ASME Section V. Any personnel making evaluations of images must be certified as
ASNT SNT-TC-1A Level II under the direction of Level III personnel or to ISO 9712. The
examination should be performed using low voltage x-ray equipment with either film-based
radiography or digital radioscopy. All images shall be stored on CD-ROM to be made available for
inspection and to be included in Manufacturing Data Books.

A minimum of two elliptical images per orbital weld shall be taken. Any relevant indication in the
orbital weld is cause for rejection and the weld shall be removed. An indication is taken to include:

 Lack of penetration
 Lack of fusion
 Cracks
 Pinholes
 Undercut
 Tungsten inclusions or porosity

Production welds shall be tested in accordance with a frequency schedule of five welds per first lot
at the start of production of each tube size and then at regular intervals (1%) of each lot/heat of
tubes during production.

Failure of any test will require that the failed tube coil is spooled back to the last approved weld
and the unwound material removed. Alternatively, if the reason for the problem is clearly
understood and accepted by COMPANY, the tube SUBCONTRACTOR may use the ‘one fail, two
pass’ methodology (to exclude failure due to incorrect sample preparation only) by taking two
additional test samples. Failure of either of the two extra samples (or absence of such additional
samples) shall require spooling back to the last approved weld and all intermediate material shall
be removed. The isolated material may be returned to the production line only if it has been
successfully reworked in accordance with SUBCONTRACTOR’s procedures and subject to
COMPANY’s written consent.

Weld repairs are not allowed. Any weld failing to meet the requirements shall be cut out and the
tubing re-welded. Any tube or weld sections that have been rejected shall be obviously marked
and destroyed to preclude from being used erroneously. A log of rejected radiography images
shall be maintained.

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Sample welds for each welded line shall be cut and destructively evaluated for tensile strength,
corrosion pitting, microstructure (ferrite count and inter-metallic compound analyses), and bend
tested in accordance with the relevant codes and/or procedures.

5.25.5.1 VISUAL CHECK

All tubes shall be examined visually during manufacturing for defects or damage.

5.25.5.2 NDT CHECK

X-ray inspection on 100% of the tube welds shall be performed prior to bundling and results shall
be reported to COMPANY.

5.25.5.3 DIMENSION CHECK

Dimensional inspection on 100% of the tubes shall be performed prior to bundling and results
shall be reported to COMPANY.

5.26 Welding of Subsea Distribution Units (SDU)

Welding shall conform to relevant international standards AWS D1.1 and ASME IX as well as
additional requirements of this specification.

5.26.1 NDT Requirement for SDU

All aspects of the SDUs shall be NDT tested utilising a COMPANY reviewed procedure as per
DNV/ASME/BPVC Section V for Non Destructive Testing. Extent of NDT testing to be determined
and reviewed by COMPANY. All pressure retaining welds shall be examined by NDT.

5.27 Welding of Diverless Connectors

Welding requirements for Subsea Diverless Connectors shall be as per connecting pipework and
conform to DNV/ASME IX / NACE MR0175/ISO 15156 and any additional requirements of this
specification.

5.27.1 NDT requirements for Subsea Diverless Connectors

Welding requirements for Subsea Diverless Connectors shall be as per connecting pipework and
shall be NDT tested utilising a COMPANY reviewed procedure as per ASME/BPVC Section V for
Non Destructive Testing.

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6 WELDING AND NDT DOCUMENTATION

6.1 General
CONTRACTOR shall ensure all documentation produced by CONTRACTOR or their suppliers in
relation to welding and NDT activities complies with the requirements stipulated in the CONTRACT.

6.2 Documentation
The final as built welding related documentation of the completed CONSTRUCTION shall include,
as a minimum, the following:

 Weld Procedure Specifications

 Weld Procedure Qualification Records
 Welder Performance Certificates
 NDT Procedure and Qualification Records
 NDT Inspection Reports
 Quality Control Records
 Welding Logs and Drawings
 Material and Consumable Records
 Mill Test reports and certificates
 Material Traceability documents.

CONTRACTOR shall retain the radiographic film, a copy of the examination procedures and
personnel qualifications used for the contracted work for 5 years or according to the CONTRACT
requirements.

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7 ENGINEERING CRITIAL ASSESSMENT (ECA)

7.1 General
For pipelines exposed to global yielding (Strain ≥0.4%) it shall be required to perform an ECA
according to DNV-OS-F101 Appendix A.

The yield strength of the weld metal should be selected to ensure that the yield strength of the
deposited girth welds overmatches the actual yield strength of the parent pipe material at both
ambient and maximum design temperature.

Consumables shall provide adequate toughness at both the maximum and minimum design
temperatures. Fracture mechanics testing shall as a minimum, but not limited to, be compliant with
the requirements defined in Appendix A, Subsection D (Girth welds under Strain-based Loading
Assessed According to ECA Static – Full) of DNV-OS-F101.

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