is bp wain Sey ANDREW DEVELOPMENT PROJECT SPECIFICATION sooo. 01 WELDING AND NDT OF DUPLEX LINEPIPE [¥9 0"s==5 TO BS 4515-2 (1999) ie) WG DOCUMENT NO. —_| 37AND-F041G7001-Y-SD-0040-000 BP DOCUMENT NO. ADP-ME-SPE-8015-000 A ian sues ro ev aes “eine [are | aa) euenr‘COMMENTS SHEET REVISION | REVISION REVISION al 77/08/2012 | ISSUED FOR REVIEW/COMMENT co zaroaizot2 | ISSUED FOR CONSTRUCTION S7AND-FO41G7001-¥:S0-0040.000 Rev CtBF Exploration Operating Company Lid ror lng and NOT of Duy 4515-2 (1999) WELDING AND NDT OF DUPLEX LINEPIPE TO BS 4515-2 (1999) Table of Contents 1.0 INTRODUCTION 1.1 Purpose of Document 4 12 Salety nnn . 4 1.3 Defntons. 4 14 Abbreviations 5 15 HSEQ for Pipeline Welding Operations soe 1.6 Pre-Production Consultation 8 1.7 Duties ofthe Contactor 8 1.8 Qualiy Conformance. 8 1.9 Records 9 4.10 Contractor's Personnel 2.0 NORMATIVE REFERENCES. 12 2.1 Specification Compiance....rnnsnnnsnnnnnsnn o 12 22 Conflict of Information 12 23 Revisions. 13 24 Referenced Documents 13 2.8 Codes and Standards = vot 3.0 MATERIALS. 3.1 General soon ' o 16 32 Storage : 16 4.0 INFORMATION TO BE SPECIFIED AND ITEMS TO BE APPROVED 4.1. Information to be Speciiod by COMPANY : 17 4.2 Items Subject to Approval by COMPANY ~ 19 5.0 EQUIPMENT... Page ol74 S7AND-FO4iG7001-¥-50-0080-000 Rov CTing and NDT of Duplex Linepipe to BS 4516-2 (1999) BP Exploration Operating Company Ltd ‘Andrew Development Project weim 28 6.0 WELDING PROCESSES. 61 General - - 7 on 62 GTAW. 24 63 Mechanised Welding Equipment. 24 7.0 WELDING CONSUMABLES 28 74 General 26 7.2 Storage and Handing. 27 8.0 TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCECURES...29 a 29 82 Records 29 8.3 Welding procedure 30 8.4 Changes Affecting Qualification and Approval (Essential Vatiables) css 8.5. Testing of Butt Joints for Procedure Qualification... 34 86 Testing of Filet Welds for Procedure Qualification a4 8.7 Testing of Repair Welds or Procedure Qualification 46 9.0 TESTING QUALIFICATION AND APPROVAL OF WELDERS. AB 9.1 General = 48 9.2 Changes Affecting Qualification and Approval (Essential Variables) ...-unen80 8.3 Non-Destrictve Testing nnn 50 ee 50 10.0 PRODUCTION WELDING 10.1 ipo End Preparation 52 102 Fusion Faces. 5} 103. Alignment. ne) 10.4 Line-up Clamps and Pipe Support... 54 105 Tack Weld. ee 54 age 2 74 S7AND-FO4TG7O01-¥-S0-0040-000 Rev CTnd NOT of Duplex Linepipe to BS 4815.2 (1999) wrens woke : 10.6 Working clearance. 10.7 Stay APCS nn oe 55 10.8 Weathor Condition. sn cB 10.9 Proheating 56 10.10 Branches 87 10.11 Inter-sun Geaning 58 10.12 Weld Metal Deposton.. 58 10.13 Temporary Atach ments nnn —— 58 10.14 Interupted Welding 59 10.18 Suspect Welds 59 11.0 INSPECTION AND TESTING OF WELDS. ee) 114 General 60 11.2 Visual Inspection. on) 11.3. Radiographic Testing 62 11.4 Utrasonie testing 68 11.5 Dye Penotant Examination 6a 120 ACCEPTANCE AND RECTIFICATION OF WELDS. oo 12.1 Non-Destructive Testing Acceptance Criteria. —) 12.2. Rectification of WEIS. eT ANNEX D ADDITIONAL REQUIREMENTS FOR PIPELINES SUBJECT TO HGH STRAIN LEVEL! [At Introduction. - 78 a2 Genera 73 3. Weld Procedure Qualftation Testing 7 Ad Production Welding 7 Page del 74 _ S7AND.FOATGTOOI-¥-SD.0040.000 Rev CT‘BP Exploration Operating Company Ltd ‘Andrew Development Project Seeman won&o 10 14 12 1a wTRODUCTION Purpose of Document ‘This specication whon read in conjunction with the referenced standards, specications, other sted documents and relevant data sheets, defines the minimum technical requirements for the welding and NDT of duplex lnepipe, spools, flanges and ftings (bulkheads) in accordance wih BS 4516-2: 1999, Paragraph numbers in this specication correspond to BS 4516-2: 1999, Medications to BS4515-2: 1999 are dented as Add or Modified to Read inthis specication ts not the intention ofthis document to be applied to anything oher than the anticipated \worksoop2 contained within the Caisson Breakout to the platform and & epacically nat Intended as guidance or implementation of ary kind in relation to rgid subsea flowines/pipetines. Satety Al risks to personnel and the environment resuting from the Andrew Project should be AS Low As Reasonably Practicable (ALARP). Safety is the primary consideration during design and all risks associated wih the design shall be minimized by adtering to tho relevant governing design codes, and COMPANY Intemational procedural requirements. Definitions Approval CConsent given in wrtng, on behalf of COMPANY in advance of an event, by a person with appropriate authority. Approval by COMPANY does not raiove CONTRACTOR from any of ts contractual obigations ‘nor from hating to make good any par ofthe item to be olivered found to be defective subsequent to ‘COMPANY's approval ‘COMPANY 'BP Exploration Operating Company Lid or any of is subsicaries or representative agents. ‘contactor “The Party contracted by COMPANY to be responsible {or the welding and NOT. Linepipe Generic statement covering spools, anges and ftings. Shall Indicates mandatory requirements Should Indicates preferred course of action. Page 4 of 74 ‘STAND-FO41G7001-Y-SD-C040-000 Rev G1BBP Exploration Operating Company Lta Andrew Development Project WwGIM: Welding and NDT of Duplex Linepipe to BS 4515-2 (1999) SUPPLIERMANUFACTURER Aparty which supplies materials, equipment or services to CONTRACTOR. EMPLOYER Read COMPANY. 14 Abbreviations accor [ASNT Central Ceriiation Programme ALAR. ‘As Low as Reasonably Practcablo ANSI ‘American National Standards insite an ‘Automatic Radiography ASNT American Society fr Non-Destructive Testing asTu American Society fr Testing and Materials aur ‘Automated Utrasoni Testing aws, American Welding Society paw Fedora Institue for Matarals Research and Testing (Germany) BGAS-CSWIP Bish Gas Approval Scheme ~ Conticaton Scheme for Welding and inspection Personnel BiNoT British institute of Non-Destructive Testing es Bash Standare cng Chartered Engineer cei ‘carbon Equivalent (Inleratonal Institue of Welding Forma) co, Carbon Diese nA Corson Resistant Aly oswir CCottiction Scheme for Welding and nepecton Percnnel ow charpy V Notch Dip ing Diploma Ingenieur (Europe) wot Double Wall Double mage pws! Double Wall Single Image ECA Engineering Cricl Assessment ewe European Welding Engineer Page l74 STAND. FO#TGTOOI-¥-S0-0040-000Rev G1Welding and NDT of ‘Linepipe to Bi BP Exploration Operating Company Lid 2, Andro Development Projet 515-2 (1995 welM is euaw esrcaw om az HSE seo Hv 0 to! We Le er wor wut Not nist on Po Pom Pen PoMaW POR wes. RE Group Instruction for Supply Gas Metal Are Welding Gas Shielded Flux Cored Are Welding Gas Tungsten Arc Welding Heat Afacted Zone Heath and Satety Executve Health, Safty, Environmental and Quality Vickers Hardness Inside Diameter Image Qualty Indicator Intemational Standards Organisation International Welding Engineer Ligui Penetant Examination Magnetic Particle Testing Minimum Design Temperature Miimetres ‘Manual Utrasonie Testing Non-Destructive Testing ‘National inttute of Standards and Technology (USA) Oven (Outside Diameter Lesa nt hho-Bessyo Formula Carbon Equi Personnel Centicatlon In Non-Destructive Testing Pulsed Gas Metal Are Welding Procedure Qualtcation Record Preliminary Welding Procedure Speciation Faaiographic Examination Page 6 oT STAND-FOAIG7OOT.{2° Exploration Operating Company Lid foam Oeopment Plesk wein Sey ‘Welding and NOT of Duy 10 BS 4515-2 (199 RT Fachographie Testing rus Foot Mean Square saw ‘Submerged Are Welding ‘SMAW Shielded Metal Are Welding sus ‘Spoctid Minimum Vel Strength swe Single Wall Examination sw ‘Single Wall Viewing swst ‘Single Wall Single Image a “The Welding Insitute (UK) ur Utrasonic Testing ve Visual Examination vw Visual Inspection wes Welding Procedure Spacticaion wea Wilding Procedure Qualification wear Wilding Procedure Qualification Test 1.5. HSEQ for Pipeline Welding Operations. ‘Welding, cuting, NDOT, and associated oporations shall be undertaken ina safe mannor and with dus regard to individual heath and eafety, and the minimisation of environmental impact Consistent wih COMPANY requirements. Welding, cuting, NOT activites, and associated ‘operations shall feature in CONTRACTORS operational safety planning and n the safety ‘aut schedule, ANS! Z49.1 or similar codes shouldbe followed. ‘Measures shal be taken to ensure adequate venation and contol the qualty of breathing air during welding operatons. [As a minimum, raciography operations shall conform tothe lonising Ratan Fegulations 1990 (SI 1999 No. 3282) and the Approved Code of Practice and Guidance ~ "Working with lonising Racaton: lonsing Regulations 1998, Environmental guidance shall be taken from EN 14717 when undertaking welsing and is associated processes. Page7of7 _ S7AND-FO8iGT001-¥-S0-0080-000 Rev CTBr Exloaon operating Company Les 2, Snaan Bove eee Welding and NOT of Duplex Linepipe to BS 4515-2(1999) weiter wr 16 Pre-Production Consultation PPre;production meetings shall be held wih COMPANY and any appropriate third-party Inspection personnel inorder to ensure that al patios fly understand the requirements ‘These mestings shall be held belore welding procedure qualification testing and belore commencement of fabrication, COMPANY Weiding Engineer shal be consulted a the following stages: ‘During bid evaluation to agree the basic welding and NDT methods proposed and to ‘achise on acceptabilly. ‘+ Before weld procedure quaiticaton for approval of the proposed welding procedures (WPS). ‘+ Before production welding for approval ofthe final WPS. Duties ofthe Contractor Construction, welding and pipe-lay shall be carried out by a well tained and qualified ‘workforce employing reliable, modem, and well maintained equipment and shllalso be fly compliant wih safe and environmentally sound werking practices at limes, Uniess advised otherwise by COMPANY welding and associated equipment including, but rot lied te: heating equipment, fuxos, gas filer metals, weling units, mechanical handing, testing equipment, and NDT equipment shall be supplied and appropriately calibrate. Sub-contractors shal also comply wit this specication, Quality Conformance ‘The CONTRACTOR shall demonstrate tothe safstaction of COMPANY that his activites within the scope ofthis document comply with 1SO 8884 Parts 1 and 2 and the relevant sections of BS EN ISO 9001 Prior tothe commencement of work, the CONTRACTOR shall submit to COMPANY for review and approval, a Quality Plan and procedural specications, which shall incude procedures for storage and control of materials and welding consumables, welding and non-destructive testing and supporting qualification records. The Qualty Plan shall doting all eub-contractors involvement within the work, "Names of individuals Welding Engineers / Welding Inspectors responsible fr imalementation of qualty assurance and quay conto functions shal be Incuded. Page@ 74 STAND-FO4iG7001-¥-S0-0040-000 Rew Ct[BP Exploration Operating Company Ltd Andrew Development Project WGIM: Welding and NDT of Duplex Linepipe to BS 4515-2 (1998) 1.9 Records Documents required by this specication shall be gathered, collate, indexed, stored, and ‘inally presented to COMPANY for sooure long term storage ‘A log idontiying, by number, each pipe or fing and identifying the weld nunbers joining thom to other items shall be compile. Each citcumferetial weld (whethor a fad joint or shop-made weld) shall be allocated unique number, wich shal be used for reference tothe weld in reports and tet documents ‘A documentation shalbeavalablen an agreed, good qualiy, electronic format 1.10 Contractor's Personnel (1) General Personnel associated with welding including engineers, welders, welding operators, \walding inspectors and non-destructive testing technicians shall be properly trained and ‘ualifed to recognised industy standards by examination andlor by individual tet. 2) Welding Engineers ‘A competent and suitably qualified Welding Engineer shal be employed. ‘The Welding Engineer shall be responsible for the technical aspects of all welding ‘operations including the following: ‘Selection of welding processes, equipment and consumables, Preparation and qualification of welding procedures. Quaifeation of weders. Providing technical oversight ofthe production welding Liaison wth COMPANY and the NDT sub-contactrs. Tho minimum experience and qualification level for tho Welding Enginoer should be: CChartored Engineer (C Eng / Dipl Ing) holding as a minimum a degree in engineering, lurgy or materials science and having specialised traning in welding technology. The requirements of 1S0 14781(FDIS) / EN 719 should be met as demonstated by the European Welding Engineer (EWE) or Intemational Welding Engineor (WE) qualification, Profoscional Momborchip of The Welding Inctute (UK) le decirablo and a rinimum of § years relevant experience in the pipeline welding or fabrication industry is deemed ceeential, Pageoot7e *sree won&o ° ” Welding inspectors Competent and certicated welding ir numbers to ensure that all welding related actives are adequately inspected. paction personnel shall be employed in suifcent Welding Inspectors shall have a sound knowledge of welding processes and their application to pipeline welding, and possess the knowledge and skis to cary out the tasks siven in the aocepted Quali Plan, including those necessary forthe following: *+ Conduct of routne inspections and checks on sito or at SUPPLIER'S in a systematic ‘+ Production of accurate records and reports. Welding Inspoctors shal, as a minimum, hold current certiication to any ofthe folowing standards: CCSWP (TWH, UK) ~ Welding Inspector. [BGAS.CSWIP (TW, UK) - Welding Inpector PCN (BINDT, UK) — Weld inspection Level 2 AWS QC! (1996 or later acon) ~ Certfiad Waldng Ir Spector (CWI, Akecnative Welding Inspector cetticaton is unacceptable unless accepted by COMPANY. |A Senior Welding Inspector shall be employed to supervise the work of the welding Inspectors. The role of senior welding inspactor requis at loast 10 years relovant fexperionce and sound knowledge of welding processes and their appicaion. Formal engineering training through apprenticeship and technical college education are required ‘Senior Welding Inspectors shall, as @ minimum, hold curent cortfcation te any of the following standards: ‘+ CSWIP (TW, UK) — Senior Welding Inspector. ‘+ BGAS-CSWIP (TW, UK) ~ Senior Welding Inspector (SWN or Senior Pipeine Inspector (sP. ‘+ PCN (BINDT, UK) - Wold Inspocton Lovel 3. ‘+ AWS Ci (1996 or later exton) ~ Senior Cortied Welding Inspector (SOW NDT personnel NDT personnel shal hold curent Level 2 certification (or equivalent) epectc towels testing {or th appropriato NOT mothods to, as a minimum, any of he folowing standards: CSW (TW, UK). BGAS-CSWIF (TWI, UX PCN (BINDT, UK} ‘ACCP (ASNT), SSNT-TO-1A (ASNT. Page 1074 STAND-FO4IGYO0T-¥-S0-0040-000 Rav OTBBP Exploration Operating Company Ltd Andrew Development Project Welding and NDT of Duplex Linopipe to BS 4515-2 (1996) NDT personnel certificated tothe requirements of a writen practice under th ‘TC-1A shall not be used, unless the wien practice and the personnel cetficaton has ‘been reviewed and accepted by COMPANY forthe specific work Personnel engaged in AUT shall be qualified in accordance wth GIS 42-209, Page 110174 SYAND-FO«1G700%-¥-S0-0040-000 Rev G1[BP Exploration Operating Company Ltd ‘Andrew Development Project 20 24 22 De rr cons wa &o NORMATIVE REFERENCES ‘Specification Compliance ‘This specication has been writen to be In ful complance with the appropriate BP Engineering Technical Practoes (ETP's) and Group Instruction for Supply (GIS for Pipeline ‘Welding in accordance with BS 4515-2: 1909, ‘The CONTRACTOR shall be in complete compliance wit the requirements of he following GIS documents unless instructed atherwige by this speciation: ais e011 Guidance on Industry Standard for Welied Fabication and Construction ais 18-012 Guidance on industy Standard for Storage and Contd of Welding Consumables is 43.330 Welding of Corrsion Resistant Alloy, Internally Clad, and Mechanically Lined Piptines, 29” October 2007 ais 42330 ‘Automated Utrasonic Testing of Pipeline Gith Welds Note 1 Wain the GIS documents CONTRACTOR shall replace the words ‘must’ and ‘should’ with ‘shal to read as mandatory requirements, Any ‘shal’ or ‘must’ in commentary (txt in blue lalis) does not pacity an ETP requitement Note 2 Technical deviations, non-appicable paragraphs and clauses of IS 42-236 to ths epecication ate detaiod within (JPK-DR 008 & 008), CONTRACTOR shall comply in ful with the latest issues of relevant codes, statutory ‘equations and other documents referenced witin the contract and herein, ‘CONTRACTOR is ‘ofthe work, sponsible for the qualty of materials and workmanship in performance Conflict of information In the event of any conf, inconsistency or ambiguity between the contract documents, this Special or any ler spect amd aboucisled dat stews, or wil ty OF the applicable codes, standards and rogulations the CONTRACTOR shall immecitely inform COMPANY in wating and receive ween claoaion from COMPANY bbtore preceding wth the work. age 126174 S7AND-FOATG7O01-¥-S0.0040.000 Rev Gt[BP Exploration Operating Company Lid fren Developer eles wen ey ‘Welding and NDT of Duplex Linepipe to BS 4516-2 (1999) Oo} 23 24 25 0 Project Documents ‘The folowing documents pertaining tothe Andrew Project are related or applicable to this Speciation: DEV-AAD-MP.SP-JPK-1052 Speciation or Duplex Linepipe DEV-AAD-MP-SPAIPK-1053 Speciation for Duplex induction Bends DEV-AAD-MP-SP-JPK-1168__Duplox Flanges and tings Speciation DEV-AAD-ME-SP-JPK-1096 Specification for Subsea Vales Revisions ‘The latest issues for the relevant standards, codes, statutory regulations and specications referenced herein shall be appled othe work. Referenced Documents It ls the responsibilty of the CONTRACTOR to ensure that he has received rom COMPANY all specications, ete which are referenced within applicable spe:fications to tenable him to understand and comply with all aspects of the work to be performed for COMPANY. Codes and Standards The CONTRACTOR is responsible for the quality of the work and compliance with the requirements ofthe applicable Intemational Codes, Satuory Regulations and Specifications as listed, The following Codes, Standards and Specifications with thir latest published ‘amendments shal apply ‘Amercian Society for Testing Materials ASTMASTO ‘Standard Test Methods and Defntions for Mechanical Testing of Stool Products ASTM A380 Recommended Practice for Cleaning and De-scaing Sinless Steel Parts, Equpment and Systems AsIMauzs ‘Stancara fest Motnod for Detecting Letrmental ntermeatic Phases in Wrought Duplex/Austontc Stainless Stools ASTM Ese ‘Standard Test Methods for Vickers Hardness of Mtalic Matorials ASTM E562 PPracce for Determining Volume Fracton by Systematic Point Courting Page 130174 S7AND-FOATG7O0I-¥-S0-0040000 Rov GiBP Exploration Operating Company Lid ‘Andrew Development Project een ene Won ASTMENEI5| ASTM G48 ‘Standard Test Method for Classification of Fim Systems for Industrial Radiography ‘Standard Test Methods for Pting and Crevice Corrosion Resistance of Stainless Stools and Related Aloys by Use of Feri Chride Solution (2) Amorcan National Standards Insitute (ANSI) / American Welding Society (AWS) ANSIAWS AS 32 ANSVAWS B5.16 ANSVAWS C53 ANSVAWS 240.1 ‘Speciation for Weling Shiskding Gases ‘Spectcation forthe Qualification of Welding Engineers Recommended Practice for Air Carbon Are Gauging and Cutting ‘Saoty in Walting Cutng, and Alied Processos (9) Bish Standards and Regulations 8S 45162: 1900 BSEN ATS ENTI9 8S 7446-1 ‘8S 7910:2008 BS EN 10204 [BS EN 12074 BSENISO 14175 BSEN 14717 Speciation for Welding of Stel Pipalines on Land and Ofshore. Duplex Stainless Stoel Pipelines NonDestrucive Testing - Qualification and Certification of NDT Personnel - General Principles Welding Co-ordhnation. Tasks and Responsible. Fracture Mecharics Toughness Tests, Method for Deteminaton of Kc Gitieal CTOD and Crial J Valves of Metalic Materls Guide to Mathods for Assessing the Acceptabilly of aus in Metalic Structures Metalic Products ~ Types o Inspection Document Welding Consumables. Qualty Requirements for Manufacture, ‘Supply and Distibuton of Consumables for Welding and Aled Processes Welding consumables. Gases and Gas Mixtures for Fusion Welding ‘and Alle Processes ‘Welding and Alied Processes. Environmental Checklist (4) ternational Standards Organisation 180 148 Metalic Materials — Charpy Pendulum Impact Test (V —notch) ‘Page 140174 S7AND-Fo41G7007-Y-SD-0040-000 Rev GtExploration Operating Company Lid Andrew Devopmert Praect Linepipe to BS 4515-2 (1998) weim Welding and NOT of Dus 150 2504 Iso 3452 1803034 1804196 1505173 180 sse0 180 6807-1 180 9001 180 1169041 180 14731 1580 15156 180 17636 180 17697 \s0 17640 180 9001 (5) Other 11000 No, 3032 SNT-TC-1A Faciogrephy of Welds and Viewing Gondtons for Fims-~ Utitsation ‘of Recommended Pats of Image Qual Indicator (0's) "Non-Destructive Testing -Penetrant Inspection - General Principles. ‘Quality Requirements for Welding. Fusion Welding of Metalic Materials, Parts 1-2 Destructive Tests on Welds in Molale Materials - Transverse Tene Tests Destructive Tests on Welds in Metalic Matorials~ Bend Tests NonDestrucive Testing — Industial Radiographic urinators — Minimum Requirements Metall Materials - Vickers Hardness Test - Test Method Qualty Management Systems ~ Requirements Non-Destructive Testing — Indust Radiographic Fims ~ Part Ctassitction of Fim Systems for Indusial Radiography Welding Coordination. Tasks and Responsbiltios Petroleum and National Gas Industies ~ Materials for Use in HS Containing Envitonmentsin Ol and Gas Production Non-Destructive Testing of Welds - Radiographic Testng of Fusion Welded Joints Non-Destructive Testing of Welds - Visual Testing of Fusion Welded soins NonDestructve Testing of Welds - Uttasonic Testing of Welded soints (Qualty Management Systems. Requirements ‘The lonsing Radiatione Regulations 1909 Personnel Qualffcation and Gertiicaton in Nondestuctite Testing Page 150174 S7AND.FOATG7O01-¥-S0.0040000 Rev Gi[BP Exploration Operating Company Ltd & ‘Andrew Development Project ‘Welding and NOT of Duplex Linepipe to BS 4515-2198 WGIM' 20 aa a2 MATERIALS General ‘This specication applies to ilams manufactured in accordance withthe documents iste in section 22.1 of this document. Storage Linepipe materials shall comply with grade, dmonsions, matefals qually and end preparations as defined by the applicable specifications and standard. Materials challbe secursly stored above ground using non metalic dunnage. Solid CRA materials shal be stor under cover ona prepared surface to minimise extemal contamination End caps shall remain in place uti the materials are rquited or fabrication lend caps are removed from the pipe during storage and internal surface contamination is, suspected by COMPANY, the Ferrxy! test (ASTM A380, 7.3.4) shall be appiod to each pen end. end caps are removed from ftings during storage, the entice intemal surtace shall be subject othe Ferony tet. {a materia isnot properly identfied it shall be quarantined untl its source s confirmed. The COMPANY shail agree on the selected method for dentiyng the material prior wo woking Dissiilar mates shall be kept segregated trom the rest and marked propety inorder to alow oasy traceabilly. Page 16<174 __ SYAND.FO41G7001-Y-S0-0040000 Rev G1BP Exploration Operating Company Lid nace Devcon Bea wen Welding and NDT of Duplex Linepipe to BS 4515-2 (1996) 40 INFORMATION TO BE SPECIFIED AND ITEMS TO BE APPROVED 4.1 Information to be Specified by COMPANY Information to be supplied by COMPANY is given as addons or caificaons of ‘amendments othe appropiate sections of BS 4515-2: 1990, CLAUSE | BS W515: 1909 SECTION ‘SUPPLEMENT ‘@ | Wihather batch testng of ‘Bach testing of elocwodas and War ‘electrodes and iller mates s | _matorl shall be caried out. See section roqutea. 7.41 BS 45152: 1990. 'b | Whether diferent batches of | — Difrent batches of electrode and ilar ‘lectrodes andtiler metals are_| mates shall be indvdualy Wetfieg tobe indvidualy ientiable | and completely separated. Seo sacton 7.2 and completly separates, OF BS 4515.2: 1098. | Winether an aferatve location | No aematve locations are require for 's speciled or te excavation | —ropairtest weld. See section 1b of BS {or the opair wold test 45152: 1000, | Whether strain ageing data “The use of Pstarial data maybe ‘and! oF adational tats are permitted subject to meeting the required asthe basis fr Fequiemonts ofthis specticaton and it ‘welding procedure approvalfor | agreed by COMPANY. See section 8.1 ¢ | pipe resting. of BS 4515.2: 1999, © | Thotype and number of e= ‘Retest shal not be porilid, unless tests required inthe event ofa_| can be proven that a test alu was the proceduie test falure. result ofa problem withthe testing technique. Re-tsts wil be subject to approval of COMPANY. See eection 8.1 of BS 45152: 1000, 7 | Whather any adcitional 100% LPE shall be carisd ou on methods of non-destructive completed filet welds, testing are required for butt joints. @ | The mated and acceptance | Whare specified by COMPANY, hardness levels or any hardness tess | measurements shall be carted out onthe required. macro specimens inthe weld metal and the HAZ using a method and meeting requirements as spectied by COMPANY. Soo section 8.5.2.4 of BS 4515-2: 1990, | Whether the proportion of ‘When speciieg by COMPANY the fect nthe wold and HAZ proportion of erie inthe microstructure microstructures isto be Shall be detormined and shalio within the etermined and the mits tat_| range spectied by COMPANY. In adcton, apply. presence of any thi phase stall be Feported to COMPANY. See section 852.5 of BS 4515.2: 1000, 7 Whathera temperature lover | The impact tests ehalbe carted out at than the minimum design 46°C or the minimum design temperature fomporatureis tbe used as | whicheveris lower. Soe section 8526.1 iheimpacttesttemporatue. | of 85 4515-2: 1000, age 17 af 74 SAND FO61G700%-¥-80-0040-000 Rev CrBP Exploration Operating Company Lid Andrew Development Project WGIM: Weldi 1nd NOT of Duplex Linepipe to BS 4515-2 (1999) ‘CLAUSE | BS 05152: 1089 SECTION ‘SUPPLEMENT T | Whether corion fsing is | ~ Corosion tosng shale undertaken in required, accordance with Annex C of BS 4515-2: i = 2 4900. Kk | Whither a proposed change to | Weloere wil require re-quaiicaion when ‘a welding procedure COMPANY datermines tha a change to equipment wil require re welding procedure or equipment warrants ualficaton ofthe wolders. Ik Seo section 2.5 |of BS 4516.2: 1099, T—} Whar provaiing weather | —Widing shall be perfrmed in sean areas, concitons are such thatthe | segregated fom ferous tems, wth {qualiy ofthe completed weld | adequate protecton from adverse weather ‘would be impaired. ‘conations and changes in huniiy. See ‘section 10.9 of BS 4815-2: 1989 and as. ‘maditiod by section 10.9 of his spection, ‘| The method(s) and requency | NDT for ginh welds shall be urderiaken on ‘al vicual inspect andnon- | completed welds as follows: estructve testing 100% visual mtemal & extemal; {100% ATIAUT, 100% LPE (Spools Only) ‘Manual Utrasonic Testing (MUT) shall bo Used Yo ait in ofa sizing and iocation ‘when PT s the primary NDT technique. See section 11.1 0 BS 45152: 1909 and ‘as modified by section 11.1 ofthis ‘specication, | Whether competed welds aro | — Completed waide may ba ground whan to be ground, ‘agreed wth COMPANY to facttate NOT provided the wallthcknese complies with {the minimum spectied it Ginding shall ‘ensure no sre raisers and aemoath transtion exists. See section 11.1 of BS 4515-2: 1999 and as modledby section 11.1 of this specication. ‘© | Whather NOT accoplance | NDT acceptance citer shal ae based O8 criteria are to be based on ‘ualty contol or ECA. Whereminimum {qualty conto or engineering | design temperature Is iowor than -46°C an Ciel assessment EQAIs required. See section 12.1.2 of 12.1.3 of BS 4515-2: 1909 and as modified by section 12.1.2 or 12.1.3 fis _ specication, >| Whetitera more aiingent limit | Root penetration shall nol exceed Sm, {or root penetration is required. | See Table Sc of BS 4515-2: 199. [Test variables curing pting [Tho corrosion tostng sal bo >arrod out corrosion tating f duplex ‘lng he fllosing teat variable ‘Stans soe 2) Test temporature22%CCr al25°C and 25% Crat a0°C. 1) All surfaces tobe tested ©) Pin probing is required. 6) One re-estis permite, ©) No adtonal requirements Soe 0.3 and 0.4.2 of BS 4518.2: 1999, Page 180174 STAND.FOATG7O0I-Y-SD-0040000 Rev G1fepearnorerncaneny won Se Welding and NDT of Duplex Linepipe to BS 4518-2 (1990) 42 Items Subject to Approval by COMPANY “The items to be approved by COMPANY are included inthis Speciication as adkitions or clarifications or amendments tothe appropriate sections of BS 4515-21990 ‘CLAUSE | BS 5152: 1000 SECTION ‘SUPPLEMENT @ | Conumabies tobe used ‘Only consumables which awe received The Prior approval of COMPANY shal be used. Soo coction 7.1 of BS 4515.2: 1908 and as = ‘modified by section 7.1 of hs Speciation. | The definion ofa batch when | Abatch is detned asa single reat of flor batch esting of electrodes and | wre a single blend of flux, ofr covered filer materials is require | a single neat of cored wire witha single ry ‘land of fax cover or core. Sea sacion 7.4 G1 BS 4515-2: 1090, ‘© | Technique and equpmenifor | The atachment o anads direc t aipiox ‘attachment of aneda bonding | shal gonorall be avoldod. Whore leads. applicable, the procedure forthe atlachment of anode bonding leads shall be subject fo COMPANY approval See Ssocton 8.1 of BS 4515-2: 196 ‘@__| Testweld producto on pipes |” For tein spools qualiation tet welds, the shorter than fl length so of pipes shoror than fl ongth is accepted; however the length shal be subject fo COMPANY approval See Seeton 8.1 b of BS 4515-2: 1999 and ‘madiiod by soction 8.5 of ths specication. ‘© | Explanation for NDT fafure va [An explanation shall be gan tothe testwoldis tobe destrucively | ‘satstacion of COMPANY fer the presenco tested or r-wolded tothe same | of any flaws inthe test weld ouside the procedure. ‘spectied acceptance criteria before approval is ven fo the test piece tobe ‘subject to destructive testing, See section 8.1.dof BS 4515-2: 1909, T | Waiting procedure qualfeation | ~The wela procedure specication and tact das and WPS for procedure qualification test records shall be producton welding Subject o approval by COMPANY prior to the commencement of producton welding, ‘Soe section 8.1 gofBS 4515-2: 1099 and ‘as modtied by secon &.2 ofthis, speciation | Use of ral weicing, Fol welding shal ony bo used wih ‘approval ol COMPANY, provid itis within ‘he rango of parameters alowed by the relevant WPS and provided thet the assembly is adequately suppoted ether ‘Sie ofthe weld. See socton 83 of BS | 4515-2: 1098. age 1974 S7ANO-FOATGTO01-¥-S0.0040-000 Rev CT[BP Exploration Operating Company Lid ‘Andrew Development Project wen ey _Welding and NOT of Duplex Linepipe to BS 4515-2 (1999) ‘CLAUSE | BS 46752; 1090 SECTION ‘SUPPLEMENT | Allemata metho for feria Seterminaton. ‘Tho volume fraction of ferie shal bs elermined in accordance with Annex B of 'BS 4515-2: 1999 and as mosified by section 85.2.5 ofthis specication, 1 | Ghaspy V-notch pact testing the eeumferontal postion, ‘Not appicabo for pipe thicknesses Tess than 5mm, See section 8.5.2.6 of BS 4515- 2: 1999 and as moctied by secion 8.5.2.6 this specication T | Sinlation ofa lt wed joint Tor ‘welder approval using lat pale filet welds ‘Simulation of a slat weld joint using fat plate filet welds shal not be permite. | Alteratve methods of NOT for ‘welder ost pcos ‘With the prior approval of COMPANY. Soe ‘section 916 of BS 4515-2: 1909.nd as odie by secon 86 of tis Specticaton T | Ging a welder a second ‘opportunity to gain approval "A woldor may be gvon a secon’ ‘opportunity, subject to COMPANY ‘agreement, to gain APPROVAL. This ‘pon does no, however, apply whan Sestructive tet falures have occured In ‘hase circumstances, tha welder shallbe restrained prior o resting. Ses section 2 of BS 45152: 190, m | Aldecumentation rlatng to welder qualification tests, ‘Al documentation relating to welder {ualfication tess shal be approved by COMPANY before the welders allowed to Undertake production work. See section 8.9 ‘1 BS 45182: 1090, | The Bonding out by ainaing of minor imperfections within the joint preparation area, ‘Not permite. The joint shal bs re- prepared inthe event of small score marks, indentatons etc being present within the jeint preparation area. See secton 10.2 of BS 4515-2: 1999 and as moifiod by section 102 ofthis Speciation, ‘| Mathael af marking Yor urasanie ‘eating. iT used, he method of marking uasone datum points shal be included nthe llrasonic procedure for weld examination land shall be subject to COMPANY approval. Se section 10:2 of ES 4516-2: 1900 and as modified by secten 102 of this Speciicaton, | Mathod of ebianing minimum misalignment, other than ‘Only rotation ofthe pipos shal 98 used for ‘oblaiing minimum msaignment. See ‘otaton ofthe pipes. Section 10.4 of BS 4515-2: 1999 and as tadiiod by section 10.4 of ts Specticaton ‘| Amatve alignment methods — | ~Aignment methods ctor than rtomal ine- ‘ther than internal inp tp clamps shal be subject to COMPANY clamps. approval. Se section 105.1 ol BS 4515-2: 1999, Page 2074 {TAND-Fo4iG7001-¥-SD.0040-000 Row GY[BP Exploration Operating Company Ltd Andrew Development Project teling and NOT Dupes Lnopipe to BS 4518-21900) wen So ‘CLAUSE | BS 4515 1999 SECTION ‘SUPPLEMENT 7 | The stage at which ine-ap Tnfemaline-up amps shal noi be clamps are roloasod. removed unt ter compton ofthe root fun and hot pass. ExtemalIne-ap amps Shall ot be removed unt at last 60% the cleumference of the jit nformly spaced has boon fled. See section 105.1 Of BS 4515.2: 1009 and ae mosiied by | _ section 10.5.1 of his specication ‘=| The stage at which the pipe | Not applicable. Reiated to landin lowored anto skids or support is | For subsea spools, spas shal not bo removed rom tings. ‘moved or lifed uti at east 13" ofthe wold has boon doposted, unless it can bo ‘demonstrated as acceptable tough ‘aloulaton, 1 | Wack welds are required, the | Tack woids using bullets of masa proposed welding procedure | identical othe base pipe may be used shall be subject to approval by | subject to COMPANY approval The COMPANY. CONTRACTOR shal provide procedures for removal of bulets, tack weks, and the base matara aftected by tack welding as the joint weld progresses. Se section 10.6 Of BS 4515-2. 1999 and as moded by ‘section 10. ofthis specication. ‘| Repair of pipe material where | Permission to repair stay arcs shall be stray acs have occurred, ‘given by COMPANY. Soo section 10.8 of BS 45152: 1900 V__| The proposed welding ‘Atbranch simulation tet wed required for procedure for branch branch welds where the angle beeen the. onnectons where the angle | main ine and branch is oss than 60°. See DDetween the main and branch is | section 10.11.1 of BS 45152: 1099, lose than 60° W | The utasonie examination “Tho ulfasonic examination of ipa marl procedure for pips material ‘around planned cut-outs for nozzles shall around a planned cutout. be in accordance with the requrements of the pipe material specication. & writen procedure shal be submttd fo COMPANY for approval. See section 10.113 of BS __ 4515-2: 1988, x | Alnon-desiucive tesing 'AINDT procedures to be used shal be procedures tobe used submited to COMPANY for aprroval. Seo section 11.1 of B 4515-2: 1868 ¥ | Alinspecton personnal ‘Allinspecton personnel shall fave Baan | approved by COMPANY. Soe socton 11.2 _ Seoton 11 2 ofthis pocteaton = |The technique ie BS EN T3516) Only cass B techniques of ISC 17635 shal be used fr radiographic bo used or techniques with equivalent examination sensitviy approved by COMPANY. See section 114.1 of BS 45152: 1999 and as modifid by Section 11.4.1 of tis speciation, {STAND-FO4IG7O01-¥-SD.0080-000 Rev CT Page 2 ol?[BP Exploration Operating Company Ltd ‘Andrew Development Project Welding and NDT of Duplex Li onus —_—_ WIR ‘CLAUSE | BS 45152 1099 SECTION ‘SUPPLEMENT ‘aa | Rezoptance erfria Ter uasorie | Acooptance ertera Tor uirasonis ‘examination. ‘xaminaton shal be in accordance with section 12.1.2 of BS 4515.2: 1899 and as ‘odie by sections 11.5.1 ang 12.12 of this specication, ‘be | Any propasaltorepaira weld, | COMPANY shal approve all wed ropa. Seo eection 12.2.1 of BS 4515-2: 1999 and 8 modfied by sections 122 ofthis specication. | Any repairwelds axcooding |The limits to ho Tongih of wold pars for 20% ofthe wel length for ful | partial penetration sal be as spectid in Penetration repair oF 90% of the | clause 122.1 of BS 4515-2: 1998. Full wel length for a partial penetration repairs are not perited. The Penetationrepa Allowable size of repair excavatons, subject to instalation stress, shallbe demonstrated by stress analysis subject to COMPANY approval ‘da | Awoling procedures Tor repair |All weld repair procedures shallbequalfied ‘woes. ‘and submited to COMPANY for approval A {ull ponetraton repair test shall approve all, repair procedures excopt fr baxkwald ‘opairs. Soe socton 122.3 of BS 4515.2: {000 and as modified by sections 12.23 of this spectcation, 6 | More than one attempt at repai_| Repairs shal not be attempted more than once, Soe eection 12.2.4 of BS 4515-2: ‘908. | Use af back weld repair: ‘Back weld repairs shall not be paited Seo section 12.2.4 of BS 451542: 1099, Page 220174 S7AND-FO4TG7O0T-¥-S0.0040-000 Rev GTBBP Exploration Operating Company Lid ‘Andrew Development Project Welding 50 Scenes ——_ WIR ind NDT of Dus EQUIPMENT A Welding equipment shall be calibrated and maintained in a condlon that ensures ceontieuiy of operation and the production of welded joints that consistantly meet the quality requirements ofthis specfestion, In the cage of eem-automatic and mechanisedautomatic welding, the weldng unit, the Wwalding power supplies, and the ascociated control software used for procedure qualification shall be of the same typelmodelWersion as those used in production. MANUFACTURER'S model and type of equipment and software shall be identified in the ‘Procedure qualification record Independont calibrated instrumentation shal be provided to measure relovant parameters, such a8 current, voltage, welding speed, prehe production and interpass temperatures during Gauges for measuring the weld preparation, wld bead profile, and the profile of wold repair excavations shal also be provided. Equipment including hand tools shal be celected, stored, and operated in oder to avoid contamination of CRA materials with carbon ste Pipe handling equipment, pipe end preparation machines, rollers, and ine up clamps shal ‘not damage oF contaminate the CRA materials Low moting point metals or thei alloys shall not come into contact with the CRA. ‘Copper backing bars may bo used for wading provided use is in accordance with section 105.1 of this specification. Copper contact tubes shall be visually checked aftor each weld pass to onsure that they are not boing fused int the weld pool “Magnetism of CRA pipes by welding equipment has caused problems of arc instability in previous projets. Therefore the CONTRACTOR shall have equipment avaiable to both ‘measure magnetism within th pipes and demagnetise them if required. ‘Shop equipment shall be subject to COMPANY approval Page 201 74 S7AND.FOATG7OOI-¥-S0-0040.000 Rov G75° Explorton peraing Company Lid 2, Andrew Development Project Linepipe to BS 4515-2 (1! wen Welding and NDT of 60 WELDING PROCESSES Ads. 61 General Mechanised and automatic gas shielded arc welding processes are proferred and should be used whenever possible for pipeline gith welding Single torch, multorch, and tandem are welding techniques may be employed Semiautomatic and manual arc welding techniques may be used in appistions were ‘mechanised or automatic welding processes are inappropriate “The root and hot pass of pipeline girth welds shall be deposited by @ gas shikded sold wire ar welding process, “The root and hot pass of branches and fitings may be completed by sold wire gas shilded welding or SMAW. ‘Soifshioldod cored wir welding techniques shall ot be used, Welding techniques requiring the use of permanent backing rings shall not be used. For double or multiple jointing, SAW may be used forthe fil and cap passes a wolding technique which In the opinion of COMPANY, isnot old proven fs offered for se, an agreed series of welding and reliably trials shall be succosstuly completed betore the commencement of welding procedure qualification testing NDT tials may also be required by COMPANY. “The bore of materials covered by this Speciation shal be purged during deposition of the \wold to ensure that no oxidation or coking of root run and intemal surface occurs 62 GTAW But welds and pressure containment filet welds in ON 5 (NPS 2) and smaller pipes shall be performed using GTAW forall passes, [AIL GTAW equipment shall use either high frequency staring unit or alternative programmed lou statin uni ai terse loperoul antl, A cre decay ‘device should also be fited, together wih a gas lens, to improve gas shielding of weld pool 6.3 Mechanised Welding Equipment When mechanised or automatic processes are proposed for circumferential welding, i, ‘mainline oF riser welding, tein welding, oF for multiple jointing of pipeine subassemblies, Page 240174 S7AND-FOAIG7O01-¥-S0.0040-000 Rev GTepee onerncaron wen Se ‘Welding and NDT of Duplex Linepipe to BS 4518-2 (1980) tho bid proposal shall include full dotals of the processes to be used, the associated ‘welding equipment, and he proposed area of aplication For mainine welding applications, the proposal shall Ist the number of weling stations. (oat pass to tral capping pass), either onthe fring tne (otfshore lay barge) cr speatbase land shall detail the equipment and number of welders and other personnel raqui ‘operate each station. ‘A similar love of dota shall be provided for tien welding and mui jointing Mechanised 26 or 5G welding equipment should be operated in conjunction with data logging faites capable of recording the essential variables associated with the arc Including wire fead speads and travel speeds. The equipment shal, on a weld by weld basis; record parameters at @ minimum rate of ‘once per 10 degrees of angular rotation and shal indicate the angular postion of each measurement. ‘This data shall be readily reievable for monitoring purposes and shall form part of the pipeline construction data package, Data logging shall be mandatory when welding with ether mul torch or multi wr systems, Each mechanised welding station shall be demonstrated to bo fully operational before itis ‘employed to weld any joins that wil be incorporated into the pipeline. ‘This operational demonstration shall be repeated as agreed with COMPANY. but should, 2S a minimum, be repeated after any maintonance requiring signiicant equpment stip down, interruptions 2 7 days in pipeline welding and when a welding spread is broken down and transferred from one section of he lne to another. ‘The proposal shall detal tho intended level of technician support for equipment ‘maintenance and shall also list the principal spares that wil be avalabie in order to ‘maintain equipment serviceability forthe duration ofthe pipelay It shal also adviso ita manual welding procedure isto be quali for producson o repair welding ‘Page 25ai74 __SYAND-FO41G700%-Y-S0-0040-000 Rev G1[BP Exploration Operating Company Ltd ‘Andrew Development Project tating end NOT Duple Linepipe to BS 4515-2 (190) wen &ey 70 a 0 ® ° WELDING CONSUMABLES General as: Filor Meta ‘The solecton of electrodes, filer materials and wireflux combinations shall be approved by the COMPANY. Each batch of welding consumables shall be purchased from manufacturers operating ‘qualty system based upen ISO 9001 or EN 12074 and shall have a menufacturer's Corticate conforming to the relevant EN, ISO or AWS filer metal specication. ‘SAW fle wite shal be tested in combination withthe same brand and classificton of hx as ‘hat to be used during production wolding. SAW fluxes shallot be used to enhanc the alloy ‘content of the weld mal “The use of consumable insors shall require COMPANY approval Shielding Gas ‘Shielsing gases shall be argon. Shielaing gases shal not contain hydrogen. Shielding gases shall meet the requirements of BS EN ISO 1417S or AWS A5.32 and have 18 dew pont of ~60°C (-88°F) or lower Gasos shall be premixed and botled by SUPPLIER and shall have ceriicates of compliance. Gasos shal bo held inthe containers in which they are suppliod and stored, wth adequate suppor, na secured ar ‘Subject to COMPANY approval, standard Av/CO; compositions may be mixed at site ithe mixing is a part of a mechanised process which utiizes a fall safe cut of when the proportions fall ouside of those specified inthe approved welding procedure, {Gas mixtures containing hydrogen shall not be used fr elther shielding or purging unless ‘approved by COMPANY. Backing Gas ‘The Internal surtace ofthe pipe and weld shall be adequately purged by continuous argon {9 flow during deposition ofthe weld to ensure that minimal exidation oocurs. ‘+The gas escaping from the purge gas chamber shall be continuously monitored for ‘oxygen content using a COMPANY approved calibrated oxygen mentoring device. Page 250174 S7AND-FOAIGTOOI-¥-S0-0040.000 RavGT[BP Exploration Operating Company Ltd ‘Andrew Development Project welM: ‘Welding and NDT of Duplex Linepipe to BS 4515-2 (1980) 72 0 '+ Wilding shall not commence until the oxygen content of he purging gas has equalized within the butt and shows @ maximum of 0.1% (1000ppm) using a COMPANY approved ‘monitoring device ‘+ Iniemal purging shal continue unl a weld throst thickness of émm has been established. ‘Positive ow of backing gas shall be maintained during lacking and weldng, ncucing capping passes i pipe wal hickness is loss than 10 mm. ‘pipe wal thickness is greater than 10 mm, postive flow may be terminalbd and bore sealed once more than 10 mm of te weld has been completed, ‘Storage and Handling Aas Welding consumables shall be individually marked, stored and handad in accordance with the manufactures recommendations and GIS 18-012. The CONTRACTOR shall maintain ‘and implement a consumable storage and handling procedure, which shal be submited to the COMPANY for approval GTAW filer wires shall be degreased prior to use and shall subsequently be handled with lean gloves. Degreasing agents shal leave no chloride or suphide containing residues on the surtace, Al consumables shall be delvered according to manufacturers data sheets, which shall contain all the relevant mechanical and metallugical information for a given grade. The fiter metal shal be supplied with certification in accordance to EN 10204 8.1 which shall, contain al he relevant mechanical, chemical and metallurgical Information, ‘Aadional Batch Testing by Contractor (Only the batches of consumables tested during qualification ofthe wold procedure shall bo used for production welding. Each batch of consumables shall be used sequentially with the new batches being opened only after consumption of all electrodes from the preceding batch Each cast and batchlot of consumables for production welding shall be subectod to tho batch tests during qualficaton of weld procedures. “The testing shall bain accordance with Section €.5 ofthis Specticaion. The results shall ‘moot he lovee required forthe relevant weld procedure) ‘The as-deposited weld metal compostion sal be such thatthe weld meta: ‘© Matches the minimum 0.2% proot stress and tensile strength ofthe parent material at both ambiont and maximum design temperature. ‘+ Matches the minimum 0.2% proof stress and tensile properties ofthe stronger material when welding dissimilar matorais. ‘Provides adequate toughness atthe minimum design temperature. Page27 174 S7ANO-FOAIGTOOT-¥-S0-0040-000 Rev OT[BP Exploration Operating Company Ltd Andro Bovlopment Moje wein Se ‘Welding and NDT of Duplex Linepipe to BS 4518-2 (1990) Ensures adequate cortosion resistance to the process fds under the design operating conditions ‘The PRE of consumables shall be equal to or greater than 24.0 for 22% Crand 400 for 25% Cr. The hydrogen content af the wire as-Suppled shall be ppm maximum and be vociad bythe consumable manufacturer. ‘The fort level shall be 26% - 65% nal regions of weld met Page 280174 S7AND.FOATG7O01-¥-S0.0040.000 Rev GiBF Exporaon Opening Company Ltt rare &. ‘Welding and NDT of Duplex Linepipe to BS 4515-2 (199% 80 TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES 81 General Aad ‘A list of the proposed welding and repale welding procedures together wih a schedule for their qualification shall be prepared, ‘This shall be submited to COMPANY for approval with the pWPSs before commencement ofthe WPT, Welding, NOT, and mechanical testing of the WPGT welds shall be winessod by COMPANY or an approved third part. ing of mecharical ests shal include the positioning ofthe notches ‘or CVN and 'AWPS wrtten with more than one supporting POR shall not permit optional processes, but shall uniquely specify the process for each pass. 82 Records Ad: (1) Welding Procedure Specification information ‘The information detailed in Tablo 8.1 of ths Specification shal be detalled on the WPS using the CONTRAGTORS standard format: ‘The POR documentation package for each WPS shall comprise of ‘Assan records. NDT resuts. Mechanical est results and macrographs. Consumable certcaton Parent material corticaton, ‘The folowing data shall also be avalabe, if requested by COMPANY Welding Engineer: Caitration cortifcates for equipment and measuring devices. ASNT Witten Practice (whore applicable ~ soe section 11.2). ‘Welding Inspactor and NDT personnal corticaton. NOT procedure qualification records. Test house approval cetfcates. “The approved WPS and POR packages shal also be available in a good quatty electronic format, Page 29.0174 S7AND-F081G7001-V-S0-c00-000 Rev C1wae g Lr to BS 4515-2 (1999) weim ‘Welding and NOT of Duy ea Oo} @ Welding procedure For new pipeline construction projects, new welding procedures shall be prepared and {qualified on contract maria Welding procedures shall not be transferred trom either one CONTRACTOR to CONTRACTOR, or, to SUBCONTRACTOR without requaliication. For the purposes of undertaking further work to an existing pipeline, the orginal fabrication welding procedures may remain vail indefiitely. However, COMPANY Welding Enginesr shall be consulted betore re-using these WPSs, Welding Procedure Parameters During wold procedure qualification, al relevant procedure data, irespectve of whether the item is aisted essential variable, shal be captured and recorded. ‘Sufcint Information shall be recorded to allow full replication of the procedure qualification weds. ‘A ecord ofthe data shall be kept for the purpose of aiding production and to assis withthe slagnoss of problems, but need not be formaly entered onto the POR. “The methods of measuring the welding parameters and the records to be hept shall be agreed wth COMPANY Welding Engineer. When a partcular welding consumable or group of consumables Is qualified to weld several diferent components or pipe sizes, every effort shall be made to ensue that the parameters spectied on the individual WPSs are standardisod, Final WPS and WPA, Following WPOT the pWPS shall be revised to rellect the parameters recerded during {ualfication, The revised WPS values for current, voltage and rave spoed shall be either: + Within the range recorded during WPQT, noting that transient and anomalous values should nat be used to establish the paramétor range, of + The mean value +10%, “The revised WPS shal stato parameters for each pass. However. fil passes (Le. not root. hot pass, and cap) have similar values the parameters may be combined on tha WPS. a Page a0 ol 74 _S7AND-FO4iG7O01-¥-S0-0040-000 Rev CTee Repalatige nea comeey| won Se Welding and NDT of Duplex Linepipe to BS 4515-2 (1996) (9) AroEnergy “The aro energy for each pass shall be calculated using the recorded values of cure, ‘voltage and travel speed from the POR without the addon ofa percentage. For multiple (electrically isolated) tandem electrode welding processes eg. SAW or PSMAW, the cffective are energy per pass shall be calculated as the sum of indviual arc energies for teach electrode For pulsed procedures, the efecve arc energy shal be calculated onthe basis of AMS values, For 2%4Cr duplex the arc energy shall be resticted to 0.8 ~ 2.5mm. For 25%4Cr duplex tho arc onorgy shall be restricted to 0.8 ~1.5kImm, CCaloulation of are energy assumes each welding process has an efficiency oft Ag (4) Retests Re-toating i permitied subject fo COMPANY approval, provided the CONTRACTOR can ‘demonstrate thatthe test falure was due to eror in test procedure, spaciman preparation ‘0 dotect in the mechanical test specimen. Otherwise no re-osts shall be permite inthe event of any tensle, CVN or corosion tet fares and also for adverse metallographic test ‘bserations including the presence of harmful intrmetalc phases. 84 Changes Affecting Qualification and Approval (Essential Variables) Aas ‘The restictons listed in Table 8.1 of this Specification apply to all welding procedure ‘specications in addon to those given in BS 4515-2: 1999 Table 1. When any of tho changes detaled in Table 8.1 are made, a new WPS and fll qualification shal required Table 81 WELDING PROCEDURE SPECIFICATION DETAILS AND CHANGES AFFECTING APPROVAL, ‘CHANGES AFFECTING WELDING PROCEDURE rem APPROVAL (ESSENTIAL SPECIFICATION DETAILS OVAL (ES The specie are waldng process | A change trom one are coreombination of processes | wolng process to another a fad the order in uti the processes aroused ‘| The number of walang torches per | Any change otrised wong bug Welding process Page stat 74 S7AND-FO81G700'-¥.50-0040-000 Rev C1BP Exploration Operating Company Lid Andrew Development Pcie wei Welding and NDT of Duplex Linepipe to BS 4515-2 (199% ‘CHANGES AFFECTING WELDING PROCEDURE mem [APPROVAL (ESSENTIAL SPECIFICATION DETAILS OAL ae 35 | Forsombautomate ana ‘The welding unt, power mechanised waldng processes | suppl type, MANUFACTURER, rrodel nd eofvare version, a6 | For 1G woated welding Welding heed ane, pacing from op dead eon and tract of tan ‘ase matoal ‘| Spociied Standard end Unig | Any change specteation ‘Numbeeng Systom (UNS) Number 1 | Composiion fpreduct analysis for | Achange nthe Ping ro, Wa Ny Fostance Equvlart ‘Number (PRE value ‘ceeding 1.50 2siuhare PrenarcGres Me). sais 6% | Manuicturing method ™ "Any chenge be | WelsedSeamiess “Any change Diameter © | Nominlousce carter ot pipe | A change outside of be rangesin Table 2 Thickness @ | Nomina wallickress ofthe pipe [A change outside o fangeostte 181 Whore Smt “ot configuration (wah ketoh Incudingtlerances) | Pipe end preparation inuding the alowing Angles) of bevel manual weting) | Any change exceeding 221 ‘Ange () of bevel (mechanised | Any change exceedirg 205° ‘esting | Wat of ot oap “ny change exceedirg 255m 8 tral micaigenent Any nese Tecrade orfier | 1 | The folowing formation needed for each welding iorchand Tor metal och 11 | Nominal diameter of ierlecrede | Ary change forthe ist roe cores passes orloner 1Onm a the field ‘Any nerease forthe uth fas onwards or cutie of {ower 1mm [Ray aning orprereament ofthe | Any change ‘alg consumes 7S | Number ot wres for esohun | Any ehango 16 | The use ofa consumable inset for | Any dion or lean ‘he oot pase “Shsidng gas artic | ht | Shildng gas ‘hy change ne vad orbackng gas rare or nominal % change in ompostion 2 | Backing gow ‘Any change nie ae ‘ame or nominal % change I compestion Page a2 o174 _S7AND-FO4IGTOOH-¥-S0-0040-000 Rav CT[BP Exploration Operating Company Ltd STrmanwnsim —_—_ WGI ‘Andrew Development Project Welding and NOT of Duy ‘CHANGES AFFECTING WELDING PROCEDURE mem APPROVAL (ESSENTIAL SPECIFICATION DETAILS a Matos of nroduing te backing | Any change oss 18 | Sheng gas fow ata “Any change sue at recorded on WPS. ‘Weldng parameter |_| | The folowing information is needed foreach wine size and each wold pass | Etectea wee stekou (SAW, Any change ouside at GMAW, FCAW) recorded onthe WPS. | are wotage “The folowing mis on are al Wegeeae ‘ner shal spy OTe + 22%Craloys, 08 | We tee speed —— 18 [Backoround curentinany pubes | Se og a ‘skin, TE_| Peak ourertin any plead wading T_[ Pulse uration |_| Pules Shape “0 Travel speed 710 | Wiallecrede spacing for mul tiellectrede weking heads THT | Hotwire diameter, food speed, ‘urent and vatage [22 | Calvated vaue of are ener Waldingposiion | & | Angle of pip axis tothe horzoral | Any change exceeding 320°, ‘xcept tha qualieatin both he 5G and 26 rositons ‘over all ether waldhg postions Wilding echnique | _m | The oloninginlrmation i neaded or each wie size (Daven salves may Be used for leon un) Tai | The ampttue of manual weaving [ Any increase m2” [Maximum ampituse of any ‘ny change outside Fat mechanized woe recorded on the WPS TS | Frequency of any mechanized ‘m4 | Dual imp atthe side of any mmahanzed waste Lneupmatied |r| Use of tacking ‘Ry adtion oF deeton Preheat and | Preheat and inerpass temperature | Any change interpass co, ioeperature | Metied ot accelerating wo | Anychange cooing Fepair wale “B_| Amount of eiginal wad remaining | Any decrease in hiciness a7 | Type of par wold "Any change rom corps removal ofthe eigral wel to Data! removal oe versa wy ‘Speci to Forging, Casting, Extrusion ote Page 3074 S7AND.FOAIG7O01-¥-SD.0040000 Rev GTBP Exploration Operating Company Lid Andrew Development Project Welding and NDT of Duplex Linepipe to BS 451 (1999) @) Diameter {Ads The pipe diameter shall be within the lmits shown in Table 8.2. r DIAMETER RANGE OF APPROVAL FOR WOT "TEST PIPE DIAMETER (mm) RANGE OF APPROVAL (mm) 603 03 woaeD azo 303108239) 25.920 <610 328.910 610 D>e10 2610 85 Testing of Butt Joints for Procedure Qualification \When an interna tne-up clamp wil be used in production welding, the length othe nipples sed inthe WPOT shall be sufleint to accommadate the ful length ofthe clamp. “The minimum length of any nipple piece used during qualification shall be 1m (3,3) length (F 1.5 pipe dameters, whichever Is the greater “The minimum length of test rings forthe WOT tests of fitings and flanges shel ‘to agreement with COMPANY. bo subject (1) Non-Destructive Testing Ads, ‘+ The NOT procedures for WPCT welds shall be qualifed and subject to approval by COMPANY. ‘+ WPT weide shall be viually examined as goon as possible alter completion of welding wth 100% coverage ofa weld surfaces ‘+ WPGT welds shall meet the same requirements for VE and weld profibs as those spectied for production welds. ‘+The ul ercumference ofthe WPOT welds shall be examined by RT and UTAUT and by LPE. Technique and acceptance criteria shall bein accordance wih sections 11.4, 1.5, {and 11.8 ofthis Specticaion +The LPE shal inciude the intemal rect bead surface and the adjacent HAZ. + Acceptance by COMPANY Welding Engineer shall be required prior to sectoning of ‘WPGT welds fr mechanical esting, 2) Destructive Testing {852.1 Test Specimens Mosiied to Page’4 ol74 _S7AND-FO4IGT00T-¥-S0-0040-000 Rev OT[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM: ‘Welding and NDT of Duplex Linepipe to BS 4515-2 (199% Mechanical testing shall be conducted as spectod in BS 4515-2: 1999 and the adtional requirements as gvon in Table 8.8 ofthis specication. Ads, The blanks from which the mechanical test pisces are machined may be cut from the ualfication weld by the use of plasma cutting, but its dimensions shall be sufficient to Allow the material ofthe finaly machined test piece to remain unafocted by the haat trom the euting operation. Page iScf74 STAND FOMGTOOI-Y-SD-004G000RevGiBBP Exploration Operating Company Ltd caevimnmenscs weno ‘Welding and NDT of Duplex Linepipe to 8S 4515-2 (1999) Table 8.3 ‘TYPE AND NUMBER OF TEST SPECIMENS FOR PROCEDURE QUALIFICATION TEST" ‘Number of Specimens fr Wall Thickness © 127mm Tonaie Charpy Def strngth —ALWSIE page feet acre srsion oe’ “rose’ “hn oot, Sie, IPE! Maro ig | CTOD. Co mon ‘Wold Tanai’? Bene” Bend? (ore, /HVIO (sototay" Test seman a ona cleo eo eae sian gesaencelneeaa z 3 ee ea 2 pia: 2 1 2 2 6 8 28 a 2 Tuber of Spesinens or Wal Teinese > 127m on aves front = Root Side. act Macro CTOD Corrosion Pe “come “tart, foot, Site Tea Maco iro rs Pipe (Goes Matl) ent! anatomy ena rena 3) isa ea ec ° 2 Se 2 Soot ts se ts 2 NOTES: |. Specimen locations eal be in accordance with Figure 8.1 . One root-bond specimen and one side bend specimen shall be taken from each of two test welds, oF for pipe less than or aqual fo 34mm (1,315 in) ameter, two full section tensile Strength specimens shall be taken ©. When an'EGA is to be used for defect acceptance levels, three allweld metal tensile specimens shallbe taken; 4. TOD tests shall comprise a minimum of one setof weld metal and two sets of HAZ samples (Gee clause 8.52.10 4th paragraph); {8 An ECA and CTOD tess are only required for spools where the minimum design temperature is lees than -@6°C and of thicknesses > 40mm. An ECA and CTOD tests ae mandatory ‘hen pipeline instalation is by reeling o Say {Test roquired fr room and maximum design temperature Page 36 of 74 7ANO.FOsTG7001-¥-SD-0040.000 Rev GtBBP Exploration Operating Company Ltd Andrew Development Project ‘Welding and NDT of Duplex Linepipe to BS 4515-2 (1999) Fi LOCATION oF. (PX ey 1) Root or side bond 2) Tranevarse orto 5} Allott toneio SJeroo. S)Macrosecton 6} Charpy vNoch 852.2 Tranaveree Tenia Test As Transverse weld metal tensile spscimens shall be in accordance with ISO 4136, have a rectangular erase section and sample th fll material ticks ‘The wald reinforcement and the intemal weld bead surface shall be machined or ground ‘lush withthe parent material surtac. ‘Specimens shall not be fattened Page 7 0174 S7AND-FO410700%-¥-S0-0040-000 Rev G1[BP Exploration Operating Company Ltd Andrew Development Project Welding and NDT of Duplex Linepipe to BS 4515-2 (1999) “Transverse tensile tess shal be carried out at both ambient temperat dosign tomperatue. “The results of requirements forthe base material with respect tothe spectied tensile strength transverse weld tensile test shall meet or exceed the epecifisd minimum ‘Transverse weld tensile spacimens shall fall ata location within the HAZ or base mal “The position of falure shall be recorded, i weld metal, HAZ or base metal. For acceptance, transverse wold tensile specimens shal fal at a location within the HAZ oF base metal I base motas of itlerent strength levels are used, then acceptance criteria shal be based on the lower strength base metal 85:2.3Macro-Examination Add ‘Throw macro-examination test places shall be taken from each WPGT. The lations shall bo at 12, and 6 o'clock (soe Figure 6.1) and approximately 80° apart ‘When gith welsing longtuinaly seam-weliedlinepipe, an additonal macro-section shall be extracted from the gintheld atthe T-ntesection region between the gith weld and ‘seam weld ‘Al macro-examination specimens shall be polshed to a metallographic (1m) fish and ‘etched ina suitable COMPANY approved etchant “The etched specimens shall be examined at 10 times magnification PPhoto-macrographs ofthe macro-sections at approximately 3 to 5 mes magaliation shall be included in the POR documentation ‘Toe macro-secton eal reveal + No cracks, ‘= Thorough fusion between adjacent layers of weld metal and between wed metal and ‘base metal 4+ Ful fusion at the rat. Noack of cross penetration (5mm undercut {Aino point hall the weld surface, ID or OD, a below the acfacent base metal, ‘+ Weld reinforcement shal blond smoothly into the adjacent base metal ‘Any observed defects shall be within the limits givan in sections 11.3.2 and 12.0 ofthis specication, 8.52.4Hardness Survey Page 380174 STAND.FOATG7OOI-¥-S0.0040000 Rev GFa werent woo ‘Welding and NDT of Duplex Linepipe to BS 4915-2 (1996 ads ‘The hardness testing technique shall be the Vickers method with an applied load of 10 kg in accordance with ISO 6507-1 ar ASTM E92, ‘Tho hardness surveys shall be undertaken on each ofthe macro-examintion specimens spoctiod in 8.5.23 Each survey shall consist of three rows of indents. One traverse shal be located below the ap, one above the root (or intemal surface) and one at miétickness. The postions are shown in Figure 8.2 of this Spoctcation. Tho midthickness traverse may be waived for single sided welds below 12.7mm. COMPANY Welding Engineer may requite addtional hardness indent postions, e.g. when a consumable type has not been sarpled by the three specified traverses 'A tabulation or diagram showing the resuit and location of each indent, idnttying the ‘maximum and minimum values, shal be included in the POR documentation, ‘A photo-macrograph shall be taken showing the whole macro section, ilustrating the locaton of all hardness indents Individual HAZ and wold metal hardness values shall not exceed 33¢HVy for 22%4Cr upex oF S7BHV4 for 25%6Cr dupe. ‘The parent material hardness values shall not exceed the values permitted in the relevant ‘mater spoctction, Page 90174 S7AND-FO416700%-Y-80-0040000 Rev G1Br Exporaon Operating Company Ltt ara Sevopmont let wen %ey Welding and NDT of Duplex Linepipe to BS 4515-2 (1998) Figure 82 GIRTH WELD HARDNESS INDENTATIONS NOTES: + Parent materal indentations shall be atleast 20mm from the fusion tne. ‘+The frst HAZ indentation shall be placed as cose fo the fusion ine as possible. Further indentations into the HAZ shall be separated by approximately 0mm, roWever the ‘minimum oenteo-cenre separation requirement of 25 or 3 times the mean agonal of ‘he nearest indanfaton shallbe maintanad (rt. ASTM E92-82 (2003) and ISO 6507-1). ‘+The same survey pattern shal ba applied ta double-sided weds, 8.5.2.5 Micro-Examination Ag 'A microstructural assessment shall be undertaken to determine the austenite / ferrite balance in the HAZ and the weld metal at the root, cap and mid thickness postions in ‘accordance wth BS 4515-2: 1999 Annex B and ASTM E562, The micro-examination shall show a erie content of 35-65% inthe weld metal TT Duplex / Super duplex steels are welded with a higher alloy, fully austeritic weld metal, ‘the assessment shall apply only tothe HAZ. “The need for detaled microstructural assessment of issmilar metal joints welded with duplex stainless steel consumables should be determined by discussion wth COMPANY ‘and, measured, the austeitefrite balance shouldbe recorded fr informaton purposes onl, Microstructure evaluation shall be conducted in accordance wth ASTM A923 Method A, to Lelong te presen oF ules ners pisses, whit ty alles wuginens oF contosion resistance. A reference sample showing an ‘affected microstructure’ shall be used to calibrate the etching method, ‘The microstucture at X400 magnification s show no signs of sigma phase, nitrides or ‘ther deleterious phases and shall be classified in accordance with ASTM AG23 Page a of74 _S7ANO-FOS1GT001-¥-S0-0040-000 Rev Ct[BP Exploration Operating Company Lid ‘andrew Development Project weil & “Unaffected Structures’ or othernise. Annotated photographs of the weldHAZ shall be relecenced and included within the WPOI package. Inthe event that these alloys are welded with highor aly, flly-austeiic weld mata, tho ‘assessment shall apply only tothe HAZ. 8.5.2.6 Charpy V-notch Impact Testing Ads. “The test pieces shall be prepared and tested in accordance with ISO 148 and EN 1045-1 ‘+ Thvee sets of Charpy specimens shall be taken from the 12 o'sock and 3 o'clock postions as shown in Figure 8.1. One set shal be notchad a the wold centri, ono set A the fusion line and the final set at the fusion ine +2mm as detaled in Figure 4 (BS. 515-2: 1909), ‘+ All specimens shall be notched with the axis of the notch perpendicular to the pipe ‘surface, ‘+ Full size (1omm x 1omm) specimens shall be usod where possible. For subse ‘specimens, tha energy requirement shall be reduced pxo rata, Le., a 75mm x tom Specimen shall achieve 75% of the required ful size value, a 5mm x 1Omm specimen shall achiove 50%, + For wall thicknesses greater than 20mm, additonal sets of weld metal, fusion ine and fusion line + 2mm Charpy specimens shal be tested a the external surface. ‘+ Additonal cts of Charpy Impacts may be required by COMPANY Weldng Engineer (For fexampl, where very thick ppe isto be utleed or the combination of welding processes fr consumables has not been adequately sampled by the locations spectied above. + Paral penetration repair weld procedures shall be impact tested with notches located at: 1. The ropa controine 2. The fusion Ine between ropar wold metal and parent materi 3, The fusion ine between repair weld metal and orignal weld metal. + Inctvdual samplas may be replaced If there is evidence of @ weld defect onthe fracture surace, + Re-testing may be alowed fllowing discussion with COMPANY Welding Engi ‘Tho impact testing shall be undertaken at -46°C or the minimum dosign temperature, \bichever is lower and the acceptance criteria shall be as per Table 8.4 ard the ductile ‘shear area shall exceed 50%. Table 8.4 PACT TEGT NEQUINEMENTS (GvN CRITERIA) MATERIAL 0. HAZ WELD METAL 2auGr A Rr Dupe =o Average 40 Minium 8.52:7 Corrosion Testing Page i of? S7ANO-FOAIGTOOT-¥-SD-0040-000 Rav CTexploration Operating Company Lid fnaren Development Pee won Sey ‘Welding and NDT of Duplex Linepipe to BS 4515-2 (1996) A 22%Cr and 25%:Cr wolded matoils shall be required to pass the feric chloride corrosion test as detailed in Annex C (BS 4515-2: 1999) athe appropriate temperature highlighted in ‘Table 8.5; the maximum weight loss shall be 4gim® with no visible pis under a magnification of 20X permite. Tables ‘ASTM G49 Test Temperature Requirements ‘BUPLEX GRADE "TEST TEMPERATURE BKC 250 25Kcr ae Ferre chloride testing shall be performed on each procedure in accordance with ASTM G49 method A. Specimens shal be tested in the as-received condition, The tl thickness spocimons shall include tho weld orientated in the transverse direction in the centre ofthe sample. The sample shall include both heat affected zones and associated unaffected base metal. Surfaces shallot be pickled or otherwise treated prior to exposure, unless an ‘equivalent treatments intended to be applied to production wel. Probing with a sharpened steel pin shall be applied to clay the location of any piting, ‘Only one re-test shall be permitted, provided it can be confirmed that faire was not attibutable to poor welding practiceftechnique and was conducted as per the qualified wes. Corresion testing shal not proceed unl a detailed testing procedure has been prepared by the CONTRACTOR and approved by COMPANY. aks, 8.52. Weld Metal Tensie Test ‘The Weld metal tensile testing shall lise round bar specimens in accordance with ASTM asro: “+ For narrow gap welds where the width of the wold bead is Insufclent to permit a ‘conventional all-weld metal tensile test piace to be prepared, the geomet of the test piece shal be agrood with COMPANY. + Tho tensile specimen shall be propared by machining, and is size and location shall be sch thatthe gauge length consists ony of weld metal. +The longituginal ax of the tensile tast specimen shall coincide with the procedure (ualficationtost-weld axis. age a2 74 S7AND-FO4IGTOOT-¥-SO-0040-000 Raw CTsou pees wate woo ‘Welding and NDT of Duplex Linepipe to BS 4515-2 (1999) ‘+ Weld metal tonso strongths shall not be loss than the minimum tensile stangth ofthe parent materials 1 base metals of ferent strength levels are used, then acceptance: Cleia shall be based on the lover trength base mola ‘+The weld metal ios strength shall ovrmach the SMYS ofthe base material by 120MPa ="1s0MPa al room temperature where installation is by reolng or sey. Elevated {emperatue tense testing shall be conducted at the maximum design temperature and ‘exob0d the SMYS, ‘+ For the welding of spools or piping, the weld metal yield strength shall overmatch the 'SMYS at ambient and at elevated temporature unless agreed with COMPANY. +The wold metal strength in relation fo the actual pipe yield strengths shall ba considered ‘when an ECA's used or the pipeline design requires this. Ads. 852.9 Bend Testing ‘Transverse root bend and side bend specimens shall be prepared ani tested in accordance with ISO 172: ‘Specimens shal be of full material thickness and the root samples shal be noinally 26mm In with while the side bond specimens shall be nominaly 1omm in hickness. ‘Bending shall employ a former having a minimum diameter of 4x and a maximum diameter (of 6x the fl pipe wall thickness. ‘Testing shall not reves any open weld detects greator than Smm in ong Defects shall not be accoptabl in the root or hot pass location, “Tearing trom the specimen edges up to @ maximum length of Smm shall be acceptable provided that itis not associated with any wold defects At: 852.10 CTOD testing When required by section 11.0 of this specication fracture toughness tests shall bo Condicted at the minimum design temperature, The required minimum GTOD value shall be 0.15mm unis otherwise jusiied through an ECA. (CTOD testing shall be undertaken in accordance wit the requirements of BS 7448, Parts 1 and 2, by a testing laboratory specially approved for CTOD testing by COMPANY. ‘Testing shall be based on the use of through thickness notched, single edge rotched bend (SENB) specimens (BS 7448 Part 1 paragraph 5.1) in the NP oviontaton, unless agrood ‘otherwise by COMPANY. “Test specimens shall be notched and faigue cracked to sample the microstructures at the ‘weld centre ine and inthe coarse grained HAZ adjacent to th fusion tne. Page 430174 STAND-FOATG700%-Y-S0-0040-000 Rev C78 Exportion Operating Company Lid g, dan Govsognet ec Welding and NOT of Duplex Linepipe to BS 4515-2 (199% weim ‘The numberof valid test results employed to determine the charactristic CTOD of the wold metal and HAZ microstuctures shall comply with BS 7010 paragraphs K2.3 and 7185. Post test metallography shall be used to idently the ination point and the associated rmirostructure on a minimum of tires HAZ specimens selected by COMPANY. ‘The ination point of brite events shal be identified by metallography. The specimen ie considered quali ‘+The pre-crack tip isnot more than 0.5mm from the fusion ine ‘Grain coarsened HAZ microstructure is present vithin @ region confined by a plane perpendicular to the crack plane through the eack tp anda paral plane 05mm ahoad Of the rack tp. 8.6 Testing of Fillet Welds for Procedure Qualification Ads Welding consumables proposed for filet welds shall be tested in a butt weld configuration Jn accordance with section 8, Detals ofthis test and the ecope of mechanical evaluation ‘shall bo agreed wth COMPANY. ‘The ilet wold WPT shal simulate production welding conditions and shall be undertaken In the 1F, 2F, BF, oF 4F poston as appropriate “The weld bead depostion sequence for multipass filet welds shall ensure fat the final weld bead isnot deposited onthe pipe wal (1) Non Destructive Testing As ‘The NOT procedures for WPOT welds shall be qualified and subject to COMPANY approval. \WPOT welds shall be subject to VE as soon as possible after the completion of welding with 100% coverage ofthe weld surf ‘The full length of the WPQT shall be subject to LPE. COMPANY acceptance shall be required belore sostioning of the WPGT welds for macro examination and hardnoss testing (2) Macro Examination Ad Page 44174 S7AND-FO4IG700T-¥-80.0040.000 Rev GtBP: seamen wom we ° iding and NDT of Duplex Linepipe to BS 4516-2 (1999) ‘Macro sections shall be taken trom the WPOTT atthe 1/4, 1/2, and 3/4 weld length postions: {and prepared for examination and macro photography in accordance with section 8.5.2 \When examined at 10 tmes magnification the macro-section shall reveal: No cracks. ‘Thorough fusion between adjacent layers of weld metal and between wel metal and base metal Fl usin at the root No lack o erss panetaton. Max undercut 0.5mm, [Ato paint hal the wold surface lie below the adjacent base metal Both the intemal rect profie and the extemal weld reinforcement shall bland smoothly into the adjacent base metal CCxginal phote-macragraphs of macro-examination specimens (highightirg hardness indents) at 305 tines magnification shal be included inthe POR documentation Hardness survey Adds “The hardness testing technique shal be the Vickers method with an applied losd of 10kg in ‘accordance with ISO 6507-1 or ASTM E92. 1 The hardness surveys shallbe undertaken on each ofthe macro-examination specimens. Bb. A tabulation or dagram showing the result and locaton of each indent, identying the ‘maximum and minimum values, shall ba ined inthe POR documentation ©. Apihoto-macrograph shall be taken showing the whole macro section ilustrating the location (fall hardngee indents, Individual HAZ and wold metal hardness values shall not excead 334HVy, for 22%Cr duplex or S7BHVyp for 25°4Cr duplex. Hardness impressions shall be located as shown in Figure 8.3. Page 50174 S7AND-FOATG7001-¥-S0.0040000 Rev G1[BP Exploration Operating Company Ltd &, ‘Andrew Development Project nt wei Welding and NDT of Duplex Lin 87 0 @ 108 Figure 6.3 LOCATIONS FOR FILLET WELD HARDNESS INDENTS NOTES: + Parent mater indentation shal be atleast 20mm from the fusion tin. ‘Tho fist HAZ indontaion shal be placed as lose tothe fusion line as possble. Furor Indentatons into the HAZ shall be separated by approximatly O.Smm, rowever the minimum ceritoto-contre soparaton requirement of 25 or 8 times the mean diagonal of the nearest indontation shal ba mantained (et. ASTM E92-€2 (2003) and 1SO 6807-1). ‘Tosting of Repl Welds for Procedure Qualification aks General Wielding consumables proposed fo filet welds shal be tested ina butt weld configuation in accordance with clause 15, Details of this test and the scope of mechanical evaluation ‘hall bo agread with COMPANY on a project by projct basis. ‘The filet wold WPT shal simulate production welding conditions and shall be undertaken in the 1F, 2F, 3F, or 4F position as appropriate The weld bead deposition sequence for multipass filet welds shall ensure “hat the final ‘wold bead is nat doposited on the pipe wall Non destrucve testing of WPGT Tho NOT procedures for WPQT welds shall be qualified and subject to approval by COMPANY. \WPOT welds shall be subject to VT as soon as possible after the completion of welding with 100% coverage of the weld surface. ‘The fl ongth ofthe WPOT shall be subjoct to MT/PT as appropiate Page #6174 S7AND.FOATGTO01.¥-S0.0040.000 Rev Gr‘BP Exploration Operating Company Ltd &. Be uta pea cer deers eerie eee ect wen [Acceptance by COMPANY Welding Engineer shall be required before sectioning of WPOT \walds for macro examination and hardness testing, ©) Destructive testing (4) Macro examination and hardness testing Macro sections shall be taken trom the WPGTT atthe 1/4, 12, and 3/4 weld length positions and prepared for examination and macro photography in accordance wih clause section 8.62, Assessment shal bein accordance with 86.3. Hardness testing shall be performed as quired by 8.6.8 (a), (b), (9), (hand (). Hardness Impressions shal be located as shown in Figure 8.3. Page a7 174 S7AND-FO4IGTOOT-¥-S0-0040-000 Rav CTBP Exploration Operating Company Ltd ‘Andrew Development Project wei: _Welding and NDT of Duplex Linepipe to BS 4515.2 (1999) 90 TESTING QUALIFICATION AND APPROVAL OF WELDERS 98.4 General Ads ‘Welders shall be qualified prior to producton walang, ‘Walder qualification tests shal be caried out on ful-sie pipe nipples ofthe pipe size that will be welded on the pipeline. Niplas shall be visually sealed at each end unl at least ‘the root bead and hot pass have been completed around the ful crcumferevce. Testing shall be witnessed by a COMPANY representative or a COMPANY approved third-party Inspector and test resuits shal be provided to COMPANY. Welders shall be qualfed for each welding process that he/she will use. For semiautomatic wolding, mechanized or automatic welding, each welder shall be qualified far each type, MANUFACTURER, and mode! number of the welding units) and power supply to be used in production wading or for weld repat. Working in accordance with a quaified WPS, each welder shall make the welcs or pats of ‘welds that helshe wil be aquired to make on the pipeline. Separate qualification shall be undertaken for each ofthe folowing weld categories: But joints, 16 rol wong. Bt joints, 26 (vad 220" from the horizontal), ut joins, 5G (vad «20° from the vertical. Buttons, 66 (vai between 20" and 707), Branch connections the welding postion ofthe branch shal be as above forbut welds). Flt wold (weldoro be qualifed in each relevant poston) [A welder who has satisfactorily completed a welding procedure qualification testis automatically qualified for that procedure. Page 874 S7AND-FOAIGTO0H-¥-SD.0040.000 Rov CTBP Exploration Operating Company Lid ‘Andrew Development Project ‘Weldin 0 @ ° enim ——_—_ WIR nd NDT of D Ads, re-exting Qualification Previous welder qualification tests may be accepted by COMPANY provided they are fully documented and supported by production records demonstrating satistadory welder performance witin the preceding six months. ‘These tests shall have been conducted utlizing @ WPS substantially the the current work and, for automatio, mechanized or semi-automatic welding procedures, uizing the same type, MANUFACTURER, software package, and madel number of welding unt and power supply. me as that for ‘Additionally, these tests shall have been conducted by the same fabrication CONTRACTOR and witnessed by COMPANY, or have been conducted by # COMPANY approved independent testing laboratory Add, Technical Appreciation In addition to the practeal welding test and betore the commencement of production Welding, welders shall be required to attend @ briefing session arranged jointly with COMPANY Welding Engineer. ‘This briefing shall detail the elements of good welding practice and the specication requirements applieable to production welang “These requirements shall be further emphasized during regular too-box sessions, Each welder shall be issued a card or booklet summarising these requiremen's. This shall be writen inthe welder ist language and English ‘This card or booklet shal be avaliable for reference at al ies when welding. Aas Carresion Testing Walder qualifications test on duplex /super duplex materials shall be subject to corosion testing as per BS 4515-2: 1999 - Annex C and as modiied by section 85.27 of this Specification age a8 74 SAND -FO81G7O00"-¥-80-0080-000 ev C+ete Oeapgcce wein So ‘Welding and NOT of Duplex Linepipe to BS 4515-2 (1 92 Changes Affecting Qualification and Approval (Essential Variables) Ads ‘The following changos shall require re-qualfication ofthe welder: ‘+ A change trom one welding process to another welding process or combination of ‘welding processes. ‘+ A-change in the drecton of welding from vertical upwards progression to vertical ‘downwards progression, o ice versa ‘+ For crcumferental but joints a change in pipe diameter or wall thickness outside the ranges givon in Tablo 2 of BS 4515-2: 1988, ‘Achange in ant design, e., a change from a single U bevel toa single V bowl. “The deletion or aden ofa backing ring, For SMAW and cored wice welding ochniquos, a change of consumable trade name, ‘Any change in the nominal composition of the shildng gas. 9.3 Non-Destructive Testing Ass (Quaiication bt welds shall be assessed by VT and shal also be subject to FT. Qualification filet welds shall be assessed by VT and MT/PT as appropiate. “The need for adltional UT andlor mechanical testing willbe advised by COMPANY. ‘The agreed NOT regime shall reflect producton NOT and shall examine the full wold longtteircumference. Qualification of welders using semi-automatic GMAW (solid or cored wire) mechanized oF ‘automatic welding shall be by VT, RT, MUT, and mechanical testing to include root and side bends. Ifthe application of AUT for the inspection of production ginh welds has been agreed by COMPANY, it may also be used for assessment of the welder qualiiaton weds. However, the accoptance criteria shal be in accordance with 19.3.4. “The need for addtional RT to complement AUT will bo advised by COMPANY. 984 Retests (1) Welder qualticaton tes fait [No welder who falls @ qualification test shall be permitted lo undertake a “test unt a period of appropriate re-raining has been complated. ‘The scope of his retraining shall be approved by COMPANY. Page Sof 74 S7AND-FOAIGTOOH-¥-S0.0040.000 Rov CTWelai @ 2° exploration Operating Company Lid fnarew Development Poe wen ey snd NOT of Du} Retesting of welders ‘Any welder who, in the opinion of COMPANY | either consistently ignoring good welsing practice or specication requirements or is responsible fora high level of repairs during production shall be removed from the work, and shall undergo a retraining programme approved by COMPANY before a test may be considered, COMPANY shall retain the option to permanently remove any welder from the work for continued poor performance. Page Si 174 S7AND-FOSIGTO0N-¥-S0-0040-000 Rev CTeee te wou%o en 101 Pipe End Preparation Adds (1) Mi bovet 1 pipes are supplied with mil beveled ends, the API SL. standard bevel should normally be provided, However, alternative bevels may be supplied In order to conform to the joint design specified inthe WPS or, i he case of ned pipe, to accommodate the seal wed 2 Field bevel Inthe field, wold bovols shall be propared witha loating head beveling machin, ‘Tne beveling machine shal indexiolow the pipe ID surface contour in order to ensure a consistent rot face dimension, ‘The beveling machine shall nt damage or contaminate the CRA surtace, [Mechanised plasma cutting may be accopted for tio in wold, but Is use shall be kept toa ‘The edges of plasma cut bevels shall be let free of slag and the cut surface shall be ‘ground to a smooth, unfrm surface by removing approximately 2mm (0,08 in) of metal, ‘Alter feld beveling, the dimensional tolerances st the pipe ends shall conform to the qualfied welding procedure, ach pipe end shall be checked for conformity withthe approved preparation, ‘Additionally, a zone extending 100 mm (¢ in rom the new field bevel shal be examined by VE and UT to the requirements ofthe appropiate pipe material specication LLPE shall be avaiable as necessary to assist in the clarification of any detects observed by ve, ‘COMPANY may permit minor imperfections in the pipe ends to be repaired by grinding, bofore assembly for welding, provided the remaining wall thickness is accept confirmed by UT. Weld reps 1 pipe ends shall not be permited Page 2 074 S7AND-FOAIGTOOT-¥-S0-0040-000 Rev CTBP Exploration Operating Company id anaeu Doveosmert Roja wan %ey ‘ing and NT? Dp Lineppe to 4515-2 (1000 102 10a Fusion Faces A ‘Surfaces to be wolded shal be free of primers, paints, oF coatings. Antispatter compounds shall not be applied to surfaces to be wolded, including weld bevels and weld beads. Fusion faces and adjacent material shal be tre from fins, planar defects or cracks, tears, moisture, scale ust, grease or anyother foreign mater, mmackately before welding ‘Surfaces contaminated with cll or grease shall be cleaned utiizing COMPANY approved solvent Degreasing of base metal shall extend atleast SOmm (2 in) trom the edge ofthe fusion {aces on both ID and OD surfaces. IF on contamination of the CRA surface at the open pipe onds is suspected, then a Ferronyl test (ASTM A2K0, 7.2.4) shall be performed and any contaminaton shall be removed by an agreed technique. Alignment As Pipes shall bo aligned with care and misalignment shall be minimised by ration ofthe pipes inorder to obtain the bast possible ft up. Longitudinal welds shall le within the top half ofthe pipe cicumference and should be ‘separated by a minimum of 100mm (4) “The maximum misalignment shall be 1.0mm for < 6'élameter pipe and 1.5m for 6° pipe and greater. ‘Any misalignment in pipe tofiting gith wold setups which excoods 2,0mm (0.08 in at any Point onthe intemal surface shal be subject to corrective action agreed with COMPANY. Slight misalignment should be corrected using a softfaced hammer of mass rat exceeding kg (11 by. Hammering shall not impinge on the weld area. Bronze-headed hammers shall not be used on CRA materials Heat chall not be used to coract excessive misalignment ‘When @ change in OD, ID, or wall thickness occurs, @ transition piace with a maximum taper of + in 4 shall be employed Page S8ch74__ STAND.FONGTOOI-V-SD0040.000 Rev G1BBP Exploration Operating Company Ltd ‘Andrew Development Project {ati nd NST a Dpto lnepipe to BS 481521 Weim) & 108 co) 105 ‘The welding procedure shall be qualiied to comply with the maximum misaligyment given by the specitid pie end tolerances, ‘The root gap shall be accurately checked and shall conform to the mits detailed in the wes. Line-up Clamps and Pipe Supports Use of Lino-up Clamps Adi: For pipe to pipe joins over 180mm (6 In) diameter, intemal line-up clamps shall be used. For osin welds, external line-up lamps may be used fo all pipe sizes. Detals ofthe alignment clamp proposed for the production welds shall be submitted for COMPANY approval tore the commencement ofthe WPQT program, The design ofthe line-up clamp shall minimise damage to the pipe surfac contaminate the CRA. 1 external clamps are used, the root run shall be deposited using an uphil welding technique and shall be at least 50% complete betore the clamp is removed. External clamps shall not damage the extemal pipe coating. ‘When an intemal line-up clamp Is used, the root run shall be 100% complete before the lamp is removed. However, in ether case, the pipes on either side ofthe joint chal not be raised, lowered or ‘moved in any way untl both the root and second pass (hot pass) have been completed, Unless it can demonstrated to the satstaction of COMPANY that the root pass alone is adequate to resist the deformation, fan intemal line up clamp incorporates copper backing bar, the backing bar shall be subject ofl rcurforentia vsual examination ‘+ On commencomant of production welding tis examination shall be completed after each \Woldin oder to ensure that no fusion ofthe capper i taking pace. ‘+ The frequency of examination may be reduced to once every ton welds 2s successful produston becomes establshed. Tack We Ads: “The use of tack welding shall be minimised Page Sof 74 BTAND.FOATG7OOI-V-SD 0040.00 Rev G1serena won&o Welding and NDT of Duplex Linepipe to BS 4518-2 (1990) uti tacking shall use “within the bevel bullet tacks of minimum length 25mm (tn). ‘Tho material used forthe bullets shall be compatible with the finepipe m: full waceabilty and shall be approved by COMPANY. il, subject to “Tack welds shall be made by qualfied welders using uphill welding in accordance with an approved WPS, Tacking shall be incorporated into the WOT, fis tobe used in production soins to be tacked shall be adequately supported and a minimum of four tacks shall be Used for clameters gre than 100mm (4 in). Additonal tacks may be “equired for lameters greater than 300mm (12 in. “Tacks shal be removed by cretl ning as wong progresses. COMPANY may agree to waive LPE of the ground area fllowing tack removal 10.8 Working clearance “The working clearance around the pipe in the region of the wold shall be sufcent to provide adequate accoss forthe welding and NOT of the jon. 107 Stray Ares Mada to Roa: Tie: Stray res and Eathing Ads COMPANY shall have the option to require ‘bur fom the pipe Welding are strikes or are burns outside the wold preparation shall bo removed by careful grinding, and subsequenty checked by LPE. “The wall thickness al each ground area shal be checked for compliance with ‘he spected ‘minimum wal thickness. Fepairs by welding of under thickness areas ater grinding shal not be permite. Al earthing connections shall be secursly attached to avoid stray arcing. Copper earth clamps shall be protected by CRA material to provent copper contamination tothe material boing woide. Page 50174 S7AND-FO4TG7O0T-¥-S0.0040-000 Rev GT[BP Exploration Operating Company Ltd ‘Androw Development Project Welai 109 0 SE ceamesim —_—_ WGI Rey 1 blending to remove the effects of arc bums reduces the wall thickness below he spectod ‘minimum, welding shall nt bo used to repair arc bums. The defective pipe secon shal be cutout and the pipe r-bevelled and e-welded. Weather Conditions Ada: Welding shall not be undertaken when the quay ofthe completed weld would be impaired by the provaling weather conditions, such as alrbome moisture (mist or rin), high winds, or blowing sands Where necessary, woather protection shall be provided and pipe ends shall be covered to prevent water or other extraneous matter being channelled into the weld region Preheating Modified to Read: “Tite: Preheating,Inte-Pass Temperature and Post Weld Heat Treatment Ak General Preheat isnot usually required for welding, but i's essential thatthe weld zore is dry and {198 trom moisture. Any preheating that may be necessary shall be simulated inthe WPOT and shal not damage the external pipeline coating. “The minimum metal tmperatue for wong shall be 20°C. Inter pass temperatures for parent pipe materials and weld metals shall be cosy monitored and shall not exceed the lesser of ether the temperature measured during the WOT or the folowing requirements: + 150°C for 20%, 2 125°C for 25%, In order to faciitate production welcing, scoalerated canting atwean wll pans can he achioved by forcad air or the application of water jackets, \When usod in preduetion, forced cooling shall be qualified by the WPT. Direct water cooing shall not bo used. Page 55174 S7AND.FONTG700%-¥-S0-0040-000 Rev G1wat gop eretom oe wom&> (2) Temperature Measurement Preheat temperature shall be measured ata distance of between 7Smm from each edge of the weld bevel at a minimum of four circumferential locations, each approximately 90° pat. Care shall be taken to avoid damage to any coatings. “Temperature measurement shall be made on the heated face of he pipe ater ime interval following the removal of he heat source to allow for temperature equalisation. ‘The time interval shall be 1 minuto por 12.7mm of wall hickness, e.g. 2 minutos for 25mm thick material ‘The metal temperature should be confimed Immedately before the commencement of welding and around the whole joint whilst welding staking lace. Intor-pass temperature shall be measured on the parent material atthe edge of the weld bbovl near tho wold start location immediately before the passage ofthe ac ‘The maximum speciiodinter-pass temperature shall not be exceoded, Inter pass temperature checks shall be made during welding, For continuous welding, iter-pass temperature shall be measured atleast thre times per complete revolution. Temperature-inciating crayons, which melt on attaining the spectic tomperatue, may be used to check preteat and inter-pass temperature, but shall not be marked on weld bevels, Weld beads, or surfaces to be welded. Temperature-ncicating crayons or pal shall not be use. which indlcate temperatu by eolou change, (8) Post Wold Heat-Troatment Post weld hea treatment is proibite. 10.10 Branches Ast: Procedus for vuln, joint preparation, setup, welding and NOT shall be subject to COMPANY approval (Welding SSot.in fiting welds shal be inpected as oon: Page? 74 S7AND-FO4IGTOOT-¥-S0-0040-000 fav CTBBP Exploration Operating Company Ltd Recon Sevaoyeet ea Eee _—_ wa tom to.12 to.9 “+ Where accessile and following completion of the fll weld the rot bead shall be ground ‘lush on te inside ofthe pipe, location clearly marked with indelible pen and inspected by visual and LPE. Weld caps tobe subjected to visual and LPE. ‘+The fll welds shall be examined with radiography using the SIWESSWY technique with the fim inside and radiation source outside, using a minimum source to fim distance of ‘500mm, A minimum of four equlstanty spaced separate exposures shall be used for branches <150mm nominal bore. Tho DAVEISWY technique may only be used i ‘approved by COMPANY. In each event the centre racaton beam shall passthrough ‘ch wold region boing testod at normal Incidence tothe weld face, ‘Sot on fting weld shall be inspected as follows: ‘+ Tho root bead and wold cap shall be examined by visual examinaton. Visual ‘examination ofthe root bore shall be undertaken through the bore ofthe fing frm the butede of the pipe ‘+ Wild caps shal bo examinad by LPE. Where access allows UT shal be undertaken from the inside surface of he tting. Inter-run Cleaning Ad ‘The method of wed cleaning shall be spected in the WPS, ‘Upon completion of each welding pass, the weld shall be visually inspected and cleaned as aquired before stating the next pass. Stop starts shall when necessary, be ground and Visible defects and high points shal be remaved by grinding betore any further weld passes are deposited Excessive mechanical working f the weld bead surface that may mask surface defects or ‘thersise inhibit proper visual inspection is prohibited Contact tips shall not be fused into ‘wold metal. A visual inspection ofthe contact ips ‘and the weld surface shal be undertaken between weld passes to confi that no copper has been deposte. Weld Metal Deposition For 2G and 5G welding, a minimum of two welders or welding machines shall work ‘simultaneously, one on each side ofthe pipe. 1,50 that they do not coincide wth those in ‘The wold stops and stars shall be stag ‘adjacent weld passes. Temporary Attachments “The use of temporary attachments is only permed with he prior approval of COMPANY. Page 58174 S7AND-FO4TG7OOI-Y-SD-0040000 Rev GtBP Expl ‘Andrew Development Proje Welding and NDT of r044 10.15 ration Operating Company Ltd Temporary attachments shall be made by qualified welders according to an approved wes, ‘Temporary attachments shall be removed by careul grinding and the finally grcund surface shall be subject LPE. ‘The wall thickness ofthe pipe shall be checked by UT. Interrupted Welding Welding shall be undertaken on a continuous basis with due regard for the contol of Interpass temperature except if inspection on completion of the roathot pars has boon agreed. ‘This interruption shall be simulated in the qualification ofthe welding procedure ‘A procedure shall be in place to ensure that in the event of an unavoidable interuption, ‘Welding is restarted in a controlled manner. This procedure shal, as a minimum, cover the application of any necessary NDT, removal of condensation from the Joint, andthe re-ntaton of purge gas flow. ‘Suspect Welds [Any weld suspected of nat having been produced in accordance wit the appreved welcing procedure shall bo cut out and may be subjoct to investigation at the dscretion of COMPANY. Page 590174 STAND-FOATG7001-¥-80-0040-000 Rev C7[BP Exploration Operating Company Ltd wert tat wom ‘Welding and NDT of Duplex Linepipe to BS 4516-2 (1999) 110 m2 0 INSPECTION AND TESTING OF WELDS As General Every pipeline weld shall be subject to individual examination and non-destructive test Using reliable, modem, and proven techniques, and shall be shown to mee! the design ‘acceptance criteria in all respects before the pipeline is put into service. Girth welds shall be subject to full internal and extornal VT and 100% NDT ¢. The NDT regime and the principle NOT technique, Le. ether X radiography or MUT/ALT, shall be ‘agreed by COMPANY on & project-by-project basis. ‘When MUT/AUT is applied welded caliration blocks shall be prepared and the need to ‘employ specialist UT techniques such as surface waves and angled compression probe ‘scans shal be assessed, But wolds in intomally clad or sold CRA line pipe or state risers having a wal thickness. 220mm (0,8 in) shallbe examined by MUT/AUT. Before NDT testing, each joint shall be thoroughly cleaned of spatter and other extraneous material. ‘Tho extant of any grinding shall be minimised to ensure that surface breaking defects are rot masked during cleaning Visual Inspection Ads: Goneral Completed welds shal be fully examined by VE in accordance with ISO 17687 or BS EN 1970 immediately upon complation of welding ‘Adequate ghting (500 lux min) shal be provided for this examination which shall be both cextomal and internal (where access permis). Internal examination shall be required for production spotter welds using a portable remote cameralendoscope for viewing and recording, as agreed with COMPANY. ‘The remote viewing technique and the associated calibration procedure shall be ‘domonstrated to the satisfaction af COMPANY boelore the commencement ofthe WPOT program, Page 60 174 S7AND-FO81GT00T-¥-S0-0040-000 Rav OTsenna wou @ [AVE procedure including the detal ofthe remate viewing system and its calibration shall be submited for COMPANY approval prior commencement ofthe WPQT program, Personnel using inernal viewing equipment shall have undergone @ traning program ‘acceptable to COMPANY and shall have good vision In accordance with BS EN 473 ‘The Intl internal VE shall be performed folowing completion of the root and hot passin Corder to eliminate the need fr through thickness ropa, Acceptance Criteria Add ‘Visual inspection ofall welds shall meet the requirements of Table § (BS 4515-2) and as dotaled below. Welds not meeting these requirements shall be removed from fe pipaline. {ntemal surface: +The rootpas shale of egret nd ha bln! moa wh ha lp wa 1 Rulpenetaton sabe acheved oversee ng o head wh no ase ed Cru tough bang pest + No autace broaing fects shall be vale; and, when an ital baking ba Crnyed cat oping fhe weed mel over rer pn wa rasa rt Be secon + Thermasmum dap fro conv shal bo th sor of 10% of th wa sks or Sam, th tal ang toe cont sh not ecaed moe than 0% oe weld lrg ue sabe asecad iy cogay. + Themanmum bore preuton el be ram {Wade showng nest oxtaton ore meting the above requramens shale ramoved ‘romtheppsing. Exornal surface: ‘+ Tho wold preparation shall be completly ilo. {The wold reinforcement shall be in the range 1-3mm (0,040.12). ‘The wold bead shal be of regular shape and the weld metal shal blond smoothly withthe parent material around the tl circumference ofthe jon. ‘+ Ovorap ofthe weld cap onto the parent material shall be minimal and not exceed 2mm ‘on ether side ofthe jit. ‘+ No-surface breaking defects shal be vise. ‘+ Undercut exceeding 0.5mm shall be unacceptable and shal be blended out by light burr ‘ringing or fling prior to NDT. I blending reduces the pipe wal thickness below the Spectied minimum the entire weld shall be cul out and the pipe ends re-bewlled and ‘walded, + Wolds not meeting the above requirements shall be removed from the pipeline. "Page 61 at74 __ S7AND-FOHTGTOOT-Y.S0-0090-000 Rev CiBr ExeaionOperting Company i Ase neta & Welding and NDT of Duplex Linepipe to BS 4515-2 (1999) welm 118 Radon Testing (1) Genera Ads: Radiographic teting shal be conducted using Xray equipment. Where the use of Xray equipment is impracticable, Irsium 192, Yiterium 169 or Selenium 75 may be used subject to approval by COMPANY. Other sources of gamma rays are not permitted ‘Raciographic practice shal bein accordance with this speciation and ISO 17886 and this specification, “The single wall exposure for single wall viewing (SWEISWV) technique with ‘he radiation ‘source located inside the pipa!fiting shal be the prefered technique for RT of gith welds, andthe minimum standard of radiography produced shall be In accordance with Cass B. Radiographic procedures shall be submited for COMPANY'S approval. before ‘commencement of WPOT program and shal be quaifod during this test program, ‘The procedure details call nce the following: + Technique {Type of equipment and kV rating brand name and spect model namelnunber of X-ay equipment “Type of fim, Intensiyng screens. Shielding Goometi relationship, dtind by sketch ‘The limit of im coverage. Expoaure dota. For Xray: exposure time, mA and KV; for gamma: Curieminutes and GGiga-becquerel- minutes Material thickness range. ‘Type of lal and positions. ‘Processing, inlucing brand name of each chemical ‘As part of the radiographic procedure qualification, three test radograrhs shall be ‘produced using each radiographic procedure planned for use. all be mage on the welding procedure qualiication welds or welds mace with the production WPS, ‘The ful creumference of each test welds be raciographed. For radlographic procedure qualification, wire-ype [Gls meeting ISO 2504, ASTM E747, or ‘COMPANY approved equivalent shal be placed across the weld on both the source side andthe film side ofthe area being examined. Page62 0174 STANO-FO4TGTOOT-¥-S0.0040-000 Rev OTWeta 2? Exploration Operating Company Lid ‘Andrew Development Project wei Se ling and NDT of Duplex Linepipe to BS 4515-2 (1988) ‘The sensitiv level obtained using the fim sie IO shall be no worse than that given in Table 11.1 of this spctcaton. ‘Te corresponding sensiviy forthe source side IO shal be recorded. any test acograph shows more than one vibe wr of the lm side IA, compared to ‘he source side 10 imago, COMPANY has the option to reject the racigraphic procadure, Film type shal be 80 11699-1 Class T2 or ASTM E1815 Ciass |, e.g, Ala Stucturix DS (F KodakIndustex 7200, or finer grain (slower film. is shown that exposure times ‘Would exceed 2 minutes using X ray equipment with this fim, the use of ISO 1 1699-1 Class "T3.or ASTM E1815 Ciass Il may be permited atthe discretion of COMPANY. Lead (Pb) intonsying screens shall be used. COMPANY may approve the use of fluoremetalic sereens, a8 an alternative, if tis demonstrated that test procedures and resuits are ofa standard acceptable to COMPANY. ‘The procedure test radiographs shall be submited to COMPANY for approva prior to the start of production. New procedure test radiographs may be requested at the dscrtion of COMPANY whenever any change Is made In operating technique or whenever production raciographs diter appreciably from the detl, contrast, dentin or density of te qualifying radiographs. Except fr emall, localized areas caused by weld weave or discontnuits, the radiographic 4mm shall be permited, even f demonstrated trough the ECA, ‘+ Irespective of detect height, defects with a longth greator than 7 times wall thickness {after nteraction assessment) shall not be permite, ‘COMPANY reserves he right to madly the ECA acceptance crea 122 Rectification of Welds (1) Removal Fans els /AWPS for epair welding shall be approved in accordance with secon 8 Defects shall not be repaired in any part of the weld without prior approval by COMPANY. All repairs shall be witnessed by COMPANY, and the relevant NDT records shall be made avaiable to COMPANY at that time. For completed welds ull panetration repairs are not permite. ‘othe pass repairs shall ot be alowed on duplex! super duplex stainless see. Page 70 of74 __ 7AND-FOATGTOOT-¥-SD.0040-000 Rav GrBBP Exploration Operating Company Ltd ‘Andrew Development WGIM: ‘Welding and NOT of Du 10 BS 4515-2 (1999) Partial penetration repairs are permitted to within émm trom the pipe intemal surface, however the intemal purge gas shall be reinstated for repairs within 1Omm of th intra ‘surface, This Is subject to COMPANY approval and a suitably qualified procedure. Only ‘one attempt at a weld repair shall be permitted, i unsuocesstul, complete removal ofthe weld i require. No more than one separate repairs allowed in any single weld ‘Smal crater cracks shall be removed by local grinding and repaired, Excavations shall bo made to simulate those expected during production using the ‘appropriate profile and depth. The excavation shall be mimicked and a crawng included within the WPT documentation package. ‘No tnteral oot repair are alowed. For rpairof ae buns, 908 108. @) Preparation for Re-Welding bs The minimum allowable repair longth shall not to be loss than 50mm. The limits ofthe length of weld repairs are spected in clause 122.1 of BS 4515.2: 1998, Lo. 0% of the ‘Weld lenath maximum paral penetration repair. Full penetration repairs are notpermtted ‘The fl ength ofthe weld (weld plus the repair length) shallbe examined ‘A tll record ofall repairs shall be maintained by he contractor. The record shal be made ‘as each defect discovered, and shal include the following: ‘The weld pumber The type and sizeof defect. ‘The cteumferentil location (defined to an approved system) {An estimate ofthe depth (assessed by ultrasonic test where possible) ‘A mimie ofthe ropa profile and sketch including dtal of depth, postion relative to the ginal weld, wich, and length of excavation. [Name andor numberof he welder wha produced the defect Repair welding procedure number. Name andi number of repair weer. Copy ofthe inepacton repent forthe rep Date of repat (3) Qualifications Ass: Fepair Procedure: Page 71174 S7AND-FO110700%-Y-S0-0040000 Rev GtWelding ae eareraer & Linepipe to BS 4515-2 (1999) weiM ind NDT of Dut Weld repairs shall be made in accordance with a COMPANY approved resar welding procedure ‘The repair wold procedures shall be qualified in accordance wih section 8 of this speciation + However, tis not necessary o make a ful cicumferential repair wed, It is only required ‘o make sufficient repair weld to provide material fr mechanical testing “+ Individual repair weld precedure qualfication excavations shal be limited to a length of somm (12). ‘+ Tho radial postion ofthe test repair weld shall be approved by COMPANY. Single pass repairs are only permite for cap defects, Each repair ype tobe used in production shall be separatly qualtid “The repair Wald procedure qualification chal be Inspected by the same NOT that was used forthe original wed Mechanical testing shall be undertaken in accordance with section clause 8 of this speciation ‘Toe portion of weld cutout fr repair shal be tapered athe sides and ends to gve adequate ‘access for r-nelding ‘+ Motal may be removed by thermal gouging folowed by grining. {Grincing shall be used forthe last Sim (0,20 in) through othe bottom ofthe excavation. * Airare gouging sal be controled by @ procedure documenting the alowed vaiabos as requied by AWS C53, Page 720174 STAND-FO4iGT00T-¥-S0-0040-000 Rov 01BP Exploration perating Company Ld fndrow Development Pact wow ey Welding and NDT of Duplex Linepipe to BS 4515-2 (1999) ANNEX D ADDITIONAL REQUIREMENTS FOR PIPELINES SUBJECT TO HIGH STRAIN LEVELS At Introduction ‘This socton applies to pipelines subject to plastic doformation during instalation, e.g, instalation by recing, ‘When evaluating the amount of sain atthe weld expected during instalation, te eects of misalignment, pipe strength variation, and coating sifess shal be considered A2 General A241 Lnepipe Pipatines welded in accordance with this appendix shall use linepipe that comles with the ‘addtional hgh strain requirements of GIS 43-311, GIS 43-312, or GIS 43313. 22. Welding Processes Welding processes not proviously used by the CONTRACTOR with tho proposed Installation method shal require fll scale qualification tials. The extent ofthe tials shall bo

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