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GIS 42-101
Applicability Group
Date 3 May 2005
GIS 42-101
BP GROUP
ENGINEERING TECHNICAL PRACTICES
3 May 2005 GIS 42-101
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Carbon, Carbon Manganese, and
Low Alloy Steel Pipework (ASME B31.3)
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GIS 42-101. This Guidance on
Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as
follows:
British Petroleum
GS 118-5 The Fabrication, Assembly, Erection and Inspection of Carbon, Carbon
Manganese and Low Alloy Steel Pipework to ASME B31.3.
Amoco
A PN-PLT-31.3-C Piping—Plant—ASME B31.3—Construction Specification.
A PN-PLT-31.3-CG Piping—Plant—ASME B31.3—Construction and Fabrication Guide.
A PN-PLT-31.3-P Piping—Plant—ASME B31.3—Fabrication Specification.
ARCO
ES 200 Piping Design.
Copyright 2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organisation. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
Table of Contents
Page
Foreword ........................................................................................................................................ 2
Introduction ..................................................................................................................................... 5
Chapter I Scope and definitions ..................................................................................................... 6
300 General statements................................................................................................................ 6
300.1 Scope ......................................................................................................................... 6
Chapter V Fabrication, assembly, and erection .............................................................................. 7
327 General.................................................................................................................................. 7
327.1 Quality assurance and positive material identification ................................................. 7
327.2 Material control ........................................................................................................... 8
327.3 Pipework marking ....................................................................................................... 8
327.5 Fabrication facilities .................................................................................................... 8
328 Welding.................................................................................................................................. 8
328.2 Welding qualifications ................................................................................................. 8
328.3 Welding materials ..................................................................................................... 11
328.4 Preparation for welding ............................................................................................. 11
328.5 Welding requirements ............................................................................................... 12
330 Pre-heating .......................................................................................................................... 15
330.1 General..................................................................................................................... 15
330.2 Specific requirements ............................................................................................... 16
331 Heat treatment ..................................................................................................................... 16
331.1 General..................................................................................................................... 16
331.2 Specific requirements ............................................................................................... 17
332 Bending and forming............................................................................................................ 18
332.1 General..................................................................................................................... 18
332.2 Bending .................................................................................................................... 18
332.4 Required heat treatment ........................................................................................... 18
335 Assembly and erection......................................................................................................... 19
335.1 General..................................................................................................................... 19
Chapter VI Inspection, examination, and testing .......................................................................... 20
341 Examination ......................................................................................................................... 20
341.3 Examination requirements ........................................................................................ 20
341.4 Extent of required examination.................................................................................. 20
342 Examination personnel ........................................................................................................ 20
342.1 Personnel qualification and certification .................................................................... 20
343 Examination procedures ...................................................................................................... 20
344 Types of examination........................................................................................................... 21
List of Tables
Table 1 – Acceptance criteria for welds (to be read in conjunction with Table 341.3.2 of
ASME B31.3) ....................................................................................................................... 23
Table 2 – Acceptable radiographic sensitivity levels (using wire type IQI to ASTM E747 or
BS EN 462-1)....................................................................................................................... 24
List of Figures
Introduction
a. Guidance for fabrication, assembly, erection, and inspection of carbon, carbon manganese,
and low alloy steel pipework is based on American Society of Mechanical Engineers
(ASME) B31.3, Process Piping, 2002:
1. Chapter I Scope and definitions.
2. Chapter V Fabrication, assembly, and erection.
3. Chapter VI Inspection, examination, and testing.
b. Guidance statements of this GIS are modifications to ASME B31.3.
c. Modifications to ASME B31.3 are identified as Add, Modify to Read, or Delete.
d. Paragraph numbers in this ETP correspond to ASME B31.3.
e. Paragraphs of ASME B31.3 that are not revised remain applicable.
300.1 Scope
300.1.3 Exclusions
Add
(e) Sea transport.
(f) Transmission pipelines in land or subsea locations, including risers.
(g) Pipelines of significant length and diameter, e.g., transfer lines between processing units,
storages, and jetties that are specified by BP to be engineered as main pipelines.
(h) Production piping systems, as designated by BP.
Production piping is covered by BS EN 14161 and ASME B31.4.
(i) Underground drainage systems.
(j) Steam piping systems within plot limits of power stations and steam generating stations
outside process areas.
Steam piping is covered by ASME B31.1 and BS EN 13480.
There is no ETP currently available to cover this category. However, guidance on
these systems can be found in ACES A PN-BLR-31.1-E and BP OUS RP 5-5-4.
(k) Heating, ventilating, and domestic water systems within buildings, including offshore
accommodation modules.
(l) Hydraulic systems.
327 General
Add
328 Welding
Add
(g) Welding procedure specification (WPS) shall require requalification if any of the following
changes are made:
1. Change outside welding parameter tolerance ranges specified in qualified welding
procedure specification.
2. Increase of more than 1 gage number in electrode size from that used in qualified
welding procedure.
3. Change in type of current, e.g., ac to dc or, in dc welding, change in electrode
polarity, except where these changes are within electrode manufacturer
recommendations.
4. For impact tested procedures, increase in either maximum electrode diameter or
weave width or if maximum interpass temperature is raised above 250°C (480°F).
5. For critical applications, as directed by the engineering design.
(h) If a limitation on weldment hardness is specified in engineering design, macrographic
examination and hardness measurements shall also form part of welding procedure
qualification (WPQ).
Depending on service duty, weld metal and HAZ hardness may be subject to specific
limitations. Perhaps the best known limitation is 22 Rc (248 HV 10) placed on
carbon and low alloy ferritic steel weldments in sour duty in accordance with
GP 06-20. Hardness limit of 200 HBN (210 HV 10) is also often placed on carbon
steel weld metals in corrosive refinery environments (NACE RP0472). Guidance on
need for hardness limitation should be provided by engineering design.
A hardness test may also be used to determine effectiveness of heat treatment
procedures. In absence of specific restrictions on hardness, requirements of
Table 331.1.1 of ASME B31.3 may be used for guidance.
(i) In addition to mechanical testing, welding procedure test samples shall be subjected to
radiographic examination.
(j) Magnetic particle/dye penetrant and ultrasonic examination shall be applied to test samples
if they are to be used in evaluation of production welds.
(k) Nondestructive examination shall be completed prior to machining of test pieces.
(l) Ideally, welder performance tests for positional welding should be performed in both 2G
and 5G positions. However, subject to agreement of BP, welder performance test may be
undertaken in 6G position. In that case, each welder shall also demonstrate his ability to
deposit acceptable root runs in both 2G and 5G positions. With the agreement of BP, this
may be achieved by radiography of welder’s first production welds in 2G and 5G
positions.
(m) Welders and welding operators shall be qualified by visual examination and radiography.
Subject to provision of authenticated CV and with agreement of BP, welders and
welding operators may be qualified on their initial production welds.
(n) Welder and welding operator qualification tests shall be witnessed by inspector.
The above additions and modifications to qualification requirements have been
made on basis of fabrication experience and allow welding to proceed with
improved level of confidence in both procedural qualification and welder skill.
Ultrasonics may be used in lieu of radiography if material thickness restricts
suitability of radiography due to decreased sensitivity or extended exposure time.
Add
328.4.3 Alignment
(a) Circumferential welds
Add
(3) Bore misalignment in circumferential butt joints shall not exceed 1.5 mm (1/16 in)
without BP approval.
(c) Branch connection welds
(3) Add
Weld metal shall not be deposited to correct contour, shape, or tolerances without
permission of BP.
Add
(e) Fabrication tolerances
1. Unless approved otherwise, fabrication tolerances shall comply with Figure 2.
2. Category M tolerances shall be used:
a) For service temperatures greater than 460°C (850°F).
b) PN 150 (Class 900) ratings and above.
c) If specified by engineering design.
328.5.1 General
(b) Modify to Read
Welds shall be marked with welder/welding operator identification symbol using marker
pencils or paints that comply with 327.3.
(c) Add
Tack welds that are to become an integral part of root weld shall be ground to feather edge,
while those not intended to become part of final weld shall be removed as welding
proceeds.
(d) Modify to Read
Peening shall not be permitted on any pass.
Add
(g) Unless otherwise stated in manufacturer installation instructions, welding adjacent to inline
valves shall be performed with valve in fully opened position.
Soft seated valves (e.g., butt welded or socket welded ball valves) should not be
welded inline unless a weld procedure has been qualified to demonstrate that soft
seats are undamaged or unless soft seat has been removed prior to welding.
(h) Butt welds and pressure containment fillet welds in DN 40 (NPS 1 1/2) and smaller pipes
shall use GTAW, with addition of filler metal, for all passes.
(i) GTAW shall be used for root pass of butt welds in pipes of DN 50 (NPS 2) and DN 65
(NPS 2 1/2). GTAW is also preferred technique for root pass in all alloy steels.
(j) SMAW may be used for subsequent passes, provided electrode size does not exceed
2.5 mm (3/32 in) for second (hot) pass, and welders have demonstrated their ability to use
SMAW on pipe of these diameters.
(k) GTAW equipment shall use either high frequency starting unit or alternative programmed
touch starting unit. A current decay device should also be fitted, together with a gas lens, to
improve gas shielding of weld pool.
(l) GTAW shall only be used under enclosed shop conditions, unless adequate weather
protection is provided at each outdoor location where this technique is to be used.
If gas shielded processes are being used, moderate air currents can result in loss of
shielding gas leading to weld defects. Thus, sufficient screening must be used under
such circumstances to keep winds and draughts away from welding area.
(m) Back purging shall be employed for joints involving alloy steels and/or weld metals with
nominal chromium content of 2 1/4% or more. Purging shall, as a minimum, be maintained
for root and second (hot) pass.
(n) SAW and, if permitted, FCAW and GMAW shall not be used for pipes smaller than
DN 150 (NPS 6), unless otherwise agreed by BP.
(o) Intermediate cooling
1. Welds should be completed without intermediate cooling.
2. However, if this is impractical, intermediate cooling under insulating blanket is
permitted but only after completion of 30% of final weld depth.
3. Heat treatment cycle detailed in 331.2.4 shall be applied to P-Numbers 3, 4, 5, 6, and
7 materials.
4. Before welding is permitted to restart, weld surface shall be subject to magnetic
particle examination and any preheat reestablished.
5. Pipes shall not be moved or lifted until at least 50% of final weld depth has been
deposited.
(p) Vertical down welding is not permitted.
(q) Temporary attachments
1. Temporary attachments to outside surface of pipe shall not be made without BP
approval.
2. Attachments that are permitted shall be removed by grinding, followed by magnetic
particle inspection.
3. BP may require ultrasonic check to establish that remaining wall thickness is not less
than design minimum.
(r) If practical, fillet welded joints for pressure containment should have minimum of three
weld passes, two of which should be showing for visual inspection.
The above additions and modifications to welding requirements have been made on
the basis of fabrication experience and allow welding to proceed with improved
level of confidence in workmanship and practice.
Add
330 Pre-heating
330.1 General
Add
a. Oxy-fuel gas welding or cutting torches may only be used for preheating if fitted with
proprietary preheating nozzles.
b. Quenching or other means of accelerated cooling from preheat temperatures shall not be
used.
Add
331.1 General
The above modification is made to clarify the requirements for local post weld heat
treatment.
332.1 General
If designing pipe spools, particularly in P1 materials, the potential of induction
bending should be considered to avoid use of large numbers of individual elbows
and minimise extent of fabrication welding. Multiple bends of varying angles may be
included in spools made from single lengths of parent pipe using this technique.
Engineering design should consider manufacturing tolerances and need for heat
treatment following pipe bending. Bend manufacturer procedures should be
reviewed to confirm that adequate control is being exercised in heating, cooling,
and inspection of bends.
Typical tolerances on completed bends should be:
• Ovality at cross section of bend should not exceed 5%.
• Wall thickness after bending should not be less than nominal design thickness.
• Angle of bend should be within 0.009 radians (0.5 degrees) of nominal.
Following heat treatment of cold pulled bends in low alloy steels, it is recommended
that a quality control check by means of hardness testing be performed, at least in
the early stages of production. The hardness testing should be performed on one
bend per heat treatment batch at four locations around pipe circumference using
portable hardness tester of a type approved by BP. In the absence of specific
restrictions on hardness, requirements of Table 331.1.1 may be used for guidance.
332.2 Bending
335.1 General
335.1.1 Alignment
(a) Piping distortions
Add
1. Application of heat for correction of minor distortions shall only be undertaken with BP
approval.
2. Such heating shall be performed in accordance with approved procedure, and maximum
temperature employed shall not exceed 450°C (840°F).
3. Spot heating techniques shall not be used.
4. Under no circumstances shall materials be quenched to correct alignment.
Add
341 Examination
341.3.1 General
(a) Modify to Read
Final examination shall be performed after completion of heat treatment.
Add
Examination procedures shall comply with 327.1.1.
344.2.1 Definition
Add
Visual examination shall include examination of internal surface of weld, if possible, using
suitable optical instruments.
344.5.1 Method
Modify to Read
a. X-ray techniques are preferred for shop radiography of pipework up to 25 mm (1 in) wall
thickness.
b. If use of X-rays is impractical, gamma ray isotopes may be used, subject to BP approval.
c. In each case, prior to production radiography the technique shall be qualified using source
side image quality indicator (IQI) of wire type to ASTM E747 or BS EN 462-1, whichever
is applicable.
d. Single wall, single image technique should be used if possible.
e. Lead intensifying screens and fine grain high contrast film shall be used.
f. Film density shall be 2.0-3.0 through thickest portion of weld.
g. IQI specified in accordance with BS EN 462-1 shall have radiographic sensitivity that
complies with Table 2.
h. If complete joint circumference is radiographed in a single exposure, four IQIs placed at
/2 radian (90 degree) intervals shall be used.
i. Set on branch connections if permitted by engineering design, should be subject to
intermediate radiography.
1. Film shall be on bore side of joint.
2. Radiography shall be performed when weld depth is similar to wall thickness and
before reinforcing fillet is applied.
complete to depth of approximately 30% of wall thickness. This minimises the need
for through wall repairs.
Following repairs to the root and reexamination, the weld should be completed and
subjected to final examination.
Add
345 Testing
Add
a. Before starting fabrication, the fabricator and BP shall agree which types of welding
defects are to be regarded as notifiable prior to rectification.
b. Fabricator shall subsequently advise BP of need to perform such repair, which shall be
subject to approval prior to commencement of further work on defective welds.
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3 May 2005 GIS 42-101
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Carbon, Carbon Manganese, and
Low Alloy Steel Pipework (ASME B31.3)
Table 1 – Acceptance criteria for welds (to be read in conjunction with Table 341.3.2 of ASME B31.3)
Weld metal centre line, FL and FL+2 mm testing is mandatory. The need for other notch locations to be tested shall be identified
by the engineering design.
<25 mm (1 in) wall thickness = charpy specimens to be taken from weld cap.
≥25 mm (1 in) wall thickness = charpy specimens to be taken from the root and cap regions.
CL
A B
CL
CL D
A
A
A
CL
A
E
1.8 D1 t 1
1.8 D2 t 2
ASNT
Add
CP-189 Qualification and Certification of Nondestructive Testing Personnel.
ASTM
Add
E 747 Standard Practice for Design, Manufacture and Material Grouping
Classification of Wire Image Quality Indicators (IQI) Used for
Radiology.
AWS
Add
QC1 Standard for AWS Certification of Welding Inspectors (1996 or later
edition).
Add
BSI Standards
BS EN 462-1 Non-destructive testing - Image quality of radiographs - Part 1: Image
quality indicators (wire type) - Determination of image quality value.
EEMUA Standards
EEMUA 153 Process Piping-Supplement to ASME B31.3.
BP
GP 18-02 Guidance on Practice for Storage and Control of Welding Consumables.
Bibliography
[2] ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
BP
[3] GIS 36-103 Guidance on Industry Standard for Positive Material Identification (PMI).
[6] BS 5383 Material identification of steel, nickel alloy and titanium alloy tubes by continuous
character marking and colour coding of steel tubes.
[8] BS EN 14161 Petroleum and natural gas industries – Pipeline transportation systems.