Pearl GTL

Project
Shell Project No: HP-3000-QAT
Project Document Number: T- 4.250.901

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

LINDE ENGINEERING

Contractor Project No :
Project Rev.: A

Page 2 of 17

5887

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION

21.04.2008

Ready For Construction

BR

UA

ZG

RFC

23.12.2007

Issued for Company comments

BR

AU/MC

ZG

ICC

05.12.2007

Issued for Review

BR

AU/MC

ZG

IFR

22.11.2007

Issued for Internal Review

BR

AU/MC

ZG

IIR

Date

Description

GAMA
Rev.
No.

Project
Rev
No.

Prepared Checked Approved

By
By
By
ORIGINATOR

Status

Document Title:

METHOD STATEMENT FOR PURGING OF

STAINLESS STEEL

LINDE ENGINEERING AG

Document No.

Contractor

Gama Qatar Co. W. L. L.

LOC470
GAM

MTS

MEC

GTL

006

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T-4.250.901

Vendor Code

Rev No: A

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

TABLE OF CONTENTS
1.

SCOPE ________________________________________________________________________5

2.

PURPOSE _____________________________________________________________________5

3.

HSSE _________________________________________________________________________5

4.

REFERENCE __________________________________________________________________5

5.

DEFINITIONS _________________________________________________________________6

6.

RESPONSIBILITY ______________________________________________________________7

Welding Supervisor __________________________________________________________________7

Welding Inspector____________________________________________________________________7

7.

METHOD ______________________________________________________________________7

Welding preparation__________________________________________________________________7

Purge dams types ____________________________________________________________________7

Purging_____________________________________________________________________________7

Measurement of gas flow rate __________________________________________________________8

Welding ____________________________________________________________________________8

Oxygen level measurement_____________________________________________________________9

8.

INSTALLATION - CYLINDER METHOD ___________________________________________9

9.

PROTECTION OF LARGE DIAMETER WELDS (NPS equal to or more than 14) ________10

10.

CLOSURE WELDS ___________________________________________________________10

11.

TGX WELDING______________________________________________________________10

12.

SAFETY REQUIREMENTS____________________________________________________10

13.

WITNESSING AND REPORTING ______________________________________________10

14.

FIGURES ___________________________________________________________________11

15.

ATTACHMENT ______________________________________________________________14

T-4.250.901 Rev. A

Page 4 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

1. SCOPE
This method statement describes the modalities established by GAMA for gas backing
protection of stainless steel piping butt welds for C2 ASU Pearl GTL Project.

2. PURPOSE
Purpose of this Method Statement is to ensure that all gas backing protection activities
are carried out correctly, with minimal risk of injury or damage.

3. HSSE
All works shall be in compliance with the State of Qatar laws and regulations, Ras
Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG
& QSGTL and/or its PMC requirements and instructions.
In addition all employees and GAMA subcontractor employees on site will have
through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety
induction for site safety, health, environmental and security prior to work activities.
Other training courses will be attended as required by LINDE ENGINEERING AG or
QSGTL and/or its PMC as required.

4. REFERENCE
ASME B31.3

Process Piping

AWS-D 10.4

Recommended Practice for Welding Austenitic Chromium

Nickel Stainless Steel piping and Tubing

T-4.234.542

Project Quality Plan

T-4.250.938

General Welding Procedure

T-13.377.441

Quality Control Requirements of Welding

DEP 30.10.60.31

Oxidation of Stainless Steel Weldments

T.4.250.931

Welding Consumable control

DEP 30.10.60.18

Welding of metal (Amendments/supplements to API RP 582)

DEP 31.38.01.11

Piping - General Requirements

DEP 31.38.01.31

Shop & Field Fabrication of Steel Piping

Amendement T.13.376.796E

T-4.250.901 Rev. A

Page 5 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

T-4.250.938

General welding procedure

T-4.250.939

Welders performance qualification

T-4.250.920

ITP fabrication of Piping A/G & U/G

Date:

21.04.2008

5. DEFINITIONS
Company

: QSGTL or its PMC

Contractor

: LINDE ENGINEERING AG

Sub Contractor

: GAMA QATAR

Contract

: QSGTL Pearl Plant - C2 ASU Project

WSD

: LINDEs (welding supervision & documentation system)

ITP

: Inspection and Test Plan

QCP

: Quality Control Procedure

QCR

: Quality Control Record

WPS

: Welding Procedure Specification

PQR

: Procedure Qualification Record

WPQT

: Welding Procedure Qualification Test

NDT

: Non Destructive Testing

WQT

: Welding Qualification Test

GTAW

: Gas Tungsten Arc Welding

NDE

: Non Destructive Examinations

WPS

: Welding Procedure Specification

GTAW

: Gas Tungsten Arc Welding

Ppm

: Parts per million

T-4.250.901 Rev. A

Page 6 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

6. RESPONSIBILITY

WELDING SUPERVISOR

The Welding Supervisor is responsible but not limited to:

assure the correct observance of this procedure;
assure the correct position of purge dams and the right purging time;
assure the total removal of purge dams;
Certify the purge dam installing and removing.

WELDING INSPECTOR

The Welding Inspector is responsible but not limited to:

verify the correct observance of this procedure;
Check the purity of gas as indicated in Para 7

7. METHOD

WELDING PREPARATION

Welding preparation shall be made in accordance with GAMA General Welding

Procedure (T-4.250.938)
For diameter 3 and above, temporary tack welds shall be normally made on the
groove with bridging. Bridging material shall be of same specification of the base
material. For diameters equal to or less than 2, permanent tack welds in the root
shall be made, according to the applicable WPS, using gas backing.
In case that the tack welds on the root have been made without gas backing, they
shall be removed by grinding and the ground area shall be checked with
penetrant test.

PURGE DAMS TYPES

The following types of purge dams can be used:

soluble paper, when it can be removed by hand or by brushing, or blowing, or
flushing (where permitted), etc.;
removable foam rubber plugs or internal rings, having an open section suitable
to be filled with gas, along the weld root (see details in the Para 9)
Cylinder method (see details in the Para 8).

PURGING

Argon 99.99% shall be used for backing purging.

Before starting welding, an adequate purging shall be made in order to eliminate
the oxidizing atmosphere inside the pipe.
T-4.250.901 Rev. A

Page 7 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

The operations for a proper purging are as follows:

tape seal the weld joint;

assure that the gas venting orifice has a flow capacity equal to or greater than
that of input side, for assurance of a near zero interior purge gas pressure (a
purge gas pressure buildup during welding will result in excessive root bead
concavity);
input argon at a flow rate of 24 liters per minute;
minimum gas flowing time prior to commencing the welding/tacking to achieve
complete purging shall be as per the following table:

Nominal
size
4
6 10
12 16
18 22
24 28
30 34

(*1)

(*2)

Pipe

Minimum purging time (minutes) according to the

distance between purge dams (see notes 1 and 2)
150 mm
300 mm
450 mm
600 mm
1
1
2
2
2
4
6
8
5
9
14
18
10
19
29
38
12
23
35
46
14
27
41
54

The above table has been calculated on the basis of AWS D10.4
Recommended Practices for Welding Austenitic Chromium Nickel
Stainless Steel piping and Tubing.
For lengths more than 600 mm (for example, in case of closure welds
where purge dams cannot be installed) refer to figure A.
MEASUREMENT OF GAS FLOW RATE

All gas bottles shall be equipped with proper pressure gauges and flow meters, in
order to allow the regulation of the pressure of gas and to check the actual flow
rate.

WELDING

After purging, and before starting welding operation (GTAW), the gas flow-rate
shall be reduced to the value established in the applicable WPS.
During welding, the seal-tape shall be removed just in advance of welding
progression around the joint, in order to minimize purge gas loss and atmospheric
contamination through the root opening.
The backing gas purge shall be maintained until at least two layers of weld
deposit have been made.
T-4.250.901 Rev. A

Page 8 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

OXYGEN LEVEL MEASUREMENT

The permissible level of oxygen shall be less than 1%.

Measurement shall be carried out by welding-gas oxygen analyzer SGI-2
(Dansensor) and shall be recorded in the purge dam tracking record.
At the beginning of each method of protection, oxygen measurement shall be
made on the first production joints having the following diameters, in order to
confirm the minimum purging time established in the table shown in Para 7 (the
reference distance between dams shall be 300 mm) and qualify the Argon gas
protection/capability and arrangement.
4 10 16 22 28 32
When the values of the table have been confirmed, the times established in the
table must be strictly observed by the Welding Supervisors or established time
shall be maintained.
The Welding Inspectors shall check on a random basis (minimum one joint every
day) the oxygen level during surveillance of welding activities, using the calibrated
instrument. If any of the joint found with an unacceptable limit of oxygen content,
flow rate and flushing time shall be increased and checking shall be repeated.
Minimum next five joints shall be checked for each failure of purging noticed
during random inspection in order to monitor the correctness of purging system.
In case of high level of oxygen content, the oxygen measurement shall be
performed also on the argon contained in the bottle.
If the measurement exceeds the maximum permissible oxygen content, the bottle
shall be removed and segregated in the stock area separately from the other
Argon bottles. A red card indicating, REJECTED shall be attached to the bottle.

8. INSTALLATION - CYLINDER METHOD

This method is applicable in particular when soluble paper plugging cannot be
adopted (e.g. for absence of line flushing operations).
This system allows the weld protection with low gas consumption.
The method consist of sealing discs with double packing washer made out of
silicon, heat resistant up to 280C / 330C, placed directly next to the welding
joint.
The minimum distance between the sealing disc and weld joint is 60 mm.
Flexible packing washers are adjustable to the corresponding pipe diameter.

T-4.250.901 Rev. A

Page 9 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

For complex spool configurations (e.g. elbows) it is recommended to test the

cylinder pulling out, before joint clamping or tack welding.
The cylinder remains in the pipe until the completion of the welding joint (see
figure B).
Then the cylinder shall be pulled out, through the next pipe end, using a release
cable.

9. PROTECTION OF LARGE DIAMETER WELDS (NPS EQUAL TO OR

MORE THAN 14)

In order to reduce the gas consumption, removable foam rubber plugs can be
used or internal rings, having an open section suitable to be filled with gas, along
the weld root. Minimum distance from plug to weld joint shall be 150 mm.
Removal shall be made by means of cable fixed to the plugs.

10. CLOSURE WELDS

Closure joints during piping installation, where purging dams cannot be applied,
shall be protected by filling the line with backing gas; in order to reduce the gas
consumption, advantage from line valves interceptions, when available, can be
taken.
The minimum time of purging shall be calculated according to (see Figure A).

11. TGX WELDING

TGX welding shall be used only with LINDE approval. Separate WPS and PQR
shall be done; TGX Wire can be used without purging. TGX can be used where
the internal slag can be properly cleaned without affecting FSI.

12. SAFETY REQUIREMENTS

Personnel are not permitted to enter confined spaces for the purpose of
installation or removal of purge dams without a work permit.

13. WITNESSING AND REPORTING

The Welding Supervisors shall maintain a log of all purge dams, recording date of
installation and removal using GAM-QCR-QAC-GTL-090.
The LINDE shall witness the removal of all purge dams and initial the purge dam
log accordingly.
A copy of the purge dam log shall be forwarded to LINDE weekly.

T-4.250.901 Rev. A

Page 10 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

14. FIGURES
A

Purge evacuation of oxidizing atmosphere

Cylinder method

T-4.250.901 Rev. A

Page 11 of 17

Q A T A R

T-4.250.901 Rev. A

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

Page 12 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

FIGURE B

Cylinder method

Legend:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)

T-4.250.901 Rev. A

Protective gas entry with attachment for cable release.

protective gas exit
heat resistant sealing discs
nuts
supporting discs
porous stainless steel core
pipe for porous stainless core
Flexible arms.
nozzle
rigid pipes
spring safety hook with release cable
Dividing filter.
Protective gas pass

Page 13 of 17

Q A T A R

Doc. Title

METHOD STATEMENT FOR PURGING OF STAINLESS STEEL

Doc. No.

GAM-MTS-MEC-GTL-006 Rev. D

Date:

21.04.2008

15. ATTACHMENT

GAM-QCR-QAC-GTL-090

O2 PURGE MONITER IS USING SAME EQUIPMENT SIMILAR (OR)

ACCURACY

T-4.250.901 Rev. A

Page 14 of 17

C2 ASU PEARL GTL PROJECT

RAS LAFFAN INDUSTRIAL CITY

PURGE DAM TRACKING RECORD

ITP NO:

REPORT NO:

TEST CODE:

DATE:

ISO NO

WELD
NO

GAS
FLOW
RATE

OXYGEN
LEVEL

PURGE DAM INSTALLATION

DATE

GAMA

LINDE

PURGE DAM REMOVAL

DATE

GAMA

NOTES:

ORGANIZATIONS
GAMA QATAR REP
LINDE REP
QSGTL REP

GAM-QCR-QAC-GTL-090

DATE

NAME

SIGNATURE

LINDE

ARGWELD

WELD PURGE MONITOR

MKV
Measures the content of Oxygen in the purge gas to indicate
when it is safe to carry out a weld

Keeps waiting time to a minimum

The monitor can tell the operator exactly when the Oxygen
level is low enough to commence welding. No estimating or
guesswork is involved, so no time or gas is wasted waiting
for the correct Oxygen level to be reached.
Saves on excessive use of inert gas
The exact Oxygen content is shown on the monitor so no
more inert gas than necessary has to be used to ensure that
the weld will be free of oxidation.
Prevents weld failures
Premature starts on welds are avoided, high quality welding
is ensured. Coked porous and discoloured welds can be
prevented.
Highly portable
Its small size makes is easy and very convenient to use in
all weld purging situations. Battery operation allows it to be
carried anywhere.
Titanium / Duplex / Stainless Steel
The MKV monitor can be used to weld Titanium, Duplex
and Stainless Steels.

Low cost
The monitor is available at a low relative cost and is a perfect
accessory for use with any pipe weld purging system or
argon welding enclosure.
Continuous monitoring of oxygen levels
A continuous read out of the Oxygen level is given, even
when welding is taking place. This can avoid unforeseen
purging problems that could cause quality failures after the
weld has started.
Calibration and Certification
Our instrument is supplied calibrated and certificates for
Industry Standards are included. Re-calibration is available
to operators at any time. Continuous calibration on the front
of the instrument is provided.
Extra Range
The MKV monitor indicates Oxygen levels down to 100
parts per million (PPM) 0.01% and measures accurately
down to 0.1%.

Specifications
Measuring Range
Accuracy
Size in mm
Power
Scale
Weight kg

0.01% - 20.9 % Oxygen

(100 ppm to atmosphere)
At 20% 0.2%
At 2% 0.02%
155 x 81 x 38
Battery type PP3 9v
LCD (Liquid crystal display)
0.210

Argweld Inflatable Pipe Purging Systems are also

available from Huntingdon Fusion Techniques. These
are used to dam the volume inside pipework where gas
purging is to be carried out.
For pipework where the inflatable systems cannot be
removed, we manufacture purge film kits for making water
soluble dams.

Shipping Weights and Dimensions

Size in mm
Weight Kg

310 x 260 x 80
0.870

With Tungsten inert gas welding, before commencing the

weld, it is essential to know that the Oxygen content in the
welding volume has been reduced to a satisfactorily low level.
The Argweld Weld Purge Monitor is specifically designed to
measure Oxygen content down to 0.1% with a high degree of
accuracy and to indicate levels down to 0.01% ( 100 ppm).
The Argweld Weld Purge Monitor can be used as a continuous
measuring device throughout the weld process or as a
sampling instrument for spot checks. Visible demonstrations
and routine inspections for quality control are made simple.
The monitor can be used with any pipe weld purging system
or argon welding enclosure.
Small, portable and very simple to use
The Argweld Weld Purge Monitor is supplied in a robust
housing. It comes complete with a stainless steel probe, a
2 metre length of rubber tube, a rubber vacuum bulb and a
carrying strap. The instrument can be stored in the plastic
foam lined case in which the unit is shipped. Our operating
instructions and calibration & test certificates are supplied in
the case along with the instrument.

Argweld Flexible Enclosures have been designed for

welding Titanium and other reactive metal components.
These are in wide use for welding of Titanium components
for the aerospace, medical and racing car industries and
for the welding of stainless steel components to eliminate
the expensive cleaning of oxide discoloration.
Special enclosures can be designed and manufactured to
suit all applications.

It can be used in a continuous monitoring mode by connecting

the rubber tube to the exhaust port on the purging device or
enclosure and allowing the exhausted gas to flow free over
the sensoraway to the atmosphere.
Alternatively, the monitor can be used in the sampling mode.
The stainless steel probe is inserted either through the weld
joint gap into the volume being purged or the exhaust port
of the purge device. The rubber bulb is then used to draw a
sample of the gas across the sensor.
The LCD scale displays the Oxygen level in 13 mm high
figures which can easily be read from a distance of several
metres.
Once the desired Oxygen level is achieved, welding can
begin.
Nothing could be simpler!

We also manufacture a wide range of other products for pipework

fabrication and welding. Ask for details about:
Trailing shields
Weld Backing tape
Water Soluble Weld Purge Film
Pipe Purging Plugs
Titanium Weld Purge Monitor
Tungsten Electrode Grinders
Multi-Strike Tungsten Electrodes (thoria-free)

Huntingdon Fusion Techniques Limited, Stukeley Meadow, Burry Port, Carms SA16 0BU United Kingdom
Telephone: +44 (0) 1554 836 836
Facsimile: +44 (0) 1554 836 837
Email: hft@huntingdonfusion.com
http://www.huntingdonfusion.com

(AD05 LT APM MKV GE JUL04)

Copyright 2001-2004 All rights reserved. This publication may not be reproduced by any means without the written permission of Huntingdon Fusion Techniques