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GS 118-10 Welding of Transmission Pipelines
GS 118-10 Welding of Transmission Pipelines
WELDING OF TRANSMISSION
PIPELINES
Supplementary to BS 4515: 1996
December 1998
(Amended February 2000)
APPLICABILITY
Regional Applicability: International
This BP Group
AMENDMENTS
Amd Date Page(s) Description
___________________________________________________________________
01 01 Feb 2000 19-20 Reference BS EN 1435 replacing BS 2910
23-24 Amendment to Table 8(j)
29-30 Amendment to list of referenced standards.
Section Page
1. GENERAL .......................................................................................................................1
1.1 Scope and General Applicability .................................................................................1
1.3 Definitions .................................................................................................................1
1.4 Information to be supplied, items to be approved and requirements to be
agreed and documented ..............................................................................................2
1.5 Equipment .................................................................................................................4
1.6 Welding Processes......................................................................................................4
1.7 Welding Consumables.................................................................................................5
1.8 General Requirements.................................................................................................6
GS 118-10 PAGE i
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4.13 Partially Completed Joints.......................................................................................17
APPENDIX A.....................................................................................................................27
DEFINITIONS AND ABBREVIATIONS ........................................................................27
APPENDIX B.....................................................................................................................29
LIST OF REFERENCED DOCUMENTS ..................................................................29
APPENDIX C.....................................................................................................................32
ALTERNATIVE TECHNIQUE FOR BATCH TESTING OF WELDING
CONSUMABLES.........................................................................................................32
FIGURE C1........................................................................................................................33
PROCEDURE FOR ESTABLISHING BATCH TEST REQUIREMENT......................33
GS 118-10 PAGE ii
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FOREWORD
The Introductory Volume contains a series of documents that provide and introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In particular,
the ‘General Foreword’ sets out the philosophy of the RPSEs. Other documents in the
Introductory Volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.
This Guidance for Specification specifies all BP general requirements for welding of
transmission pipelines that are within its stated scope, and for use with a supplementary
specification to adapt it for each specific application.
The value of this Guidance for Specification to its users will be significantly enhanced by their
regular participation in its improvement and updating. For this reason, users are urged to
inform BP of their experiences in all aspects of its application.
Application
This Guidance for Specification is intended to guide the purchaser in the use or creation of fit-
for-purpose specification for enquiry or purchasing activity.
This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.
This document completely supersedes the earlier BP Standard 192 Part 1 (April 1986) which
was later reformatted into BP GS 118-10 (1986), both former documents being based on BS
4515:1984. This document is based on BS 4515:1996 and reflects the extensive revision of the
base document.
Users are invited to feed back any comments and to detail experiences in the application of BP
RPSEs, to assist in the process of their continuous improvement.
For feedback and further information, please contact Standards Group, BP International or the
Custodian. See Current Status List for contacts.
GS 118-10 PAGE iv
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1. GENERAL
1.1.1 This BP Group RPSE specifies general BP requirements for the welding
of transmission pipelines in accordance with BS 4515: 1996.
The titles and numbering of the text of this BP Group RPSE follow
those of BS 4515:1996 for the convenience of the user. As a result of
this, gaps in the numbering sequence may occur. Text either qualifies,
substitutes, modifies or adds to its requirements those of BS 4515:
1996. Where additional text is to be read as an extension of the text of
BS 4515:1996, the text numbering of BS 4515:1996 has been extended
accordingly.
1.3 Definitions
Any specific application of the terms and responsibilities for the parties
defined as follows is a matter for the Conditions of Contract on a
project.
GS 118-10 PAGE 1
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responsibility for ensuring that all construction,
inspection and testing are undertaken in accordance
with the requirements of this GS
1.3.23 batch: a single cast of filler wire, a single blend of flux, or, for
covered electrodes , the combination of a single cast of
core wire with a single dry blend of covering.
GS 118-10 PAGE 2
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(iv) Whether any change in heat input is considered significant.
(See 2.4, Table 1 j5.)
Where BP have specific requirements, these are stated below under the
appropriate clause numbers. However, in addition to the items
identified by BS 4515: 1996 the following additional approvals are
required:-
GS 118-10 PAGE 3
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(x) Alternative 'pup' piece length. (See 4.1)
(xi) Angle of field bevel if different from mill bevel. (See 4.2)
(i) Use of wall thickness and pipe diameter grouping for welder
qualification on severe duty pipelines. (See 3.5)
1.5 Equipment
The contractor shall supply all necessary equipment for welding, heat
treatment, mechanical handling, testing and radiographic processing.
GS 118-10 PAGE 4
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1.7 Welding Consumables
1.7.1 General
1.7.2.1 General
Each coil of filler wire, bag of flux and tin or packet of electrodes shall
be clearly marked with its batch number (and shall be stored completely
separated). The storage and handling of welding consumables shall be
generally in accordance with BP Group GS 118-4. The contractor's
detailed proposals shall form part of the quality plan.
(a) argon,
(b) carbon dioxide
(c) gas mixtures that have been proved to be satisfactory as a result
of procedure approval tests.
When a gas mixture is used which has specified additions e.g. 2% O2,
5% CO2, the variation of such addition shall not exceed ±10% of that
stated.
GS 118-10 PAGE 5
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Basic coated low hydrogen electrodes or other approved low hydrogen
process shall be used for any fillet welding directly on to the pipeline,
but rutile coated electrodes may be used for fillet welds between non-
pressure bearing parts such as structural supports.
1.8.3.1 Responsibility for quality assurance shall rest with the contractor. The
contractor shall devise and implement a quality plan for the systematic
control of the construction, inspection and testing required by the
particular contract. This quality plan, which shall be based on ISO
9002/9003 shall be submitted to BP for approval prior to production
welding, and shall include evidence that the inspector and his team are
independent of production management.
1.8.3.2 The inspector shall ensure that all documentation required by this
Standard is gathered, collated, indexed, stored and subsequently
presented to BP. He shall compile a log identifying by number each
pipe and fitting, and indicating the weld numbers joining them to other
items. Each circumferential weld (whether a field joint or a shop-made
weld) shall be allocated a unique number, which shall be used for
reference to the weld in all reports, radiographs and NDT documents.
GS 118-10 PAGE 6
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2. TESTING, QUALIFICATION AND APPROVAL OF WELDING -
PROCEDURES
2.1 General
Procedure approval tests shall be carried out on pipe, made from the
same material, from the same source and in the same supply condition
that is to be used for pipeline construction.
GS 118-10 PAGE 7
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diameters shall be qualified separately,
unless approved otherwise approved
by BP.
(l) Direction of welding For all tie-ins (closing welds), all welds
where external line-up clamps are
used, and for all repair welds, vertical-
up welding shall be used for the root
runs. For pipe diameters less than 150
mm and for all welds to valves, flanges
or fittings including fillet welds, the
GS 118-10 PAGE 8
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complete weld shall be vertical-up.
(q) Type of line-up clamp if used For pipe over 150 mm diameter an
clamp, internal line-up clamp shall be
used.
Where the use of an internal clamp is
impracticable, an external line-up
clamp shall be used.
GS 118-10 PAGE 9
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(t7) Ambient temperature Minimum ambient temperature below
which preheating is to be applied.
For pipe outside diameters up to and including 114.3 mm, two sets of
three Charpy impact specimens shall be taken at the 9 o'clock position.
For pipe outside diameters over 114.3 mm, two additional sets of three
specimens shall be taken at the 6 o'clock position.
When specified (separately) for severe duty pipelines, two sets of three
CTOD specimens shall be taken. An all weld tensile test to BS 709 :
GS 118-10 PAGE 10
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1983 is also required on each weld from which CTOD tests are taken,
on material from a location as close as possible to the CTOD tests.
2.5.2.2.1 Requirements
If any specimen breaks outside the weld at a tensile strength below the
specified minimum tensile strength, the material shall be considered
suspect and its physical properties shall be investigated before any
additional tests are made.
2.5.2.2.2 Method
2.5.2.4.1 Requirements
2.5.2.4.2 Method
2.5.2.5.1 Requirements
2.5.2.5.2 Method
For pipe diameters up to and including 114.3 mm, one set of Charpy V-
notch test specimens shall be notched in the weld metal and the other in
the heat affected zone.
For pipe diameters over 114.3 mm, the additional sets of Charpy tests
at the 6 o'clock position shall be notched and tested as the other
samples.
GS 118-10 PAGE 11
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For pipe wall thickness over 20 mm, both sets of test specimens at the 3
o'clock position shall be positioned at the weld root. One set of test
specimens shall be notched in the weld metal and the others in the heat-
affected zone. For weld metals, the percentage of shear area of each
fracture surface shall be estimated and reported. If the results are
inconsistent with the measured energy, BP may require further
investigation before approving the test results.
Detailed CTOD testing was removed from BS 4515 when the 1996
edition was prepared, leaving only a minor note (3) to clause 2.5.2.5.1.
It is suggested that use should be made of BS PD 6493 for any ECA philosophy. The
selection of material and sampling of each respective zone for CTOD testing shall
take into account the importance of identifying the zone of potentially lowest
fracture toughness. All CTOD tests shall be conducted in accordance with BS
7448: Part 2: 1998 at the minimum design temperature.
Where possible the specimens shall be full wall thickness, preferred geometry and
the pipe curvature shall not be machined from the sample. The exact notch
positions and geometry in the CTOD test samples should be subject to agreement
but should include the weld metal and the heat affected zone.
2.6.2.4.1 Requirements
Section 2.7 of the new 1996 edition of BS 4515 deals with the testing of repair welds
for procedure qualification and is deemed to meet BP’s general requirements
without a supplement.
GS 118-10 PAGE 12
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3. TESTING, QUALIFICATION AND APPROVAL OF WELDER
3.1 General
If the following additional item is changed, the welder using the new
procedure shall require re-approval:-
3.8. Retests
3.9 Records
The details of each welder’s approval test and test results shall be
recorded by the contractor and be available for inspection by BP. The
contractor shall submit all documentation relating to welder approval
tests to BP for approval prior to the welder commencing production
work. BP will specify the period for which records shall be maintained.
(The content and requirement for this may vary from project to project
and will be individually specified).
Welders for mechanised welding shall be approved for all parts of the
operation. The inspection, testing and re-testing of welds for approval
purposes and records shall be in accordance with the following:-
GS 118-10 PAGE 13
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(i) Visual examination to clause 3.6.
4. PRODUCTION WELDING
Branches, fittings and attachments shall be sited away from other welds
(including longitudinal and circumferential welds) on the pipeline. The
minimum separation between any two welds shall be the largest of the
diameter of the branch or fitting, six times the wall thickness of the
thicker component, or 150 mm.
The pipe end bevel may be specified by the contractor and shall be
suitable for the welding process to be used. In general, the API 5L
standard bevel will be considered suitable for manual welding
processes, but for thick-wall pipe or for certain types of GMAW
mechanised welding, an alternative compound bevel may be proposed.
The bevel design shall be subject to agreement by BP.
Before welding, the pipe shall be cleaned inside and out using power
driven wire brushes, grinding or other method approved by BP, for a
minimum distance of 40 mm from the edge of the weld bevel.
GS 118-10 PAGE 14
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4.4 Alignment
4.5.1 Power operated internal clamps shall be used for pipe of over 150 mm
diameter, and they shall be demonstrated as capable of reducing the
maximum permitted out-of-roundness of the as-manufactured pipe
sufficiently to meet the alignment requirements of clause 4.4. External
clamps shall be used only when the root run is deposited by the vertical-
up technique.
4.5.2 For on-land pipelines, at least the root run and the second run shall be
completed before the pipe is lowered on to skids or, in the case of
fittings, the support is removed, unless the contractor is able to
demonstrate to the satisfaction of BP that the root run alone is adequate
to resist deformation and cracking.
Tack welds are allowed for vertical up welding only. All tack welds
shall be deposited by approved welders and in accordance with the
welding procedure specification. Where pre-heat is required for the
root run, this shall be applied prior to tack welding and maintained until
the joint is completed.
If grinding to remove the effects of stray arcs reduces the wall thickness
below the minimum specified in the data sheet, the defective pipe
section shall be cut out and the pipe re-bevelled and re-welded. If a
‘pup’ piece has to be used to replace the defective section, its length
shall not be less than twice its diameter. Note that stray arcs are also
possible between the pipe and the return cable and shall be avoided by
good electrical connections.
GS 118-10 PAGE 15
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4.9 Weather Conditions
When necessary, the end of the pipe shall be covered to prevent water
being channelled into the weld root. Windshields shall be used when
necessary.
4.10.2 Preheating
4.11 Branches
GS 118-10 PAGE 16
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4.12 Inter-run Cleaning
GS 118-10 PAGE 17
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5. INSPECTION AND TESTING
5.1 General
Note that the BGAS Transco and CSWIP examinations are run by TWI Training &
Examinations Dept. The Certification body for CSWIP is TWI Certification Ltd,
Granta Park, Great Abington, Cambridge, UK. PCN is administered by the British
Institute of Non-Destructive Testing (BINDT) at Northampton, UK).
Both Institutes are able to verify the validity of individual certificates. Certificates
are issued for specific periods only and an out-of-date certificate is invalid. Care
should be taken to ensure that the certificate and approval category covers
competence in the required skills for the job. e.g. BGAS Transco Senior Pipeline
Inspector covers welding inspection and radiographic interpretation, but CSWIP
welding inspector and radiographic interpreter are discrete and different
categories.
5.4.1 General
GS 118-10 PAGE 18
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(c) All welds to valves, flanges and fittings.
On a pipe-lay barge, the weld shall not be moved past the weld repair
station until the interpretation of the radiograph is complete and the
weld is judged satisfactory. Unless otherwise approved by BP, coating
and wrapping of the joint shall not begin until the weld is judged
satisfactory.
For normal duty pipelines, the first five welds of each thickness and
diameter made by each welder shall be 100% radiographically tested. If
any of these welds requires a repair, all subsequent welds by the same
welder shall be 100% radiographically tested until five consecutively
produced welds are judged to be satisfactory. Thereafter, BP will select
at least one weld from every ten welds, and radiograph this 100%. If
any of these one-in-ten welds should require repair, BP will require
some or all of the other nine to be radiographed 100%.
Note 2. Attention I is drawn to the ‘Code of Practice for Site Radiography’ prepared
by the Oil and Chemical Plant Contractors Association and published by Kluwer-
Harrap Handbooks, Brentford. Attention is also drawn to the need for audible and
visual warning arrangements and for regular monitoring of radiation levels.
The above paragraph and two notes formed section 37.2 ‘Protection’ of BS 4515:
1984 - but were not included in BS 4515:1996. The proposal of WEE/21/7 was that
the warning should be covered in separate regulations, rather than in the base
standard for pipeline welding but, as it is uncertain where such warnings are
covered elsewhere, it is deliberately included in this BP GS.
(The following items were additional to section 37.3 of BS 4515: 1984 but the
format of the whole section - now 5.4.2 of BS 4515: 1996 has changed, the list has
GS 118-10 PAGE 19
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been dropped and reference has been made to BS 2910. In 1997, BS 2910 was
superseded by BS EN 1435. Amendment No 1 of this GS draws on BS EN 1435 in
respect of the following details of radiographic technique and assessment of
radiogrpahic sensitivity. .
(b) type of film Fine grain, high contrast, direct type BS EN 584-
1 Class C3 or better.
(d) limit of film The limit of diagnostic film coverage length for
pipes over 1 metre in diameter shall not exceed
one third of the pipe circumference. (BS EN
1435 Para 5.6)
GS 118-10 PAGE 20
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thickness is below 12 mm and its use shall be subject to approval by
BP.. If approved, sensitivity levels will be specified by BP.
5.5.1 General
(a) Following field cut back of pipe, a zone extending 100 mm back
from the new field bevel shall be ultrasonically tested for
laminations.
(b) A zone 100 mm wide around the planned cut-outs of nozzles for
laminations.
The acceptance criteria for ultrasonic examination within the pipe ends
and at the planned cut-outs for nozzles shall be to quality grade B4
given in Table 1 of BS 5996, unless an alternative quality has been
agreed with BP.
The following welds shall be tested using the magnetic particle flaw
detection method:
GS 118-10 PAGE 21
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(c) All fillet welds.
The above requirement which related to 36.3 of BS 4515: 1984 was not included in
BS 4515: 1996 but is retained in this BP GS as the qualification of a welding
parameter range is routinely carried out.
GS 118-10 PAGE 22
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6. ACCEPTANCE AND RECTIFICATION OF WELDS
6.1.1 General
GS 118-10 PAGE 23
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(j) Porosity (other than elongated Not to exceed a total area, when
porosity in the root run) projected radially through the weld of
1% of any 600 mm2 of projected weld
area. An isolated pore greater than
20% of the pipe thickness or 1.5 mm,
whichever is the smaller, in any
direction, shall be considered
unacceptable.
6.2.3 Re-welding
Root sealing or single run repairs shall not be practised. There shall be
no internal welding on sour service pipelines. For severe duty pipelines
a repair shall only be attempted once, thereafter the weld shall be
completely removed. For normal duty pipeline a second repair may be
made. If this second repair fails to meet the requirements of clause 6.1
the entire circumferential weld shall be cut out and re-bevelled.
GS 118-10 PAGE 24
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(i) The weld number.
(v) Name and/or number of the welder who produced the defect.
GS 118-10 PAGE 25
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ANNEX C TO BS 4515 (INFORMATIVE).
PROPOSED WELDING PROCEDURE SPECIFICATION
This informative annex is for guidance only. Where necessary the contractor shall
undertake trials to establish an adequate level of preheat to ensure compliance with the
requirements of this standard. The precise preheat level shall be as proven satisfactory
by the welding procedure qualification test. A minimum preheat of 150°C shall apply to
the welding of fittings, repair welds and tie in welds.
GS 118-10 PAGE 26
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APPENDIX A
Definitions
Abbreviations
BGAS Transco A qualification and certification system, formerly known as ERS, for
pipeline inspection personnel, originally instituted and run by the former
British Gas Engineering Research Station, Killingworth, UK. Now
known as BG Approval Scheme and managed by TWI Certification Ltd
for Transco
BS British Standard
HV Vickers hardness
GS 118-10 PAGE 27
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managed by The British Institute of Non-Destructive Testing (BINDT)
Northampton, UK
GS 118-10 PAGE 28
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APPENDIX B
A reference invokes the latest published issue or amendment unless stated otherwise.
American Standards
API Standard 1104 Standard for welding pipelines and related facilities
British Standards
BS 709:1983 Methods of destructive testing fusion welded joints and weld metal in
steel.
BS 4515: 1996 Specification for process of welding of steel pipelines on land and
offshore
BS 5996: 1993 Specification for acceptance levels for internal imperfections in steel
plate, strip and wide flats, based on ultrasonic testing.
BS 7448 Part 1: 1991: Fracture mechanics toughness tests. Part 1 Method for determination
of K1c, critical CTOD and critical J values of metallic materials
BS 7448 Part 2: 1998 Fracture mechanics toughness tests. Part 2 Method for determination
of fracture toughness of weldments in metallic materials.
BS EN 439: 1994 Welding Consumables - Shielding Gases for Arc Welding and Cutting
GS 118-10 PAGE 29
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BS EN 462-1: 1994 Image quality indicators (wire type). Determination of image quality
value. * Partly replaces BS3971: 1980 (1985)
BS EN 499: 1995 Welding consumables. Covered electrodes for manual metal arc welding
of non-alloy and fine grained steels. Classification.
BS EN ISO 9002: 1994 Quality systems. Model for quality assurance in production,
installation and servicing.
BS EN ISO 9003: 1994 Quality systems. Model for quality assurance in final inspection and
test.
BP Group RPSE
GS 118-10 PAGE 30
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German Standard
Note:
1. The definitions for employer and inspector replace those given in BS 4515:1996.
GS 118-10 PAGE 31
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APPENDIX C
Batch tests of welding consumables are not intended to undertaken as a routine measure for all
pipelines, but may be required by BP for certain offshore pipelay operations and land-based
pipelines designed for certain categories of critical service. When batch testing is specified by
BP it shall be carried out in accordance with this Appendix by the consumable manufacturer
rather than by the pipe-welding contractor. All batch test welds shall be made as all-weld-
metal deposits as defined in former standard BS 639: 1986. In the following list of steps, the
illustrative results (given in parenthesis) refer to this Addendum, Figure C1 :-
(i) BP will define the Charpy test requirements for the welding procedure qualification
test (Average 50 J at -10°C).
(ii) The contractor shall obtain acceptable results from the welding procedure qualification
test at mid-wall thickness (Average 80 J at -10°C).
(iii) The consumable supplier shall prepare an all-weld-metal deposit using the same batch
of consumables that was used in the welding procedure qualification test. Where more
than one size of consumable is used, a separate deposit should be made for each size.
Consumables used for the root run only do not require batch testing.
(iv) The consumable supplier shall test a set of three Charpy test pieces, of the same size as
those taken from the welding procedure qualification test, at the temperature of the
welding procedure qualification test (Average 160 J at -10°C).
(v) The consumable supplier shall test further sets of three Charpy test pieces, decreasing
temperature by -10°C per set, until the average falls below that specified for the
welding procedure qualification test:-
150 J at -20°C
140 J at -30°C
90 J at -40°C
40 J at -50°C
(vi) By interpolation, the temperature will be found, at which the all-weld-metal deposit
gives the same energy as that measured in the welding procedure qualification test
(-42°C).
(vii) All batch tests shall be carried out at this temperature, against the same energy
requirement as that specified for the welding procedure qualification test (50 J).
GS 118-10 PAGE 32
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FIGURE C1
Procedure for Establishing Batch Test Requirement
GS 118-10 PAGE 33
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