DUQM REFINERY PROJECT – EPC PACKAGE 2 PIPELINE WELD NUMBERING SPECIFICATION

Revision History

Amendment Revision Amender

Amendment
Date Number Initials

09-04-18 O1 R Akilan Issued for client Review

5-Jun-2018 A1 R Akilan Issued client comments incorporated

20-Jun-2018 O2 R Akilan IFCR (Issued for Client Review )

9-Sep-2018 B1 R Akilan IFD (Issued for Design )

Related Documents

Document Number Document Name Description of Content

Refer Section 3.2

Holds

Section Number Short Description of Hold

Definitions and Abbreviations

Term Comment

Refer Page 4& 5

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CONTENTS

ABBREVIATIONS ............................................................................................. 4
DEFINITIONS ................................................................................................. 5
1. INTRODUCTION ..................................................................................... 6
1.1 General............................................................................................................................ 6
2. SCOPE ................................................................................................ 6
3. PROJECT DOCUMENTS, CODES AND STANDARDS ............................................... 6
3.1 American Petroleum Institute ........................................................................................... 6
3.2 Project Documents .......................................................................................................... 6
4. QUALITY, HEALTH, SAFETY AND ENVIRONMENT................................................ 6
4.1 Safety Representative ..................................................................................................... 6
5. WORK PROCEDURE ................................................................................. 7
6. LINE UP .............................................................................................. 7
6.1 Initial Planning ................................................................................................................. 7
6.2 Line - Up Operation ......................................................................................................... 7
7. MAINLINE WELDING ................................................................................. 7
7.1 Initial Planning – Mainline Welding .................................................................................. 7
8. WELD NUMBERING AND WELDER’S IDENTIFICATION ........................................... 8
8.1 Weld Numbering Instructions ........................................................................................... 8
8.2 Constructing the Weld Number ........................................................................................ 8
8.2.1 Service Identifier ....................................................................................................... 8
8.2.2 Prefix Identifier .......................................................................................................... 9
8.2.3 Sequential Number ................................................................................................... 9
8.2.4 Suffix Identifier .......................................................................................................... 9
8.3 Welders Identification Instructions ................................................................................. 10
8.4 Pipe Tracking Instructions.............................................................................................. 11

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ABBREVIATIONS
CS Carbon Steel

GMAW Gas Metal Arc Welding (Automatic Welding with Gas Protection)

NDE / NDT Non-Destructive Examination / Non-Destructive Testing

Duqm Duqm Refinery Project

RA Risk Assessment

ROW Right of Way

SMAW Shield Metal Arc Welding (Manual Welding)

UT Ultrasonic Testing

TBT Tool Box talk

QHSE Quality, Health, Safety and Environment

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DEFINITIONS

Company Duqm Refinery and Petrochemical Industries Co. LLC (DRPIC)

Contractor Joint Venture (JV) of Petrofac International LTD & Samsung Engineering
Co. Ltd.

Project Duqm Refinery Project

Works Carbon Steel Line Pipes Line Up, Welding and Weld Numbering Activities

Shall Indicates a mandatory requirement in order to conform to this

Specification

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1. INTRODUCTION
1.1 General
Refer to the Pipeline overall route map document no.DRP001-OUF-650000-Y-PP-
002 , Pipeline Schematic Diagram document no. DRP001-OUF-650000-Y-FSK-001,
and Pipelines Design basis document no. DRP001-OUF-SPE-Y-650-001 for full
description of the Duqm Refinery Project.

2. SCOPE
This document outlines the requirements for carbon steel line pipes Line Up and
Weld Numbering activities during the construction phase of Duqm Refinery Project.
It defines the rules for safe and proper line up and welding activities and ensures
compliance with Contractor/ Company requirements.
The Project CS pipeline systems consist of 5 numbers product Export pipelines as
summarised in the Pipelines Design basis, document no. DRP001-OUF-SPE-Y-650-
001.

3. PROJECT DOCUMENTS, CODES AND STANDARDS

3.1 American Petroleum Institute

API 1104 Welding of Pipelines and Related Facilities

3.2 Project Documents

The latest revision of the following project documents shall form a part of this
specification.
DRP001-FED-OUF-650000-Y-PP-002 Overall System Route Map
DRP001- FED-OUF -650000-Y-FSK-001 Pipelines Design basis Summary
DRP001- FED-OUF -SPE-Y-650-011 Specification for pipeline construction
DRP001- FED-OUF -SPE-Y-670-002 Specification For Pipelines Welding

4. QUALITY, HEALTH, SAFETY AND ENVIRONMENT

Contractor shall comply with project requirements on QHSE. Project QHSE is
covered in the latest revisions of the following documents.
DRP001-FED-OUF-PRO-Q-000-003 Vendor Quality and Environmental
Requirements
Contractor shall have written QHSE plans and procedures and shall comply with
project QHSE requirements. Contractor’s QHSE plans and procedure shall be
approved by Company. Contractor shall have quality assurance system in place that
meets the project requirements.

4.1 Safety Representative

The Safety Representative shall visit the Works periodically to audit compliance with
this Instruction and assist in the identification of any unsafe conditions. Safety
Representative shall also ensure that safety coaches receive proper training and
assist Pipe gang and Welding Foremen in conducting RA and TBTs.

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5. WORK PROCEDURE
As a minimum, the work procedure shall include:
 Plan/layout of entire line up and weld numbering operations
 Methods of carrying out line up and weld numbering
 Resources, such as equipment, machinery and manpower to be utilised during
line up / welding and weld numbering

6. LINE UP
6.1 Initial Planning
Contractor shall make plans for safe access to the facilitate line up. Contractor shall
align and weld together the joints of pipes into a continuous pipeline. All pipeline field
welds shall be executed in accordance API 1104 Welding of Pipeline and related
Facilities and all applicable approved welding procedures.
The pipeline production welding may be either Manual Welding Process (SMAW),
GTAW and/or mainline automatic welding, Gas Metal Arc Welding Process
(GMAW).
6.2 Line - Up Operation
Prior to alignment, the end of each pipe joint shall be bevelled in accordance with
bevel design on the approved welding specifications / procedure using a pipe-facing
machine for GMAW or oxy acetylene with grinding for SMAW. All refuse from pipe
facing machine shall be removed from ROW and disposed in approved dumpsites.
Bevelled ends, whether mill or field made, shall be smooth and uniform and the
dimensions and geometry shall be in accordance with the joint design in the approved
welding specifications / procedures. Burns, small score marks, indentations or other
small defects within the joint preparation area shall, at the discretion of the
Contractor’s inspector, be blended out by grinding, otherwise the joint shall be re-
prepared. The bevelled ends of each joint of pipes and in the area (50 mm from
edge) immediately adjacent shall be thoroughly cleaned of paint, rust, mill scale, dirt
and other foreign matter by use of power driven wire buffing wheels or hand wire
brush.
The inside of each joint of pipes shall be inspected and adequately cleaned to remove
dirt, debris and other foreign matter.

7. MAINLINE WELDING
7.1 Initial Planning – Mainline Welding
Contractor shall provide welding machines, line-up clamps, bevelling machines,
welding electrodes, welding wire, gas, and all other equipment and supplies required
for the welding operations as qualified by PQRs.
Qualified welders and welding operators shall use approved welding specifications
and procedures to perform production welding. For automatic welding, welding shall
be performed using approved and qualified equipment.
Contractor shall monitor welding at a level required to ensure compliance with the
requirements of project welding specifications referenced in Section 3 of this
specification.

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8. WELD NUMBERING AND WELDER’S IDENTIFICATION

The Construction Manager/Superintendent shall be responsible for ensuring that
Line up and weld numbering activities are planned out for safe and timely
completion.Line up and weld numbering operations are led by the Pipegang Foreman
and Welding Foreman who have in their possession all the required and approved
work permits, latest/controlled drawings, project specifications / procedures
Quality Control shall monitor and verify Weld identification process to ensure that
welders properly identify their work according to Section 8.3 of this Specification.
The unique weld number shall be used to ensure each weld is uniquely identified and
traceable through all stages of welding and NDT. This shall also apply to Welder’s
Identification, which shall have a unique I.D. number traceable to the welder’s
qualification.
8.1 Weld Numbering Instructions
Each weld number shall be given a series of unique “identifiers” by Quality Control,
which represents crew, sequence number and repair history of the weld. Quality
Control shall track each unique weld number in an electronic data base.
For pipeline welds, the number shall be placed on the work side of the pipeline and
on the upstream side of the weld so that it can be easily read from a distance of 3 m
(10 ft). Weld numbering shall be located on the pipe such that the identification will
be visible when viewing the pipe as laid in the pipeline ditch.
For fabrication welds, the number shall be placed on the pipe assembly beside the
weld so that it can be easily read.

8.2 Constructing the Weld Number

Weld numbers shall consist of four parts, which are:
 the “Service” which denotes the pipeline service fluid,
 the “prefix” which identifies the weld categories,
 the centre part “unique sequential number” which identifies each weld in a
sequential way,
 the “suffix” which identifies the repair and/or cut out history of the weld.
The complete weld number shall be clearly marked on each and every RT film and
NDT report.
8.2.1 Service Identifier
The service identified for welds shall be in accordance with table 8.1 below
Table 8.1: Service identifier

Service Pipeline Service area

PG PLPG Product

NP Naphtha Product

JP Jet A-1 Product

DP Diesel Product

HSPO Heavy Sulphur Fuel Oil (HSFO)

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8.2.2 Prefix Identifier

The prefix identifier for welds shall be in accordance with Table 8.2 below.
Table 8.2: Prefix Identifier

Prefix Weld Category

ML Welds done by Mainline Welding crew (GMAW /SMAW).

TI Welds done by the Tie-In welding crew.

FTI Welds done by Tie-In crew that are not Pressure tested.

TH Welds done on test head assemblies.

8.2.3 Sequential Number

The centre part of the weld number is the unique sequential number consisting of a
5 digit number starting at 00001 and in the direction of construction as much as
possible. Mainline, Tie-ins, Final Tie-in welds all follow the same unique sequential
numbering system.
Up to 3 letters may be used as prefix at the beginning of the complete weld number
as shown below:
 ML-00004 Weld number 4 done by Mainline crew
 TI-00005 Weld number 5 done by the Tie-In crew, which ties in two welded
sections.
 ML-00006-R Weld number 6 done by Mainline crew and was repaired once
and accepted.
 ML 00007-CO Weld number 7 originally done by Mainline, then Cut Out and
re-welded by Tie-in crew.
 ML 00008-RR Weld number 8 done by Mainline crew and repaired twice.
 ML-00009-CO2-R Weld number 9 done by Mainline crew, cut twice and
the second cut out had to be repaired once.

8.2.4 Suffix Identifier

The suffix identifier shall be as shown in Table 8.3 below

Table 8.3: Suffix Identifier

Suffix Weld History

R Weld that was repaired once, sequential weld number remains the
same with addition of “R” after the weld number.

RR Welds that was repaired twice, sequential weld number remains the
same with addition of “RR” after the weld number.

CO Weld that was removed from the line, Cut Out, sequential weld
number remains the same with addition of “CO” after the weld
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number.

CO2 Weld that was removed from the line a second time Cut Out twice,
sequential weld number remains the same with addition of “CO2”
after the weld number.

A If a weld requires a complete cut out and it requires a pup piece (i.e.
two welds). Tie-in crew shall create two new welds, the original weld
that was cut out shall use the original number followed by “CO” and
the additional weld shall carry the same number as the original weld
upstream followed by the suffix “A”.

A,B,C If for some reason some welds are added to the line after it has been
originally welded and numbered, the additional welds shall carry the
same sequential weld number with the Prefix “TI” for Tie-in and Suffix
“A” for the first weld downstream of the existing weld, and suffix “B”
for the second weld etc.

8.3 Welders Identification Instructions

Each welder on the Project shall receive a unique 3 digit identification number based
on the type of welding qualification:
 Manual Welders (SMAW) Sequential number starting at 100
 Double Joint Welders (GMAW) Sequential number starting at 200
 Automatic Mainline Welders Sequential number starting at 300
If a number is assigned to a welder at welder’s qualification, and he fails his test, the
number shall not be re issued to another welder, that number will never be used.
All welders on the project shall identify their work by marking their I.D. number on the
upstream side of the weld and on the work side of the pipeline. This I.D. number shall
also identify which pass was done by a particular welder. This shall be done using
the following marking system:
Identification on work side welders shall be above the line and work side welder’s
identification below the line, as shown below.

Pass Identification

1 2 3 4 5 6 7

Work Side Welder’s ID row Ditch Side Welder’s ID row.

Root pass welders shall be the first welders to identify their work, with the ditch side
welder’s ID above the work side welder’s ID, both under the number “1” pass
identification (Bead), see example below.
Hot pass welders shall be the second welders to identify their work, with the ditch
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side welders’ ID above the work side welders’ ID, both under the number “2” pass
identification (Hot Pass), see example below.
Fill pass welders shall be the next group of welders to identify their work, with the
ditch side welders’ ID above the work side welders’ ID, both under the number “3,4,5”
etc. depending on which fill passes were done, see example below.

Pass identification

1 2 3 4 5 6 7

100 102 104 104 106 106 107

101 103 108 108 109 109 110

Welder’s Identification Number Work Side Welder’s Identification Number Ditch Side

All welders’ identification numbers shall be tallied using Welder’s ID Tally Sheet and
recorded in the project database.

8.4 Pipe Tracking Instructions

Unique pipe numbers shall be transferred outside to both ends of each pipe joint on
the project. Identification shall be made by suitable marking using indelible
permanent marking crayons, and marked at the 10 o’clock position on the coating so
it could be read after pipe is laid in the ditch. Identification by stamping shall not be
permissible.

All pipes numbers and pipe length shall be tallied and entered in the Pipe Book,
including pipe measured lengths, diameters, wall thicknesses, grade, heat numbers,
pipe suppliers, bends, etc.

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