Provision of provide flow line & OGM construction (068-SC-18)

Welding

2.11.1 GENERAL

All welding activities shall be strictly in conformity with OWNER specifications and detailed
procedures prepared, approved before any welding activities. In the event of a conflict
between these applicable documents, the most stringent one shall be followed.

2.11.2 WELDING PROCESS

Based on pipe grade, size, thickness, etc for this project, we propose the welding processes
for this project as follows:
Welding process will be Shielded metal arc welding process (SMAW).
For welding of trunk line pipes (equal and over 6”), SMAW will be applied downhill; for welding
of flow line pipes (up to 4”), SMAW will be applied uphill.
For welding of pipes at well site and OGMs, GTAW will be applied for welding of pipes up to
2’’, combination of GTAW & SMAW will be applied for welding of pipes over 2”.
All welding of stainless pipes if possible shall be completed by GTAW.

2.11.3 WELDING EQUIPMENT, TOOLS AND SUPPLIES

All welding machines should be checked, serviced and kept in good mechanical condition
during construction period, and welding machines should be made available for accurate
current adjustment.
The ground clamps shall be made non-arcing and shall be placed close to the point of welding
wherever possible.

2.11.4 MAIN WELDING CONSUMABLES

l Storage and handling of main welding consumables such as electrodes,

wires shall be in accordance with approved procedures, each tin or packet
of electrodes or reel of filler wire shall be clearly marked with their respective
batch number.

l Argon gas for gas tungsten arc welding shall meet the requirement of Argon
99.995% as required.

l Necessary records of these welding consumables issued on daily basis shall

be made available for traceability, and record of electrode baking shall also
be made available.

l Adequate drying ovens will be provided and proper precautions shall be

taken in the storage and handling of low-hydrogen electrodes. Before use for
welding, Low-hydrogen electrodes shall be heated in accordance with WPS,
and then they may be stored in 150 degrees Celsius ovens. These electrodes
removed from the 150 degrees Celsius oven must be used within four hours,
those not used within four hours must be returned to be reheated as required.
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l Welding consumables for production welding shall be exactly same as that

for welding procedure qualifications and welder qualification tests.

2.11.5 QUALIFICATION OF WELDING PROCEDURE SPECIFICATIONS ( WPS)

2.11.5.1 previously qualified WPS

Previously qualified WPS that can cover and cater for the welding activities of this project may
be submitted to OWNER for approval prior to WPQT.

2.11.5.2 Preliminary WPS

Preliminary WPS shall be prepared and submitted to OWNER for approval, which shall
include the following information but not be limited to welding process, welding consumables,
base materials, fitting-up tolerance, pre-heating requirements, layers to be deposited, welding
direction, current type, inter pass temperature (maximum)…etc as required by Form QW-482
of ASME IX.

2.11.5.3 Welding procedure qualification testing (WPQT)

l Based on approved WPS, respective WPQTs will be performed accordingly.

Proper quantity, size and kinds of base materials will be selected in full
conformity with applicable specifications and procedures.

l The parameters of qualifications such as current, voltage, travel speed, run out
length interpass temperature shall be monitored and recorded by calibrated
clamp meters or portable arc monitors and digitals thermometers which will form
part of procedure qualification record (PQR).

l After cooling for a minimum 24 hours to ambient temperature, test pieces shall
be subject to visual inspection, ultrasonic testing, dye penetrant inspection,
radiographic testing before destructive tests.

l Destructive tests including Charpy test, Macro section, Hardness testing shall be
fully and strictly in accordance with applicable specification and procedures.

l OWNER can witness all welding procedure qualifications at his own discretion
upon being informed in advance.

2.11.5.4 Approved for construction WPS

Based on welding procedure qualification tests, a welding procedure
specification for construction will be prepared. The complete package of WPSs,
WPQRs and mechanical tests reports shall then be submitted for approval by
OWNER.
AFC WPSs are essential for commencement of production welding.

2.11.5.5 Welding procedure essential variables

Any change to WPS essential variables defined in ASME IX or applicable specification will
result in WPS requalification.
 Provision of provide flow line & OGM construction (068-SC-18)

2.11.6 WELDER QUALIFICATION

All welders to be deployed for this project shall pass welding test in full accordance with
AFC WPSs. Any change to essential variables listed in ASME IX shall result in qualification
of the welder.
Qualification tests shall be in compliance with ASME IX.
OWNER can witness qualification tests at his discretion upon being informed in advance.

2.11.7 PRODUCTION WELDING

All welders shall only perform welding activities strictly covered by the AFC WPSs in
accordance to which they are qualified. AFC WPSs shall be strictly complied with.

2.11.7.1 Pipe cutting, beveling and cleaning

a) Where pipes or fittings of unequal wall thickness are to be welded, the ends shall be
processed in conformity to the end preparation shown in ASME IX.
b) All field bevels shall be cut evenly and the land finished at right angles to the longitudinal
axis of the pipe without rough surface.
c) All the bevels shall be clean from dirt, mill scale, tears, cracks, gouges ,etc which might
affect the weld quality.
d) Pipe with length less than 2 times the outside diameter shall not be used.

2.11.7.2 Fit-up and alignment of pipe

For fit-up of pipes with wall thickness less than 6mm, the misalignment shall be less than 12.5
percent of the wall thickness, while the maximum internal misalignment shall be 1.5mm.
For trunk line fit-up, self-made external clamp will be used.

2.11.7.3 Tack welding

Tacking welding shall be done in accordance with the root parameters of WPS for this joint.
Tacking welding shall be at least 25mm in length and shall be spaced around the
circumference with sufficient number to make pipe or fitting firm, and they have to be ground
to a feather edge prior to start of root pass welding.
When GTAW is applied, ends of pipe spools should be blocked to prevent wind from going
through the pipe spools.

2.11.7.4 Pre-heating

Pre-heating will be applied by specially designed gas torches. As a minimum, joints shall be
heated to remove moisture prior to welding.

2.11.8 ARC STRIKES

Arc strikes shall be avoided outside the weld bevel. Should arc strikes occur outside the weld
bevel area, they shall be removed by grinding and inspected by magnetic particle examination
to ensure freedom from cracks. The remaining wall thickness shall be checked by ultrasonic
 Provision of provide flow line & OGM construction (068-SC-18)

testing. Materials below the minimum required thickness shall be replaced, and no repair
welding in this regard is permitted.

2.11.9 WELDING ENVIRONMENT

In the event of adverse weather impairing welding activities, proper measures shall be taken
such as windshields or enclosed welding stations to prevent strong winds, sand or dirt
particles. In case of heavy humidity or raining, welding will be not performed. After each weld
pass, all slag and scale must be removed prior to laying down another pass.

2.11. 10 TIME OF FINAL INSPECTION AND NDT

Final inspection and NDT of welds not subject to heat treatment can be performed as soon
as the weld has cooled down to ambient temperature.

2.11.11 NON- DESTRUCTIVE INSPECTION AND TESTING

Inspection and testing of welds including visual examination, radiographic inspection,

ultrasonic inspection, magnetic particle inspection, dye penetrant inspection shall be strictly
and fully in conformity with OWNER specification and approved NDT procedures, and extent
of NDT shall also be strictly and fully in conformity with OWNER specification and approved
procedures.

2.11.12 WELDING RECORDS AND DOCUMENTATION

Throughout production welding, up-to-date welding log & records shall be made available on
daily basis, they are including weld number, pipe size, material grade, spool number, isometric
drawing reference, WPS reference, welder number, NDT report numbers, repairs and re-
welds records, etc.
Welds traceability shall be fully and effectively ensured.

2.12 Nondestructive Testing

It shall be noted there are two applicable standards, one is ANSI B31.4/API1104, another is
ANSI B31.3, will be adopted according to this ITB and specifications, so the NDT inspection
extent and standard will be deferent for pipelines (flowline and trunkline) and process pipings
(well sites pipings and OGM pipings). The X-Ray detecting rate for pipeline welds will be
100%, and it shall be 5-10% or according to the instruction of third party supervisor for piping
welds.
Radiographic examination of welds will be provided in accordance with the specifications and
approved examination procedures. Such examination will be performed by a qualified third-
party nondestructive testing (NDT) inspection company. It is expected that X-ray, ultrasonic
detection and other Nondestructive Testing methods will be utilized.
We will set up one NDT laboratory as well as NDT testing crews in our main camp at Adar.
The NDT testing crew will examine the Pipeline production welds to evaluate the weld quality
as soon as the weld is completed (after 24 hours). The pipeline NDT crew will utilize external
X-ray detectors to examine the girth welds. The examination results from each weld inspected
will be sent to the NDT laboratory then processed and interpreted immediately so that results
can be obtained in the timeliest manner. An independent testing crew will be used on all
process piping welds, tie-in and repair welds. This crew will also be assigned to any special
 Provision of provide flow line & OGM construction (068-SC-18)

crossing point that may be responsible for welding individual crossing sections. The results of
the inspection of these welds will be completed at the NDT laboratory.
The Client’s representative will be provided with free access to examination processing
facilities at all times.

2.13 Field Joint & Repair Coating and insulating

Contractor will be responsible for coating all the pipe joints and any other locations as required
ensuring complete protection of the buried pipe.
According to the ITB, there are two type of line pipes, one is non-insulated (3PP coated) pipe,
another is insulated pipe. So the coating methods of field joint & repair part will be different.
For the non-insulated pipe, Field Joint & Repair coating will be as per DIN 30678 ITB.
For insulated pipe, Field Joint & Repair coating and insulation will be 3PP coating + Calcium
Silicate or Glass Fiber or Cellular Glass insulation + Heat Shrink Sleeves (HSS) protecting
layer. The method of 3PP coating construction is the same for non-insulated field joint. The
layer will be adopted by two polyurethane half shells for weld joints, length of polyurethane
half shell shall be more than 0.5m, and the thickness of the polyurethane half shell will be
same as the parents pipe, The thickness of HSS coating will be at least 2.25mm. The width
of HSS shall be more than 600mm. and the sleeves shall be wide enough so as to overlap
onto mainline coating by a minimum of 50mm on each side of the weld joint once installed.
Before doing the field joints coating or insulating, contractor will submit the procedure for
OWNER approval.
Field joint insulation and any insulation damage repair will be in accordance with the
specifications, manufacturers recommended procedures and procedures approved by
OWNER based on ITB. The thickness of Joint or damage insulation shall also be 25mm/38mm
(as per design) and external protection shall be qualified Heat Shrink Sleeves vapor barrier.
Heat shrink sleeves shall be designed for temperature up to 85 degrees Celsius for Mug-lad
Basin Oil Development FSF pipelines. The installation of heat shrink sleeves will be in
accordance with the specifications, manufacturers recommended procedures and procedures
approved by OWNER based on ITB.
The coating of field joints or damage repair shall be at least as equal in effectiveness to the
coating applied over the main body of the pipeline. All such field joints and repairs must be
inspected with the holiday detector in the presence of Owner’s representative.

Backfilling of pipeline trench shall not be performed until weld joint to be completed with the
coating and insulation.

2.14 Lowering-in, Padding and Backfilling

The welded and coated pipe will be lowered into the trench by side boom tractors equipped
with roller pipe cradles. The pipe will be inspected with a holiday detector prior to lowering-in.
All damaged coating will be repaired and the repair will be re-inspected. Prior to lowering-in,
the trench bottom will be padded, where necessary, with suitable excavated backfill material.
Should the backfill material not be suitable then the backfill material will be made suitable by
the use of the “Ozzie Padding Machine”. All material used for backfill shall be of an acceptable
quality free from large lumps, wood or other extraneous materials. In particular, backfill in
contact with pipe shall be entirely free from stones, rocks or boulders.
Once the lowered-in pipe has been placed in the bottom of the trench and the as-built survey
has been made, the pipe will be shaded with suitable excavated backfill material utilizing an
auger back-filler. After the pipe has been shaded, backfilling of the trench will then be
 Provision of provide flow line & OGM construction (068-SC-18)

completed in accordance with the specifications utilizing dozers and backhoes for most
sections. Where required on steep slopes, trench barriers will be installed in the trench prior
to backfilling. Trench barriers will be in accordance with the Project typical drawings. The
lowering-in crew will also install prefabricated set-on weights in areas where such weights are
used as a buoyancy control technique.