TWI-2009-Improved Welding, Inspection and Integrity of Clad Pipeline Girth Welds First Progress Report PDF

18807/5/09
September 2009
Improved Welding, Inspection and Integrity of

Clad Pipeline Girth Welds
First Progress Report
For: A Group of Sponsors

Contents
Executive Summary
Background
Objectives
Work Carried Out
Plan for Next Six Months
1 Introduction 1
2 Objectives 2
3 Benefits 3
4 Work Carried Out 3

4.1 Materials and end preparation 3
4.2 Welding trials 4
4.2.1 PTL contribution 4
4.2.2 Allseas contribution 4
4.2.3 TWI welding trials 4
4.2.4 Fronius welding trials 4
4.3 NOT trials 5
4A ECA trials 6
4.5 Summary of the Work Carried Out to Date 6
5 Plan for the Next Six Months 6
Tables 1-2
Figures 1-5
Appendix A: Test certificates of material supplied by JSW

Appendix B: pWPS proposed for the pipe samples to be made by PTL
Appendix C: NOT work plan to be carried out by TWI and RTD
Appendix D: ECA workplan to be carried out by TWI
18807/5/09 lWI Ltd

Executive Summary
Background
Corrosion resistant alloy (CRA) pipe materials are finding increasing use for the transport of hot and
corrosive fluids in flow lines and associated risers in oil and gas production systems. Although initial
material and installation costs are high compared to carbon steel, significant savings in life cycle costs
can be accrued since corrosion inhibitor injection is not required and inspection and maintenance are
generally reduced. Clad pipe normally comprises a steel pipe with a 2-3mm thick internally clad layer
of CRA material, eg 316L, Alloy 825 or Alloy 625. These materials, although, offering a good balance
between technical suitability and overall material cost, present a number of problems for manufacture.
Several factors conspire to reduce the production efficiency of CRA clad pipeline compared to C-Mn
steel pipe including:
• Reduced welding speeds.

• Sufficient weld metal must be deposited at the first welding station before the internal gas purge
can be safely removed.
• An intermediate inspection must be carried out following the hot pass to ensure that the root weld
is sound, since a weld root repair following completion of the joint is difficult to accomplish in
practice.
This project is intended to address the welding of clad pipelines and there are three aspects which
this work programme aims to cover, namely:
• Welding trials.
• Acceptance criteria and ECA guidelines.
• Development of a more sensitive inspection approach for intermediate inspection of root and hot
pass.
The Sponsor Group currently comprises:
Air Liquide
Allseas Engineering BV
BP Exploration Operating Company
COR US
Exxon Mobil Development Company
The Japan Steel Works Ltd
Petrobras
Pipeline Technique Ltd (PTL)
Rontgen Technische Dienst BV
The total budget for the project including contribution in-kind is currently £700K. The project is
currently partly funded with one more full project Sponsor required to bring the project to fully funded
status.
Objectives
• To reduce root/hot pass completion times.
• To increase overall welding productivity and improvement of girth weld performance by optimising
filler wire and process selection.
• To develop and demonstrate reliable weld inspection techniques of partially completed girth welds
in metallurgically clad pipes.
• To develop a procedure for ECA of girth welds in clad pipelines.
• To develop reliable inspection techniques linked to ECA requirements.
Work Carried Out

Most of the work carried out to date has been in defining the workscope for the project and in the
logistics of transporting, preparing and shipping samples to the interested partners. This activity has
taken slightly longer than originally anticipated but, thanks to the contribution of PTL, has now been
18807/5/09 1WI Ltd

completed. All participating partners have correct pipe samples to enable them to start welding trials
and all are believed to be in progress with work.
lt is planned that welded pipe samples will begin to be delivered to the project within the next quarter.
Plan for Next Six Months
The progress on the project for the next six months will be as shown in the project plan which will be
discussed at the meeting on the 29 September 2009. lt is anticipated that the milestones achieved
within the next six months will include:
• Development of TOPTIG procedures for root and hotpass welds 316L and 625 clad pipes.
• Production of six full girth welded samples for 316L and 625 clad materials to be used for NOT
and ECA work.
• NOT evaluation of full girth welded samples for ECA work.
• Production of deliberate defect samples for development of NOT techniques.
• Baseline testing of supplied girth welds.
• Agreement on supply of X70 pipe for further trials in 201 0.
18807/5/09 TWI Ltd

1 Introduction
Corrosion resistant alloy (CRA) pipe materials are finding increasing use for the transport of
hot and corrosive fluids in flow lines and associated risers in oil and gas production
systems. Although initial material and installation costs are high compared to carbon steel,
significant savings in life cycle costs can be accrued since corrosion inhibitor injection is not
required and inspection and maintenance are generally reduced. Solid CRA pipe materials
contain expensive alloying elements, particularly for the more highly alloyed materials used
in sour environments. Since high strength substrates can be used with CRA clad or lined
pipes, wall thicknesses, material costs and pipeline weight can be reduced when compared
to solid CRA materials. Corrosion resistant alloy pipe materials, both solid and clad, are,
however, more difficult to weld than carbon steel, and lay rates are relatively low for such
pipelines. Today, the relatively high costs of pipeline materials and offshore installation
have limited CRA pipe materials usage to those applications where no technically
acceptable alternative solution exists.
Clad pipe normally comprises a steel pipe with a 2-3mm thick internally clad layer of
CRA material, eg 316L, Alloy 825 or Alloy 625. CRA clad pipes are manufactured in two
forms: metallurgically-bonded or mechanically-lined. Metallurgically-bonded pipes tend to
be more expensive than mechanically-lined, but pose fewer problems during installation
girth welding. Depending on manufacturing route, pipe outer diameters (ODs) range from 6
to 24in, although most application experience to date has involved smaller diameter pipes.
The most common clad pipe girth welding method is to use CRA filler throughout the
complete joint using TIG (GTA) and/or MIG (GMA) welding processes. Several factors
conspire to reduce the production efficiency of CRA clad pipeline compared to C-Mn steel
pipe including:
• Reduced welding speeds.

• Sufficient weld metal must be deposited at the first welding station before the internal
gas purge can be safely removed.
• An intermediate inspection must be carried out following the hot pass to ensure that the
root weld is sound, since a weld root repair following completion of the joint is difficult to
accomplish in practice.
To reduce pipe wall thickness, higher strength steel substrate may be used. Where the
steel strength exceeds that of API 5L Grade X65, the use of Alloy 625 or 309Mo filler
materials may not consistently achieve the required weld metal strength. An alternative
welding procedure using higher strength CRA filler has yet to be established.
Currently, inspection of the fully CRA, coarse grained girth weld volume in clad pipelines is
carried out using AUT. This method typically deploys simultaneously a number of focused
compression angle beam probes, each focused at a through-depth zone in the weld. This
technique is currently deployed on completed welds only. If unacceptable defects are
identified in the root and hot pass at this stage, excavation of the full weld depth is required
for repair. lt is for this reason that inspection is typically performed on the root and hot pass,
before further welding continues. Currently, intermediate inspection of the partially
completed welds is carried out using radiography. The film radiography technique however
is less sensitive to some defect types than the final AUT inspection that is applied to the
fully completed girth weld. Inspection of girth welds in lined pipelines for root and hot pass
is not possible with AUT because of the interface between substrate and CRA liner. Internal
inspection techniques such as alternating current field measurement (ACFM) and eddy
current inspection techniques may be developed for internal inspection of the root and hot
pass in such girth welds.
Due to the dissimilar materials abutting at the weld joint, both radiography and ultrasonic
inspection techniques have limited capability for the detection of flaws at the dissimilar
materials interface. The combined use of AUT and ECA for the development of acceptance
criteria for clad pipeline girth welds is not common; this limitation could have adverse
effects on lay rates. ECA of any component requires a good knowledge of materials and
mechanical properties. For the case of clad pipe, the stress-strain curves and fracture
1880715109 TWI Ltd

toughness of all constituents of the weld need to be determined, along with the stress
intensity factor solution, limit load solution and residual stress state, taking account of the
mismatch in physical and mechanical properties between CRA, weld metal and substrate. A
robust clad pipeline ECA procedure has yet to be established, but will be addressed in this
project for installation/operational stresses up to the specified minimum yield strength of the
pipe.
These limitations in current welding and inspection practice for clad pipelines have
significant effect on installation costs and pipeline integrity. This project will address these
issues through the development of high productivity root and hot pass welding procedures,
the use of high strength filler materials, the development of an ECA approach to defect
sizing and the development of reliable inspection techniques.
There are three aspects which this work programme aims to address namely:
• Welding trials.
• Acceptance criteria and ECA guidelines.
• Development of a more sensitive inspection approach for intermediate inspection of
root and hot pass.
The Sponsor Group currently comprises:
Air Liquide
Allseas Engineering BV
BP Exploration Operating Company
COR US
Exxon Mobil Development Company
The Japan Steel Works Ltd
Petrobras
Pipeline Technique Ltd
Rontgen Technische Dienst BV
The total budget for the project including contribution in-kind is currently £700K. The project
is currently partly funded with one more full project Sponsor required to bring the project to
fully funded status. The project spend data is shown in Figure 1.
Since the last Sponsor Group meeting, Pipeline Technique Ltd have joined the Sponsor
group and are contributing effort in-kind to machine pipe samples and provide welded
samples for ECA and NOT evaluation. Efforts are being made to sign up further Sponsors
and the Sponsor Group will be informed as new Sponsors join.
Fronius are also contributing to the project by developing procedures for welding clad
pipeline material owned by the project with their proprietary cold metal transfer (GMT)
welding system. Fronius do not have the status of a Sponsor and will receive no project
information but will report their results to the project group. However, Fronius would like to
obtain results of mechanical testing pertaining to any GMT welds submitted to the project,
subject to agreement of the Sponsors.
This report covers progress on the project to September 2009.
2 Objectives
• To reduce rooUhot pass completion times.
• To increase overall welding productivity and improvement of girth weld performance by
optimising filler wire and process selection.
• To develop and demonstrate reliable weld inspection techniques of partially completed
girth welds in metallurgically clad pipes.
• To develop a procedure for ECA of girth welds in clad pipelines.
• To develop reliable inspection techniques linked to ECA requirements.
18807/5/09 2 1W1 Ltd

3 Benefits
For those applications reqUinng the transport of hot, sour or highly corrosive fluids,
operators are being driven towards the use of CRA pipeline material for reliability and safety
reasons. The additional pipeline material and installation costs will be justified on the basis
of the risk and consequence of failure rather than on an economic argument. Clearly the
need to minimise the risk of environmental damage and ensuring adequate worker safety
will be paramount. Nevertheless it is envisaged that the project will have a significant
impact on the cost and reliability of clad pipeline installation.
Costs quoted in 1992 for construction (labour plus welding equipment) of a given diameter
pipeline were $250,000/mile for C-Mn steel and $395,000/mile for clad pipe. Whilst 2007
day costs are likely to be much greater, the cost differentials are expected to be similar.
Thus, even a moderate increase in lay rate could have a significant impact on clad pipeline
installation costs.
Specific benefits of the proposed scope of work in this project include:
• Increased clad pipeline welding speed by increasing root and hot pass welding speeds.
The aim of the project is to produce defect free welds with root and hot pass speeds
ranging from 500-1 OOOmm/min using the two candidate processes.
• Reduced installation time and costs. The productivity of a pipeline installation using a
laybarge is often determined by the time at 'bead stall', which is the critical path. By
improving the welding speeds for root and hot pass, the project will aim to reduce the
installation time and therefore the costs.
• Improved integrity of the welded joints. By developing a reliable NOT technique for
inspection of root and hot pass coupled with ECA methodology for developing alternate
acceptance criteria, the integrity of the root and hot pass in the girth weld will be
improved.
4 Work Carried Out

4.1 Materials and end preparation
A number of clad pipeline materials have been supplied by Corus and The Japan Steel
Works Ltd (JSW) for use in the development of welding trials, evaluation of NOT techniques
and ECA work. Test Certificates supplied by JSW to accompany these pipes are contained
in Appendix A. Test Certificates for the material supplied by Corus are still outstanding.
The details of the pipe materials received at TWI are summarised in Table 1.
There is still an outstanding offer of clad X70 material to the project from JSW. This material
may be received in 2010 but is yet to be confirmed by JSW.
Following receipt of the pipe materials at TWI, the pieces were allocated for welding trials.
Subsequent to Pipeline Technique ltd (PTL) joining the project, these were allocated as
follows:
TWI: cut and prepared pieces for welding trials with TOPTIG.
Fronius: cut and prepared pieces for welding trials with CMT.
PTL: samples for girth welds.
Allseas Engineering BV: samples for girth welds.
A summary of the allocation of pipe pieces within the project is shown in Table 2.
The pipe preparation used on all of the samples prepared by PTL is shown in Figure 2. This
is proposed for all samples to be produced by PTL and to be used by TWI and Fronius.
Allseas have a facility for preparing their own pieces for welding. Details of the proposed
Allseas preparation used will be circulated to the group as part of their pWPS data. The
18807/5/09 3 TWI L1d

contribution by PTL to prepare samples is staged to allow modifications to be made at a
later date if necessary with some material being held back.
The pipe ends were prepared by PTL in Aberdeen to a good standard. The pipes did not
appear to cause any particular problems, indicating that the roundness and wall thickness
were relatively consistent. Examples of prepared pipe ends are shown in Figure 3. The
samples were marked so that they could be matched after cutting to adjacent faces
allowing minimum misalignment during welding trials.
4.2 Welding trials

4.2.1 PTL contribution
In addition to PTL preparing materials for use by TWI and Fronius, they are also supplying
girth welded pieces for ECA and NDT trials. Two sets of welded pieces are to be produced
(see Table 2). The preliminary Welding Procedure Specifications (pWPS) for these welds
are contained in Appendix B. lt is intended that these samples will be manufactured in the
next quarter.
4.2.2 Allseas contribution

Allseas Engineering BV will supply a number of welded samples as part of their
contribution. One full girth welded sample has already been completed in metallurgically
bonded clad 20" x 21+3mm 316L material welded with 2209 filler material. This material
has been supplied from Allseas own stock and they have been asked to supply test
certificates for this material and a Welding Procedure Specification. In addition to this,
Allseas have agreed to supply a full girth welded specimen in 625 clad material and two,
root and hot pass girth welded samples containing deliberate defects. lt is anticipated that
these defects will comprise:
1 Concave bead (with crater cracks at stop/starts if possible).

2 Excess penetration.
3 Porosity (root and hot pass).
4 Lack of root penetration (without misalignment).
5 Lack of root penetration (with misalignment).
6 Lack of root fusion (>1 mm).
7 Heavy oxidation of the root (coking).
8 Lack of sidewall fusion on the hot pass (>2mm).
The two defect samples will be manufactured in October of 2009 and there will be
opportunity to review the defects, their method of implantation and size at the Sponsor
Group meeting to be held on Tuesday 29 September at TWI.
lt has been agreed that the sample welded with Alloy 625 will be manufactured subsequent
to this.
4.2.3 TWI welding trials

TWI has been carrying out preliminary trials with the Air Liquide TOPTIG torch at TWI.
Initial trials have concentrated on setting up the torch for welding in the prepared samples
produced by PTL.
The TOPTIG torch used for the trials has been modified by Air Liquide for narrow gap
welding and is shown in Figure 4. TWI trials are ongoing and although some early
preliminary work is expected to be presented at the progress meeting on 29 September
2009, the bulk of this work will be completed in the final quarter of 2009 and presented at
the third Sponsor Group meeting in February 2010.
4.2.4 Fronius welding trials

Although Fronius have declined to join the project as a full Sponsor, they have offered to
carry out welding trials in partnership with CRC Evans to produce welded samples on X65
and X60 samples with their proprietary Cold Metal Transfer (CMT) equipment. Fronius have
18807/5/09 4 1WI Ltd

received prepared samples in Austria and will be carrying out work in the next quarter.
Fronius have offered to demonstrate welding of the samples to interested parties using this
technique and will be allowed limited access to future Sponsor Group meetings to report
their results.
4.3 NOT trials

A meeting was held between Rontgen Technische Dienst BV (RTD) and TWI on 7 April
20o9 to discuss the workplan. A workplan was agreed and this is shown in Appendix C.
As part of this work and after some discussion, it was agreed that preliminary geometry
samples would be best represented by samples actually containing root and hot pass
welds. In order to get initial results, it was suggested that these would be made
longitudinally by TWI. To this end a MAG welded sample was produced with a 2209 filler
and containing a root and hot pass. The sample was inspected visually and by radiography
to assess the quality and this was circulated to the NDT group at TWI and subsequently to
RTD for initial evaluation. A macrosection of the sample made is shown in Figure 5.
The aims of using the longitudinally welded pipe were to:
• Establish implications of the root/hot pass only geometry for UT.

• Investigate use of longitudinal/shear waves for inspection of the root region through
cladding.
• Investigate frequency effects.
• Establish implications of surface curvature for coupling sound into a component.
All initial Phased Array (PA) work was performed in an immersion tank using the Micropulse
system. The P-scan system was used for the Time of Flight Diffraction (ToFD) investigation.
The sample was inspected using two types of PA probe:
• A 5MHz linear array, 32 element, 1mm pitch, active aperture 32mm. This probe is
sensitive to curvature, ie the aperture was excessive. The focal laws assumed that the
surface is flat (ie curvature not compensated for) therefore there is poor beam forming.
In addition, temporal resolution was poor due to the large pulse width.
• A 15MHz linear array, 128 element, 0.2mm pitch, active aperture 12.8mm (only 64
elements used). This probe is less sensitive to curvature, the surface is almost flat.
However, there is possible excessive attenuation within the cladding at high beam
angles.
The inspection setup was complicated by the curved coupling surface presented by the
longitudinally welded specimen. For every position, the settings (wedge angle/focal laws)
had to be updated. In the case of the 5MHz probe, the focal laws could not be optimised
due to excessive aperture/curvature mismatch. The specimen was considered to be 'clean'
lengthwise, but amplitude fluctuations >6dB were monitored in the root/hot pass region
during the l-wave tests.
it is recommended that, since the root/hot pass region is small, the use of high frequency
probes could have the advantages of better temporal resolution to discriminate between
flaws and boundaries, however, attenuation could be severe within the cladding. The
geometry requires the use of high angle beams, hence inspection design must focus on
optimising the sound field characteristics between 55 to 75•. Further investigation of using
shear and longitudinal wave techniques must be performed on girth welded specimens, the
curvature in the longitudinally welded specimen not being present in the actual application.
The sample was also inspected using TOFD, with 1OMHz probes at 45• with a 32.5mm
probe centre separation (PCS).
18807/5/09 5 1W1 Ltd

The results from this inspection clearly show the top of the hot pass and the back wall echo.
The inspection also shows a degree of root mismatch which can be confirmed on the
sample. However, further work will be needed to demonstrate if this technique can
discriminate between flaws and geometric features.
Further work will be carried out on full sized girth welds to be made by PTL and Allseas
Engineering BV. These will include fully welded samples and root and hot pass welds made
with intentional defects.
4.4 ECA trials

The ECA work cannot progress until the welded samples have been made by the partners
in the group but will begin shortly. The plan for the ECA work to be carried out within the
project is contained in Appendix D.
4.5 Summary of the Work Carried Out to Date

Most of the work carried out to date has been in defining the workscope for the project and
in the logistics of transporting, preparing and shipping samples to the relevant parties. This
activity has taken slightly longer than originally anticipated but, thanks to the contribution of
PTL, has now been completed. All participating partners have correct pipe samples to
enable them to start welding trials and all are believed to be in progress with work.
lt is anticipated that welded pipe samples will begin to be delivered to the project within the
next quarter.
5 Plan for the Next Six Months

The schedule for the next six months will be shown in the project plan which will be
presented for discussion at the meeting on the 29 September 2009. lt is anticipated that the
milestones achieved within the next six months will include:
• Development of TOPTIG procedures for root and hotpass welds 316L and 625 clad
pipes.
• Production of six full girth welded samples for 316L and 625 clad materials to be used
for NOT and ECA work.
• NOT evaluation of full girth welded samples for ECA work.
• Production of deliberate defect samples for development of NDT techniques.
• Baseline testing of supplied girth welds.
• Agreement on supply of X70 pipe for further trials in 2010.
18807/5/09 6 lWI Ltd

Table 1 Clad linepipe supplied to the project
Wall thickness Outside Diameter Length

Supplier Identification Specification mm " (mm) m
Corus YBVG2 X65/316L 25.4 + 2.5 24 (609.6) 12
YBVG3 5
YCDG2 X65/309L Mo welded overlay 15 + 3 20 (508) 12
JSW P-10444 X65/316 13 + 3 14 (355.6) 12
P-10450 12
P-20090 X60/625 22.2 + 2.5 22 (558.8) 12
P-20093 12
Table 2 Allocation of pipe pieces throughout the project
Wall thickness Outside diameter Total length

Specification mm " (mm) m Details
X65/316L 25.4 + 2.5 24 (609.6) 12 & 5 Prepped in first batch August 09 by PTL
PTL pipe sample to produce:
2 x 1G full girth welds with 2209
24 prepped pieces 260mm at TWI
18 prepped pieces 390mm at Fronius
X65/309L Mo welded overlay 15 + 3 20 (508) 12 Not currently allocated to trials. Stored at TWI
X65/316 13 + 3 14 (355.6) 12 & 12 2m used for longitudinal trial samples
One 1Om sample at All seas Engineering Delft to produce:
2x 5G samples with intentional defects with 2209
1 x 5G full girth welds with 2209 (material supplied by Allseas)
One 12m length held at PTL
X60/625 22.2 + 2.5 22 (558.8) 12 & 12 Prepped in first batch August 09 by PTL
PTL pipe sample to produce:
2 x 1G full girth welds with Alloy 625
24 prepped pieces 260mm at TWI
16 prepped pieces 390mm at Fronius
All seas 1 x 5G girth weld with AIIQY_ 625
18807/5/09 TWI Ltd

TWI GSP 18807 Clad Pipe GSP Financial Summary
800000
£ OOK
700000
600000
500000
£400000
300000
200000
100000 - Planned spend

-e- Actual Spend
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Oec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
Figure 1 Project spend data for TWI group sponsored project 18807 September 2009
18807/5/09 TWI Ltd

So• .. ,.
P E 1•
R2 +02
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1880715109 TWILtd
a) Image ref HPIM1641
Figure 3 Prepared pipe samples produced by PTL·

a) Whole sample
b) Typical detail of preparation showing preparation ach1eved despite typ1cal out of roundness
associated w1th the longitudinal seam weld region.
18807/5109 TW1 Ud
25mm
Figure 4 Narrow gap TOPTIG torch
18807/5109 lWILtd
Image ref 2009-6-29-10-7-14-002
Figure 5 Macrosection of MAG welded longitudinal sample used for preliminary evaluation of the root
and hot pass JOint geometry by lWI and RTD
18807/5109 TWILtd
Appendix A
Test certificates of material supplied by JSW
18807/5/09 TWI Ltd

CUSTOMER :TWI
USER .-
P.O. NO. .-
P.O. Item No. .-
JSW JOB NO. .-
MANUFACTURING DATA REPORT
ITEM CLAD SAMPLE PIPE
DATE OF ISSUE January 21, 2009
DISTRIBUTION
CUSTOMBR
lfmTKO
JW NY
JW LA
JW DSSD
TOTAL
THE JAPAN STEEL WORKS, LTD.

MURORAN PLANT
DPCUMENT ALE INDEX
CUSTOMER : TWI
USER : -
P.O.No. : -
PROJECT : -
JSWJOB No. : -
Index No. Title ofDocument Page
1 Tally Ust 1-2.
2 Material Test Results for Clad Steel Plate 3-8
3 Inspection Certificates of Clad Unepipe 9-12
@ THE JAPAN STEEL WORKS, LTD. MURORAN PLANT

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Quenchk'lr: 950 - 985.0 X llu'. 0 nm. Water oooled •Dimenalonallnspcctfan:kceptabiD
Te~erin&: 560- 57s-o x 1 hr. 20 min. Nt coo1ad •V'ISUIIInl,oec:tfon :Acceptable
T: Top B: Bottom C: Tral\8\'cnc l: l.onJltudhal Z: Nannal M: 1/2Thlcknen Q: 1/4Thlcknen P: 3/4ThlcJinas Av.: AvnDI S: &rfaeo
YP.: Yield Point Y.S.: 'i",.ld Siren&lh T.S.: Tcn<llo Strena1h El.: Elonption RA: Roduotlon of Area Y.R.: Yield RaUo (0.21): 0.1Sotrsat
(tt.11): D.11£JffGct (0.021): 0.021affset. (Q.SI): 0.51Undor load S.F.: Shear Fracture O.F.: Cfuwp Fr.acture LE: L.ate111l Expans\an TH : Thic1cne11
Q.l.. : G,.,.. Lonoth D : o;amotcr W: Wod!l! LL :Lower Limit U.L : UPOar Limit La~ :Ladle Anolyals Check: Chook And;.;, (f\oocllct Analysb)
B.M.: Bue Metal C.M.: Clad Metal C.P.: Compodto Plrte RT: Room Tcmpcraturo .0: Cfad mete! in tcn5irm sldo +U: Cladllelalln compJeaaiot'l &We
We hereby certify that the material covered by this report moDt the n:quirements herein,
Note 1:Sol.AI fer fadle analysis & Total AI for check anD/sis
Note 2:Chcck analysis of base mabll & dadcfnc metal mako reference to rcpn:sentfltivo p!.to
®
·!m:
Test Rm.tltl : Acceptable
Material Test Results
JRNo.
Customer Plate Job. No.
User Data of flu
Project DoteoiTost
OrdarNo. Item : _ ___,stm,..,..
r...
,._,a,od..,Ste=d.cl'lato='---
JSW Job. Ne : BPNBBO
Heat. No. J&N PO. Ho. Materill Oe;imatlon
ASTM A2&4{5L-X65 + A240 831603)
0705168-14-3)1 • 2. 07 ASTMA2SH3
1188-.49 API5L-X65
Ploto No. : SS633 , SS634· ASTM A24D--0Sa UNS 831603
Thlcknea Width lcnlth WelchtO<I) Quarllty

DlmcnsionCmm> (12.5+25) X 1.079 X 12.400 0 . 1.580 Tot.l : 3.160 2
- -
-
Suo Metal Chemical ..ltlon I)
8emant 02 <3 04 •5
Lodle LL - 2 - -
-2
c Soea. U.L 0.15 0,21 OAO
~ec:k LL - - -
Soco. U.L 0.15
0.051
-
7.71
0,2
0.17
~40
~35
0705168 Cheok B - -- - --
-
~
'::::
!168 ~~
Check - $I
Tendon Ten
Tnt ec!men aze • W: 39.1 G.L: 5D.9
Y.S. T.S. EL YA
~~I)
Pal <MPal 00
449
598
631
-
2 .0
-
-
QSO
•1 : NI+Or+Cu+Mo
111<2:V+Nb+n
03:AI/N
o4:PCf.I=C+SV30tMn/2()t{)u/20+NI/60+Cu'20tMo/15+V/10+5B
OOS:CEQ=C+Mn/8$i>Oul/15«Cr+Mo+V)/5
HntTmtment
Plate & Test sample: Quenchint & Tomparine •Ultrasonic Exmnlnation:Aeceptable
Qucmchlns:: 950 ,., 980•c X 1 hr. 5 min. Wtter cool:ed ·Dimensional Inspection:Acccpbbla
Temocm&: 560- sso·c x 1 hr. 15 mm. Aroooled •Vlsu~ ln$pecllon :Acceotable
T: Top B: Bottom C: Transversa L: l.o~tulinal Z: NOl'I'Nil M: 1/2Thickneu 0: 1/4lhicknes:J P: 3/-4'1bicttnes Av.: A'nrq"e S: Surf•co
YJl.: Yield Point Y.S.: Yield Strantth T.S.: Tensila S1:ren&th El.: Bonptian RA: RedLJCtion of /Vu Y.R.: Yietd Ratio (o.21): o.2JofFset
(D,1J) : 0.11offnt (0.021): 0.021ofbot (0.9): IJ.51Under Load S.F.: Shear FrKture C.F. : CleMip Fracture LE : Uto~l &pmslon TH : Thlcknass
G.L: Gauac l.cnath D : Diameter W: Width LL : l..owar Umi\ U.L: Upper Umit Lade : ladle AnalysTs Check: Cl!eck Anafysls (Product Ana)joc!s)
B.M.: Base Metal G.M.: Clad Metal CP.: Compa.sita Plato RT: Room Temperature •O: Clad metal in tensiM side •U: ctadMtaJ In oomprcsslcnstds
We hereby certify that the ~rn~terial covered by this rtJicrt meet the l'llquirementa: herein.
Note t:Soi.AI for ladle analy$11 & Totll AI for ohack anafv&ls
Note 2:Chcck ana}yals of base metal & cladd"m& metal make refonnce to reprosenbtive plate
Tht Results : Acceptable
.Q. Mana&e.r of InsptctJon Group

V!iP" The Japan StaoJ Worka LTD. Muroren Plant
Contractor :
(' 0 MURORAN PLANT
Company MATERIAL TEST RESULTS THE JAPAN STEEL WORKS LTD
Project
Item NICKEL-BASE AU.OY CLAD STEEL PLATE IR No. : -i;H;::2--f5':::44~2::--::';3-,-;;1:-:::::-:;=:-;:-;-;;;;-
Order No. JSW Job. No. : BP2-3319,BHZ-4004 (HZ2-544Z)
Pipe No. K93
Dimonllion(mm) · ( 215 + 25) X .
1698 .
X 6500
MatsrW ASTM A26S(API6L-X60 + API5LD Gr. LC2262)
Woisbt (kg) • ~ 2 •095 QTY• · 1
Date oflssuo
Date ofToat ..
: Aug. I, 2003
• -;Au-;'g:'-;'1:..;20;;;;0;;3------
Tensile T e s t Chomicel Composition CWt.S)

.Test: 38.1 mm Width , Gauge l.ongth mm
'"
Specification 60.8
I T.S.
,~·)
Y.S. ( Bese MeW) Lodlo Prnduct
( o.ss u.. ) Mo•
Y.S./T.S. - Spec.
\ "
.~.
Test Nb.f.V+TI : .IS max. .08
Heat No. Temp. Bue Co+Ni+c.-+Mo : .60 max. .48
415/656 520 min. 20.0 min. .92 mu.
('C) Metal AJ/N : 2.0 min. 6.3
0305811-3-1
ECB0-3
)1
a;: ~~. 474 -572 53.5 .83
:.:. ( Clad MeW )
Cb+Ta : 3.15/4.16 3.42 3.46
El em 1 t
e.!:~:.a~ ~.
c
..
Si ~p
:~
C h e m I o a
S NI er
-~ ~
C~_s_i_t
~V
= =- -. -= ;: ~
AI
l_o_n_l Wt._~ l_
N~TI
- - - - ~ ,;:~
=
I mu. :::. .:.: .:.
:::. =:::. ~ ·= =
I'\eclftcaticn -
I Cl~~:.al ;!. n:;, -
le~~:wl ;_:
... -1i
max,
-i ~ ¥o -
~:.
l!i
- ~:. -
·~~"ri
- Rer. Ref.
- r:
-
·· ·HeatNo;\
c\:"~~:a1 ~.
max.
~:.
-i-
_,... ~ ~ r!l L!! ~
mas.
~ -~·
-
Rof. -
~!!.
-
--=
I max. Ref.
03D6811
Ladle
.06 .15 1.41 .010 .0004 .28 .03 .02 .15 .030 .026 .0041 .032 .015 .0001 - - - - .36 .16
ECllO
c~:taJ .030 .27 .24 .001 .001 61.80 21.10 - 8.90 - .28 - - .30 - 3.40 .10 3.41 .01 - -
Note)
Prnduot
- - - -
ECllD-3 ~::a] .041 .29 .24 .006 .001 61.18 21.41 - 8.84 - .24 - - .30 - 3.60 .12 3.45 .01 - -
w)J
Quenching : 930 9~ 'ex 45 min. Water cooled Ncte)Product WJalyais make reference Dimensional loapeotlon : Acoeptehle
30 mfn.Alr cool eel to i"epresentatfve Plate VJSUal Inspect!oo : Acceptable
I' , ' .._·,r\1 · s'f'f.'::,
Caq.=C+Mn/&+(N"tfCu)/15+(cr+Mo+Vl/5 Ultrucnic Ehamination : Aoc:aotabla
' Test Result :
-,,, ,j;
Hz~u1.Z.,
,.~~
We hereby certiiY that the material covered by

this raport meet the requlreu:umts d.iscribed hereJn. MIUll.ger o!Jnspaction Group
·o J. s. 1 1
·:
Contractor .' 0 () MURORAN f'L.ANT
Company MATERIAL TEST RESULTS THE JAPAN STEEi.. WORKS LTD.
Project
Item NICKEL-BASE ALLCY CLAD STEBL PLATE IRNo. : H2-5442 -4-2
Order No. JSWJob. No. : BP2-3319,BH2~04 (HZH442)
Pipe No. K98 Material A5TM A265(API5L-X60 + API 5!.0 Gr. LC2252) Date oflssua : ""Aug;=-·:.;1;,:•.;2:;00:;:3,__ _ _ _ __
Dimondon(mm) • ( 215 + 26) X 1698
•
X 6500 . Welsh! Oti) • ® 2 095 .
QTY I .. Date ofTest · Aua I • 2003
Specification Test Spaeimen :

T •
n s I I e
38.1 nun Width •
T ••
t
Gauge l.eDgtb : 50.8 mm
Chemical Composition (Wt. I)
·\_ Y.S. I T.S.

( 0.61 U.L.) Mpa
El.
(I) v.s.rr.s. - ( Base Metal ) Spec. Ladla Product
\
Location Test Nb+V+Ti : .15 max. .OB
Heat No. 11& Temp. Base CU+Ni+Cr+Mo : ,60max. .(7
416/665 520 min. 20.0 m!n. .92 .....
Direction ('C) MataJ ~ : 2.0 min. 6.1
Bottom Room Base
(45 567 51.0 .78
0305834-21-2 Trens. Temp. MataJ ( Clad Metol )
)I
EC4-4 Cb+Ta : 3.16/4.15 3.35
Element c 51 Mn p,
c
s
h •NIm 0i
Cr
I
Cu
• c
Mo
0 m
•V 0 • AII I i
N
0 n (Wt.S )
Nb 1i B Fe Co Cb Ta ea.. Pem
Ladle .12
Base Metal mox.
.45
mox.
1.55
mas.
.015
mas.
.010
mas.
.35 .20
mas. max. mas.
.20 .20
max.
.080
mas.
.010!
.040
.010
max.
.060
mas.
.020
mas.
.0005
mu.
- - - - .38
max.
.21
mas.
~ecification Ladle .10
Clad Metal mas.
.50
mas.
.50
mas.
.015
max.
.015
max.
58.00 20.00/
min. 23.00 - 8.~~
10.00
- .40
mas. - - .40
mas. - 6.00
max.
1.0
mas.
Ref. Ref. - -
Product .12
Base Metal mox.
.45
mu.
1.65
mox.
.015
mas.
.010
max.
.35 .20 .20
max. mas. llllU.
.20
max.
.060
mox.
.010/
.040
.010
max.
.050
max.
.020
mox.
.0005
max. - - - - .38
max.
.21
max.
Heat No\ Product
.11
Clad Metol mox.
.55
mas.
.54
max.
.020
mas.
.020
mas.
58.35 19.80!
min. 23.25 - 7.85~
10.15 - .40
mox. - - .45
mox. - 6.00
mas.
1.0
max.
Ref. Ref. - -
0305834
Ladle
Base Metal
.os .17 1.(3 .011 .0004 .27 .03 .02 .16 .030 .022 .0043 .032 .013 .0001 - - - - .36 .16
EC4
Ladle
Clad Metal
.030 .17 .24 .001 .002 62.30 21.00 - 8.80 - .22 - - .27 - 3.20 .10 3.36 .01 -
Nota)
Product
Base Metal
- - - -
Product
Clad Metal - - - - - - -
He!' Imntmont(PJAtg nnd ThJt IO!Jlule)
Quenching : 930 - 950 ·ex 36 min. Water cooled Note)Product Bn4lysfs mab reference Dimensional lnspacUon : Aecep"ble
Temperina: : 575 - 595 ·ex 1 hrs. 40 min.Air cooled to rop~untat:lvo Plate VLSUaJ Jn~paction : Acceptable
~.Ex.~ Ceq.=C+Mn/6+{NI+CU)/1&t{Cr+Mo+V)/5 UllralonJc Examination : Acceptable
~~ ~·<
R
E
T' V Pcm=C+SV30+(Mn+Cu+Cr)/20+Nl/50+Mo/16+V/10+58 Test Rasult : Ac:ceptablo
• ~:la· E
~
• '0 3.11. 14
•'
~
E We hereby eartHY that the mo.terial covered by .-<-1'.~
this report mut the requirements ctiscn"bed herein. Maoaser o! Inspection Group
Contractor :
n -
n····' MURORAN PLANT
CcmplliiY MATERIAL TEST RESULTS TiiE JAPAN STBEL WORKS I..TO
ProJect
Item NICKEL-BASE AlLOY C!J\D STEEL PLATE lR No. : -;;H;';;2-5~442;;;;';;-;-;;,2-4;:;.-_:;2====r
Order No. J5W Job. No. : BP2-3319,BH2-4004 (HZZ-5442)
Pipe No. K142 Material ASTM A255(API SL-1(60 + API5LD Gr. LC2262) : .;Sep:=.2::6:'-.2;::003::=------
Dete of Issue
Dimension (mm) • ( 21 6 + 2 5 ) X 1 698 X 6 100 Welsbt (ks) · @ · 1 966 QTY · I Dole ofTest
• Sep 23 2003
' ' ' ' '
.Tansfle T a s t Chemical Compos~tlon (Wt.l)
Speclflcation ITest : 38.1mm ~ 3augo Length : 60.8 mm
\... Y.S. I T.S.
~~·, Y.S./T.S. - (Base MeW) Spec. Ladle Product
Test ( 0.65 U.L. ) . Mpa Nb+V+TI : .15 max. .08
Heat No.
\ !Location
& Temp.
("C)
415/565 520 min. 20.0 min. .92 max..
:'~
Cu+Ni+Cr+Mc : .60 milL
AI/N : 2.0 min.
.49
7.4
03D5812-20-2
EC65-6
)2
s;:: ~= 460 670 62.8 .79
::: (Clad MoW)
Cb+To : 3.16/4.15 3.42
: =~ ===
Chemlca Compooltlon(Wt.S)
~m
, .. ~~
.12
,;:. ~ :::. ::. ~- ~:. ~ 1·~~';.' I·=~ - - -
~
-
Geq.
~:.
PC!Il_
.!.
,;:. ::;: - -
~ -i .::. 2~:i~~t I~;,~~ ~.
'\ecificadon ••u
Cl.'t~:tol
*-=-
I
Ref. Ref.
=.!. =
max. min.
a!:~~;.J ~!.
.45 .20
,;: ~~. ~:: 1-~~ - - .;! .!.
~
~- mnx. •040 max.
Heat No.\
C~M~:al :!. max. ,;~. ~::. 15!i~s i;,~~~ - - - .!. ;:. ~~- Ref. Ref. - -
03D5812
s ..':~:t.JI •
06 .16 1.42 .010 .0004 .29 .03 .02 .15 .030 .035 .0047 .035 .013 .0001 - - - - .36 .16
EC66 Cla~:lal .030 .23 .24 .003 .001 61.40 21.10 - 8.90 - .29 - - .29 - 3.80 .10 3.41 .01 - -
Note)
a!:'::::~ - - - -
ii~::a! - - - - - - -
: 930 - 955 ·ex 30 min. Water coolod Note)Product analy>Is make reference Dimensional Inspection : Acceptable
: 675 - ooo ·ex 1 hro. 0 mfn.Air cooled to representative Plate Vlsuallnspec.tion : Acceptable
Ceq.=C+Mn/6+(Ni+Cul/15+{CrtMo+Vl/5
~.
Uhrasanlc Eumlnation : Acceptable
1ll+nR Test Result :
,_..-
We hereby certiCy tbot the material covared by ?'47a-.:>e=
'03. ~.l4
tbl3 report Dlt!et the requirements dlscribed herein, Mana.s:er of Inspection Group
Contractor :
n 0 MURO~N PLANT
Company MATERIAL TEST RESULTS THE JAPAN STEBL WORKS LTD
Project
Item NICKEL-BASE ALLOY CLAD STBI!l. PLATE IRNo. : H2-5442 -2-34
Order No. JSW Job. No. : BP2-3319,BH2-4004 CHZ2-5442)
Pioe No. Kl85 K186 Material ASllol A265WI 51..-X60 + APISLD Gr. LC2252) Date of Issue ; Sop. 12, 2003
Dimenslon (mm) • ( 21 5 + 2 6 ) X .
l 698 .
X 6 lOO Weight (ka) · @ 1 966 .Q1Y • 2 . Date of Test ..
• Sep 6 2003
Tensile T e s t Chemical Composition (Wt.S)

SpecificaUon fTest ; 38.1 mm Width Cause Length 50.8 mm
1\. Y.S. IT.S.
~~-) Y.S./T.S. - (&se Metal) Spec.
: .15 mu.
LscDe Product
\
Test ( 0.51 U.L. ) Mpa Nb+V+11 .08
Heat No. & Temp. Cu+Ni+Cr+Mo : .60 hlax. .49
.
415/565 520 ID!n. 20.0 ID!n. .92 mu.
("C) :-& AI/N : 2.0 min. 7.4
0305812-19-2
BC74-6
)1,2
';::.
=· 448 559
Chemlc_
53.1
_I
.80
C_o D
Baso
Metal
p o s I t I o ( w t ' }
( Clad Metal )
Cb+Te : 3.15/4.15 3.42
=-i=
E le m It c Si p NI Cr Cu V AI N Nb Tl B l'e Co Cb Ta Ceq. Pcm
&s'::.::t& ~- ~:. -!!: -i ::::. ~ ~ ..:.:. ! = ::::. 1-~~

-=~
- - - - ~:. ,;~
: ==
1i- ::. ,;:. -! ..:.:. I~ :.~ ~ ::: ;: ..!!
Lad!•
\"cclficatlon _
Clad Metal ~~:. ,;':. ID!n,
Ret Ref. - -
Heat No
\J§~u:~
~~":~
~~!.
~
.45
..... .:.:.
max.
max. IS!!~ ~~: I

mas.
~:.~~
•040
.;: = max.
~:.
I·=~
:.:. ~-
-
Ref.
-
Ref.
~
-
,;!!.
-
0305812
a..~~~tall •
06 .16 1.42 .010 .0004 .29 .03 .02 .16 .030 .035 .0047 .035 .013 .0001 - - - - .36 .16
EC74 Cl~:tall .030 .34 .26 .001 .001 61.40 21.20 - 8.90 - .30 - - .30 - 3.60 .20 3.41 .01 - -
Note)
a::~":"' - - - -
Cl~~;:ol - - - - - - -
Heat
; 930 - 960 'ex 30 ID!n. Water cooled Note)Produet, analysta make reference Dimensional lnapccUon : Ac:ceptablo
v..uallnspection n:a-
Temperinlf: 576 1>.~s·cx
,:Jir. '1111~
1 hrs. 0 mln.Air cooled to represantative Plate
Ccq.=C+Mu/6+(Ni+Cu)/15'(CrtMo+\?/5 Ultrasonic EsamlnaUon
:
:
Acceptable
Acceptable .
&!
'n•<R Test Result : FP
~ ~!I: .....-:;
"
[V o '
We hereby certifY that the material covered by
this report moot the requlremanta dfscrlbed bereln.
~
Manapr cf Inspection ~up '-..J
03.9.18
!Paao: q
Customer : Material : API 5L-X65 + ASTM A240
P.O.NO. : UNS S31603 "' •n!U-• "'"'·
Item : 14" ORA UNEPIPE(ZONIH)
JSN Job No. : BP6-3BBO
PC. No. : 1o-1
Pipe No. : P-10444
INSPECTION CERTIFICATE OF CLAD UNE PIPE
*Minimum pipe ~~~ for one pipe out of SO jointer pip~
1. Otmenslonai lnsp8ctlon may be 11.0 M.
1-1 Results : B Acceptable 0 Unacceptable
1-2 Datcoflnspecti~on
:~~ Spec.
*
lon&th ±600
1-3 In"'eoted by ~ _ 12200
1-4 JSN DWG. No. • Rev. I Inside SDeo.
Diameter
I Plate No. I SS257

r~-..,w=-=el&flt..,..,.,(t),---,
1.53 I ±1.0
~321.0
Ave.
Mox.
Min.
Outside 1-..21!
Sa:!!'OC."-1-~+...!!..-J.....!:'-~,--i
() ....• ,. .... Diameter -11+5

~353.0
•
e .~~~~~==~~=~~~
"
·~~
I
l "
i
•. ·.+.
TCIJ
"
k---------~-----------x------~··~·~·-~
••
6
'~•• .{.~
~ ..
Out of
-filr Body
1-..21!
RolJndness Max.S.2.
s~
lOO!,_.+...!!..+...!!.-J.....!:'--i~-1
Se!!
" 6 ~ ••••url111 ••l•t ef ttt1l tlllchcn

(l<t.ulll
4 •
Total -1.0/+1.6
Thickness 16.0
2. Hydrostatic Test
Z-1 Applicable Specification No. SP-06232 Spec.
S1nilllrtno., Total
2-2 Date ofTest : Oct. 10, '07 Mox.12.0
2-3 Result : B Aooeotable D Untcccptable Se eo.
Squareness Max.l.S
3. Radioaraphio Examinetion
3-1 Applicable Specification No. SP-Il8235-2
() 3-2 Date of EICaiTiination : OoL 11, '07 Speo.
3-3 Result : B Acccpta~e [J Unacceptable Residuol Max. 20
Mametism Gauss
.<>.&'
3-4 Inspeoted by -:;~,=z.;;:;;;;;~~~·evel- Rl
4. N.D.E. ( UT, d PT )
4-1 Appll ilble SpeciRcatlen No. UT· .. SP-08235-3 5. Martdns 1111d V..ual Inspection
MT···SP-06235-4 5-1 AppUcable Specification No, SP-08232
PT···SP-Il8235-5
5-2 Date of Inspection : ~Oot.~,!-12~·c.!'0~1-=...,,...,--
4-2 Date of Examination :Oct. 11, '07 5-3 Stamp and Stencil : B Gowl 0 NoGood
5-4 Result of VT : B Good D NoQood
-4-3 Temp. during Examination : 18 "C
H Rusuft : B Aoo·e~ble _,..,~Jj;!, IUne<~·table
.-97.--:;:?
5-5 Inspeoted by . -~ :::
4-5 Inspected by ". •n l
11
~
Prepared by
.
® THE JAPAN STEEL WORKS, LTD. MURORAN PLANT
JPaae: (0
Customer : M.terial: API5L-X65 + ASTM A%40
P.O.NO. : - .. --- UNS S31603 ~• on too ··• m•;·
Item : 1~· ORA UNEPIPE(ZONE-1)
JSN Job No. : BPG-3660
PC. No, : ID-1
Pipe No. : P-10450
INSPECTION CERTIFICATE OF CLAD LINE PIPE
*Minimum pipe I~ for one pipe out of 50 jointer pipes
1. Dimensional InspeCtion maybe 11.0 M.
1-1 Results : B Acceptable 0 ~eptable Unit Cmml
1-2 Date of lnsoecdon : Oct. 11 '07
.--:?"
• Spec. Actual
'
~
Length ±600 11,404.0
1-3 Inspected by 12200 ...............
1-4 JSN DWG. N~ Rev. 1 Inside So eo. A B F G
Diameter
I Plato No.l SS633 I I Woi&ht(t)

1.52 I ±1.0
cp 321.0
Ave.
Me >e.
+0.3
+ 0.8
-0.1
+0.4
+0.0
+0.4
-0.1
+0.2
Min. -0.1 -0.8 -0.4 -0.4
Outside Sneo. c D E
.... ..,. ....• .... Diameter -1/+5
+ 1.1 +1.5 +1.2
'\
ed...
</>353.0
Out of So eo. c D E
1. . ;t ..!.!P..: ~
-~
"
Roundness
• Mox.5.2 Z.7 Z.1 3.1
•
•
•
·~ ...
"
,A,
••u ..
~ -i- .
•
Wr Body
Sneo. .,....
t1-b t1-c tl-d
r.···,.....'..!,
4
15.8 15.9 15.9 15.9
b.: laaaurl"r p•l"t •f tortal tlllDIInn 1:2-a t2-b 12-c 12-d
Total -1.0/+1.6 15.9 16.0 16.9 15.8
Thlcknoaa 16.0 .a... t3-b t3-a t3-d
15.6 15.9 15.9 15.6
t4-a t4-b t4-c t4-d
2. Hydrost:atl'c Test 15.7 16.0 15.9 15.8
2-1 Applicable Specification No. SP-06232 Spec. Tolal ......
~
Stniahtne1 Totol
4.0
2-2 Date ofTen : Oct. 10, '07 Max.12,0
2-3 Rosult :B Acceptable D Unac;:ceptable Spec. A G
SQ.uarcnus
Max.1.5
B Good B Gocd
0 No Good 0 No Good
3. Radiographic Examination Locel Spec. End Body
3-1 Applicable Specification No. SP-06235-2 lrTecula-
Max.1.6
B Good B Good
rities D No Good 0 No Good
~
3-2 Date of Examination : Oet. 11, '07 Speo. TOP BTM.
3-3 Ruult : B Acooptablo Cl Ut1a~eptabte Residual Max.20 N s
3-4 fnspacted by
,_ (Level-Ill
Mamotism Gauss 2 8
4, N.O.E. ( UT, MT )
4-1 Applicable Specifimon No. UT.. ·SP-1!6235-3 5. Marklnc and Visual Inspection
MT.. ·SFYIS235-4 5-1 Applicable Specification No. SP-06232.
PT.. ·SP-06235-5
5-2 Drate oflns;~ectlon : OcL 12. '07
4-2 Date of Examination :Oct. 11, 'D7 5-3 Stamp and Stencil : B Good [] NoGood
5-4 Resutt ofVT : B Good 0 NcGood
-
16 "C
....-w:~
4-3 Temp. during Examination :
~-
4-4 5-5 Inspected by
4-5 Inspected by vei-U)
...--, /
~~-~ 1/ ;9/ "'''7·b~
~-~ '''<3(:A:; .. ~~ •
Prepared by
~ THE JAPAN STEEL WORKS, LTD. MURORAN PLANT

... . ....
' [Pa.. : I r
Custcmer Material: API5L-XOO t N'I51.D GR
P.O. NO. : -- LC22&2
!Um : u• ORA ClAD UNE PIPE
JSW Job No. : ...JB~P:.~!-33~1!!9_-:---:---------
Item No. : 1H
Pipe No. :
.. ·~·
. ,.
• IIUN
' .
CEiHJACATE OF CLAD LINE PIPE
1. Dimendonal lnspection
1-1 Results ·: B Accoptabfo D Unaaocptablo Unk(mml
1-2 Data of lnspoct;on : ·.llNl!l"'":·25<:;!·o.!03'2---,:::,-
1-3 lnspocted by • ~..,?/;r...,......, 12,440.0
1-4 JSWDWO.No. ~~ I~llo....• ·Sooc. A B F 0

I LIUIIIII::II.~ Aye. + D.8 + 0.8 + 0,3 + D.3
.~ 1s;- I ·•1-""'w"'•"':""m.---,1 B.F :t:u ,our OF
1!1512.0 'w~ •-• 1.3 1.3 2.7 u
• ., I
IOutside Sooc. 0 D E
111561.4 + 2.1 • l.il + 1.8 "\
JOutof s.... 0 0 E
fw Body Mox.8.4 4.8 2 2.9 '\
Soec. tl-o tl-b tl-o tl·d
~-! 25.2 25.5 25.4
12-. t2-c
lt_otal_ •"-7 2s.s 2s.a
Thlcknel;sJ-<!.71+1.1 t3-o • tO-o
25.3 25.5
2.Hyd~Test
2-1 AppliQiblo Specification No. sp,noco
6.5
2-2 Dato of Teat : Nov. 22, OCI
2-3 Rellllt : B Acceptablo [] Unacceptabls _Spoe. A
3. Radlo.,...hlo Exorn!nation
3-1 Appicab!e Specification No. SP-oto45-2
a-2 Dato of Examination : Nov.25. 03

3-3 Ro1uft
: B ~_/!_~ ~nocC<ptablo
3-4 lmpooted by ~(Leyol-11)
4. ND.E. ( UT, MT and PT)

4-1 Appl!coblo Specification No. UT···SP-il2045-3 5. Mlrldna and VIsual lnspcctJon
MT···SP-02045-4 5·1 Appii!'Oblo Spoc;fication No. - 0
PT···SP-il204H
5-2 cite of Inspection : _,N;oov:;;·27:::;·03:::.,,....=-:.
4-2 Date of Exam~etion :Nov. 25,03 5-3 Stiamp ,;.d Stone~ : B Gocd [] NoGood
5-4 Rollllt c.r'VT : 11 ,Oood,_ ~od
5-6. bi,Peotcdby ~?~
App...od by,
@ THE JAPAN STEEL WORKS, LTD. MURORAN PLANT
L
'!' !··~ ... . -.:..•. ·.• . . ·.·
-- ·:
Pap: ) '}
Cu.tomar : Material:""' 5~-Xeu + APISLD GR
P.O.NO. : ·- I..C2262
Item : 22"' CHA CLAD UNE PIPE
JSW Job No. : BP2-3319
Item No. : ID-2
Pipo No. : P-20093
INSPECTION CERTIACATE OF CLAD UNE PIPE

1. Dimcndonal Inspection
1-1 Results . : B Acceptab:le D Unacceptable Unit(mm)
1-2 Date of lnsJ~ection~.
, 2 03 " Spec. Actual
'
~
lenath •2001+2.50
1-3 ............ by -~~ .;. 12200
1:!.1010
1-4 JSW DWG. No. • C2 ov: Inside S•o• A B ·F a
Diameter
A.,O ±1.8
Ave. +0.8 + 0.1 +D.3 +0.5
Wei&ht(T)
4.3 B,F %2.2
1\512.0 ""'"'
Mtlt 5.1
1.8 1.9 1.1 1.3
Out.ldo s.... c 0 E 1\
•')
'·-
Di111'116let
;6&1.4
+S.41-a.o +2.6 ~1.8 +10
'\
Out of s-.. " 0 E
Rowxlnea
far Body
Max.8.4
Sooc.
4.5
tl-.
u
11-b
3
11-c
'\
tl-d
25.4 w 25.7 25.4
t2-a 12-b t2-o t2-d
-
Tobl 24.7 25.3 25.4 25.5 25.3
Thldaic.s -o.71•1.1 tO-a t3-b 1!-c .._..
25.1 25.2 25.1 25.1
14-b t4-c t4-d
2. Hydrostatic Teat 25.5 25.7 26.8 25.5
2-1 Appnooblo Sooclllcatlon No. SJ>-02040
2-2 Dote ofTost : Nov. 22,03

Scoo.
Total
Max.12.2
Total
8.5 " ~
2-3 Result : 8 AQcaptablo D Unacceptable Spec. A a
SquareNtaa B Good B Good
llu.1.5
D No Good 0 No Good
3. RadioJI'Iphic Examination Loool Spec. End Bodv
3-1 Appfioable Speoilioatlon No. SP-02045-2 m-..,.to- M...0.5
B Good B Good
ritlu 0 No Good 0 No Good·
)
~
3-2 Date of Examlmdlon :Nov. 26.03 Spoc. TOP Bn.t
3-3 R11u!t ResidUIII Mall. 20 N .S
Mamatism • Qaua& 7.0 4.0
3-4 lnsp..,od by
4. ND.E. ( UT, MT and PT)

4-1 Appklblo Specifiearion No. UT•••SP-0204S-3 5. M•rtcinaand VlsuaJ lnspectJon
MT--·SP-02045-4 5-1 Aoollcablo Specific.ttion Ne. ~0
PT···SP-D2045-5
5-2 Date of lnspoction : ~Nov~.~27!:.•.!!032..,~,....,.
4-2 Data of Examination : Nov. 28.03 5-3 Stamp and Stenci : B Qood [] N~
4-3
4-3
5-.1 RosuttofVT
lnsp~dby
: B?Good ~9lood
' .
~:~~~~~~~~~
,, .
4-4 I
G:~:('j ?·
. r··
I . -·.
:.:·;·
~-
.
~r
.l~:...
:_.;
Approved by,
-
~ TliE J""AN STEa WORKS, ~TO. MURORAN PLANT
~--··---~--~-------
Appendix B
pWPS proposed for the pipe samples to be made by PTL
18807/5/09 TWI Ltd

I Proposed pWPSNo: TWI '-u• ovl ~· u·
p j pel j n e lding Procedure

PQRNo:
DATE: ""
18.08.09
Technique Ltd:ification(pWPSJ REV,
,_,
"~~"~""u", "uouuoalic 316L CRA Clad Pipe- 24" X {26 +2.5mm)
~~~~CT """"
: GSPIJIP 18801
WELDING PROCESSES : AUTQ.GMAW
NO. OF WELDING TORCHES : ROOT: SINGLE BUG/SINGLE TORCH. A= Bevel AnA le= 5" +/- 1.0"
HP & FlU: SltG.E BUG/ SINGlE TORCH. l :Land Thickness: 1.5 +f. 0.2rrun 26.0 +
CAP; SINGLE BUG/ SINGLE TORCH. Ex= Extension= 1.0 +/- 0.2mm 2.5mm
JLwe~"'i,'"'~""iffiosrr~~T,;',.-----------~'5G~ROO~T~& ~'"!'!'.!."'!§JI~!!!!!~~~---1 R = Radius= 3.2mm Clad

__ .
;J_--=1_- ~;z..-,.;;,-)i
:DIN OS.F101 Root Gap: 0.0 • 1.0mm
N.l T1DN..t.l COilF ; 2007 EDITION
; APISL. • AST!.I2.W.OS. UNS 531603

: X65 PIPe & 316l CI.AO
TEST DIAMETER (OD!
TEST _WALL THICKNESS
: 609.6nm (241
: 26 Omm CS • 2.5mm Clad
E~r- I
D~ETER RANGE QUALIFIED (ID) : nla
~.---------'~~~~~--------~
~
i
:JO"C(REUOVALOFMOISllJREOHLY)
: 180TOO"C
: PROPANE GAS TORCH Single Pass Cap
BY :DIGITAL THERMOMETER/
~ ~~~=-----------~, : INTERNAL LINE UP ClAMP

)
: ON RUN 2 COMPlETION
: HIGH f>URITY ARGON @20 • 50 Liri'l.
PURITY : IMXIMUM OF 0.5'4 OXYGEN BEFORE WELDING
BACKING GAS REMOVED : ON RUN 2 COMPLETION
r
PI'~E~MOYE~O~F~R~OM~I~.O~WE;L~...:G~S~T~ATIO~,~=~---~''ON~RIO~~ lilli;iiO(fu;<Wi(,.iro~ii$,---j
: I MINIMUM PER STATION
; 1 HOUR MINIMUM (TBQ)
I nu~' AD+~' PASS & FIRST FILL PASS : 36 HOUR MINIMUM (TBO) Number of FUI Passn" TBQ
I;;;;:.~·-·. ROOT &RU<2 OEPOSITE
A'IVO • To Be QuaUn.d.
~.
UP • To Be Confirmld.
I • Top Diad C.ntr+.
IFILI~RIMETo"- MA.NUfACT\JRER SANO~K SAN<MK SB/ ST • SINGLE BUG/
TYPE SINGLE TORCH
(mm) 1.2
(+I·)
COMPOSillON TBC} (%)
(ltrlmin) 25-30 25
VOLTAGE (volls)
j.oVEI<AGEWEUl"G CURRENT (amps)
-:.:~ED SPEED (mlmln)
(cm/min)
5-6 55-6.5
~::TH PO~IT=
(Hz)
ll:L ~ TOO
WELDING·. HEAD ANGLE • TBC, ELECTRODE SPACING FROM TDC • TBQ & DIRECTION OF ROTATION' TOWARDS TDC .
* ~
. THE HEAT INPUTS ARE CALCULATED FROM THE TIP SPEED .
. THE SHROUD CUP DIAMETER =TBQ mm.
4. (S) DENOTES STRIPPER PASS AND MAY BE USED AS NECESSARY.
::0. PREHEATTEMPERATURE MEASUREMENTS MUST BE TAKEN 75mm FROM BEVEL EDGE.
~.INTERPASS TEMPERATURE MEASUREMENTS TAKEN WITHIN 25mm OF BEVEL EOOE.INTERPASS TEMPERATURE TO BE CHECKED BEFORE EACH PASS/ ROTA nON .
. ALL SURFACES OF WELD PREP TO BE CLEANED PRIOR TO WELDING .
. DEMAGNETISATION EQUIPMENT MAY BE APPLIED FOR THE 1ST TWO PASSES WHEN REQUIRED TO REDUCE MAGNETISM TO <20 GAUSS.
!I~ SILICA I SCALE DEPOSITS TO BE REMOVED FROM WELD SURFACE BY SAW BLADE OR FILE BElWEEN PASSES, AS REQUIRED.
~~-WATER QUENCHING AFTER WELD COMPLETION IS PERMITTED FOR AUT PURPOSES, FROM A MAXIMUM TEMPERATURE OF TBQ DEG C.
11. DETAILS OF WELDING EQUIPMENT : POWER SUPPLY, MANUFACTURER, MODEL No., SOFTWARE VERSION= TBQ.
12. FORCED AIR COOLING TO BE QUALIFIED AS REQUIRED.
Test •T"t
~ompooy' Pipeline Technique Ltd. ~ompany: TWiltd
Name' Mark Smith Nam"
Date' 11.08.09 Date'
Sigoed' Sigoed:
1
pWPSNo:
Proposed
pi p e Li n e lding Procedure
PQRNo:
DATE:
!ha
18.08.09
Technique Ltd:ification •ev 1.1
"l'l'""""v" . "UM"dtic 625 CRA Clad Pipe- 22" x (23 +2.5mm)

: GSP/JIP 1S807
: AUTO-GMAW
: ROOT ; SINGLE BUG I SINGLE TORO!, A= Bevel Angle= S9 +/- 1.0°
HP & FILL : SINGLE BUG I SINGLE TORCH. L =Land Thickness= 1.5 +/· 0.2mm 23.0 ...
CAP : SINGLE BUG I SINGLE TORCH Ex., Extension "1.0 +/-0.2mm 2.5mm
R =Radius =3.2mm Clad
Root Gap= 0.0 -t.Omm
: 2007 EDITION
R
: API5L + ASTM
: X60 PIPE & 625 CLAD
: S58.8nm {22")
: 23.1mm CS + 2.5nm Clad
: nla
: 180TBO"C ill
: PROPANE GAS TORCH Single Pass Cap
:DIGITAl THERM~ETERI
TEMPILSTIK
: MACHf.IED
:INTERNAL LINE UP CL.AMP
: ON RUN 2 C~PLETlON
lill~~~~~:!!!_!!~~-----joH~IGH~F\J~RITYARGON@20-501../nWl
: t.IAXII4Jt.l CF 0.5'4 OXYGI:N BEFORE WELDING
ON RUN 2 cot.IPLETlON
1 MINit.IUt.l PER STATION

HOT PASS 1 HOUR MINIMUt.IITBO)
FD..LPASS 36 HOUR MINIMUM ITBQ) Number of Fill Passu= TBQ
To Be Qualified.
a. Confirmed.
I ( c.ntr•.
•SINGLE BUG/
SINGLE TORCH
(mm)
(t /-)
(%)
(ltr/min)
(volts)
(amps)
{mlmin)
(r.mlmin)
TORCH POSITION FOR 1GR WELDING: HEAD ANGLE= TBC, ELECTRODE SPACING FROM TDC = TBQ & DIRECTION OF ROTATION= TOWARDS TDC.
THE HEAT INPUTS ARE CALCULATED FROM THE TIP SPEED.
THE SHROUD CUP DIAMETER= TBQ mm.
(S) DENOTES STRIPPER PASS AND MAY BE USED AS NECESSARY.
PREHEATTEMPERATURE MEASUREMENTS MUST BE TAKEN 75mm FROM BEVEL EDGE.
INTERPASS TEMPERATURE MEASUREMENTS TAKEN WITHIN 25mm OF BEVEL EDGE.INTERPASS TEMPERATURE TO BE CHECKED BEFORE EACH PASS/ ROTATION.
ALL SURFACES OF WELD PREP TO BE CLEANED PRIOR TO WELDING.
DEMAGNETISATION EQUIPMENT MAY BE APPLIED FOR THE 1ST1WO PASSES WHEN REQUIRED TO REDUCE MAGNETISM TO <20 GAUSS.
SILICA I SCALE DEPOSITS TO BE REMOVED FROM WELD SURFACE BY SAW BLADE OR FILE BETWEEN PASSES, AS REQUIRED.
WATER QUENCHING AFTER WELD COMPLETION IS PERMITTED FOR AUT PURPOSES, FROM A MAXIMUM TEMPERATURE OF TBQ OEG C.
DETAILS OF WELDING EQUIPMENT: POWER SUPPLY, MANUFACTURER, MODEL No., SOFTWARE VERSION = TBQ.
FORCED AIR COOLING TO BE QUALIFIED AS REQUIRED.
Pipeline Technique Ltd.

Mark Smith
11.08.09
TWI GSP /liP 18807
Pipeline
Technique Ltd
Proposed CRA Clad Pipe

Welding Procedures
PTM-PRJ-TWI01-GPG-001
1.0 IFR Aug.18.09 MS GH
V er. Reason for Issue Issue Date Prepared by Approved by

• Pipeline TWI GSP /liP 18807
. Technique.Ltd
Proposed CRA Clad Pipe Welding Procedures Page 2 of9
Rev 1.0
This is an electronically generated document, which has been reviewed and approved in accordance with the PTL
Management System. When printed it is considered a FOR INFORMATION ONLY copy, and it is the holder's
responsibility that he 1 she holds the latest valid version. Copying and/or disclosure of the confidential information
contained herein is prohibited without written permission of the proprietor.
TABLE OF CONTENTS
1. INTRODUCTION .............................................................................................. 3
1.1 SCOPE AND PURPOSE ................................................................................ 3
1.2 DEFINITIONS ............................................................................................ 3
1.3 REFERENCES ............................................................................................. 3
1.4 ABBREVIATIONS ........................................................................................ 3
2. TECHNICAL DETAILS ....................................................................................... 4
2.1 SPECIFICATION REQUIREMENTS .................................................................. 4
2.2 WELDING METHODS AND EQUIPMENT .......................................................... 4
2.3 WELDING PROCEDURE QUALIFICATION ........................................................ 4
2.4 WPQ AND WQT FACILITY ............................................................................ 5
2.5 INSPECTION ............................................................................................. 5
2.6 MECHANICAL TESTING ............................................................................... 6
2. 7 DOCUMENTATION ...................................................................................... 6
ATTACHMENT I: PWPS'S ................................................................................ 7
ATTACHMENT 11 : ITP ..................................................................................... 8
• Pipeline TWI GSP I liP 18807
. Technique. Ltd
Proposed CRA Clad Pipe Welding Procedures Page 3 of 9
Rev 1.0
1. INTRODUCTION
1.1 SCOPE AND PURPOSE

Pipeline Technique Ltd have been requested to provide girth welds in CRA Clad
linepipe in connection with TWI GSP/JIP 18807 - Improved Welding, Inspection and
Integrity of Clad Pipeline Girth Welds.
The scope of work to be performed involves the development of welding procedures

typical of current pipeline welding practice and manufacture of test welds. The
completed welds will be used by TWI for fracture mechanics testing and ECA.
Two types of clad pipe have been provided for testing i.e.
Pipe # A0-859 API 5LX60 22" x 25.5mm with alloy 625 clad
Pipe # A0-885 API 5LX65 24" x 28.5mm with 316L alloy clad
It has been agreed that a 5G/1GR procedure will be used to ensure consistent weld
properties around the circumference. Such a procedure would be typical for the
production of double or multi-joints.
The purpose of this document is to describe the welding activities and to propose
suitable welding procedures.
1.2 DEFINITIONS
CLIENT : TWI Ltd
WELDING SUBCONTRACTOR : Pipeline Technique Ltd
SUPPLIER : Nominated supplier of goods or services
1.3 REFERENCES
1.4 ABBREVIATIONS
Abbreviation Description
AUT Automated Ultrasonic Testina
CRA Corrosion Resistant Alloy
CVN Charpy Vee Notch
DPI Dye Penetrant Inspection
GMAW Gas Metal Arc Welding
HAZ Heat Affected Zone
HV Hardness Vickers
ITP Inspection and Test Plan
MUT Manual Ultrasonic Testing
PWPS Proposed Welding Procedure Specification
RT Radiographic Testina
ST/SB Sinale Torch/Single Bug
Pipeline
TWI GSP/JIP 18807
Technique. Ltd
Rev 1.0
VDRL Vendor Document Reciistration List

WPO Weldina Procedure Qualification
WPOR Weldina ProcedureOualificatian Record
WPS Weldina Procedure Soecification
2. TECHNICAL DETAILS
2.1 SPECIFICATION REQUIREMENTS
This proposal is based on welding and inspection being performed in accordance
with the requirements of DNV OS-FlOl with flaw acceptance criteria and target
mechanical properties as per Sections 2.5 and 2.6 of this document.
2.2 WELDING METHODS AND EQUIPMENT

2.2.1 Welding Processes
Mainline welding for both pipe diameters will be performed using the mechanised
GMAW process with a narrow groove and internal clamping.
Single torch techniques will be used as appropriate to the pipe size and run
sequence.
Shielding gas composition will be optimised during initial development test but will
be based on Ar-He-C0 2
Preheating for the purposes of moisture removal only will be by flame heating.
2.2.2 Welding Equipment

Automatic Welding System
The proposed automatic welding equipment is the PTL HALO system.
Pipe Facing Machines

Pipe facing machines will be Tri-Tool Pipemaster or similar and will be i.d. clamping
with special adaption for CRA.
Internal Line-up Clamps

The internal line-up clamps will be combined alignment, clamping and purging.
2.3 WELDING PROCEDURE QUALIFICATION
2.3.1 Welding Procedure Tests
Welding procedures will be qualified in accordance with requirements and the

referenced Specifications.
This will consist of the following:
• Two test welds in 22" x 25.5mm with alloy 625 clad. Filler will be 625.
• Two test welds in 24" x 28.5mm with 316L alloy clad. Filler will be 2209.
• Pipeline TWI GSP I JIP 18807
. Technique. Ltd
Rev 1.0
WELDING SUBCONTRACTOR's proposed Welding Procedures are included in

Attachment I.
2.4 WPQ AND WQT FACILITY

WELDING SUBCONTRACTOR's scope of supply will consist of the following:
Mobilisation and provision of Test Facility inclusive of workshop area, maintenance

and storage area, jigs and fixtures, lifting and forklift loading, cutting equipment,
power and utilities, office accommodation and telephone/fax communications.
Test pipe will be delivered uncoated and the tests will be performed using short test
coupons and not full pipe joints.
Welding plant and equipment will be as follows:

1 x Automatic welding station with 1 No welding bug
1 x PFM to suit pipe size range
1 x ILUC per pipe size
1 x HPU
Consumables and spares as follows:

Spares and consumable parts for above equipment
Welding wire
Shielding gas and distribution
Personnel will include:

1 x Facility Supervisor
1 x Welding Engineer
1 x Welding Foreman/Supervisor
2 x Welders/Operators
2 x Technicians
1 x QC Inspector/Data Recorder
2.5 INSPECTION
2.5.1 Quality Control
The Inspection and Test Plan for the welding programme is included in Attachment
11.
2.5.2 NOT Methods

NDT methods will be as follows for both pipe sizes:
o Visual
o DPI
o RT inspection
2.5.3 Flaw Acceptance Criteria

The flaw acceptance criteria will be as defined in DNV-OS-F101 Tables 04 and DS.
• Pipeline TWI GSP/liP 18807
. Techniqueltd
PTM-PRJ-TWIOl-GPG-001
Rev 1.0
2.6 MECHANICAL TESTING

WELDING SUBCONTRACTOR will perform preliminary checks on mechanical
properties during the procedure development phase of the work, however, formal
testing will be carried out by TWI.
Target properties are given in the following table:
2.7 DOCUMENTATION
WELDING SUBCONTRACTOR's proposed list of documentation for the WPQR includes
the following:
• WPS's
• Joint fit-up reports
• As-run welding data
• NOT test reports
• Equipment calibration certificates
• Pipe certification
• Consumables certification
• NDT personnel certification
• Pipeline TWI GSP I JIP 18807
. Technique.Ltd
Rev 1.0
ATTACHMENT I: pWPS's
TWI GSP/JIP pWPS-625-001 Rev 1.1 (1 Page)
TWI GSP/JIP pWPS-316-001 Rev 1.1 (1 Page)

Technique. Ltd
PTM-PRJ-TWIO 1-GPG-001
Rev 1.0
ATTACHMENT II : ITP
ITP FOR WELDING PROCEDURE QUALIFICATION TEST Rev 1.0
OPERATIONAL ACTIVITY CONTROLLING DOCUMENT ACCEPTANCE CRITERIA RESPONSIBLE VERIFYING DOCUMENT PTL TWI Other
PERSON
1. Review Project document control Specifications are Weld Eng AFC documents R TBA TBA
Specifications procedures/DNV-OS-FlO 1 approved and available
for use
2. Check approved pWPS Proposed Welding Procedures Procedures are approved Weld Eng/QC AFC document R
is available at VDRL N"TBA and available for use at Supervisor
workstation workshop
3. Receive material, Pipe Tracking Procedure Materials are identified Weld Eng/QC Material log and R
check identification, VDRL N° TBA and traceable Supervisor Certification
quantity, sizes and
condition
4. Check welding Welding Procedure Identification present and Weld Eng/QC Certification R
consumable and gas Qualification Testing Manual details conform to pWPS Supervisor
certification, type and VDRL N° TBA
condition
5. Verify welder Welding Procedure Welder is approved and Weld Eng/QC PQR log R
identification Qualification Testing Manual identifier traceable to test Supervisor
VDRL N° TBA welds
6. Verify test coupon Welding Procedure Identification is present Weld Eng/QC PQR log R
identification Qualification Testing Manual and recorded in PQR data Supervisor
VDRL N° TBA sheets
7. Check equipment Welding Procedure Valid, current certificates Weld Eng/QC Certification and register R
calibration Qualification Testing Manual Supervisor
VDRL N° TBA
8. Verify welding Welding Procedure Consistent with pWPS Weld Eng/QC PQR log w
parameters Qualification Testing Manual Supervisor
VDRL N° TBA
Technique. Ltd
Rev 1.0 Proposed CRA Clad Pipe Welding Procedures Page 9 of 9
9. Monitoring of test Welding Procedure Monitoring performed and Weld Eng/QC PQR log w
coupon Qualification Testing Manual recorded Supervisor
VDRL N' TBA
10. Check NDT Technician NDT Procedures Manual for Correct and in-date Weld Eng/QC Valid certificates R
certification WPQT and Test Matrix Certificates Supervisor
VDRL N' TBA
11. Visual, MP! & RT NDT Procedures Manual for Weld meets specified Weld Eng/QC Inspection reports R/H
inspection of weld WPQT and Test Matrix criteria per DNV 05-F-101 Supervisor
VDRL N" TBA Tables D4 and DS
12. Release and dispatch Welding Procedure Correctly identified and Weld Eng/QC Dispatch notes M
to test house Qualification Testing Manual packaged material Supervisor
VDRL N' TBA
13. WPQR Document Welding Procedure All relevant and validated Weld Eng/QC WPQR document R/H
Qualification Testing Manual records included Supervisor
VDRL N' TBA
Appendix C
NOT work plan to be carried out by TWI and RTD
18807/5/09 TWI Ltd

Improved Welding, Inspection and Integrity of Clad Pipeline Girth Welds
TWI Group Sponsored Project
NOT Development Plan
Introduction
Reliable and rapid inspection techniques are required to assess the integrity of the CRA weld
following deposition of the root/hot pass and on completion of the weld fill. The intermediate
inspection is required to demonstrate an absence of defects and a satisfactory internal root profile
before completion of the weld. The inspection of the completed weld is complicated by the dissimilar
nature of the weld joint materials.
Wor1< packages
1) Meeting with RTD to determine way forward for proposed inspection method.
a. Software requirements
b. Instrument requirements
Completion date: 8 April 2009
2) Acquisition of inspection equipment

a. Probe scanning equipment
b. Instrumentation
Action: RTD to assist TWI
3) Identify appropriate flaw types and sizes
Completion date: May 2009

Action: TWI (DSH)
4) Geometry Considerations
a. Manufacture longitudinally welded test blocks from clad pipe to top of hot pass.
b. Ultrasonic trial to plot standing echoes using the following techniques
i. Focused pulse echo (phased array probes)
ii. TOFD
iii. Swept beam pulse echo
iv. Focused TOFD
v. Secondary creeping waves
vi. Consider longitudinal and shear wave propagation
c. Consideration for modelling but without more sponsors this cannot be undertaken
within the program. (RTD to consider the use of their propriety software)
Completion date: July 2009
Action: a. TWI (DSH), b. TWI (BCN) & RTD, c. RTD
5) Realistic weld samples

a. Manufacture completed welds with no intentional flaws. These to be inspected by
RTD to ensure clean welds for the mechanical testing. Inspection to be performed
with the RTD automated inspection system. RTD will also consider the use of
computerised tomography (CT) radiography to inspect the weld samples.
b. Manufacture two sets of welds with root and hot pass for NOT development (one
each for RTD and TWI).
i. One weld with no intentional flaws to further investigate full range of signals
from geometry.
ii. One weld with artificial defects for technique development.
Completion date: December 2009

Action: a. TWI (AIIseas) & RTD, b. TWI (DSH)
6) NOT technique development program

i. Basic trials to identify flaw signals
ii. Develop a method to automatically identify flaw signals.
1. Discuss methodology and analysis algorithm with RTD
2. Propose data analysis algorithm to RTD
3. Assist RTD to write algorithm
iii. RTD to develop inspection software and instrument capable of delivering on-
site inspection algorithm
Completion date: June 2010

Action: TWI (MAS & BCN) & RTD
7) TWI to design test blocks with flaws in critical areas, the signals from which may conflict
with geometric/material interface signals identified at 6), for trials with developed
inspection algorithm.
Completion date: September 2010

Action: TWI (MAS)
8) Perform inspection on welds developed during welding technique using manual data
analysis.
Completion date: October 2010

Action: TWI/RTD
9) Perform demonstration of developed inspection technique on welds manufactured with
developed welding technique containing real flaws.
Completion date: November 2010

Action: lWIIRTD
10) Report inspection methodology
Completion date: December 201 0

Action: lWI
Appendix D
ECA workplan to be carried out by TWI
1880715109 TWI Ltd

18807/4/09
September 2009
Testing and ECA Workscope

Contents
1 ECA Procedure 1
2 Overall Work Programme 1
3 Testing Procedures 1
3.1 General 1
3.2 Tests to be conducted 2
3.3 Hardness testing 2
3.4 Charpy V-notch impact tests 2
3.5 Tensile tests 2
3.6 SENT specimens 3
3.6.1 Crack orientation and location 3
3.6.2 Loading conditions 3
3.6.3 Testing conditions 3
4 ECA 4
5 NOT Defect Acceptance Criteria 4
Table
Figures 1-6
lWILid
1 ECA Procedure
Current procedures for ECA (eg BS 7910, DNV OS-F-101) usually assume the material to
be analysed is homogeneous. R6 (the UK nuclear power industry procedure) and the
European FITNET procedure do, however, address the issue of bimaterial and clad joints,
and in particular the calculation of reference stress solutions for a limited range of crack
types. The project will also draw on the results from TWI's recent internal research work to
develop a general procedure for assessing flaws in girth welds of clad pipes. Particular
attention will be given to flaws located at the fusion boundary and weld root; in particular,
flaws located in the weld rooUhot pass weld metal and HAZ/fusion boundaries of the
cladding and C-Mn steel, where their growth could compromise the integrity of the cladding.
The crack locations to be considered in the ECA are summarised in Figure 1, with priority
being given to embedded flaws at locations 1 and 2, since extension of these flaws would
compromise the integrity of the cladding. The assessment procedures will be based on
installation or service strains of up to 1% strain. Elastic-plastic finite element analyses will
be conducted to provide appropriate calibration factors and verification of the procedures
developed. lt is envisaged that the correction factors derived from FEA will affect the plastic
collapse axis (L) of the failure analysis diagram (FAD) rather than the fracture axis (K or
-.li5r). These factors will probably result in a modification to the reference stress solutions
currenHy given in BS 7910:2005.
The ECA will utilise the fracture mechanics and tensile data obtained from the experimental
tasks (see Section 3 Testing Procedures below) to derive tolerable flaw sizes for the weld
root region and fill for operation at near room temperature. The impact on flaw tolerance for
operation at 150'C will also be assessed.
The flaw sizes predicted by ECA will be considered in designing and assessing the
reliability of the NOT methods.
2 Overall Work Programme

The work programme will be divided into four tasks, as described below:
1 Testing of 'conventional' clad pipe girth welds provided by project sponsors, to obtain
relevant fracture toughness data that can be used in ECAs. This will serve two
purposes:
a) Generation of baseline data, to compare the results with data from the experimental
weld procedures and base metal-filler combinations
b) Validate the suitability of experimental specimen geometries, specifically for testing
the rooU hot pass and clad material.
2 Testing of experimental girth welds produced in the GSP to obtain relevant toughness
data that can be used in ECAs, and compare these with the baseline data generated
under Task 1.
3 Develop an ECA procedure for the girth weld in the clad pipe and perform ECA's
leading to tolerable initial flaw sizes/positions for the different weld geometries and
material combinations tested.
4 Collaboration with NOT to "translate" these flaw sizes in UT acceptance criteria. Note
that the NOT part of the GSP will focus on Phased Array, and therefore the acceptance
criteria will be set-up for this technique.
3 Testing Procedures
3.1 General
Testing procedures for girth welds in clad pipe are essentially based on conventional
methods where ferritic material is assumed to comprise both weld metal and parent pipe.
The differences in work hardening behaviour between the weld metal and parent pipe and
the need to consider the significance of flaws in the root in clad pipe may require a
modification to existing procedures. Fracture toughness testing will be carried out on the full
girth welds and test weldments which have been welded using the CMT and TOPTIG
18807/4/09 lWiltd
processes, see Table 1. The testing program will also include Charpy, tensile and hardness
tests.
3.2 Tests to be conducted

The following mechanical tests will be conducted on the fully completed girth welds. Owing
to size limitations, not all these will be conducted on the partially completed welds.
1 Hardness.
2 Charpy impact.
3 Tensile tests (on base metal and weld metal).
4 Fracture toughness tests (SENT tests, based on DNV RP 108). Testing will include
notching into one or more of the following regions: (see in conjunction with Figures 2-4).
a) Weld material fill
b) HAZ fill
c) Weld material root I hot pass
d) HAZ root I hot pass
e) Clad material weld root
f) Clad material HAZ
Sample welds will be produced in the 2G and 5G positions. Samples produced in the 5G
position will be clearly marked to ensure that mechanical test pieces can be taken from the
highest heat input positions.
3.3 Hardness testing

Hardness tests will be performed in accordance with DNV-OS-F101, October 2007,
Appendix B, Figure 11. One set of hardness measurements will be taken per girth weld to
be tested. In addition, measurements will be made along the weld centerline, from the weld
cap to the root.
3.4 Charpy V-notch impact tests

Charpy specimens will be prepared from the full girth welds and tested in accordance with
DNV OS F101, Appendix B requirements. They will be taken 2mm below the pipe outside
surface. These specimens will be notched at the following locations: Weld metal centre line,
fusion line (FL) and FL + 2mm. A number of Sponsors have indicated that testing the FL +
5mm is unnecessary.
3.5 Tensile tests

Tensile tests will be carried out at room temperature and elevated temperature, using Bmm
diameter all weld metal specimens from the weld fill region (Figure 5). These specimens
may have an oblong cross section to ensure they contain only weld metal from narrow gap
welds. The exact temperature for the elevated temperature trials is yet to be decided.
Originally 150'C was proposed, however, some of the project Sponsors thought this to be
high.
As there will be some difficulty in obtaining valid tensile data from the root weld and clad
area, TWI will use micro-tensile specimens extracted from the clad and root weld area. The
geometry for these specimens is shown in Figure 6. These will be 0.5mm thick, and are
extracted using EDM, to minimise residual stresses arising from machining. The suitability
of this geometry will be investigated during Task 18 outlined in 2 above. Use of thicker
specimens, up to the entire clad thickness, will also be considered.
Sponsors proposed that instrumented hardness testing could possibly be used to determine
tensile properties in place of micro tensile specimens, specifically for areas from which it is
difficult to extract (micro) tensile specimens such as from the root 1 clad. Availability of
proprietary instrumented hardness testing equipment will be investigated by TWI.
In any case, owing to the difficulty in obtaining specimens that only contain weld metal from
the root/hot pass region, conventional Vickers hardness testing will be carried out to assess
18807/4/09 2 lWI Ltd

the degree of softening or hardening of this region compared with the weld metal fill (main
body of weld), to ensure that the actual test specimens are representative.
Specimens will be extracted in both the cross weld direction (weld metal in the centre of the
specimen) and along the weld (all weld metal only).
3.6 SENT specimens

3.6.1 Crack orientation and location
Fracture mechanics testing will be carried out using single edge notch tension (SENT)
specimens prepared and tested to BS 7448: Parts 2 and 4 and DNV RP F108: 2006, as
appropriate. J-integral resistance curves will be obtained using the multiple specimen
method. Surface notched SENT specimens will be employed. The weld metal fill and its
HAZ will be tested using specimens notched from the weld cap as shown in Figure 2. The
weld root region will be tested using specimens notched from the .pipe ID as shown in
Figure 3. However, in order to test the new root microstructure (ie cladding, weld root, weld
metal and HAZ) the notch depth will be less than the minimum permitted by DNV RP F1 08:
200. Consequently, the following options are proposed:
1 Sub-sized specimens will be employed to test the weld metal root/hot pass and the
associated HAZ in the cladding. These specimens will be notched in the through-
thickness direction, as illustrated in Figure 4.
2 Use of very shallow notched SENT specimens, in which the fatigue crack tip ends well
within the clad material. The formulas in the DNV standard will have to be adapted to
interpret these test results.
Use of SENT specimens, which consist solely of representative clad I weld root material
(much thicker than on the actual pipes) was suggested by sponsors. Another suggestion
was to use a clad pipe with a significantly increased clad thickness, which can
accommodate the initial crack and a significant portion of the crack growth. However,
sourcing of these materials is thought to be difficult, and there are questions on how well
these would represent the clad pipe material properties. Because of these difficulties, it is
proposed not to pursue these suggestions further at this time, but concentrate on options 1
and 2 alone.
The validity and practicality of these tests will be established in separate tests on material
provided by TWI. These will take place before the baseline tests on "conventional" clad pipe
girth welds will start.
Following analysis of these test results, a decision will be made on the test geometries that
will be used in the rest of the project.
The use of SENB instead of SENT specimens will also be considered, especially where
insufficient constraint is generated in the latter. This could be a consideration when testing
very thin specimens or very shallow notches.
3.6.2 Loading conditions

Tests will be performed as per DNV-RP-F108, using clamped specimens. A suitable test
set-up will be developed for the clad only sub-sized specimens (see Figure 4).
3.6.3 Testing conditions

The test programme is summarised in Table 1.
A minimum of six tests will be performed per specimen geometry I crack location. Tests will
normally be carried out at ambient/room temperature. However, testing at elevated
temperatures will be carried out on specimens notched into the weld root of whichever
welding process gives the lowest toughness at room temperature.
18807/4/09 3 lWI Ltd

Not all HAZs will be tested. Testing will be targeted at the welding process which produces
the highest heat input in the weld root. On completion of the fracture toughness tests,
specimens will be selected for post-test metallography in order to identify microstructures at
the fatigue crack tip and through which the crack has extended.
Sponsors indicated that in addition to reporting fracture toughness in terms of J-integral,

CTOD should also be reported. TWI will use an in-house method to do this, since current
SENT testing procedures (DNV RP F1 08) do not contain a procedure for doing this.
The testing schedule is summarized in Table 1.
4 ECA
The ECA will be based on the procedures described in BS 7910 and modified using the
FITNET method where this provides useful information on the effect of strength mismatch.
However, for applied stresses exceeding yield, BS 7910 and FITNET procedures may be
non-conservative. Consequently, numerical analyses using finite-element methods will be
employed to generate relationships between applied strain (up to approximately 1%) and
crack tip driving force parameters J-integral and CTOD for specific crack locations and
sizes. Analysis will concentrate on crack locations 1 and 2 as shown in Figure 1, since the
extension of such cracks are critical with respect to the integrity of the cladding. The results
from these analyses will be used to derive correction factors that can be applied to BS 791 0
assessments to ensure that they are conservative but realistic. In order to carry out these
analyses, reliable tensile data, in the form of stress-strain curves, are required for the
parent pipe, girth weld fill and hot pass (root region) and cladding. The required data will be
obtained from the tests described in 3.5 above. Having modified the ECA procedure using
the results from FEA, a series of calculations will be carried out to define maximum
allowable flaw sizes for a range of applied stresses/strains representative of installation and
operational conditions. The fracture toughness data required will be obtained from the
SENT tests conducted (see 3.6 above).
Agreement of Sponsors will be sought before dissemination of the results via a suitable
route, eg incorporation of the results in relevant industrial codes and standards.
5 NOT Defect Acceptance Criteria

The results from the ECA will be 'translated' into UT based acceptance criteria, suitable for
use in conjunction with Phased Array inspection methodology.
18807/4/09 4 1WI Ltd

Table 1 Clad pipe I weld fill combinations for fracture toughness testing
SENT tests
WMat: HAZ at:
Weld Weld
Welding Welding root Weld fill root Weld fill
process process (20°C) (2QOC) (20°C) (20°C)
fill root Material Filler (A) (B) (A) (B) 150°C
(ij Alloy
2 625 Alloy
GMAW GMAW Yes Yes (1) Yes Yes(1) No
"iiien
c:, clad 625
~Qj X65
c: 3: 316L
Q)
> GMAW GMAW clad 309 Yes No Yes No No
c:
,<?. X65
!i) Alloy
en
Alloy
--
"'a.
0
J:
GMAW CMT
625
clad
X65
316L
686
Yes No Q No z
0 Zeron®
e GMAW CMT clad
100X
Yes No Q No z
en X65
"Qj3: Alloy
625 Alloy
]i GMAW TOPTIG
clad 686
Yes No Q No z
c:
Q) X65
E
·;:: 316L
Zeron®
Q)
a.
X
GMAW TOPTIG clad
100X
Yes No Q No z
UJ X65
!i) Alloy
en
625 Alloy
"'
a. GMAW CMT
clad 686
Yes Yes (2) Q Yes (2) z
0J:
_, X70
-w 316L
Zeron®
eo E~
~-=
GMAW CMT clad
100X
Yes No Q No z
en c: X70
"00
- o Alloy
~.2l 625 Alloy
"iiio GMAW TOPTIG
clad 686
Yes No Q No z
cf-
Q)
X70
E
·;:: 316L
Q) Zeron®
a.
X
GMAW TOPTIG clad
100X
Yes No Q No z
UJ X70
SENT testing plan for CTOD/J R-curves:
A See Figure 2
B See Figures 3 and 4
Tests will be conducted on whichever welding process (CMT or TOPTIG) produces
Q
the highest heat input. Tests on the HAZ to include HAZ due to hot pass in C-Mn
steel and HAZ in cladding (using eg sub-sized specimens (Figure 4)
z Tests at 150°C will be conducted on whichever welding process and notch location
gives the lowest toughness at room temperature (20°C)
1 Test GMAWweld fill/ HAZ in X65 material
2 Test GMAWweld fill/ HAZ in X70 material
18807/3/09 lW1 ltd

Weld fin
5
4 \ I Hot pass
2
Cladding 3
1
Figure 1 Crack locations generally to be constdered in ECA
Weld fill HAZ weld f1ll

notch notch
W (=t p1pe)
Cladding
B=2W
Figure 2 SENT specimen conta1ning weld fi I and weld fill HAZ notch
1880713109 TWI Lld

W (=t pipe)
WMrootanl
Claddtng HAZ root and
hot pass notch
hot pass notch
B=2W
Figure 3 SENT spec1mens test1ng the weld root I hot pass region notch and weld root I hot pass HAZ
notch.
WM root and
hot pass notch
WTclad HAZ root and hot

pass notch
B= 2-4 WT clad
Figure 4 SENT specimen clad only contammg weld root I hot pass notch and weld root 1 hot pass
HAZ notch.
1880713109 TWiltd
16 5
~
I
1'.. R10
./
0 M12 Thread
v:
0625
15
05
R2
0625
'
M12 Thread
Figure 5 Tensile specimen geometry for weld fill (dimensions m mm}
I· 35mm ·l I 9mm
J t::=j
- r::- J
!2mm
I
-
-""
r • 3mm
t • 0.5 mm
Figure 6 M1cro tensile spec1men dimensions for clad and weld root only testing .
1880713109
TWILtd
-
16 5
. .
I I
' .R10 •
I
.L
0 M12 Thread
/:
0625
15
05
R2
0625
'
M12 Thread
Figure 5 Tens1le specimen geometry for weld fill (dimensions in mm).
l J
A 5mm
.I
I 9mm
~-----.~-'
1
I
35mm
J
I
I
5mm
f.
I 2mm J _,
-
r•3mm
t=0.5 mm
Figure 6 M1cro tens1le spectmen dimensions for clad and weld root only testing.
1880713109 1WI Ltd

W (=t p•pe)
WMrootanl
Claddrng HAZ root and
hot pass notch
hot pass notch
8=2W
Figure 3 SENT specimens testing the weld root I hot pass region notch and weld root/ hot pass HAZ
notch
WM root and
hot pass notch
WTclad HAZ root and hot

pass notch
8= 2-4 WT clad
Figure 4 SENT specimen clad only conta1mng weld root I hot pass notch and weld root 1 hot pass
HAZ notch
1880713109 TWI Ltd

TWI-2009-Improved Welding, Inspection and Integrity of Clad Pipeline Girth Welds First Progress Report PDF

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18807/5/09

Improved Welding, Inspection and Integrity of

For: A Group of Sponsors

4 Work Carried Out 3

5 Plan for the Next Six Months 6

Appendix A: Test certificates of material supplied by JSW

18807/5/09 lWI Ltd

• Reduced welding speeds.

The Sponsor Group currently comprises:

Work Carried Out

18807/5/09 1WI Ltd

Plan for Next Six Months

18807/5/09 TWI Ltd

• Reduced welding speeds.

1880715109 TWI Ltd

The Sponsor Group currently comprises:

This report covers progress on the project to September 2009.

18807/5/09 2 1W1 Ltd

Specific benefits of the proposed scope of work in this project include:

4 Work Carried Out

18807/5/09 3 TWI L1d

4.2 Welding trials

4.2.2 Allseas contribution

1 Concave bead (with crater cracks at stop/starts if possible).

4.2.3 TWI welding trials

4.2.4 Fronius welding trials

18807/5/09 4 1WI Ltd

4.3 NOT trials

The aims of using the longitudinally welded pipe were to:

• Establish implications of the root/hot pass only geometry for UT.

The sample was inspected using two types of PA probe:

18807/5/09 5 1W1 Ltd

4.4 ECA trials

4.5 Summary of the Work Carried Out to Date

5 Plan for the Next Six Months

18807/5/09 6 lWI Ltd

Wall thickness Outside Diameter Length

Table 2 Allocation of pipe pieces throughout the project

Wall thickness Outside diameter Total length

18807/5/09 TWI Ltd

100000 - Planned spend

18807/5/09 TWI Ltd

Figure 3 Prepared pipe samples produced by PTL·

Figure 4 Narrow gap TOPTIG torch

Test certificates of material supplied by JSW

18807/5/09 TWI Ltd

MANUFACTURING DATA REPORT

ITEM CLAD SAMPLE PIPE

DATE OF ISSUE January 21, 2009

THE JAPAN STEEL WORKS, LTD.

1 Tally Ust 1-2.

2 Material Test Results for Clad Steel Plate 3-8

3 Inspection Certificates of Clad Unepipe 9-12

@ THE JAPAN STEEL WORKS, LTD. MURORAN PLANT

PIPE TALLY LIST

No."~ p~~ INom. Wall Plpo No.

•ASTM Sum of this sheet a.oo z~

B.M. BC 528 615 33.9 0.18 *1:Ni+CrtCu+Mo

Thlcknea Width lcnlth WelchtO<I) Quarllty

Tht Results : Acceptable

.Q. Mana&e.r of InsptctJon Group

Tensile T e s t Chomicel Composition CWt.S)

We hereby certiiY that the material covered by