3 QATAR GENERAL PETROLEUM CORPOKATION SPECIFICATION FOR THE FABRICATION, INSTALLATION AND ERECTION OF STEEL STRUCTURES AND STRUCTURAL STEELWORK QGPC ES-S-20 REVISION | 0 ISSUED LAST UPDATE NONE COMPILED BY ENC/3 F[s/o%. TEVS LLG -jfafas | CHECKED BY EN — ¢ kf ¢9 = pbafee) LP Aire APPROVED BY | DT. Rear COPY N°(Fe * QATAR GENERAL PETROLEUM COKPORATION | (Oil & Gas Operations) PART A -OFFSHORE STRUCTURES PART B-MINOR OFFSHORE STRUCTURAL STEELWORK | PART C-ONSHORE STRUCTURAL STEELWORK Sak cine orniet a E5-S.20 Page i REVISION!PART A 1.0 ie | 1.2 13 16 15 | 16 2.0 2 ' 0) 3.0 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) )FFSHORE STRUCTURES INTRODUCTION SCOPE FABRICATION Workmanship Personnel Materials Substitutions & Modifications 2.5 Errors and Omssions bie 1. 1 1 1 1 LANGUAGE AND UNITS QUALITY ASSURANCE. PROCEDURES General Document Submission ABBREVIATIONS CODES AND STANDARDS RULING CODE REFERENCED SPECIFICATIONS AND STANDARDS MATERIALS GENERAL STRUCTURAL STEEL OTHER MATERIALS CONTRACTOR SUPPLIED MATERIAL EMPLOYER SUPPLIED ITEMS (WHERE APPLICABLE) MARKING OF STEEL TRANSPORTATION AND HANDLING ES-S.20 Page ii RFVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 4.0 FABRICATION AND ASSEMBLY 9 41 GENERAL 9 42 PREPARATION OF MATERIALS 9 4.2.1 Marking of Components 9 4.2.2 Preparation 9 43 ATTACHMENTS 10 44 FORMING OF TUBULARS 10 | 4.5 SPACING OF SEAMS AND SPLICING IN TUBULARS 10 | 45.1 Spacing of Welded Seams - Nodes 10 | 45.2 Spacing of Welded Seams - General Assembly u 46 SPLICES IN PROFILES AND GIRDERS u 47 CONNECTIONS 2 421 Tubular Connections 2 4.7.2 Sloued Members 12 4.73 Welded Connections 2 48 FABRICATION DETAIL 2 4.8.1 Sealings 2 4.8.2 Temporary Cut Outs 2 4.8.3 Copeholes 13 9 5.0 FABRICATION TOLERANCES MM Sa GENERAL 14 5.2 LOCAL TOLERANCES FOR STRUCTURAL COMPONENTS. 4 5.2.1 Fabricated Tubulars 14 5.2.2 Plate Girders 16 5.2.3 Alignment and Fit-Up Tolerances 17 53 GLOBAL TOLERANCES FOR THE COMPLETED STRUCTURE 18 = 5.3.1 Jacket, Deck and Module Columns and Legs 18 5.3.2 Module and Deck Members 18 5.3.3 Jacket Structure 18 534 Pile Guide Tolerance 19 5.3.5 Conductor Guide Tolerance 19 ES-S.20 Page iii REVISIONfas (Oil & Gas Operations) 54 MISCELLANEOUS TOLERANCES 19 5.4.1 Bearing at Point of Loading 19 5.4.2 Deck Plate and Grating 19 5.4.3 Landings and Stairways 19 5.4.4 Fencing and Handrails 20 5.5 PILING 20 6.0 WELDING 2 6.1 GENERAL 6.2 WELDING PROCESSES 63 WELDING CONSUMABLES 6.4 WELDING PROCEDURE QUALIFICATION 6.5 WELDING PROCEDURE SPECIFICATION 6.6 ESSENTIAL VARIABLES & EXTENT OF APPROVAL 6.7 TEST CATEGORIES 6.7.1 a) Plate, Section and Tubular (greater than 610mm NPS) Bunt Welds 26 6.7.2 b) Single Sided Tubular Butt Welds %6 6.7.3 ©) T-Butt Welds 26 6.7.4 ¢) Fillet Welds 26 6.7.5 ¢) Tubular Intersections (T, K and Y joints) 27 6.7.6 2) Weld Metal Buttering 2 6.7.7 g) Repair Welds a 6.8 PROCEDURE QUALIFICATION TESTING 27 68.1 General 2 6.8.2 All Weld Tensile Test 28 6.8.3 “Cross Weld Tensile Tests 28 6.8.4 Bend Tests 28 6.8.5 Macrosection and Hardness Tests 29 6.8.6 Charpy V-Notch Impact Tests 29 69 TEST ACCEPTANCE CRITERIA 28 : 6.9.1 NDT Resulis 29 6.9.2 All Weld Tensile Test 29 6.9.3 Cross Weld Tensile Tests 29 6.9.4 Bend Tests 29 6.9.5 Macrosection and Hardness Tests 30 6.9.6 harpy V-Notch Impact Tests 30 6.10 THERMAL CUTTING PROCEDURE QUALIFICATION 30 ES-$.20 Page iv REVISIO®QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ES-S.20 | WELD PROFILING PROCEDURE QUALIFICATION 30 | DOCUMENTATION 31 70 QUALIFICATION OF WELDER's & WELDING OPERATOR's 2 aa GENERAL 32 aie Qualifications Required 32 712 Witness and Approval of Tests before Welding 22 713 Welder Identification System 22 TA Marking of Welds 22 as Welder and Welding Operator Records 33 72 WELDER QUALIFICATION CATEGORIES 33 man General 3 | 722 Qualification Categories 33 | 73 TEST PIECES 34 14 EXAMINATION AND TESTING 35 75 ACCEPTANCE LEVELS 35 7.6 ARC-AIR GOUGERS QUALIFICATION 35 8.0 PRODUCTION WELDING 36 8.1 GENERAL 36 8.2 WELDING EQUIPMENT 36 8.3 STORAGE AND HANDLING OF CONSUMABLES 36 8.4 WELDING SEQUENCE 38 { 8.5 WELD JOINT PREPARATION 38 8.6 WELD EXECUTION 38 8.6.1 Workmanship 38 8.6.2 Tack Welds 39 8.6.3 Fillet Welds 39 8.7 ARC-AIR GOUGING 39 8.8 WELD PROFILE AND SURFACE FINISH 40 8.9 WELD INTERRUPTION 40 * 8.10 WEATHER PROTECTION 4) 8.11 PREHEATING AND INTERPASS TEMPERATURE 4l 8.12 POST WELD HYDROGEN DIFFUSION TREATMENT 42 8.13 POST WELD HEAT TREATMENT 42 8.14 WELD REPAIRS 45 Pare ¥ RFVICIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 47 9.0 STRUCTURAL WELDING oA GENERAL 47 9.2 SURFACE AND EDGE QUALITY 47 9.3 WIDE ROOT GAPS a 9.4 WELD OVERLAPS 49 95 COMPATIBILITY OF WELDS 49 9.6 CONTROL OF DISTORTION AND SHRINKAGE 4 9.7 DISTORTION CORRECTION 49 | 9.8 WELDING POSITIONS 50 9.9 TEMPORARY BRACINGS AND SUPPORTS 50 9.10 REMOVAL OF TEMPORARY ATTACHMENTS 50 | 9.11 INSTALLATION OF BAR GRATING 51 | 10.0 INSPECTION AND TESTIN' 52 10.1 GENERAL 32 30.2 STAGES OF INSPECTION 33 10.3 EXTENT OF INSPECTIOY 4 10.4 ACCEPTANCE CRITERIA 54 10.4.1 General 34 10.4.2 Definitions 54 10.4.3 Acceptance Levels 54 10.5 ADDITIONAL NON DESTRUCTIVE TESTING 55 10.6 NDT TECHNIQUES AND QUALIFICATIONS 56 10.7 PRODUCTION TEST PLATES 56 11.0 SURFACE PREPARATION AND COATING SYSTEMS 37 12.0 BOLTING 38 GENERAL 58 PREPARATION 58 ASSEMBLY 58 13.0 WEIGHT CONTROL 59 13.1 SCOPE 59 13.2 PURPOSE, 59 33 DEFINITIONS 59 13.4 CONTROL DURING FABRICATION 6 13.4.1 Weight and C of G of Facility 8 13.4.2 Weighing Certificate 65 ES-$-20 Page vi REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 14.0 LOAD-OUT. SEA FASTENING AND TRANSPORTATION 66 141 GENERAL 66 14.2 LOAD-OUT 66 14.3 SEA-FASTENING 66 14.4 TRANSPORTATION 67 14.5 INSURER's APPROVAL 6 15.0 INSTALLATION 68 15.1 GENERAL 68 15.2 REFERENCE STANDARDS 6 15.3 SETTING THE JACKET 68 15.4 ON BOTTOM STABILITY 6 15.5 PILING 6 15.5.1 General 69 15.5.2 Driveability and Pile Hammer Suite ro 15.5.3 Pile Make-Up 70 15.5.4 Stabbing of Piles 0 15.5.5 Pile Penetration a 15.5.6 Pile Driving Refusal Criteria a 15.5.7 Damage a 15.5.8 Pile Acceptance Criteria a 15.5.9 Pile Installation Contingencies n 15.5.10 Grouting 2 15.5.11 Pile Installation Documentation B 15.5.12 Jacket Leg/Pile Shimming and Welding 4 15.6 INSTALLATION OF DECKS AND APPURTANCES "4 15.6.1 General 4 15.6.2 Installation of Decks 4 15.6.3 Boat Landings 5 15.6.4 Field Installed Walkways and Handrails 8 15.7 INSTALLATION TOLERANCES 78 15.7.1 Jacket 6B 15.7.2 Deck and Appurtances 15 15.8 WELDING, INSPECTION AND NDT PROCEDURES 16 15.9 MOVEMENT AND ANCHORING OF VESSELS 16 15.10 DIVING OPERATIONS 6 ES-S-20 Page vii REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 16.0 AS-BUILT RECORDS AND DRAWINGS 7 16.1 GENERAL 77 16.2 AS BUILT RECORDS 77 16.3 AS BUILT DRAWINGS 78 16.4 DRAWING STANDARDS Ie FES-S-20 Page viii REVISIO:- QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 6.81 WELDING PROCEDURE QUALIFICATION TEST REQUIREMENTS — 80 TABLE 8.81 ACCEPTANCE LEVELS FOR NON DESTRUCTIVE TESTING 82 TABLE 10.3-1 EXTENT OF NON DESTRUCTIVE TESTING 84 REVISION ES-S-20 Paze ix.QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) FIGURE 4.5-1 WELD SEAM LIMITATIONS 88 FIGURE 5.2-1 OVALITY TOLERANCE 89 FIGURE 5.22 OUT OF ROUNDNESS TOLERANC! 90 FIGURE 5.2-3 END PERPENDIXULARITY TOLERANCE, 1 FIGURE 5.2-4 PLATE GIRDER OUT OF STRAIGHTNESS TOLERANCE 92 FIGURE 5.2-5 PLATE GIRDER CROSS SECTIONAL TOLERANCES 93 FIGURE 5.2-6 JOINT MISALIGNMENT TOLERANCE 94 FIGURE 6.7-1 QUALIFICATION TESTS FOR TUBULAR INTERSECTIONS 9s FIGURE 6.8-1 TYPICAL LOCATION OF TEST SPECIMENS FOR PLATE 96 TEST PIECES FIGURE 6.8-2 TYPICAL LOCATION OF TEST SPECIMENS FOR 7 TUBULARS AND FILLETS FIGURE 6.8-3 LOCATION OF HARDNESS INDENTATIONS 98 FIGURE 6.10-1 | LOCATION AND NOTCH POSITION FOR WELD METAL 99 AND HAZ CHARPY V-NOTCH SPECIMENS FIGURE 610-2. | NOTCH POSITION FOR HAZ CHARPY V-NOTCH SPECIMEN 100 ES.5-20 Page x REVISION~ QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) MINOR OFFSHORE STRUCTURAL STEELWORK | 3.0 INSHORE STRU STEELWORK To be added at a later date a Page x REVISION ES-S-20—_ _ ‘*. PETROLEUM CORPORATION is & Gas Operations) a Ine the requirements for structural fabrication, erection, Sion, installation, materials, welding and inspection of 1d appurtenances for offshore platforms for QGPC (Oil 2DNTRACTOR 4 materials, workmanship and inspection conform with | cation and shall supply all materials, labour, tools, | to accomplish this task. ily experienced supervisory personnel in cherge of all loy only fully experienced craftsmen to carry out the 23 inspection, non destructive testing and corrosion £4 shall be the responsibility of the CONTRACTOR 2 requirements of these specifications Substitution of materials and/or modification of details NTRACTOR shall submit, in to the EMPLOYER for approval. insible for all errors and omissions in the detailing, ation of the CONTRACTOR to check the documents *LOYER of any errors or omissions, sed this shall mean approved by the re No other person or ‘Persons shal] ony; Standards/*codes of practice, specifications orQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) jp ” Part A OFFSHORE STRUCTURES INTRODUCTION SCOPE ‘The following Specifications define the requirements for structural fabrication, erection, loadout, seafastening, transportation, installation, materials, welding and inspection of jackets, decks, modules, piles and appurtenances for offshore platforms for QGPC (Oil ‘and Gas Operations). RESPONS! OF THE CON’ R Workmanship The Contractor shall ensure that all materials, workmanship and inspection conform with the requirements of this Specification and shall supply all materials, labour, tools, equipment and services necessary to accomplish this task. Personnel The CONTRACTOR shail have fully experienced supervisory personnel in charge of all aspects of the work, and shall employ only fully experienced crafismen to carry out the work. Materials The checking, preparation, fabrication, inspection, non destructive testing and corrosion protection of all materials to be used shall be the responsibility of the CONTRACTOR and shall be in accordance with the requirements of these specifications. Substitutions and Modificati ‘The CONTRACTOR shall make no substitution of materials and/or modification of details without the prior approval of the EMPLOYER. The CONTRACTOR shall submit, in writing, all such proposed-changes to the EMPLOYER for approval. Errors and Omissions The CONTRACTOR shall be responsible for all errors and omissions in the detailing, Jayout and fabrication. It is an obligation of the CONTRACTOR to check the documents and drawings and to notify the EMPLOYER of any errors or omissions. Where the Term "or equivalent approved” is used this shall mean approved by the EMPLOYER or his nominated authorised representative. No other person or persons shall have the authority to deviate from any standards, codes of practice, specifications or materials specified in these standards. ES-S-20 Page 1 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 1.4 1S 1.5.1 LANGUAGE AND UNITS ‘All documents shall be written in the English language ‘All spoken communication shall be in the English language. All dimensions and weights shall be in SI Units. QUALITY ASSURANCE The CONTRACTOR shall, as a minimum, demonstrate his compliance with the requirements of BS 5750 : Past 2 and/or ISO 9002 for all works undertaken and meet the EMPLOYER'S specified requirements. The CONTRACTOR shall submit for approval a detailed Quality Plan for Welding and Fabrication which complies with the applicable clauses and elements of BS 5750/ISO 9000 series. welding and fabrication responsibilties, authority levels and ¢ arrangements of personnel. It shall define the struct internal /external interfé level of It shall identify the items and services 10 which this Specifications applies, control and verificati It shall provide documents such as plans, procedures and instructions for the accomplishment of welding and fabricating activities to provide the required quality. The CONTRACTOR shall be responsible for ensuring that the final documentation and records provide the necessary objective evidence that the quality required has been achieved, This shall include the results Gf inspections, tests, monitoring of work performance, material and weld identification and related data such as qualifications of procedures and personnel. The CONTRACTOR shall provide all the necessary certification and documents in accordance with this Specification or any alternative Specification identified by the EMPLOYER. The CONTRACTOR shall appoint only qualified and experienced personnel with the necessary level of authority to ensure compliance with the requirements of this Specification. PROCEDURES General The documents 10 be prepared by the CONTRACTOR, to facilitate fabrication and assembly of the structures shall provide full and complete information and ES-S-20 Page 2 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ie | instructions,including shop details and procedures. Approval or review of shop drawings | by the EMPLOYER or his Representative shall not relieve the CONTRACTOR his responsibility to complete the work in accordance with the Contract Specifications. Any fabrication carried out before shop drawings have been approved by the EMPLOYER shall be at the CONTRACTOR's risk if changes or additions are required. 1.5.2 Document Submission ‘The CONTRACTOR shall, as a minimum, submit the following documentation to the EMPLOYER for approval at least two weeks prior to the commencement of work | | 2) Fabrication procedures, welding and erection sequences. | | b) Fabrication drawings including identification of material grades, plate seam arrangement drawings and plate cutting drawings with weld details in accordance with AWS A2.4 and NDT requirements ©) Drawings end caleulations of temporary works, inclusive of suppost points, Jacking points and sling points, approved by a qualified engineer within the CONTRACTOR's organisation. | d) __List of proposed welding consumables and the Supplier. | ©) PQR's, qualified WPS's and SWIS's including those for repair welding in aceordance with the requirements of Section 6.0 of this Specification for both permanent and temporary attachments. p Certificates of welders and welding operators qualified in accordance with Section 7.0 of this Specification. : 2) Documents detailing the qualifications and experience of all the CONTRACTOR's Engineer's and all QA/QC personnel. h) Certificates of any CONTRACTOR supplied material. i) __Key plans showing unambiguous member identification and weld marking scheme. 3) Post Weld Heat Treatment Procedures. K) Procedures for Inspection and Non-Destructive Testing, format of NDT certificates and associated personnel qualifications in accordance with ES-S-60. 1) Forming and Straightening procedures. m) ~ Identification and Control procedures for materials. ES-$-20 Page 3 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) n) _ Procedures for Dimensional Control. Control of tolerances during fabri to be in accordance with Section 5.0 of this Specification 0) Procedures for Weight Control and for weighing component items and the completed structures in accordance with Section 13 of this Specification. p) Loadout Procedures. BBREV N ‘The following abb: ations are used thr \ghout this specification: APL Amercian Petroleum Institute ANSI American National Standards Institute ASNT ‘American Society for Non Destructive Testing ASTM American Society for Testing and Materials AWS American Welding Socie: BS British Standards, GSECAW Gas Shielded Flux Cored Are Welding GTAW Gas Tungsten Arc Welding HAZ Heat Affected Zone 1g Image Quality Indicator MPL Magnetic Particle Inspection NDT Non Destructive Testing NPS Nominal Pipe Size PCN Personnel Certification in Non Destructive Testing PWHT Post Weld Heat Treatment PQR Procedure Qualfication Record Qa Quality Assurance ac Quality Contrdl ROL Run Out Length SSFCAW Self Shielded Flux Cored Arc Welding SMAW Shielded Metal Arc Welding SAW Submerged Arc Welding SwIs Site Welding Instruction Sheet TS Tensile Strength HV Vicker's Hardness WPs Iding Procedure Specification Ys Yield Strength Page 4 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 2.0 CODES AND STANDARDS 21 RULING CODE All structural welding and all other welding shall be performed in accordance with the general requirements of AWS D1.1 ("Structural Welding Code - Steel”), latest edition of the American Welding Society, unless different requirements or procedures are prescribed | by the Contract Specification. 2.2 REFERENCED SPECIFICATIONS AND STANDARDS The following Standards, Codes of Practice and Specifications shall apply, as appropriate. AISC Manual for Steel Construction. | American ute APIRP2A Recommended Practice for Planning, Design and Construction of Fixed Offshore Platforms. API 2. Specification for Fabricated Structural Stee] Pipe. API SL Specification for Line Pipe. API RP 2X Ultrasonic Examination of Offshore Structural Fabrication and Guidelines for Qualification of Ultrasonic Technicians. American Society for Testing and Material ASTM 370 Testing of Materials : American Welding Society AWS D1.1 Structural Welding Code - Steel. AWS A2.4 Symbols for Welding and NDT. AWS A3.0 Welding Terms and Definitions. . AWS AS.1 Specification for Carbon Steel Covered Arc Welding Electrodes. AWS AS.5 Specification for Low alloy Steel Covered Arc Welding Electrodes. AWS AS5.17. Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding. AWS A5.18 Specification for Carbon Steel Filler Metals for Gas Shielded Arc Welding. ES-S-20 Page S REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ish Standards BS 4360 Specification for Weldable Structural Steel. QGPC Engineering Standards ES-D-10 __Draughting. ES-S-60 Technical Specification for the Non Destructive Testing of Structural Welds. ES-Q-10 Technical Specification for Surface Preparation painting and coating of new structures. Es-Q.11 Technical Specification for Maintenance Painting of Offshore Production Facilities. Other Standards PCN/GEN/MT1/90 Reguirements for the Certification of Personnel engaged in Magnetic Particle Inspection of Castings, Welds end Wrought Products at Level's 1, 2 and 3, PCN/W/RTL/9O Requirements for the Certification of Personnel engaged in the Radiographic Testing of Welds. PCN/W/UT1/90 Requirements for the Certification of Personnel engaged in the ‘Ultasonic Testing of Fusion Welded Ferritic Steels in Thicknesses of 6mm and above. ‘The CONTRACTOR shall equip himself with the latest issues of all specifications, codes and standards referred to in this document, and shall make them readily available to all personnel invélved with the work. ES-S-20 Page 6 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) & 3.4 3.5 MATERIALS: eral All materials, sub-assemblies and equipment shall be siored above ground and the level of any standing water. All materials shall be kept free from dirt and other harmful matter. Structural Steel All structural steel shall be in accordance with Section 8.0 of API RP 2A or equivalent approved. Other Materials Other materials shall be in accordance with the relevant specifications listed in Section 2.2 of this Specification CONTRACTOR Supplied Material All material supplied by the CONTRACTOR shall be new, undamaged and subject io the approval of the EMPLOYER. EMPLOYER Supplies (Where Applicable to a Particular Contract] ‘The CONTRACTOR shall unload, store, protect from damage and loss, keep segregated, maintain, identify and use in an economical manner all the EMPLOYER furnished items. The CONTRACTOR shall maintain a running record of all the EMPLOYER furnished items and materials received, used in the work and remaining in stock upon completion of the work. The CONTRACTOR shall dccount for all the EMPLOYER furnished materials and shall reimburse the EMPLOYER for full cost of items lost or not accounted for. The CONTRACTOR shall take all necessary precautions to ensure that the EMPLOYER furnished materials are correctly used and shall be responsible for replacing any materials incorrectly employed. The CONTRACTOR shall properly control all the EMPLOYER furnished items by receiving at his yard and forwarding all waybills, bills of loading, packing lists and delivery notes to the EMPLOYER as promptly as possible. In case of absence of the EMPLOYER's Representative, the delivery of material shall be the responsibility of the CONTRACTOR. The CONTRACTOR shall ensure conformity with the order, including dimensions, tolerances and quality relevant to the Specifications and Drawings. The CONTRACTOR shall advise the EMPLOYER within eight (8) days of receipt with remarks and possible reservations. ES-S-20 Page 7 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 3.6 37 Marking of Steel ‘All structural steel shall be fully identified against the relevant mill test certificate. The information marked on the steel shall include the following: Item Number b) Manufacturer ) Steel Grade d) — Heat/Cast Number On structural steel, any unique identification number shall be made by hard stamping using round nosed dies only. If any material is found without the appropriate seference, it is the CONTRACTOR's responsibility to prove the identify of the material to the satisfaction of the EMPLOYER at no extra cost to the EMPLOYER. The specified identification shall be maintained at all times, and the CONTRACTOR shall ensure that stee] markings ere wansferred when cutting steel using round nosed dies only. The CONTRACTOR shall preserve the plate rolling direction in marking plates. Different grades of steel, including cut segments or shapes, plate and remnants shall be plainly marked using a system of colour codes. The steel types shall be stored in well-defined locations to avoid inadvertent mixing. ‘Transportation and Handling of Stee) Coinponen All sub-assemblies, sections, etc. shall be transported by a suitable method which does not induce any'deformations or large stresses. Locations of lifting lugs and other temporary attachments are to be specially considered to ensure that structural strength and specified material properties are maintained. Wire ropes and slings are to be used when necessary. During on and-off loading, transport, storage and handling, all components are to be treated in a manner such that they do not suffer damage, overload or deformation. Particular care shall be taken for items which have been metal sprayed, galvanised, painted, etc., and should the coating be broken it shall be recoated by an approved method to the satisfaction of the EMPLOYER. ES-S-20 Page 8 REVISION4.0 41 4.2 4.2.1 4.2.2 “QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) FABRICATION AND ASSEMBLY GENERAL Structures shall be fabricated and assembled onshore to the largest practical module or unit size in order to minimise offshore fabrication and assembly. ‘The CONTRACTOR shall consider during site assembly all temporary erection loads imposed on the structure from supports, jacking and slinging at each stage of the structural assembly. The CONTRACTOR shall consider at each stage of the structural assembly the local or overall stability from self weight and environmental loads, inclusive of scaffolding, staging, welding shelters and temporary works. The CONTRACTOR shall ensure that ail stresses induced in the structure, during fabrication and load out, are not greater than ¢ allowable stresses in the API RP2A and AISC Specification of Steelwork in Buildings, Built-in stresses due to the fabrication procedure shall be minimised. The CONTRACTOR shall take due consideration of the effect of wind induced vortex shedding on the structure or parts of the structure during construction, PREPARATION OF MATERIALS king of. All components, sections or sub-assemblies are to be marked in accordance with the shop drawings in order that the numbering system will allow identification of each member or element of the structure, Such identification is necessary for index inspection, repairs, etc.. The identification system shall be approved by the EMPLOYER before commencement of the fabrication. : Preparation Where approved, cambering, curving and straightening of structural elements may be done by either mechanical means or by the careful local application of heat. In no case shall the temperature exceed 550°C neither shall a quench technique be used. Hammering and cold forming by blows shall not be permitted. The CONTRACTOR shall submit his proposed procedure to the EMPLOYER for approval prior to any application Planing and finishing of cut edges will not be required unless specifically called for on drawings or included in surface and edge preparation for welding. ‘The structural elements shall be cut to size by thermal cuning or machining. However, for plates less than 25mm thick cold shearing may be used provided that the sheared edge is dressed back for a distance of not Jess than 1.5mm. All thermally cut edges shall be dressed to remove dross and scale. ES-S-20 Page 9 REVISION45 45.1 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ‘ot rounded to 1,5 mm radius radius and dressed off to remove the All exposed edges of plates and structural shape: shall be broken with 2 power disc to a 1.5mm resulting burrs. ATTACHMENTS ‘An attachment is defined as an element introduced for some specific and temporary function on the structure (e.g. lifting lugs, lugs for scaffolding end assembly, temporary supports, Jadders or other fabrication and erection aids). Attachments shall preferably not be made to primary steelwork. Such attachments as deemed essential shall be approved by the EMPLOYER and should therefore be planned in advance by the CONTRACTOR. FORMING OF TUBULARS Structural tubulars not supplied formed shall be cold formed from flat plate into sections in a pipemill or fabrication shop. Structural tubulers shall meet the requirements of API Specification 2B and this Specification. The EMPLOYER shall require specimens to be cut from formed sections to verify that the mechanical properties of the material are not impaired by @ particular forming process. The CONTRACTOR shall Charpy test the circumferential butt weld of the first tubular formed which has 2 D/T ratio less than 35 at no extra cost to the EMPLOYER in accordance with Section 6.0 of this Specification. The results shall be submitted separately to the EMPLOYER. Tubvlars shall be formed with the longitudinal seam transverse to the final plate rolling Girection, unless otherwise agreed by the EMPLOYER. SPACING OF SEAMS AND SPLICES IN TUBULARS Spacing of Welding Seams - Nodes The distance between circumferential seams in node barrels shall not be less than 2.5 metres unless prior approval is given by the EMPLOYER Circumferential seams shall not be permitted in the node stubs. Longitudinal seams of the node barrels shall not be offset by Jess than 500 mm without prior approval of the EMPLOYER. Longitudinal seams of node barrels shall not be positioned within 75 mm of the stub to barrel weld toe or within the perimeter of the stub to barsel welds unless otherwise approved by the Engineer. ES-$.20 Page 10 REVISIO?QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 4.6 The distance between the toes of the welds of incoming members in a T, K, ¥ configuration shall be 50mm maximum. Longitudinal node stub seams an: positioned in areas shown on Fi shall be positioned centrally in the node barrel. A clear distance of 75 mm shall be maintained between the toe of the node stub to barrel weld and the barrel circumferential seam weld. Spacing of Welded Seams - General Assembly No two circumferential seams shall be located closer together than 1m or the pipe diameter, whichever is less. There shall be no more than two circumferential welds in any three metres length unless approved by the EMPLOYER, Longitudinal seams shall be, wherever practicable, 90° radially offset and shall not be offset by less than 500mm without prior approval by the EMPLOYER SPLICES IN PROFILES AND GIRDER: Structural members may be spliced for economical use of material. Splices shall be made ‘with full penetration butt welds and shall develop the full strength and cross-section of the member jointed. The straightness of the spliced member shall equal that of an uncut member. Welded joints of axially aligned structural members of different sizes, thicknesses, diameters or widths shall be made in accordance with the Contract drawings and in suci ‘a manner that the slope through the transition zone shall not exceed 1:4. The use of the beam shall determine the location and frequency of splicing. There shall not be more than two splices in any 3m length of beam and splices shall not be located closer together than twice the depth of the beam or 900mm, whichever is greater. No splice shall be located in the middle one-fourth of any beam between two supports and not in the one-eighth of the beam span nearest any support. For cantilever beams there shall be no splice located closer to the point of support than one half of the cantilever span. The locations of all splices in critical members are subject to the approval of the EMPLOYER. ES-S-20 Page 11 REVISIO:QATAR GENERAL PETROLEUM CORPORATION- (Oil & Gas Operations) 48 4.8.1 4.8.2 CTIONS Tubular Connections Tubular connections shall conform to the requirements shown in the Contract Drawings. Joint cans shall be so oriented that longitudinal and circumferential welds are not placed in areas of high stress concentration. When not shown on the Contract Drawings, these welds shall be positioned to avoid bracing members compleiely or, alternatively, shall be positioned exactly in the plane of the bracing. Slotted Members Slotted members shall conform to the requirements of API RP2A unless noted otherwise on the Contract drawings, Welded Connections For welded connections and their requirements, reference is made to Section 6.0 of this Specification and details shown in the Contract drawings. FABRICATION DETAIL Sealings ‘All steel-fitted surfaces throughout the structure shall be completely sealed with a continuous 6mm minimum fillet weld around the edges of the fitted surface, unless shown otherwise on the Contract Drawings. Temporary Cut-outs ‘The CONTRACTOR shall avoid temporary cut-outs in primary structural steel wherever possible. When temporary cut-outs are necessary, they are to be prepared with the same care as for permanent cut-outs and with suitable radiused corners (100mm). Temporary cut-outs are to be sealed by employing the same welding and inspection procedures that govern the structural part in question. For any windows, which should only be used where essential, the EMPLOYER will prefer an elliptical shape. The locations of any such cut-outs are to be agreed with the EMPLOYER. ES-S.20 Page 12, REVISIO®QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) } — 4.8.3 Copeholes | Copeholes are generally omitted for clarity on the Contract drawings. Where | CONTRACTOR wishes to’ use copeholes, these shall be permitted es follows: | Member Thickness Copehole Radius | { Upto 12.5mm 25mm | 12.5mm to 25mm 2x T (where T is the thickness of the coped member) 25mm and above 50mm The copeholes shall not be filled with weld metal, they shal be covered with plates of appropriate dimensions if required welded 10 an approved welding procedure, at jocations approved by the EMPLOYER, The fillet portions of all welds are to be returned through the copehole and finished to a smooth radivs to facilitate MPI. ES-$.20 Page 13 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 5.1 EABRICATION TOLERANCES GENERAL All the tolerances shall be in accordance with API RP2A or the special tolerances specified below, Tolerances are not cumulative. Straightness may be measured by optical instruments or using a piano wire stretched from end to end of the member and the measurement made at the point of greatest deviation. Measurement by optical means is preferred. Tolerances shall be checked at each stage in accordance with the fabrication procedures and the final survey shall meet the defined tolerances. The final survey shall be on complete sub-assemblies and on the completed structure after PWHT, if applicable, and shall be carried ovt by the CONTRACTOR. s and centre lines of the strveture ecied 10 @ temperature of Tolerances shall be based on theoretical setting ovt p referenced to permanent approved datum points and c 20°C. All setting out and fit-ups shall be subject to a tolerance measurement. Tolerances outside this specification shall be approved by the EMPLOYER prior 10 commencement of work. Straightness tolerance of hot rolled tubulars and profiles is given in API SL and ASTM ‘A6 respectively. LOCAL TOLERANCES FOR STRUCTURAL COMPONENTS Fabricated Tubulars and Cones . Circumference The external circumference shall not depart from the calculated circumference by more than: = for tubulars of specified O.D. up to and including 650mm = + Smm - for tubulars of specified O.D. greater than 650mm 20. 25% Ovality ‘The difference between the measured maximum and minimum internal (or external) diameters shall not exceed ( See Figure 5.2-1): - for tubulars of O.D. <= 2000mm 0.75% O.D : for tubulars of O.D, > 2000mm + 15mm ES-S.20 Page 14 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) siries 5.2.1.4 5.2.1.6 Sate 5.2.1.8 Out of Roundness Out of roundness is defined 2s the difference between the actual form and the ideal form of the section as measured using a 20° arc gauge (see Fi; 2). This tolerance shal! be checked on the inside or outside of a tubular of external diameter greater than 2000mm of with a nominal external diameter to nominal wall thickness ratio greater than 65. It shall not depart from the theoretical form by more than 10% of the wall thickness of the tubular, Local Straightness Straightness shall be in accordance with the tolerances given in API Specification 2B paragraph 4.4, The straightness must be checked, in 2 minimum of two longitudinal planes displaced by 90°, End Perpendicularity The ends of tubvlars or tubular sections, shall be cut perpendicular to the longitudinal axis within the following tolerances (see Figure 5.2-3) wbulars of O.D. <= 2000mm = 3mm tubulars of O.D. > 2000mm = 5mm. Node Can Length The node can length shall be within +0 to +20mm of the theoretical length in accordance with the Contract drawings. Out of Straightness Out of straightness shall not exceed 10mm over length ‘L' for jacket legs and L/1200 for other members where 'L' is defined as follows: legs : length between consecutive ends of node barrels, braces: _length between consecutive ends of stubs. Node Stub Location The theoretical centreline of a node stub shall be positioned within 3mm of its true position. Measurement shall be made by using the permanent work point at the centre of the node barrel and the true centre of the machined free end of the stub as the reference points. Page 15 REVISIONhee GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 5.2.1.9 Pile Sleeve Shear Plates Pile sleeve/leg shear plates and leg ring stiffeners shall be positioned within 3mm or one length of their nominal thickness whichever is grezier. $.2.2 Plate Girders tre Ge General Dimensional tolerances of built-up members, including deviation from straightness and deviation from specified camber, shall conform to the requirements of paragraph 3.5 of the AWS D1.1 "Structural Welding Code" except as where amended hereinafter. 5.2.2.2 Out of Straightness For members of length upto and including 12m the maximum out of straightness shall be 0.001L For members of length over 12m the | maximum out of straightness shall be 2mm. | (See Figure 5.2-4) | 5.2.2.3 Depth | ‘The maximum permissible variation from specified depth for welded beams and girders shall not exceed: For depths up to 1000mm : 3mm For depths over 1000mm 4mm $.2.2.4 Rotation and Bow of Flange ‘The rotation and bow of the flange shall be measured as shown in Figure 5.2-5 and shall comply with the following +.0.01b or 6mm whichever the lesser (where 'b' is the flange width). 5.2.2.5 Inclination and Bow of Web The inclination and bow of the web shall be measured as shown in Figure 5.2-5 and shall comply with the following £ 0.008h or 6mm, whichever the lesser ( where ‘h' is the girder height) ES-S-20 Page 16 REVISION& 5.2.2.6 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) Eccentricity of Flange on Web ‘The eccentricity of flange on web shall be measured as shown in Figure 5.2-5 and shall comply with the following “& 0.015h or 6mm, whichever the lesser. Alignment and Fit-Up Tolerances General Whenever practicable, clamps, magnets, holding devices, strongbacks, etc, shall be used in assembling parts of the structure to avoid/minimise temporary attachments or tack welding to the main structural components. In fit-up where clamps cannot be used. spacer sirips shall be employed to ensure the correct root gap prior to tack welding, but they shall not become part of the completed weld. 5.2.3.2 Alignment For single sided butt welds, misalignment shall not exceed 1.5mm. For double sided butt welds, misalignment shall not exceed '/,, or 3mm whichever is the lesser. See Figure 5.2-6. 62s Us For full penetration butt welds the root gap shall comply with the requirements of Clause | 3.3.4 of AWS D1.1 except that for single sided full penetration butt welds the root gap | shall be 2 maximum of 4.0mm unless otherwise specified on the appropriate welding | procedure previously approved by the EMPLOYER. | For all other joints, the maximum root gap shall not exceed 6mm, but for gaps greater | than 1.5mm ih fillet welds the leg length shall be increased by the amount of the separation upto a maximum of 3mm. 5.2.3.4 Correction Misalignment within the limits of Clause 5.2.3.2 above shall be corrected by a tapered ‘weld between the parent metal edges to ensure complete tie-in. The resultant tapered weld = face shall in no case have an average slope greater than 1:4 or extend outside the width of the weld joint unless otherwise approved. ES-S-20 Page 17 REVISIO?QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 5.3.1 5.3.3 GLOBAL TOLERANCES FOR THE COMPLETED STRUCTURE Jacket. Deck and Module Columns and Legs The tolerance for the theoretical position of legs and columns referenced to the Contract drawing dimensions shail not exceed + 6mm in any direction. Every practical means shall be employed to effect squareness and accuracy in Jeg and column location and alignment in all horizontal planes. Fabrication shall proceed on a flat and Jevel surface. Frequent level checks shall be performed. When any column settles more than + 6mm out of level, the settled column shall be shimmed back into 2 Jevel plane with other columns. Module and Deck Members ‘All braces and members in a horizontal plane shall be within a vertical tolerance of + 6mm from the elevations or plan dimensions shown on the Contract drawings, ‘All horizontal or vertical braces and members shall be within + 6mm of the cenveline dimensions shown on the Contract drawit All parallel transverse beams in a horizontal plan shall have a tolerance of + 6mm or one five hundredth of the beam centres, whichever is the lesser. All diagonal braces and members where the work points are dimensioned shall be erected such that the work points are within -+ 6mm of the dimensions shown on the Contract érawings. Deviation from straightness of deck members shall conform to the requirements of Section 5.0 and Clause 5.2 above. The centrelings of the main deck beams at their ends shall be within ++ 6mm of their location on the Contract drawings. facket re ‘The overall dimensions of the structure between the top jacket horizontal member and modline shall be within + 12mm of the theoretical dimension. ‘The distance between any two adjacent bracing levels shall be within + 12mm of the theoretical dimension. ‘The diagonal distance between diametrically opposed corner legs shall be within -+ 20mm of the theoretical dimension, A triangulation check shall be carried out to ensure all dimensional combinations are recorded. ES-S.20 Page 18 REVISION5.3.4 5.3.5 54 5.4.2 5.4.3 - QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ‘The centre of the legs at deck stabbing points shall be within 6mm of the theoretical dimension. Having made the brace Nodes shall be positioned within 25mm of their theoretical position, allowance for the error in positioning the node work point, the w end of any tube shall be within 6mm of the theoretical position. Pile Guide Tolerances Pile sleeves shall be fabricated and installed so that the centre point at any section is within + 6mm of the theoretical centreline, The alignment of any pile guide shall not deviate from the theoretical centreline, as shown on the Contract drawings, by more than 12mm. Conductor Guide Tolerances The dest fit centreline for all guides shall not deviate by more than 12mm from the theoretical centreline as indicated on the Contract drawings. No single guide shall deviate from the overall best fit centreline by more than 12mm. MISCELLANEOUS TOLERANCES ring at Point of Loadin: ‘The bearing ends of bearing stiffeners shall be flush and square with the web and shal have at least 75 percent of this area in contact with the inner surface of bearing flanges The outer surface of the flanges bearing against a steel base or seat shall be withir 0.25mm for 75 percent of the projected are of web and stiffeners and not more, thar 0.8mm for the remaining 25 percent of the projected area The actual centreline of the stiffener shall be within the thickness of the stiffener a measured from the theoretical centreline location. Deck Plate and Grating The difference in elevation of deck plate or grating at joints shall not exceed 2mm. Plat and grating shall be flat and without visible warping. Joints in grating shall occur only at points of support. Butt welds on plates shal] be considered structural welds. Excessive distortion will no be acceptable. Landings and Stairways Landing and stairway locations shall not vary more than 12mm from the horizonte dimensions shown on the Contract drawings. ES-S-20 Page 19 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 5.4.4 5 Landing elevations shall be within a tolerance of 25mm of the elevations shown on the Contract drawings ‘The vertical distance between stair treads shall not vary more than 2mm and treads shall be level. Fencing and Handrails Fabrication shall be performed to such a degree of eccuracy that, when erected, the top rails shall be straight and level to the eye, and the handrail shall be plamb PILING of pipe used in fabricating piles shall be 1500mm. ent pile segments shall be spaced 90° apart as a The minimum length of a segme ‘The longitudinal seams of two ai minimum. The maximum allowable deviation from straightness in any 3000mm increment of Jength shall be 3mm, The maximum allowable deviation in any 12,000mm increment shall be 10mm. For lengths over 12000mm the maximum allowable deviation shall be 12mm. Corrective action shall be taken to prevent additional accumulation of deviation. The method for checking straightness shall be by optical instruments or taut wire along the Jength of pipe repeated at 2 minimum of three redius points, The root face on the bevelled ends of the finished pipe should not be out of square more than Smm/m of diameter except that the maximum allowable out of squzre should not be more than 6mm, Piles shall be fabricated 10 a tolerance of +/- 300mm from the length shown on the Contract drawings unless otherwise specified The outside circumference and out-of-roundness tolerances shall be in accordance with Clause 5.2 of this Specification. ES-S.20 Page 20 REVISION (QATAR GENERAL PETROLEUM CORPGRATION (Oil & Gas Operations) 6.2 63 ES-S.20 WELDING GENERAL This section covers requirements and procedures for the welding of structures in the workshop, yard and offshore. The clauses of this section do not relieve the CONTRACTOR of his responsibilities, guarantee or of any other contract bond with respect to welding performance and welding results. During welding operations, inspection and testing the CONTRACTOR shall observe and follow current regulations concerning personnel safety, prevention of fire, explosions and accidents. No exception to this section is allowed without the written authorisation of the EMPLOYER. WELDING PROCESSES All structural welding and all other welding, including teck welding, shall be accomplished with low hydrogen processes which shall deposit weld metal with a Giffusible hycrogen content Jess than 10ml per 100g of deposited weld metal. Tests 10 confirm the diffusible hydrogen level shall be conducted io BS 6693 if requested by the EMPLOYER. These tests shall be at the CONTRACTOR’s expense. SMAW and SAW (single and double wire) are acceptzble welding processes, provid! that they are operated to give 2 heat input between 1.0 and 5.0 KI/mm for the normalised steels involved, ‘The EMPLOYER may specify the use of GTAW where a high level of control is required over root profile on single sided welds. * The use of GSFCAW and SSFCAW shall be subject to approval by the EMPLOYER. Other welding processes, or any welding process where the heat input is outside the range specified above shall not be used without the approval of the EMPLOYER, If alternative processes are intended to be used, any such proposal shall, at the bid stage, state all items and areas of intended use, together with full details of the process, consumables and CONTRACTOR's past history of use. The EMPLOYER may refuse or limit the use of an intended process and may specify additional testing and inspection requirements. Ww NSUMABI ‘The use of all welding consumables shall be subject to approval by the EMPLOYER and all electrodes shall be suitable for the materials, positions and conditions of intended use. Deiails of the CONTRACTOR'S control system for the storage and control of welding consumables shall form part of the quality plan. Page 21 REVISIONQATAR GENERAL F (TROLEUM CORPORATION (Oil & Gas Operations) 6.4 The CONTRACTOR shall inform the EMPLOYER of the batch definition used by tht manufacturer. Consumables shall be batch tested in accordance with BS or AWS and shall be subject to approval by the EMPLOYER test results to BS or AWS classification for cons nical properties as a minimum: All as welded weld metz] have the following mech 2) Chemical composition of weld meial b) Tensile and yield stre: ©) Percentage elongation. 4) Charpy impact data. 69 The actual weld metal properties must meet those specified in Claus Electrodes used for SMAW shall conform to either BS 639 or AWS AS.X (where X will Gepend upon the electrode vsed). Wire and flux for SAW shell comply with BS 4165 or AWS AS.17. Flux shall be of the fully basic type. No alloying additions shall be made from the flux Wire for GTAW shall comply with BS 2901 or AWScA5.18. Shielding gas shall be commercially pure Argon For welding consumables and storage see Clause 8.3. WELDING PROCEDURE QUALIFICATION Prior to beginning work, detailed WPS's for welding the various parts of the structures 2s per the connection details on the Contract drawings shall be establish and qualified in accordance with AWS D1.1 and the following additional requirements: 2) The CONTRACTOR shal! conduct the tests required to qualify the procedures and these shall be witnessed by the EMPLOYER. b) _ WPS's shall be submitted and approved specifically for the EMPLOYER. Existing Pre-qualified procedures may be considered, subject to the submission to the EMPLOYER of full documentation verified by an acceptable third party. If pre+ qualified procedures are accepted, the EMPLOYER reserves the option to re- qualify a representative number of them. ©) A qualified welding procedure is one which has been tested 10, and has achieved the requirements of, this Specification and hes been approved by the EMPLOYER, ESS.20 Poge 22 REVISION (CS aed 65 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 6) Qualification of a welding procedure is restricted to the CONTRACTOR and the worksite where the test weid was produced, unless otherwise approved by the EMPLOYER. e) AS an aid to QC and to minimise production welding variation, the CONTRACTOR shall translate the full range of qualified WPS's into SWI: which shall be subject to approval by the EMPLOYER 1) The SWIS shall only include simplified information for the welder to work to the approved procedure. This shall include not only the welding parameter's but also guidance on the steps necessary to achieve adequate weld quality. eg. preheat/combined thickness relationships, depth of backgouge, bead widths, ete. g) Production welding shall not commence until the appropriate procedure tests, WPS's and SWIS's have been approved by the EMPLOYER. WELD EDURE SPECIFICATION Prior to qualifying the welding procedures the CONTRACTOR shall submit for approval a schedule of welding and repair procedure specifications and drawings to define the scope and the intended areas of application. Welding procedure specifications shall, as a minimum, record the information required below: a) The steel type and grade, carbon equivalent and thickness used for qualification, b) The steel type and grade, carbon equivalent and thickness ranges qualified. ©) The welding process (or processes when a combination is used) and equipment. 6) The type, size, classification and composition of welding consumables (specify wire-flux combinations for submerged arc welding). ©) For each run, the proposed type of current, arc current, are voltage and heat input. For SMAW include width of weave, electrode run out length and burn off time, for SAW include travel speed. f) Joint preparation and cleaning procedures, including a sketch showing edge preparation and joint fit-up. 8) Applicable welding positions and directions. h) The minimum preheat and maximum interpass temperatures, NOTE: During welding procedure qualification the capping passes adjacent to the parent plate shall be deposited at the minimum preheat. ES-S.20 Page 23 REVISIONJ QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ing depth of backgouge, dressing anc nent to the second side, in: sion prior 10 welding out i) The inspeci asa minimum, the deposition seque the first four layers ne weld is double sided, show the second side root deposition sequence 1) Any deposition augmentation system used. }) Consumable treatment where this forms part of the procedure, e.g. baking temperature and time, m) Tack welding procedure (tack size and separation). n) Wire stickout, if applicable. 0) For SAW, the angle of inclination of the electrode to the work piece and the vertical and the stand-off. p) The Post Weld Heat Treatment (if applicable) The CONTRACTOR shall take every possible measure to produce the degree if restraint to be expected in production. Strongbacks shall be used to restrain the test pi the welding procedure qualification. All welding procedure qualification t 1 be at the expense of the CONTRACTOR The CONTRACTOR shall ensure that copies of the approved SWIS's, relevant to the work in hand, are issued 10 each welder, welding foremen/supervisor. The CONTRACTOR shall also provide said documentation to the EMPLOYER. 6.6 ENTIAL VARI N F APPROVAL Changes whicirrequire a new welding procedure specification qualification and the extent of approval required shail be as given in AWS D1.1, Section 5, Part A except as where amended below: ewe 2) A change in base material type or grade, d) A change of material thickness outside the range: 0.8t to 1.5t. where t is the thickness of the thinnest material used on the welding qualification test, ES-S-20 Page 24 REVISION4 72 TAB 24 QATAR GENERAL PETROLEUM CORPORATION (Gil & Gas Operations) QUALTEICATION OF WELDERS AND Vi GENERAL cations Reauired ng, including tack and repair welding, on the structure shall only be pe by qualified welders and/or welding operators. Welders and welding operaiors qualified in accordance with the requirements of AWS D1.1 except as amended b section. Existing qualifications may be ccnsidered provided that they relate to a similar stander of work and use welding consumables having the same characteristics as those to be use in production. Fully correlated documentation demonstrating current qualificatior. endorsed by 2n acceptable TIP, continuous experience with the qualified process 2) Caisfactory past performance shell be submitted to the EMPLOYER for consideration alificetions shall be entizely at th Acceptance of this documentation and existing discretion of the EMPLOYER. Witness and Approval of Tests hefore Weldieg ‘All welder and welding operator tests shail be witnessed by the EMPLOYER or a Ti approved by the EMPLOYER before the welder or welding opereior is Per mitted to we cn any part of the structure. The decision taken by the EMPLOYER regarding qualification of any welder or welding operator shall be “inal Welder identification System The CONTRACTOR shall esteblish en identification system for each welder and weld. operator. The identification system shall be subject 0 epproval by the EMPLOYER, & shall give 2 unique mark for each welder or welding operator. |A welder or welding operator may not change this number or symbol afier qualifcati the performance of fabrication work. In the event thet a welder leaves or is dismissed from the works, his identity shall not assigned to aother welder employed on the ws Marking of Welds Welders and welding operators shall identify their welds at intervals of not more than 1 ‘Any welds not clearly masked may be rejected by the EMPLOYER and the repair replacement shall be et the CONTRACTORS expense, Marking shall be by an appre ‘weather proof crayon of paint stick of any colour except white, No hardstampins permitted. RFQATAR GENERAL PETROLEUM CORPORATION (Oi & Gas Operations) Welder ond Welding Operator Records ds shail have a format similar to thet Welder and welding operator approval test r shown in AWS Did tain and issue to the The CONTRACTOR shall maii ing the following information for all welders end weld CONTRACTOR (name and address). b) ‘me of each qualified welder or welding operator. ©) Date and place of birth ) Symbol used by each welder or welding operator €) Date of qualification i) Type and extent of qualification obtained by each welder or welding operator (position, welding procedure, etc.) The CONTRACTOR shail update these records on a regular basis to reviect any changes sn employment of welders end welding operziors. WELDER QUALIFICATION CATEGORIES: Genera The minimum qualification for any welder shall be for at least one category and in all positions for the category. ‘A welder qualified in any number category upto Category 3 is also qualified to weld in any category of a Jower number. A welder qualified in a category is alsb’ qualified to weld any thickness within that category. Qualification Categories Category 1 - Fillet Welders Qualified for all fillet welding where the-dihedral angle between parts is 75° or grester. Category 2 - Plete Welders Qualified for all butt and fillet weldingin plates‘or sections, except for intersections where the dihedral angle is 75° or less ES6.20) oo REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ©) 4) Pp) ‘The CONTRACTOR shall provide calibrated equipment necessary to mor A change of diameter outside the range: 0.5D to 1.5D where D is the outside diameter. A decrease in the minimum specified preheat, or an increase of more than 20°( in the specified maximum interpass temperature. Preheat may be increased up t 100° C without re-qualification subject to the minimum interpass temperatur limitations. A change in welding process to any other welding process or combination welding processes. A change in electrode polarity, A change of consumable in trade name, grade or classification Any change in wire/flux combination A change from multipass to single pass or vice-versa change in shielding gas type or nominal composition. The introduction of any deposition augmentation system (eg. iron powder or ho wire additions to submerged arc welding) Any change in the rate of addition of any supplementary consumable. Aci ge of welding position from vertical up to vertical down or vice versa ‘A change of weld preparation in shape or configuration, except that a procedure qualified on included angles between 45° and 60? shall be valid between the angle tested and 60° for a similar weld preparation, An increase in electrode diameter or weave width beyond that used in the qualification test or a change in any other parameter likely to increase heat input or decrease toughness. A change from double sided to a single sided weld but not vice versa. 1 all variables during procedure qualification tests and welder tests. REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 67 67.1 TEST CATEGORIES ‘The principel procedure test categories which require procedure qualification are liste below. The CONTRACTOR shall also qualify other procedures if they should be deeme necessary by the EMPLOYER, a) Plate, Section and Tubular (greater th nm. tt Wel Plate butt joint test pieces shall be prepared to qualify all welding of plate, sections an tubulars greater than 610mm NPS. The welds shall be qualified in the horizontal/vertice (2G), vertical up (3G) and overhead (4G) for all processes other than SAW, which wi be qualified in the downhand (1G) position. b) Single Sided Tubular Burt Welds. Tubviar butt joint test pieces shall be prepared to qualify all single sided welding lars. Test pieces shall be welded in the vertical (5G) and horizontal positions (2G Welding procedures qualified on 610mm NPS tubulars will also cover single sided closin welds on tubulars greater than or equal to 610mm. | 6.7.3 ¢) T-Butt Welds. | Plate butt welds may be used to qualify T-butt welds provided that in the plate bur | qualification the preparation is a bevel type. i.e. one piece has a fusion face perpendicule to the plate surface. If a Vee type preparation is utilised in the plate butt qualification then T-butts will t qualified separately in the positions described in 6.7.1, the testing shall be confined t j 100% ultrasonic and MPI evaluation together with a macro and hardness survey take from a test piece of the maximum combined’ thickness to be welded in the scope of work However the preheat requirements of 6.6 cannot be reduced. 6.7.4 d) Fillet Welds. Fillet welds shall be qualified in the horizontal/vertical (2F), vertical up (3F) an overhead (4F) positions on the minimum and maximum combined thickness for eac process to be used in production except for SAW which shall be qualified in the gravir (IF) and/or horizontal/vertical (2F) a5 required Fillet weld leg sizes to be qualified shall be: 1) the minimum single pass, and 2) the maximum multiple pass to be used in production. ES-S.20 Page 26 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 6.7.6 68 6.8.1 Consumables used for fillet weding shall also be qualified by plate butt procedures usir similar welding parameters in order to obtain a full range of mechanical properties ©) Tubular Intersections (T. K and Y joints). For single sided welding of T,K and/or ¥ joints the weld test piece sha be set up wi the main barrel fixed in the vertical position and welded out as shown in Figure 6.7 “Additionally in order to verify the validity of procedure qualification tests for single sid Jb to barrel (where such preparations are permitted by the EMPLOYER) and dout sided welds and to establish the acceptable standard of stub profiling the CON, TRACTC Shall set up and weld a trial procedure test piece. This shall be as shown in Figure 6.7 set shall be in accordance with the approved procedures and essential variables. Weld Metal Buttering. Double Sided. In order’ to accommodate wide root gaps in double sided joints 2 one off weld procedure shall be qualified with 2 gap of 15mm in the vertical up (3G) position Each application of this procedu nall be specifically approved by EMPLOYER in production AN APPROVED PROCEDURE IS NOT TO BE TAKEN AS A LICENSE FOR PO WORKMANSHIP. g) Repair Welds [A repair welding procedure shall be required for the repair of @ weld using @ diffe welding process, e.g. SMAW repair to a SAW weld, The repair Welding procedure shall consist of a mid-wall excavation of a full penetra butt weld in a plate welded in the vertical up (3G) position to an approved welt procedure with the excavation centred on the toe of the o: al weld. PROCEDURE QUALIFICATION TESTING neral “The type and number of tests shall be as specified in Table 6.81. Except where os by this sub-section destructive testing shall be carried out in accordance with AWS I on test specimens 2s shown in Figures 6.8-1 and 6.8-2 as appropriate. Welding procedure qualification tests shall be performed with material specified i project steel specification. The use of other material may be accepted at the srelretion of the EMPLOYER provided it complies with the project steel specifica lEs.s-20 Page 27 REVQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) The cast number and certification number shall be recorded. The steel used for the procedure test shall have a cerbon equivalent of not less ‘aximum permitted for that type of steel or within 0.03% of the maximum given in th formula below: CE = C+ Mn + Cr+Mo+V + 6 5 Weld test pieces shall be of sufficient size to allow all the test specimens required 6: Table 6.8-1 and permitted retesis. Retesting shall only be permitted on test specimen removed from the original test plate. EMPLOYER approval of the detailed NDT procedures shall be obtzined before testi; started so that the NDT procedures may be qualified in conjunction with the weldin; procedures. Welding procedure tests shall be examined by NDT in accordance wit Section 8.0 using the methods specified in Table 6.8-1. NDT shall be performed prior 1 the machining of the test specimens, but in the case of as welded tests, not until minimum of 48 hours has elapsed following the completion of the test weld. Test weld details and results of the tests shall be submitied to the EMPLOYER fo approval accompanied by the documentation detailed in clause 6.12. Should the test weld fail any of the required tests and the permitted retests, the cause 0 the feilure shall be established to the satisfaction of the EMPLOYER and rectified. Th complete procedure test shall then be repeated, 6.8.2 All Weld Tensile Test ‘All weld metal tensile test specimens are required from plate and ubular butt joir rocedure tests in accordance with 5.11.4 of AWS D1.1 6.8.3 Cross Weld Tensile Tests Cross joint or reduced section tensile tests are required from plate and tubular butt join procedure tests in accordance with 5.11 1 of AWS D1.1. 6.8.4 Bend Tests Bend tests shall be taken in accordance with 5.11.3 of AWS D1.1 and all specimens shai be bent through an angle of 180°. ES-S-20 Page 28 REVISIOQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 6.8.6 69 6.9.1 6.9.2 6.9.4 Macrosection and Hardness Tests Where PWHT is applicable, hardness tests shall be performed before and after PWHT Specimens shell be polished and etched and hardness tests shall be conducted at th Jocations and intervals shown in Figure 6.8-3. A dendritic type etchant shall be used i ensure clear definition of the fusion line. The hardness survey shall be in accordance with BS 427:Part 1 using 2 10Kg load. ‘A photomacrograph of each hardness macrosection at 2 magnification of X1 to X2 suc that the hardness indentations are clearly visible together with a sketch identifying th indentations shall be submitted with the welding procedure qualification test report to th EMPLOYER for approval. Charpy V-Notch Impact Tests h ASTM A 370 The location of the tes igure 6.8-1 and Figure 6.8-2 Charpy V-notch testing shall be in ace specimens within the plate or tubular shall be 2s shown in Fi lance w TEST ACCEPTANCE CRITERIA NDT Results The soundness of the test welds shall be in accordance with Table 6.8-1 of thi specification. All Weld Tensile Tests For all weld metal tensile tests the YS and TS shall meet the minimum specified for th parent metal. The maximum TS shall not exceed 30 N/mm? above the maximum specific for the parent metal. The reduction of area shall be not Jess than 35% and the elongatio shall be not less than 22% Cross Joint Tensile Tests ‘The TS of the welded joint shall be at least equal to the minimum specified TS for th steel grade welded. Where a result is less than the specified value, but greater than 95¢ of it, two retests may be made, both of which shall achieve a TS in excess of th specified minimum. If any specimen fails to comply with these req} testing, where approved by th MPLOYER, shall be in accordance with 5.14 of AWS D1.1. Bend Tests Acceptance limits shall be in accordance with 5.13 of AWS D1.1. Retesting, wher approved by the EMPLOYER, shall be in accordance with 5.14 of AWS D1.1. ES-$.20 Page 29 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 6.9.5 | 6.9.6 6.10 6.11 Macrosection and Hardness Tests Acceptance limits for macro examination shall be in accordance with 5.12 of AWS D1.1 ‘The hardness shall not exceed 325 H¥,9 at any individual test point. Charpy V-Notch Impact Tests ‘Acceptance levels for impact testing shall be : Minimum Average = 363 @ -20°C ‘Minimum Individual = 27J @ -20°C where the average is taken over a set of three specimens. If the minimum average impact value is not attained or if only one specimen shows ¢ value less than the minimum individual value, three additional specimens shall be selectec ‘rom a position similar to that from which the set of specimens under consiGeration w: taken, The average value of the six specimens shall be not Jess than the minimum average value ore than two Ss} mens shall show values below the minimum average value only one of which shall be below the minimi individual value. THERMAL CUTTING PROCEDURE QUALIFICATION The CONTRACTOR shall submit 2 procedure specification for thermal cutting anc demonstrate that all material cut using this procedure will have a hardness below 32: Hyjq. The procedure specification shall be subject to approval by the EMPLOYER. This procedure specification shall define the parameters which effect the base meta hardness including oxygen and fuel gas pressures, travel speed and nozzle size, and by proven on 2 steel test piece of suitable size and thickness within 0.03% of the maximum permissible carbon equivalent. Qualification testing shall comprise hardness survey's 2 shown in Figure 6.10-1. WELD PROFILING PROCEDURE QUALIFICATION ‘Where required in the contract specification and identified on the contract drawings wel profiling will be undertaken. Procedure specifications and qualification tests shall be established and submitted fo: approval to the EMPLOYER in order to ensure that all weld profiling, including ‘toe dressing will be in accordance with this specification, The trial test pieces produced in 6.7. €) may be used to demonstrate this. ES-$-20 Page 30 REVISIOQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 6.12 DOCUMEN N In order to review and approve a welding procedure the EMPLOYER shall require th following documentation, 2s a minimum, to be included in the welding procedur qualification package: a) the PQR sheets, b) the production SWIS, ©) the WPS used for the qualification test, a 4) the procedure qualification data sheet of the actual welding parameters applied weld the test joint verified by the CONTRACTOR. Additionally the EMPLOYEF may nominate a representative to authenticate the records and test results, 2) the mechanical test results, 1) the inspection and NDT results, 3) the parent material test certificates indicating the chemical analysis and mechanica properties, h) the consumable batch certificates indicating the information specified in sectior 6.3, i) the PWHT charts (where applicable). Records of the test results for each procedure qualification shall be established anc certified by the EMPLOYER. One of these shall be kept by the CONTRACTOR anc shall be available to those authorised to examine it. Another shall be given to the EMPLOYER. ES-S.20 Page 31 REVISIOSQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) Category 3 - Tubular Welders Butts) Qualified for all butt and fillet welding in plates or tubulars, except for intersections. Thi shall include tubular and box section butt welds between structural members. Category 4 - Tubular Welders (Intersections) . Not qualified fo by category 3. Qualified for all welding in pipe, tubvlars or box sect ersection the single sided welding of tubulars without backing which is cov. Category A - Automatic Welding Operators Qualified for all butt and fillet welding of plate or tubulars using an automatic proces only. 73 TEST PIECES ‘ategory 1 Plates shall be at least 12.5mm thick and the test welded in each Zundemental positio: required. Category, ates shall be at least 12.5mm thick with a single V preparation and the test welded ir each fundamental position required. No back welding shall be permitted. Category 3 Pipe shall be at least 12.5mm thick and 168.3mm nominal outside diameter and shall have a single V preparation. The test shall be welded in the 6G position. The pipe ends shall be sealed and no back welding shall be permitted. Category 4 Pipe shall be at least 12.5mm and 17.5mm thick respectively and 168.3mm nominal outside diameter with a restriction ring as per Figure 5.25 of AWS D1.1. The test shall be welded in the 6GR position. The test piece shall be at least 1m long in the case of plate or at least 406.4mm nominal outside diameter in the case of pipe. The shall be welded in accordance with 5.18 of AWS D1.1. ES-S.20 Page 34 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) EXAMINATION AND TESTING Examination and testing shall be performed as specified in AWS D1.1. All weld: qualification tests shall be subject to me ‘esting in addition to the following NDi (2) All categories 100% Visual and magnetic particle inspection ‘As welded profiles shall be of smooth contour and suitable for MPI WITHOUT dressing (b) Categories 2,3 and A nay be substituted for 100% Radiographic inspection. Ultrasonic inspection radiography, subject to approval by the EMPLO (©) Category 4 100% Ultrasonic and radiographic inspection ACCEPTANCE LEVELS Acceptance levels shall be 2s specified in Table 6.8-1. ARC-ATR GOUGER QUALIFICATION Arc-air gougers shall demonstrate, to the satisfaction of the EMPLOYER, their ability i yemove metal uniformly. This shall be 2 one off demonstration on the first welc backgouged for each gouger. The CONTRACTOR shall maintain a record of thox gougers which are acceptable to the EMPLOYER ES-S-20 Page 35 pevieinsQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.2 83 8.3.1 PRODUCTION WELDING GENERAL No welding procedure shall be used in production until it has been fully qualified by the CONTRACTOR, the SWIS hes been prepared and the associated documents have b approved by the EMPLOYER. Preparation and welding of structural members shall be in accordance with the approvec qualified welding procedures. All welds shall be continuous and full penetration unless otherwise noted an the drawings. All welding and preparation shall be performed in accor with AWS D1.1, excep as amended in this section. EMPLOYER approved SWIS ng. Each welder/welding operator shall be issued with the appropriate to the production joint on which he is wo: Each produ marked with unique identification. A permanent record shall be maintained to identify SWIS's to the weldment. Should a qualified welding procedure show unsatisfactory performance in production its use shall be suspended. The causes shal] be assessed and a modified welding procedure shall be qualified and submitted to the EMPLOYER for approval. WELDING EQUIPMENT All welding equipment shall be of sufficient capacity and shall be maintained in such condition as to ensure welds of the specified quality throughout the work, Welding equipment which in the opinion of the EMPLOYER does not meet this requirements shall be replaced by the CONTRACTOR. All electrical plant shall be adequately earthed and welding machine earth conductors shall be affixed firmly to the work piece. All return currents shall travel via the insulated earth conductor. Leakage through the ground to the machine shall be avoided. Welding cables shall be maintained in good condition at all times. Heat generating loose connections shall be repaired immediately. Iron powder units for SAW shall be calibrated once per shift. STORAGE AND HANDLING OF CONSUMABLES All consumables shall be stored and handled in accordance with the manufacturers recommendations and to a procedure approved by the EMPLOYER, these being the minimum requirements. Page 36 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.3.4 8.3.5 8.3.6 8.3.7 JES-S-20 All Welding Electrodes shall be supplied in clearly ieututied ier siiettvally sealed cartons of good condition and stored under a controlled cuviionueut ot 20°C minimum. temperature and 60% maximum humidity. The tempeisture aiid humidity shall be monitored and recorded on a weekly basis Prior to vse the electrodes shall be baked in auidase with the manufacturer: recommendations and shall be such as to produce « aitfusible hydrogen level o: 10ml/100g of deposited weld meial.(the EMPLOYER sey icquest diffusible hydroger testing to BS 6693 to confirm this). During baking elec odes shall nut be stacked greater than six high Upon completion of baking,electrodes shall be transieited iw tulding ovens at 150°C. Baking and holding ovens shall have adequate meas ul veuilletion and the temperature control and recording system shall be regularly checked and calibrated Hydrogen controlled SMAW electrodes shall be withu:awii as 1equired for immediate use and held in heated quivers at a minimum temperature ut /3°C All electrodes unused after a period of four hours or at the end of the shift, whictievct earlier, shall be scrapped. THERE SHALL BE NO RE-BAKING OF ELEC FRODES Quivers shall be in good working order and able 10 inaantatn the required temperature. ‘All unidentifiable, damaged, wet, rusty or otherwise cuutasuinated consumables 0: consumables left lying about the site or in the workshop shall be scrapped and removec at the CONTRACTOR expense. Different types/mehes uf electrodes must be clearly separated and identified whilst in ovens. SAW shall be supplied clearly identified in moisture proot cuntamers and stored in a dry location at a minimum temperature 20°C and a maximui huimdity of 60%. Identificatior must state manufacturer, grade and batch number. The manutacturer's recommendation: to restrict hydrogen content of the deposited weld metal 10 10mili 100g shall be mandatory. Unused flux shall be returned to the store or a heated flux oven at a temperature of no ess than 100°C at the end of the shift or welding operation SAW tux may be recyclec after sieving and drying to a procedure in accordance with the manufacturer: recommendations and approved by the EMPLOYER All wire consumables shall be clearly identified and stored in 4 dry Jocavion at a minimum temperature of 20°C. Identification must state manufacturer, grade and batch number, Unidentifiable wire shall not be used. Batch numbers of all consumables shall be recorded un issue Page 37 REVISIO : (8.6 8.6.1 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) WELDIN' JEN The CONTRACTOR shall develop welding sequences |W Loutio! aud uummise distortion warpage, accumulations of residual joint stresses and prevent the build up of excessiv stresses in the structure. WELD JOINT PREPARATION Preparation of fusion surfaces for welding shall be an accordauce with Clause 4 2. Butt welds shall be double sided full penetration unless vitierwise approved by WF EMPLOYER. Preparations shall be Vee type unless utherwise approved byt EMPLOYER, Where joint configuration or access inhibits the use ot double sided be voids the CONTRACTOR may propose, for approval by the LMPLOYER, the use of Single sided full penetration butt weld, Where practiceble, run on and run-off plates she be used on all plate welds in material of thickness greater than 10inin WELD EXECUTION Workmanship Clean, sound weld metal shall be provided as a base for weld metal deposition, this m. necessitate grinding or gouging. Bunering, for adjustment of weld geps or profiles, shal be pei usiued in accordance w: an approved procedure and at the discretion of the EMPLOYER ‘The use of permanent backing strips shall not be permitted ‘The welding procedure for a single sided butt weld shall provide 100% fusion of the re and be-such that distortion is minimised. Double sided welds shall be backgouged and ground from the reverse side, removing | root bead 10 sound weld metal before the second side 1s welded except where dispensation has been given. The resulting excavation shail have a profile suitable : Welding, Welding techniques which involve double sided welding without backsougi ef the second side shall be accepted entirely at the discretion of the EMPLOYER. Wr the CONTRACTOR proposes the use of a punch through technique his proposal st contain, as 2 minimum: 2) fully documented procedures in accordance with Clause 0.4 giving details of jnitial weld pass controls and inspection together with details of any treatment the second side prior to punch through. b) Detailed charpy impact data taken on the weld metal centre line of the put through bead and the associated HAZ for all thicknesses. (Figure 6.10-1). Pane 8 REVISQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.6.2 8.6.3 8.7 8.7.1 8.7.2 ES-S.20 Where 2 GMAW root run is employed to support the suaieiged <1. weld metal for the punch through technique, the CONTRACTOR shall ensure that his ruvt run is inspectec prior to the commencement of SAW. Inspection shall comprise of 100% visual plus ar initial requirement for 100% MPI until the production welding 1s proven to be of adequate quality (at the EMPLOYER's discretion). Inspection shall be un accordance with Sectior 10.0. All welding shall be to a small bead multi run technique, The weave width for SMAW shall not exceed three (3) thines the ure wire diameter 01 12mm deposited bead width, whichever is the greater, The width ut individual submergec arc beads shall not exceed seven (7) times the wire diameter Each run of weld metal shall be thoroughly cleaned of flux aid spatter and all slag removed prior to deposition of the next run. ‘The arc shall only be struck on the parent metal fusion taces, ur wo deposited weld metal Tack Welds Tack welds shall be of 2 minimum length of four (4) times the plate dnckness or 100mm. whichever is the lesser, They shall be of two passes and of sufticiemt cross section tc prevent cracking and shall be carried out with the same care, inaterials, electrodes minimum preheat and procedure as a permanent weld. For single sided welds, bridging tacks shall be used with the tacks being on the welc preparation. There shall be no tack welds deposited in the root For double sided welds where the root is tq be removed by bachyouging etc. the tack: may be deposited in the root. Tack welds that form part of the completed joint shall be ground to a feather edge anc be completely fused into the finished weld. Ail such instances shall be approved by the EMPLOYER. Fillet Welds Unless noted otherwise.on the contract drawings the minimum Jeg length of any fille: weld shall be 6mm. ARC-AIR GOUGING Only welders/personnel approved 2s per section 5.6 shall be used for arc-air gouging operations. Particular care shall be taken to ensure that the arc 1s not struck betore full air flow is established. Page 39 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) Bu 8.7.4 8.7.5 8.8 8.8.1 8.8.3 8.84 8.8.5 8.8.6 8.8.7 a Following gouging, all carbon and other residual dabris shall be thurouylily removed. Thy gouged surface shall be dressed to bright clean metal by grinding ur other mechanice method approved by the EMPLOYER. ‘The excavation shall have a profile suitable for welding If preheat is specified for welding, the same preheating shall le apped for are a gouging and cutting by a thermal process. WELD PROFILE AND SURFACE FINISH Weld profile defects shall comply with the limitations specified in Table 8.81 Welds shall not be peened. The use of needie guns does not consinute peening. The profile of as welded joints shall be as specified on the approved drawings, Tt surface of the weld shall have an even finish and shall merge smoothly with the pare. plete without abrupt irregularity or undercutting and generally be swtable for MPL When ‘toe’ dressing is required, it shall be performed in accordance with detailed contr procedures, approved by the EMPLOYER. Welds shall be profiled by dressing only where specified on the approved drawings + after inspection and authorisation by the EMPLOYER. Weld dressing shall only be performed by grinding or machining, Any Linear markin shall be transverse to the direction of welding. Surfaces of butt joints required to be flush shall be finished su as tot 10 reduce thickness of the thinner base metal or weld metal WELD INTERRUPTION ‘An interruption is defined as break in welding exceeding 15 minutes before the seco pass is complete, or exceeding 1 hour at any subsequent stage Unless specifically agreed by the EMPLOYER welding and prenieat maintenance shall ‘2 continuous operation. Welding shall not be interrupted nor shall the joint be lifted or transported before the rc rrun and the first six successive passes or one third the throat thickness, whichever is t greater, is complete. When interruption of welding is agreed with the EMPLOYER, the preheat may removed provided that slow controlled cooling of the weld area by use of insulat) blankets is ensured. In any event the joint shall be inspected visually and by MPI 1 linear defects prior to the recommencement of welding Page 40 REVISQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.10 8.10.1 8.10.2 8.10.3 8.1L B11 8.11.3 8.11.4 ES-S.20 Full preheating shall always be re-established before welding 1s :estai ted WEATHER PR: ION All weld areas shall be adequately protected from wind, moisture and/or sendstorm during the whole of the weiding cycle including preheat and post-weld vooling. Detaile: procedures shall be established for the above and shall include the means of protecting th consumables and shall be subject to approval by the EMPLOYER. Welding shall not be permitted if the ambient temperature falls beluw > °C Gas shielded welding, if permitted, shall be performed only sm workshops, unles individual approval is given by the EMPLOYER. PREHEATING AND INTERPASS TEMPERATURE Preheating shall be cerried out by electrical resistance or with gas burners specificall made and shaped for the operation. Hand held torches shal) not be vsed for preheatin purposes unless approved by the EMPLOYER, The minimum preheating temperature shall be established as follows 2) For hydrogen controlled basic SMAW and SAW, Scale C or BS 5135 shall b used in calculating preheat levels. If, however, the consumable used has a Scal C hydrogen level, the preheat shall be calculated using scale B levels. b) For each combined thickness the preheat temperature shell be calculated i accordance with the recommendations of BS 5135, provided that the hardnes acceptance criteria specified in Clause 6.9.5 are met. In certain cases, typically those listed in BS 5135 (E3 of Appendia E), the prehee temperature calculated by this method may be insufficient. In any such case th CONTRACTOR shall establish an appropriate preheat temperature, record this in th welding procedure and notify the EMPLOYER. ©) Where preheat is not required by (0), the workpiece shall be dry and at minimum temperature of 10°C within 75mm of the surfaces to be welded. The preheat temperature shall be established for a distance of at Jezst 73mm on either sid of the weld line and throughout the thickness prior to welding. Preheat should be applie: to the opposite surface to welding if possible and shall be maintained over the full lengt of the joint and throughout welding unless otherwise approved by the EMPLOYER Insulation shall be provided on adjacent areas, if necessary, to maintain the require degree of preheat during welding Page 41 REVISIOQATAR GENERAL PETROLEUM CORPORATIO. (Oil & Gas Operations) 8.11.6 8.12 8.12.1 8.13 8.13.1 ES-5-20 The temperature measurement for preheating shall be by calibrated digital thermometer, thermocouples, thermocrayons or a combination of these methuds approved by the EMPLOYER. Dering welding, the interpess temperature shall be monitored as in Ulause 8.11.5 anc shall not exceed 250°C or that temperature specified in the welding procedure specification whichever is the lower and shall not be less than the imunimum prehea temperature. ‘T WELD HYDROGEN DI ION TREATMENT For the more critical welds, e.g, closing welds involving high restraint, welding procedures shall include the precautions against hyérogen cracking and/or lamellar tearing specified in BS 5135 Note, that for such welds, the period of treatment mey need to be longer than tha cated in BS 5135 (E3 of Appendix E). For further assurance against hydrogen cracking, or where NDT os sequined within 4 hours of weld completion and is approved by the EMPLOYER, approval may be giver by the EMPLOYER for the application of 2 post weld hydrogen dirtusion treatment 1 individual joints. In such cases the entire weld shall be raised 10 a temperature of at leas 150°C for a minimum period of 1 hour per 25mm thickness of joint The temperarur shall be carefully controlled and shall not exceed 200°C POST WELD HEAT TREA MENT Post weld heat treatment shall, wherever possible, be carried aut in an enclosed furnace Where it is impractical to carry out the treatment in a furnace, local heat treatment ma be adopted by written approval of the EMPLOYER. ‘The temperature of the fabrication during post weld heat treatment shall be determine by thermocouples in effective contact with the fabrication. A sufficient number ¢ thermocouples (to be approved by the EMPLOYER) shall be applied to the fabricatio to ensure that the whole fabrication is held within the temperature range and gradier limits specified. A sufficient number of temperatures (at least four) shall be continuous! and avtomatically recorded on a chart. ‘The CONTRACTOR shall submit for approval by the EMPLOYER, PWHT procedure demailing, 2s a minimum, the following: 2) Heat treatment method (furnace or local), b) Heat treatment parameters as specified in Clause 8.13.4, ©) Thermocouple location and attachment method, 4) Details of insulation etc, Page 42 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.13.2 8.13.3 8.13.4 ESS.20 e) The type, number and location of supports installed to prevent usstortion ete. PWHT shall be performed on all joints as follows: 2) For all regions where the thickness of the thinnest plate being juined by the wel under consideration exceeds 40mm. b) As otherwise shown on CONTRACTOR drawings approved by the EMPLOYER. The ruling thickness for welds berween pasts of unequal thickness shall be that of the thinner part. All PWHT shall be performed in accordance with the requirements of BS 5500 (4.4.3 tc 4.4.5 inclusive) as specified for M1 materials over 50mm thick ‘The post weld heat treatment requirements for any special alloy steels involved, shall be gree between the CONTRACTOR and the EMPLOYER prior 10 commencement 0: fabrication. The post weld heat treatment temperature r nese Stee! shall be 610° C+: 10°C. The holding time at this temperature shall be one hour per 25mm of material thickness, with a minimum period of one hour, For furnace post weld heat treatment, the temperature of the furnace at the time the fabrication is placed in it shall not exceed 300°C. The rate of heating in the furnace shall not exceed the following: $500°C or 55°C per hour ‘ t whichever is the greater, where 't' is the material thickness. During the heating period there shall not be greater variation in temperature than 150°C over a 450mm interval of length. This shall apply to any portion of the fabrication being post weld heat treated. After holding for the minimum specified time the fabrication shall be cooled to @ temperature of 300°C at a rate not exceeding the following: 6875°C or 55°C per hour t whichever is the greater, where 't' is the material thickness. Below 300°C the fabrication may be cooled in still air Pane 43 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.13.5 8.13.10 8.13.11 8.13.12 FSS.20 ‘The CONTRACTOR shall consider the need for 2 slow heating and cvuling rate fc complex fabrications. When local post weld heat treatment is approved by the EMPLOYER, a region of at lea five (5) times the material thickness on either side of the weld or the faonication requirin post weld heat treatment shail be maintained at the specified temperature for the specific time. ‘The surrounding area shall be insulated such that the metal temperature at the outer eds of the insulation accords with BS 5500 clause 4.4.4.3 and in any event does not excet 300°C. ‘The configuration and dewil of localised post weld heat treatment shall be submitted the EMPLOYER for zpproval. This should include the number and location » thermocouples. The CONTRACTOR shell inform the EMPLOYER prior to any PWHT operation order to permit a full review and inspection to be made. All PWHT operations are subje to approval by the EMPLOYER. PWHT of nodes shall be performed on the node as a complete component in an enclos: furnace. PWHT temperature/time charts shall be clearly identified, ver CONTRACTOR and included in the structural records, ied by t No welding shall be performed on fabrications subsequent to PWHT except: 2) Welding required for installation ipto the main structure, b) _ Atachment welds onto doubler plates, c) Repairs within an area which itself would not require PWHT In no instance shall welding be permitted on PWHT nodes PWHT may be repested provided that the CONTRACTOR hes demonstrated that t mechanical properties of the weld metal, HAZ and parent metal are not degraded. Tt may be achieved through a welding procedure sudjected to @ double PWHT cycle, The CONTRACTOR shall ensure that adequate structural support is installed during WHT operation to prevent any sagging, warpage or distortion during the thermal cyc In determining the locations of supports the CONTRACTOR shall assume a YS at PWE temperature not exceeding 30 Nmm?. Where doubler plates are to undergo PWHT they shall contain an air hole which shall made good after PWHT using procedures approved by the EMPLOYER. Pave 44 REVIS!QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.14.1 8.14.2 8.14.3 8.14.5 814.7 814.8 8.14.9 WELD REPAIRS No rectification, repair or modification may be made without ine «pproval of th EMPLOYER Extent of cracks in welds or base metal shall be ascertained by use of non-destructiv inspection. The cause of cracking shall be established prior to removal and repair, a fu report issued on cause and corrective action. The removal of defective areas shall be done by machining, grinding and any othe method which produces a clean, uncontaminated surface for rewelding. The resultin excavation shall be ground to bright metal and have a contour to permit ease of repai welding. Defect removal shall be assured by MPI. Oxy-acetylene gouging shall not b acceptabl Removal and repair of cracks in weld deposits or base metal shell be witnessed an approved by the EMPLOYER who reserves the right to witness the repair Repair welding shall be performed in accordance with the approved qualified weldin procedure end the follow a) The crack and SOmm of sound metal beyond each end of the crack shall b semoved by a method approved by the EMPLOYER b) The welding sequence and technique shall be selected 10 minimise distortion anc restraint. ©) ~ Preheating shall be to a temperature of 55°C or 50°C above that specified in the relevant original welding procedure, whichever is the higher temperature. The EMPLOYER may require further tests or simulated repairs Additional weld metal shall be deposited using an electrode preferably smaller than tha used for making the original weld. The surface of the member in tubular intersectior Joints containing root cracks or transverse cracks shall be inspected by non- destructive ‘methods to detect propagation into the base metal. The intersecting member shall be completely removed if, in the opinion of the EMPLOYER, the surface of the membe: cannot be properly inspected or repaired ‘Subsequent to repair, the repair area plus 100mm on either side shall be reinspected 100% by all the NDT methods prescribed for the original weld ‘The EMPLOYER reserves the right to limit the number of repairs along production weld and to require complete rewelding of the joint. he length of any The use of single pass weld repairs and the rectification of damage at temporary attachment locations by spot weld deposition shall not be permined. Page 45 REVISIO:QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 8.14.50 Rectification, repairs and modification shall be fully identified and documented. This sha! include detailed inspection procedures, with an accurate description of the dimensions an locations of all defects and repairs for reference during final and/or in service inspection 81411 The CONTRACTOR shall maintain an up-to-date register of all welds found to contai unacceptable defects. Repairs performed both prior to and after PWHTT shall be recorde and the register shall be freely available for inspection by the EMPLOYER at an reasonable time. The register shall include the following information: 2) Weld identification. b) Weld type and thickness. ©) Welding procedure number. €) Welding process or processes. ) Welder or welding operator. Details of defect. g) Date welded. h) Date defect found. i) Repair procedure. 5) Date of repair. k) Date repair accepted by CONTRACTOR/EMPLOYER, Fe.s.70 Pane 46 REVISHQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 91 TRU AL WELDIN ENER. “All structural welding shall conform to welding procedures approved by the EMPLOYEF jtis the CONTRACTOR''s responsibility to provide adequate supervision to ensure sa adherence to the approved procedures. Welding shall not be done when the ambient temperature is below 5° C, when surface to be welded are wet or exposed to rain, high wind or sandstorms, or when welders & exposed to inclement weather. SURFACE AND EDGE QUALITY “ANI surfaces to be welded shall be 100% visually inspected and shall be free from burr tears, oracks or any other discontinuity which would adversely affect the weld qualit Sorface to be welded and adjacent surfaces shall be free from millscale, rust, greas moisture or other foreign material which would prevent setisfactorily welding. ‘Any discontinuity greater than émm in length shall be removed by Giscontinuity greater than 6mm in depth, or where the excavation would adversely affe the welding of the joint, shall be repaired in accordance with Clause 8.14 ‘An witrasonic plate scan shall be carried out in accordance with BS 5996, prior beveling and welding, 50mm either side of the following weld details: 2) Butt welds (including T-butt welds), b) Fillet welds with a leg length equal to or greater than 20mm Any areas having discontinuities in excess of grade L4 of BS 5996 shall be subject ‘approval by-the EMPLOYER prior to preparation. ‘Azeas of brace/stub to chord welds shall be mapped out on the surface of the continuc member and this area, including 50mm either side of the estimated weld locations, sh be ultrasonically checked in accordance with BS 3996 L4, prior to fitting the nc witinuous member. Where all other abutting members of thicknesses greater than 20mm are to be welded ot primary steel the continuous member shall be subjected to ultresonie excmination Shove. If any laminar indications producing @ loss of back well echo greater than 3¢ gre found the continuous member shall be re-aligned to avoid such areas, with zpproval of the EMPLOYER Ultrasonic operators shall be qualified to either level 3.3P or 3.4P, as approps CSWIP-UST-S, or to an alternative standard approved by the EMPLOYER Pave 47 REVISQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 9.3 The cut edges will be visually examined for laminations, cracks or uther defects i accordance with the requirements of Clause 9.2. ‘The hardness of thermally cut edges shall be limited to 325 Hv 10 eit speed cutting or by grinding back or machining after cutting. by controlie Thermally cut edges which will be incorporated into the completed joint shali be dresse back by grinding to remove notches and scale. Thermally cut edges which will not be incorporated into the completed joint shall b dressed back by approximately 2mm to produce a smooth profile and radiused edges. The CONTRACTOR shall qualify thermal cutting procedures in accordance with th requirements of Clause 6.10. ‘All exposed edges of plates, sections etc., shall be chamfered to a 1.Smm radius, Profiling of tubulars and other shaped sections shall be accomplished by the use ¢ mechanically guided torches wherever practicable. Any bevelled edge that has been damaged shall be restored to the tolerances indicated i the approved welding procedure specification. Where such restoration involves weldin only approved procedures shall be used and all repairs shall be recorded. W) T GAP: For gaps which exceed the limitations of clause 5.5.3 and the approved weldin procedures, one of the following options may be considered dependent upon th circumstances: : a) The joint to be taken apart and refitted. b) The joint to be taken apart, buttered and refitted. ¢) The removal of a section and fitting of a suitable insert piece. The option adopted in each instance shall be approved by the EMPLOYER. Butering will only be considered by the EMPLOYER 2s a corrective measure in certai instances. The buttering of joints in situ should be avoided. The deposition of buttere- layers on the continuous member surfaces of T, K, Y or brace/stub to chord joints 0 single sided welds shall not be permitted. Buttered layers shall be ground/machined to the required profile and subjected t ultrasonic testing, if practicable, and MPI prior to welding of the joini. REVISIOQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 9.4 9.6 97 ‘All welds completed with buitering shall be subjected to 100% NDT on completion usin the appropriate techniques detailed in Section 10.0 for each weld type. WELD OVERLAPS. Whereit is necessary for attachment welds to cross or coincide with previously complete putt welds, these latter welds shall be made flush by grinding 50mm each side of the are of contact and subjected to final inspection prior to making the attachment weld. ‘The ground portion of the butt weld shall have a gradual transition to the nominal we! profile and be free from notches or sudden changes in section. COMPATIBILITY OF WELDS ‘All welds shall develop the strength, ductility and notch toughness specified for the ste being welded. Welds forming connections between steels of different grades shall develop the san sirength as that specified for the higher strength steel and shall develop values of duct and notch toughness equal to the larger value of those specified for the being welded. CON’ F DISTORTION AND. In assembling and joining parts of a structure or of built up members, and in weldi reinforcing parts to members, the procedures and sequences shall be such as will minim: distortion and shrinkage. Where practicable, all welds shall be deposited in a sequence that will balance the appl heat of welding during the weld progression. The CONTRACTOR shall prepare a welding sequence for a member or structure whic in conjunction with the joint welding procedures and overall fabrication methods, * produce members or strictures meeting the quality requirements of this specification. T welding sequence and distortion control program shall be submitted to the EMPLOY! prior to the start of welding on 2 member of structure in which shrinkage or distort js likely to affect the adequacy of the member or structure. In making welds under conditions of severe restraint the welding shall be carried « continuously to completion or to @ point that will ensure freedom from cracking befc the joint is allowed to cool below the minimum specified preheat temperature, DISTORTION CORRECTION Distortion occurring for any reason shall not be corrected without the approval of EMPLOYER. Pane £0 REVIS9.8 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) The CONTRACTOR shall submit to the EMPLOYER for approval a correction procedure including full details of the distortion and the corrective treatment proposed. Tht procedure specification and control shall ensure that full mechanical properties ar maintained. WELDING PO: N: As far as is practicable, nodes shall be positioned so that no welding is performed in the overhead (4G) or vertical up (3G) positions. SMAW shall not be performed in the vertical down (3G) position. GSFCAW shall b: limited to the vertical up (3G) position for root passes. Welding of node stub to barrel joints shall be performed in the flat (1G) or horizonte (2G) positions except that: 2) For both positions, slope is permitied to 25°. ) For the flat (1G) position, rotation is permitted 0 3 c) For the horizontal (2G) position, rotation is permitied from 65° to 115° TEMPORARY BRACINGS AND SUPPORTS, Scaffolding suppozts and facilities for supervision and inspection of the work shall be provided as necessary. Scaffolding supports shall be sufficiently robust to preven deformation. Adequate temporary bracing shall be provided and left in position until such time as the structure is sufficiently far advanced for the bracing to be no longer required REMOVAL OF TEMPORARY ATTACHMENTS All temporary attachments shall be removed unless permission is obtained from the EMPLOYER to the contrary. Temporary attachments shall be removed by thermal cutting and/or grinding. If therma cutting is employed, the attachments shall be cut off at a minimum distance of Smm from the surface of the structure and then ground flush ‘Temporary attachments shall not be removed by breaking the back of securing fillet welds by hammering or any technique which may cause mechanical damage to the surface of the material forming the main structure. Following the removal of a temporary attachment any damaged area shall be ground 10 merge smoothly with the original surface and the surface shall be subjected to 100% MPI lES.s.20 Pave $0 REVISIONles-s.20 QATAR GENERAL PETROLEU M CORPORATIO (Oil & Gas Operations) Where gouges deeper than 5% and not more than 10% of the member thickness hay een made, these shall be profiled by grinding, inspected, and then repair welded to approved procedure. After completion of the repair the repaired area shall be subjecte to 100% MPL the repair techaique shall be subje Where gouges exceed 10% of the member to approval by the EMPLOYER. INSTALLATION OF BAR GRATING “The studs welded to the structure for the purpose of bolting down the gi shall t welded in accordance with an approved welding procedure tested in accordance wi Section 7 of AWS D1.1 (latest edition). Galvanised surfaces SHALL NOT be welded. Page §1 REVIS!QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 10.1 INSPECTION AND TESTIN GENERAL The CONTRACTOR shall formulate and implement 2 quality control plan complying wit the requirements of this specification Inspection and testing shell be performed by the CONTRACTOR in such a manner ast ensure that all the requirements of this specification and the referenced document: Inspection by the EMPLOYER and the TPT shall in no way absolve the CONTRACTO! from this responsibility. In structural welded connections, the non-destructive testing shall be done successivel after each weld has been performed including the heat treatment if applicable. The EMPLOYER may wish to inspect materials, equipment, testing facilities an fabrication at any stage and to reject any part which does not comply with thi specification The CONTRACTOR shall supply all labour, equipment, appliances and access facilitie required to permit the EMPLOYER and the TPI to perform inspection and the witnessin of testing in a safe and thorough manner. All inspection and testing shall be performed to written procedures which shall be i accordance with the Specification for Non Destructive Testing of Structural Welds ES-S 60. These procedures shall also comply with the applicable requirements of thi specification and shall be subject to review and approval by the EMPLOYER, prior t the commencement of fabrication. NDT procedures shall take account of actual weld preparations and joint access to ensuri full inspection coverage of the joint cross section. Limitations on'the use of NDT which are due to joint design or fabrication sequence shal be defined in the NDT procedures. Any limitations subsequently identified at th: fabrication stage shall be subject to the approval of the EMPLOYER prior to welding tht joint. The CONTRACTOR shall furnish a dark room and viewing equipment available at any time for the EMPLOYER or the TPI to review radiographs. Specific NDT procedures shall be qualified for single sided welds which have misalignment or root gaps in excess of those specified in Clause 5.5.3. These procedures shall include interim inspection to ensure an internal weld profile ir accordance with the design requirements and soundness of the root penetration bead. Where fatigue sensitive joints are noted on the drawings the interim inspection shal: include the use of internal viewing aids and radiography. Page $2 REVISIO!QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) On welds which are not subject to PWHT, NDT for acceptance purposes shall b performed no sooner than 48 hours after completion of welding On welds which have been subjected to PWHT, NDT for acceptance purposes may 5 performed immediately after PWHT. An initial (non acceptance) NDT shall be performe pur to PWHT to permit any necessary repairs/rectification and inspection at the earlie possible stage. However, due consideration shall be given to the relative delays betwee welding, NDT and PWHT and the possible incidence of hydrogen induced delaye cracking. Surfaces shall be clean and free from spatter and heavy oxidation or any othe contaminant which might affect NDT interpretation. STAGES OF INSPECTION ‘Asa minimum, the inspection stages employed by the CONTRACTOR for welded join shall be as follows:- 2) __ fit-up prior to the first pass, b) uring the welding of the root pass of single sided closing welds, c) following the root pass, 4) following any back gouging operation, €) following completion of welding, f) after PWHT if epplicabl Inspection of surfaces to be welded shall be as described in Clause 9.2 Inspection at stage (2) shall be visual and dimensional. 1 (b) shall be visual (with the addition of supplementary radiography fc tive joints as described in Clause 10.1). Inspection at fatigue sensi Inspection at stages (c) and (d) shall normelly be visual unless supplementary NDT required to explore the extent of visually observed flaws or previous productic performance indicates that unacceptable flaws may be present. Inspection at stages (e) and (f) shall be visual-and NDT as specified in Clause 10.3, Page §3 REVISICYERAL PETROLEUM CORPORATION (Oil & Gas Operations) QATAR GE! 10.3 10.4 10.4.3 | [Es.s.20 EXTENT OF INSPECTION For ail fabrication carried out in accordance with this Specification the exient shall be in accordance with Tables 10.3-1. ‘The CONTRACTOR shall employ any additional NDT techniques necessary to en: evaluation of welds or clarification of defect indications. 2) For welds greater than or equal to 500mm length, the pe: testing of each weld of a given type by the stated percentage (¢.g weld). tage shall mean 100% t in 10 welds b) For welds less than 500mm length, the perce: ting of th stated percentage of welds of a given type (e. ACCEPTANCE CRITERIA General ‘Acceptance levels for NDT, including visual examination, shall be 2s specified in Tab! 6.8-1 except for ultrasonic examination as amended below. Definitions Reference Level - Distance Amplitude Correction (DAC) curve with transfer correctio added. The curve shall be derived using the appropriate calibration block with 1.Smi diameter side drilled holes for buried indications, and API RP 2X V notches for surfac breaking indications, Reporting Level - 50% of reference level. All indications which exceed reporting leve: shall be recorded in the report stating type, length, height and position. Acceptance Levels The acceptance levels given below should be read in conjunction with the calibratio blocks and the flaw reporting requirements specified in Specification 72? 2) Cracks or Lack of Fusion Unacceptable irrespective of amplitude. b) Porosity or Slag Inclusion (All dimensions Jess than 3mm) Acceptable irrespective of amplitude if separation is greater than 1/4 of materiz thickness. Page $4 REVISIC10.5.2 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) c) Fine Slag Lines (All dimensions other than length below 3mm) Not acceptable if amplitude equals or exceeds the reference level, and th maximum dimension is greater than 1/4 of material thickness. For defe separation see Table 8.8-1. d) Large Slag Inclusions (Including clusters of inclusions with length and heigi greater than 3mm Not acceptable if amplitude equals or exceeds the reference level, and maximum dimension is greater than the smaller of 1/4 of material thickness ¢ 15mm. For defect separation see Table 8.8-1 ) Root Indications in Single Sided Welds (indications within 3mm « Not acceptable if a flaw indication obtained by 45°, 60° or 70° shear wave probe exceeds the echo amplitude derived from the appropriate API RP 2X V notch an the length of the indication exceeds 1/4 of material thickness. Planar indicatior are unacceptable. ADDITIONAL NON DESTRUCTIVE TESTING If the EMPLOYER or the TPI has reason to believe that a defect exists in any weld c pass, including tack welds, then the CONTRACTOR when so directed, shall perform a inspection and testing required by the EMPLOYER. If percentage checking of welds reveals a defective weld, the rate of inspection shall b increased at the EMPLOYER's discretion. The defective weld shell be repaired an reinspected. A further weld shall be selected for inspection, The defective weld shall nc be deemed to be part of the percentage inspection If the weld is deemed defective, it shall be repaired or replaced to the satisfaction of th EMPLOYER. Where the EMPLOYER deems it necessary to increase the extent of testing other than fo reasons of defects, the CONTRACTOR shall comply with such increased requirement and perform this work. Arc strikes outside of the weld preparations shall not be acceptable. Where these ar determined during inspection, the arc strike shall be ground out to a smooth profile anc subjected to MPI. Where the are strikes are caused by damaged cables the areas shall be additionally etched to ensure freedom from contamination. Page 55 REVISIOQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 10.6 NDT 1 SIQUES_ AND QUALIFICATIONS Requirements for NDT techniques, qualification tests, personnel qualifications anc reporting are detailed in ES.5.60 (Specification for Non Destructive Testing of Structure \ Welds). 10.7 PRODUCTION TEST PLATES Production test plates are not normally required. The EMPLOYER reserves the right « introduce production testing if welders are found to be operating outside the parame in the approved SWIS. The extent of testing will be decided by the EMPLOYER but | not exceed 1 in 10 initially, reducing to 1 in 25 welds. The CONTRACTOR may apply for a reduction in the number of test plates required afte a significant number of acceptable tests have been completed Production test plates shall be prepared and tested in accordance with Clauses 6.8 an 6.9. The time taken from weld test completion to receipt of results shall not exceed fiv (10) working days FS.6.20 Page $6 REVIS)11.0 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) SURFACE PREPARATION & COSTING SYSTEMS ‘All items and equipment are to be supplied by the CONTRACTOR condition as required by the relevant clauses of ES.Q. 10 and ES.Q all structural steelwork, piping and all repair painting as necessary. Page 87 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 12.1 LTIN' GENERAL This section defines the EMPLOYER's requirements regerding preperation and boltin; of structural members. The use of bolted assemblies shall be kept at a minimum and onl; used when specified on the CONTRACT DRAWINGS. Bolts, nuts and washers shall conform to ASTM A307 A325 and A490. Bolt tensionin; and inspection shall be in accordance with AISC Specification for the Design Fabricatio: and Erection of Structural Steel for buildings. PREPA\ N Holes for bolted connections shall have diameters 2mm larger than the bolt size, unles otherwise indicated on the drawings. Holes shall be drilled perpendicular to the surface of the member. Holes shall not bs made or enlarged by burning. Enlarging of holes shall be by reaming and then only with the approval of the EMPLOYER. Holes shall be clean-cut without torn or ragged edges Outside burrs resulting from drilling or reaming operations shail be removed with < reamer making a 2mm bevel Where holes are provided for the connection of equipment, piping, etc., and affect any major structural member, the said member shall be adequately reinforced as required. All holes shall be drilled and reamed as necessary prior to any blast cleaning. ASSEMBLY Parts to be joined together using high strength bolts which are in contact with the bol head and nut shall not have a slope of more than 1/20 with respect to a plane normal tc the bolt axis. Where the slope is more than 1/20, bevelled washers shall be used. High strength bolted parts shall fit solidly together when assembled and shall not be separated by any compressible material When assembled, all joint surfaces shall be free of loose scale, dirt, burrs and other defects that would prevent solid seating of the perts Bolts shall be driven accurately into holes without damaging the threads. Bolt heads shall be protected from damage during driving. Bolt heads and nuts shall rest squarely against the metal. Unfinished bolts transmitting shear shall be threaded to such an extent that no more than one thread will be within the grip of the structural members. The bolt shall be of a length that will extend entirely through but not more than 5mm beyond the nut. Bolt heads shall be struck with a hammer while the nut is being tightened. After having been finally tightened, nuts shall be locked. Page 58 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 13.2 13.3 WEIGHT CON SCOPE The following describes the requirements for the control of weight and centre of gravity for the facilities which the CONTRACTOR shall perform during fabrication. PURPOSE The object of this specification is to ensure the weight and centre of gravity of the individual offshore lifts remain within the capacity of the available crane vessels. Alsc that the overall weight and centre of gravity of the facility does not cause the loaé carrying capacity of the jacket piles to be exceeded DEFINITIONS Dry Weight Weight after installation and after removal of all tackle. All equipment installed in operating positions, but without operating Auics. Operating Weieht The weight of an item at the time of commissioning charged with operating fluids/materials to its designed maximum operating Jevel at normal fluid/material density and with no crew, luggage or consumables on board. Lift Weight The weight of an item, module or topside at the time of lifting which includes installation aids such as slings, shackles, bumpers, guides, pins, buckets and any temporary bracing required for lift or installation. However, the lift weight excludes all operating fluids, with the possible exception of any diesel fuel remaining in deck crane day tank subsequent to the crane having been tested, and gear box oil. Maximum Allowable Lift Weight The maximum allowable lift weight is the maximum allowable weight of any item, module, jacket, or deck section which is to be individually installed offshore. The maximum allowable lift weight shall be determined at the commencement of the project and shall take account of proposed craneage parameters, lift radius, sling and tackle allowances, etc. as may be required. Basic Weisht The weight of an item in the dry, operating or lift conditions with no contingency added for estimation, design change, fabrication or weighing. ES$.20 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) Factored Weigh The weight of an item with a contingency factor added for all, of a combination of an of the folowing accuracy allowances:- estimation, design change, fabrication, weighing Main Lift An item included at main lift is an item that is permanently installed in the module, deck topside or jacket during fabrication and is present at the time of the facilities’ main li and installation. \ffshi led An item is deemed to be offshore installed when it is an item that will be permaneni), installed in or on the mein lift facility but is lifted and installed separately from it, Temporary for Fabrication An item is deemed to be temporary for fabrication when it is an item that is required only Guring the fabrication phase and is removed from the facility prior to loadout. ‘Temporary for Loadout An item that is installed in the facility purely for the transportation of that facilit its shore location to the transportation barge but is removed prior to sail away. fron. Temporary ransportati Are items such as external sea fastenings which are attached to the facility for transportation but are removed prior to the lift of that facility. Temporary for Lift Is an item that is required to be installed in or on the facility for the lift condition but that is removed subsequent to the installation of that facility Hook-up Item Is an item that is to be permanently installed on the platform (not including hook-up construction temporaries) subsequent to the installation of the main facilities to complee the platform and enable it to be commissioned Zero Di -oint Is the point which all item co-ordinates are measured in the east, north or vertical planes. It is located at the centre of the jacket in the north and east directions and at Chart Datum in the vertical. For a module, topside, or deck, the location is at the south west column ES.S-20 Page 60 REVISIONQATAR GENERAL PETROLEUM CORPORATION 7 (Oil & Gas Operations) 134 node of the main trusses in the north and east directions and at the top of lower deck leve in the vertical Prefabricated Units Prefabricated units are specific sections identified by the Designer or Fabricator whic will be built as complete separate units before being installed in the module, deck o jackes, . Current as Built Weight The Current as-Built Weight is the summation of all current weight take-offs fron individual construction drawings. IN" JRING FABRICATION 2) At Contract bid stage TENDERER's shall be required to provide details of th: Weight Control procedures and program to be utilised. bd) At Consract award and where the nominated CONTRACTOR is not responsible for Detailed Design he shall be provided with the relevant extracis from the Detai Design Package containing the Detail Design Weight Control Report. This repor provides the maximum lift weight for each offshore lift together with the uppe: bound dry and operating weights. These weights shall form the Control Weight: for the fabrication phese of the project and shal] not be exceeded without prio: agreement with the EMPLOYER. If a weight limit warrantee is required in the contract this shall be identified in the particular contract specification ©) The CONTRACTOR shall be responsible for maintaining the.control af weigh and centre of gravity throughout the fabrication phase and shall provide sufficien number and quality of personnel -to achieve this end 4) The CONTRACTOR shall be responsible for weighing and reporting the weight of-all prefabricated units; a weight control schedule shall be prepared by the CONTRACTOR sso that the predicted weight for each prefabricated unit is ayailable to the EMPLOYER at unit weighings 2) The schedule shall itemise all items by fabrication drewing number and equipment number together with the calculated weights and vendor weighed weights, and should be summated to reflect the current "as built" weight f) The CONTRACTOR's weight control schedule shall be available for inspection by the EMPLOYER at all times. s) The CONTRACTOR shall provide the EMPLOYER with one copy of the weight control schedule at monthly intervals or as determined in the Contract Specification. Page 61 REVISION3) “QATAR. GENERAL PETROLEUM CORPORATION : (Oil & Gas Operations) The CONTRACTOR si I ensure that the fabrication the Design drawings issued for fabrication and are identi more than one fabrication drawing represents one design drawin; Grawing shall reference the relevant design drawing and rev The CONTRACTOR shall calculate weights by drawing. Weights shall be nei take-off weight with allowances for welding and rolling tolerances listed separately. Installed tagged equipment with actual vendor weighted weights, equipment supports, bracketing, etc, shall be calculated and reported separately on Supplier weight data sheets. Weight of pipework shall be obtained by calculating weight from the individual isometric or fabrication sketches and producing a cumulative weight total as each pipe spool is installed. The accuracy of this method shall be checked by weighing typical spools and applying an eventual correction factor to calculated spool weights. Pipe and fittings weights shall be calculated spool weights fitting weights shall be calculated by applying unit weights from piping catalogues or vendor information. Weighis of piping "specials" shall be obtained from weigh bills or vendor information. Weight of pipe supports, hangers, clips, etc., shall be calculated from unit weights or test weights. The weight of electrical/instrument equipment shall be from weigh bills, vendor information or trial weighings; weight of cabling shall be obtained from the cumulative record of lengths and types of cable installed and applying unit weights. The weight of cable tray installed shall be calculated by applying unit weights obtained by trial weighings. Weight of supports, hangers,and brackets for equipment, traywork, etc. shall be calculated and reported separately. Where hangers/supports are a multiple design a sample should be weighed and applied for the quantity installed. The weight of instrumentation/electrical accessories, glands, shrouds, lugs, thermowells, etc. shall be established by weigh bills, manufacturers data or weighing, and the weight of such items installed, reported separately. Small diameter instrument piping weight shall be calculated by length installed, unit weight being established by trial weighing. Weights of thermal insulation and cladding, strapping, etc, shall be calculated from unit weights based on vendor information or trial weighings. Weights of architectural materials such as wall panels, partitions, hardware, floor covering, ceilings, furniture, soft goods, etc., shall be calculated from weigh bills or vendor supplied information, trial weighings or from weight information contained in the schedule of weights of building materials. Weights of consumables, fastenings, etc, shall be estimated. ES-S-20 Page 62 REVISIONDd ‘The CONTRACTOR shall develop a format for a weight status report and submit to the EMPLOYER for review and approval. This report shall be submitted on @ monthly basis or as otherwise agreed. The report shall contain as a minimum the jollowii 1). Weight dy process system 2) Weight by discipline. 3) Weight by Module/Module Support Frame/Bridge/ Jacket. 4) Current weighed weight of each prefabricated unit including excess material list. 5) Temporary materials such as sea fastenings, lifting equipment etc 6) Schedule of all items included in the weighing. Weight and C. of G. of Facility ) General All topside modules, module support frames, jackets and bridges etc. are to be weighed in order to confirm that horizontal and vertical centre of gravity co-ordinates are within predicted tolerances. The contractor shall weigh each module twice during the fabrication programme, at the following stages: - When the majority of carcast steelwork has been erected, this shall be agreed with the EMPLOYER. - “Immediately prior to loadout. The module support fames, jackets and bridges etc. shall be weighed once, immediately prior to loadout. At the discretion of the EMPLOYER an intermediate weighing shall be required for any unit where the predicted lift weight is critically close to the Maximum Lift Weight. At each weighing the unit shell be raised and lowered 3 times giving 3 separate readings, to provide an average. These readings together with the average shall be entered on the Module Weighting Certificate. e Page 63 REVISION_QATAR GENERAL PETROLEUM CORPORATION ~~ il & Gas Operations) During all weighing operations, the Fabrication CONTRACTOR shall be responsible for all work carried out. The work shall include but not be limited 10 the following. and fabrication of all supports to be used. The design shall be approved by the EMPLOYER and shall be such that the out of level berween supports is not greater than 1:4000, and installation and removal of the load cells causes minimum disruption to fabrication schedules. Ensuring good accessibility for installing the weighing equipment. Keeping detailed schedules of the weight of any portion of the support which is weighed with module, Specifying, supplying and installing any local structural stiffeners required at the Joad cell position to prevent local overstressing of structure. Supplying all equipment necessary to conduct the weighin; ing and level ipplying all equip! y ghing 8 adjustment operations against accidental collapse. Design and supply of any temporary structure, equipment and devices required to prevent accidental collapse of the structure. All Joaé measuring equipment shall be calibrated at 2 frequency advised by the equipment manufacturer, but in any event, the equipment shall be calibrated immediately before the first weighing and thereafter at 3 monthly intervals, and also immediately before the final weighing. ‘Using the load measuring and jacking equipment in such a manner that in measuring the reactions at the support locations, no large re-distribution of loads occur in the unit due to structural stiffness. Immediately prior to each weighing, a schedule of estimated fabrication equipment weight shall be made, in order to determine a true unit weight (e.g. welding sets, scaffolding etc.). Notification to the EMPLOYER of time and date of load cell calibration and weighing of Prefabricated units. The EMPLOYER reserves the right to witness all prefabricated unit weighings and requires to be informed of all such weighing ~ Gates, time and location. At least 10 days prior notice shall be given. Performance of all weighing, including all associated work and calculations required for weight and centre of gravity determination. Ensuring that any temporary scaffolding standing in the ground surroundings the prefabrication can be released for weighing operations. ES-S-20 Page 64 REVISION¢ 9 D ‘The prefabricated units shall be weighed using load cells which have an accuracy within +1.5% and are of the self aligning type. The jacking system shall be a linked hydraulic jack system, with 2 means of ensuring an identical volume of fluid being pumped to each jack. The system shell be used in accordance with the manufacturers instructions. Detailed procedures are required for each weighing together with full details of the weighing system. The procedure and system shall be approved by the EMPLOYER before any such weighing takes place. All weighing operations shall be carried out to the satisfaction of the EMPLOYER. ‘Two copies of all weighing results shall be sent to the EMPLOYER. Weighing Certificate The CONTRACTOR shall submit for approval his proposed "W which, after approval by the EMPLOYER, shall be used for all weighir g Certificate Page 65 REVISION14.2 14.3 ESs20- LOAD-OUT, SEA FASTENING AND TRANSPORTATION GENERAL ‘The CONTRACTOR shall, in his "Method Statement", describe cleei!y how he intends to achieve safe and timely Joad-out, sea fastening and transportation ot the structures ana all equipment and appurtenances from his fabrication site to the otshore location. He shall submit all calcviations, drawings and other pertinent data to the EMPLOYER for review prior to any such activities. Notwithstanding any approval by the employer of his proposals the CONTRACTOR shall remain fully responsible for this phase of the Works. our, ‘The CONTRACTOR shall provide all supervision for load-out, seafastening and transportation inch temporary structures, towing frames, skids, cranes, si lifting equipment shall have valid certificates, paterials and plant required but not necessarily limited 10, . hooks and shackles etc. All AD-OU" As well as covering all migjor items load-out shall include the packzwing and protection of all loose, vulnerable items and material. Packaging shall be carried out using stout timber or steel boxes or crates secured by 20mm wide steel straps. The contents of each box or crate shall be clearly and indelibly marked on the outside and | 2 detailed inventory of such contents shall be made by the CONTRACTOR and submited to the EMPLOYER prior to loadout. SEA-FASTENIN' Sea-fastening shall include the design, positioning and fixing of all temporary bracing, tie-downs, grillages etc. between the barge, the structures and loose packaged items, in order to safely transfer all static and dynamic loads therefrom to the barge during load-out, transportation and installation. All welding and NDT shall be carried out in accordance with Sections 6.0, 7.0, 8.0, 9.0 and 10.0 of this specification. Removal of sea-fastening members shall be by flame cutting to within 3mm of the permanent structural member, or doubler plate attached to a structural member, and ground flush. The EMPLOYER shall visually inspect all areas where sea-fastening hes been removed and reserves the right to request further NDT at his discretion should it be deemed necessary 2” Page 66 REVISIONTRANSPORTATION The CONTRACTOR shall be fully responsible for the safe and timely transportation of all structures, equipment and loose items from his construction yard to the offshore location in accordance with his previously approved procedures. These procedures shall Tot be deviated from without the written approval of the EMPLOYER INSURER'S APPROVAL Notwithstanding the above clauses 14.1, 14.2 and 14.3 the CONTRACTOR shall obtain approval from his Marine Insurer for all activities in connection with load-out, sea-fastening and transportation. ! ¢ Page 67 REVISION15.0 INSTALLATION 15.1 GENERAL ak In his installation method statement the CONTRACTOR shall clearly define how he intends to install the structures. | TS As 2 minimum the statement should define : 2) Whether he intends to launch or lift the jacket(s) including his proposed equipment and method. ' b) His proposed pile hammer suite and piling sequence plus conunyency plans. | ©) His proposed welding spread. | <) proposed method of installing the topsides including his propused equipment, ) His proposals for protecting the Works during installation. ) His quality assurance plan for the installation works. 15.2 REFERENCE STANDARDS Installation shail comply with the latest revision of the following codes, standards and specifications (applicable at the time of Contract award unless otherwise agreed by both the EMPLOYER and the CONTRACTOR). APIRP2A - Planning, Designing and Constructing Fixed Offshore Structures. ALS.C. - Steel Construction Manual (Latest edition) Seen N APIRP 2X = Ultrasonic Inspection, Procedure Guide for all Craft Operating i in QGPC Offshore Oil and Gas Fields - Marine Department. . Extract from Operations Procedures Guidelines Manual Concerning Diving Operations = QGPC (Offshore Operations). = 15.3 SETTING THE JACKET ; 1 ‘The CONTRACTOR shall be fully responsible for setting the Jacket in the correct location and orientation, and to the correct elevation, as indicated on the Contract drawings. Tolerances shall be as indicated in Section 15.7 unless otherwise directed in a particular Contract Specification. ES-S-20 Page 68 'QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) FES-S-20 ON BOTTOM STABILITY. The CONTRACTOR shall be fully responsi Jacket le for the "On Bottom Stabibty” of the He must satisfy himself, during his water depth and sub-sea survey chat the mudmat design is compatible with the local sea bed conditions. Should the CONTRACTOR consider the mudmats inadequate to ensure "On Bottom Stability" during piling operations he should submit his alternative proposals to the Engineer for approval prior to setting the jacket on locati Nopwithstanding the Engineer's approval of such alternative proposals the CONTRACTOR shall remain fully responsible fo: adequacy Once the CONTRACTOR has commenced setiing the jacket on inauon no claims whatsoever will be entertained for loss of damage 10 the jacket or extra cost of materials of plant which may occur as a result of any inadequacy uf "On Bottom Stability" which may become manifest. All such cosis shall be borne by the CONTRACTOR. PILING General Piling shall be carried out in accordance with the Contract drawings and any Particular Specification and shall comply generally as follows Drivezbility and Pile Hammer Suite The CONTRACTOR shall have carried out a pile driveability analysis and shall provide a pile hammer suite capable of driving the piles to the design penetration as follows : 2) Directly b) Relief Drilling c) Pilot Hole Drilling @) — Underream Drilling ©) Insert Piles Hammers shall be in good order and any hammers operating on an eff 78% shall be rejected. iciency of less then Page 69 REVISIOY2 15.5.3 15.5.4 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) The CONTRACTOR sh the primary hammers. provide 100% back-up hammers with eq alent capacities of The CONTRACTOR shall also provide all pile driving conting in Section 15.5.9. -ncy equipment outlined Pile Make-up ‘The CONTRACTOR's spread shell be capable o! requirements for the pile installation procedure in and drilling equipment, steam gent hydraulic power a the handling and power nt of all piles, hammers supply to hammers. Pile bandling procedures shall be approved by the Engineer. Generally, the pile sections shall be lifted using rigging consisting of either slings or grommets with the mechanical connections to the piles provided by either lifting bars or padeyes. The CONTRACTOR shall cut and prepare the pile sections after driving es shown on the Contract drawi Welding of the leg pile splices shall be carried out in bear cages, of which a suitable number shall be supplied by the CONTRACTOR in Section 5.0 of these e 5.5.3 of these gouging and The add-on shall be aligned to the straightness speci specifications. The weld gap shall be in accordance with clau specifications and shall be made either by shimming and tack weldi grindin The CONTRACTOR shall take care not to allow waste Jeg annulus. rial 10 fall down the jacket The CONTRACTOR shall test the leg pile splice in accordance with Table 10.3-1. Inspection shall be in accordance with Section 10.0 of unless noted otherwise. 1 requirements of s specifications Piles shall be visually inspected prior to stabbing. any damage shall be brought to the attention of the Engineer's Representative. During stabbing of the pile lead length into the jacket legs, adequate control by guide lines and of hook velocity shall be maintained to ensure clean stabbing of the pile toe into the jacket leg. The pile shall not be allowed to free fall for a distance diaphragm is present and the diaphragm remains intact then the diaphragm shall be ruptured by repeated small free falls of the pile. ES-S-20 Page 70 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 15.5.5 15.5.6 15.5.7 15.5.8 15.5.9 Suabbing of add-ons and pile hammers shall be performed with the same deaves oF caunOR used in stabbing the pile lead lengths. ‘As soon as firm driving is experienced, but no greater then 10m, the CONTRACTOR Shall check the jacket for level, as specified in Clause 15.7 of this Speciicanon- Pile Penetration “The lead pile section shall be stabbed and driven until the pile head is win 6.5m of the jacket top horizontal brace centreline. The pile head shell then be trimmed as indicated vn the Contract drawings 10 a level at which the diameter and out-of-round driving distortions permit 2 good At of the add-on. The pile head will be prepared and the add-on welded and subjected To NDT in ee ——C—==es=———— eldly locate add-ons relative to previous pile seeton during weléing, -Drving shall be identified with the chronological driving sequence. The CONTRACTOR shall drive all lead pile sections first then may select to drive one pile including add-ons to the design penetration oz switch driving to suocessive piles after Bich aedon at his discretion. He shall ake all necessary measures to minimise stoppages ‘once driving operations have begun. Pile Driving Refusal Criteria The CONTRACTOR shall state his pile driving refusal criteria based on his pile Griveability analysis prior to commencement of driving. ‘Demage In the event of the CONTRACTOR causing damage to any of the piles, jacket or appurtenances during driving he shall notify the Engineer's Representative immediately 22a shall subiait his proposals for correcting such damage for approval ile A riteria In the event of design penetration not being achieved by driving, the pile acceplance 1a tosis shal be agreed between the Engineer's Representative and the CONTRACTOR before any contingency measures as outlined in 15.5.9 are carried out Pile Ins! jon Contingencies ‘To reduce thé possibilty of herd driving or premature refusal due to setup, the piles Ghould be driven to their final penetrations with the minimum number of pauses for add-ons and other delay’. ES-S-20 Page 71 REVISIC15.510 ES-S-20 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) in particular adé-ons should be designed wherever possible such that pile ups are not Geaply embedded in stiff clay layers during add-on welding operations In the event of a pile reaching premature refusal whilst being driven « number of contingencies may be applied as follows 2) A larger size hammer may be used 10 re-start the pile provided that the new jummer will not overstress the pile due either to its energy rating (the pile Griveability anclysis will indicate its suitability) or the pile suck-up being too great. b) Soil plug removal to relieve the inside skin friction component of the pile resistance. ©) Pilot hole drilling through any hard layer which is causing the refusal. g)__ Underseam drilling through any hard Jeyer which is causing the sts ifthe pilot hole drilling is unsuccessful. In this case total skin friction will be lost and the design penetration will have to be increased accordingly. to set-up in stiff clay and 2) above 1s unsuccessful ©) Where premature refusal is due ing the piles in which case jt is unlikely that b), ¢) or d) will be effective in re-star insert piles may be needed, ‘where i is considered insert piles may be needed as contingency (from the sols analysis) these should be made available on the barge and & fully deiailed procedure shall be included in the Particular Specifications During pilot hole,underream, or insert pile drilling operations centychsers shall be used to ensure a straight end true hole. . To facilitate faster recovery of the spoil, air lifting will be permitted. sn att cases above, the CONTRACTOR shall submit othe Engineer's Representative, for his approval, full details of the procedures he intends 10 adopt Grouting CS LLrrr——™S—rT—C—r TC “ $= = aon used the cement grout for plugging or otherwise shall be made using high sulphate resisting portland cement to ASTM A-150 Type V or similar approved Cement shall be mixed with 40 percent seawater by weight. ie, Cement 94 Ibs/sack 50 kg/sack Seawater 38 Ibs (5.3 gall) 20kg (6. Page 72 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 15.5.1 anons approved lost oval oi the Engineer. To con:rol losses in fissured limestone, corel or gravel circulation material may be added to the cement slurry with the epp After the grout has been: mixed the CONTRACTOR shall take samples 101 esting ‘of both density and compressive strength the resus of which shall be subject 10 the approval of the Engineer. a rti‘“Ci;w™sSs—sts—s—sC—s—s—s—Ss—SC—s——s—SsS——————C grouting or within 24 hrs. after completion of grouting The CONTRACTOR shall have available at all times all equipment, materials and experienced personnel necessary 10 carry out the grouting operations 1 the satisfaction of the Engineer. before any grouting operations are carried out the CONTRACTOR shall submit fl geuzils of his proposed procedures to the Engineer for his approval. Je Installation Documentatior From the beginning of pile placement operations, the CONTRACTOR shall mainuin ¢ complete, accurate record of all work carried out, Upon conclusion the driving of cach pile, the CONTRACTOR shall supply the Engineer's represensative with two copies of @ report in chronological sequence giving, in partcvlar, the following information for each pile driven : 2) Platform and pile identification b) Penetration of pile under its own weight c) Penetration of pile under the weight of the hammer. 4) Blow counts throughout ériving with hammer identification per 250mm penetration. 2) Unusual behavior of hammer or pile during driving, Interruptions in driving, including "Setup" ime. 2) Lapsed time for driving each section. h) Elevations of soil plug and internal water surface after driving 3) Actual length of each pile section and cutoffs jy) Pertinent data ofa similar nature covering driving drilling, grouung or concreting of grovted or belled piles. ES-S-20 Page 73 REVISIC15.59.12 15.6 15.6.1 15.6.2 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) k) ile diameter and wall thicknesses. 1) Reference level for recording penetrations m) Hammer type, size and reference number. 1) Estimates of short fall of the hammer and hemmer efficiency ) Any other information pertinent to the pile driving/drilling operauons. Jacket Lee/Pile Shimming an Welding “The piles are attached to the top of the jacket by shims and welding ¢s indicated on the Contract drawings. Welding shall be in accordance with Section 8.0 of this Specification. Usps shall be plugged with pieces of bar and welded The CONTRACTOR shall tes the Jeg pile splice in accordance with the requirements of ‘Tzble 10.3-1. Inspection shall be in accordance with Section 10.0 of this specifications unless noted otherwise. ALLATION, YECKS AND APPURTEN ANCE: General ‘The CONTRACTOR shall submit full details of his proposed installation procedures 0 the Engineer for his approval prior to any work being carried out, No ems shall be installed during pile driving operations. installation of Decks Decks and offer structural items shall be installed within the tolerances specified in Section 5.0 of this Specification. Deck leg stabbing points shall be welded in accordance with the Contract drawings 286 Section 6.0 of this Specification. The CONTRACTOR shall test the Jeg pile splice in accordance with the requirements 0° Table 10.3-1. Inspection shall be in accordance with Section 10.0 of this specification: unless noted otherwise. Unless agreed otherwise by the Engineer, the CONTRACTOR shall remove all riggin: and installation aids. ‘Temporary attachments may be removed by thermal cutting of grinding If therm: cutting is employed the attachments shall be cut off 3mm from the permanent work an ES-S-20 Page 74 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ground flush. “All untreated surfaces and touch-up areas shall be coated in eccordance watt: une Contract drawings and ES-Q-10. 15.6.3 Boat Landines Boet landings (where applicable) shall be installed in eccordance with the Contract Grawings to the correct elevations, The jacket elevation shall be checked and the stab-in point field trimmed as necessary prior to installation 15.6.4 Field Installed Walkways and Handrails The CONTRACTOR shall install"field installed” walkways and handrails as indicated on the Contract drawings and the tolerances indicated in Section 5.0 of this Specification rrrr—-—“=Et—“‘(Ee——CL Specification and iouch-up painting shall be cerbied out in accordance with ES-Q-10 15.7 INSTALLATION TOLER AN! The CONTRACTOR shall install the jacket(s) deck(s) and appurtenances to the following tolerances (unless indicated otherwise in the Particular Specification) 15.7.1 jacks 2) Position = 5 metres radially from their theoretical location. © of the theoretical direction 1.5° prior to piling, 1:100 after piling. b) Orientation - ©) Verticality €) Elevation £300 mm ©) Pile Cutoff - £25 mm. ae eck and Appurtenances . a) Elevation 425 mm b) Level = Max, slope 1:600 ©) Grating + 2 mm between panels. ES-S-20 Page 75 REVISIOQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 15.9 “Welding, Inspection end Testing shall comply’ with the relevant clauses of Secoohs 6.0, 7.0, 8.0, 9.0 and 10.0 of this Specification {OVEMENT AND ANCHORING OF VESSE] The movement and anchoring of all vessels shall be carried out by the CON’ TRACTOR Inaceordance with QGPC (Offshore) "Procedure Guide for all Craft Opersting ln QGPC Offshore O3] and Gas Fields” latest edition, issued by Marine Department QGPC (Offshore) ‘ll anchor pattems and mooring techniques including flowline marking methods shall be approved by Marine Department prior to mobilisation of the CONTRACTOR’ spread No variation t0 approved methods shall be made without wrinen consent of Marine Department, QGPC (Offshore). DIVIN' PERA’ IN: All diving operations shall be carried out in accordance jth QGPC (Oifshure Operations) aaeeer fom Operation's Procedures Guidelines Manval concerning Diving Operations” atest edition. ES-S-20 Page 76 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 16.0 “AS-BUILT" RECORDS AND DRAWINGS 16.1 NERA The CONTRACTOR shell prepare full "as-built" records and drawings Jor presentation to the EMPLOYER at the completion of the Works. 16.2 "AS-BUILT" RECORD! ‘These shall include, but not necessarily be limited to 3 2) Detailed Scope of Work highlighting responsibility b) CONTRACTORs detailed czleulations (where applicable) ©) Materials Specifications including Vendor's information 4) __ Inspection and test certificates. 2) Steelwork mill certificates. 2) Progress Charts end manpower histograms ) Progress meeting reports. Sr —r—————s—F orders ete 9 3) Completion Certificates. 3) Piling Records. f 1) Installation daily log reports, including weather standby time. 1) Sea fastening. m) Load out. n) __ Installation Methods. 0) Temporary Works including calculati p) _ Bill of Materials. i) Weight Control Report. 1) Any other pertinent information. ES-S-20 Page 77 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) “The CONTRACTOR shall submit 5 (ive) copies of these 7ecords bound io A4 size volumes within two months of demobilisation. 16.3 "AS-BUIL’ DRAWINGS" Doring the progress of the Works the CONTRACTOR shall mark up t0 CoP! of the Approved for Construction” drawings to reflect the “as-bullt' uation. These prints will be certified by the Engineer's Representative who shell retain one copy. On completion ‘of the Works the CONTRACTOR shall prepare one reproducible set of “as-built” ee reflect the Spal "ae built” state of the Works as handed over to the EMPLOYER The CONTRACTOR shall submit within wo months of demobilisation 3) The full set of "As-built” reproducibles 2) Three sets of A3 shot down prints bound 3) Two 35mm microfilm negatives of each “as-built” drawing suitably mounted on aperture cards. 16.4 DRAWING STANDARDS ‘All drawings which are requized from the CONTRACTOR under this Secon of the Specification shall comply with ES.D.10 ES-S-20 Page 78 REVISI!QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLES ES-S-20 Page 79 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ‘TABLE 6.8-1 - WELDING PROCEDURE QUALIFICATION TEST REQUIREMENTS ‘WELD PROCEDURE TYPE OF JOINT ‘Test REQUIREMENTS - Ore uit Welds in Pat & Tubular intersections Tubular (mn) (Note 6) = ‘Thekness Teclds Jinswad] iso | i<=100 | t 600 NDT Requirement MP wer | MeL | MPI MPL MPL ar | Rtur | UT UT ur. Transverse Tensile 2 2 2 one | NONE | NONE ‘All Weld Tensile 1 1 1 NONE NONE Bend Tests yrace | ssiz | «sine | None | NONE | NONE 2ROOT | Macro's& | Plate a 1 1 | 2 NONE | NONE Hardness Tubular 2 2 2 2 4 4 Cap | NONE 1 1 KONE | NONE A was Meal ae 9 Root | NONE 1 1 NONE | NONE 1 charpy [Haz | Noe? | NONE 3 3 NONE | NONE 3 Tests Fe P waz | Noe7| NONE | NONE 3 NONE | NONE 3 Midet waz |Now7| None | NOTES | 3 NONE | NONE 3 Root _| ES-S-20 Page 80 REVISICQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) NOTES FOR TABLE 6.8-1 DT and mechaucal testing 1,0 Test plates for repair procedures shall be subjected to the say as that applied to the original procedure test plate. 2.0 As defined in clause 777 of this specification 3,0 Non Destreutive Test methods have been abbreviated t0:- MPI - Magnetic Particle RT - ur - esses less than SOmm_ 4.0 Post Weld Heat Treatment will not normally be specified for thich 5.0 A complete set of root impact tests (WM, FL, FL+2, FL+5) are req and double sided weld red for all single sided ids the soot test shall be greater than 20mm thick. For double sided w usion zone, taken from the int 6.0 Tubular Intersections (T, K and Y configurations) shall be a separately as shown in the table. Full mechs -al tests shall be carried out on butt welds deposited in accordance with this specificatio 7.0 HAZ tests shall comprise: Fusion Line oO Fusion Line + 2mm Fusion Line + Smm . JES-S.20 Page 81 REVISICTABLE 8.8-1- 4 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) CCEPTANCE LEVELS FOR NON DESTRUCTIVE TES{ING ae ae fae creas es om - a i mee a uly Dinas ocana Rona | 2 wn Ym 8 pr ees a ames [peteoeeretes 4 | ee acer ena feng tgif eee |e es oe ee fees os a ee ae ees ——— a es See ee Pa a Sea ae tees ee Reinforcement Shape ‘The resforeement shall blend smoothly with ue parent meal | ee eee ‘not interfere with the specified non destructive testing. |" a eal Pas =aeee ES-S-20 Page 82 REVISIO.ad QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ABBREVIATIONS AND NOTES FOR TABLE 8.8-1 ness. In the case of dissimilar thicknesses € applies to U eis the parent metal w is the width of the defect. Lis the length of the defect. his the height of the defect. @ is the diameter of the defect, NOTES: 1, The simultaneous prescence of more than one type of allowable defect within « given } assessed, of weld is permitted and each type should be individually “The area to be considered should be the Jength of the weld affected by pososiy multplied by ES-S-20 Page 83 REVISIO:QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 10.3-1 - EXTENT OF NON DESTRUCTIVE TESTING hem Visual | MP1 + [ore 1.0. | EABRICATION YARD/SHO} A) | Pilesackes Lers/Bracings Longitudina) & Circumferential But Welds 1<= 10mm 100% 190% — 100% w 25mm 100% | 100% 100% | Imersection of Longitudinal & Circumferential 100% 100% oe 100% Bur Welds T,K, ¥ Joins 1005 100% } Boat Landing i B) | Jacket Sub Butt Welds 100% 100% 100%. I Tubular Butt Welds 100% 100% 50% } Fillet Welds 100% 20% — | I omnes | ©) | Coreiacker Fillet Weld 100% 100% | Q Core/Doubler Fillet Weld 100% 100% a Doubler/Jacket Fillet Weld 100% 100% | Main Girders & Beams D) | Full Penetration Bun Welds 1 <= 10mm 100% 100% 100% 10 <1 <= 25mm 100% 100% 100% | or 100% } t> 25mm 100% 100% 100% —_ , Fillet & Partial Penecration Welds 100% 100% | NOTES | — T, K, Y Bum Welds 100% 100% 100% - ES-S-20 Page $4 REVISIO®QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 10.3-1 - EXTENT OF NON DESTRUCTIVE TESTING (cont'd) F item | MPL UT RT. E) | Deck Stringers All Bun Welds 100% 50% 20% NOTE 5 Fillet & Partial Penetration Welds 100% 20% NOTE 4 F) | PadEves All Bua Welds 100% 100% 100% — All Fillet Welds 100% | 100% — G) ces & Mink worl All Bunt Welds 100% 10% 10% a All Fillet Welds 100% 10% — NOTES: 1, All SAW shall be 100% examined for transverse (chevron) cracking using ultrasonics the probe positioned on the weld cap. 2. All full penetration welds in which part of the welding is by the GMAW process shall be 100% examined by ultrasonics. 3. All welds subject to repair shall be re-examined to the original method. 4, When the fillet weld Jeg length is greater than or equal 10 20mm, this shall be tested by ultrasonics. 5. Radiographic examination may be required by the EMPLOYER in lieu of ultrasonics for butt welds less than 25mm. 6. For definition of percentage inspection refer to clause 10.3 7. All intersections of full penetration welds at tee or cross joints shall be radiographed or ultrasonically inspected and all copeholes shall be magnetic particle inspected, <8. Where joints are between two different inspection categories the requirements of the higher category governs. 9. The values given in the table are minimum requirements. The EMPLOYER reserves the right to increase the above values if deemed necessary. ES.S-20 Page 85 REVISION(Oil & Gas Operations) QATAR GENERAL PETROLEUM CORPORATION TABLE 10.3-1 - EXTENT OF NON DESTRUCTIVE TESTING (cont'd) _ lem Visual | Mp. UT xr | 2.0 | OFESHORE LATION | All Bun Welds | 100% | 10% | 10% — All Fillet Welds 100% 20% = | ES-S.20 Page 86 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLES Page 79 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) | “ELD PROCEDURE TYPE OF JOINT | TEST REQUIREMENTS ‘ONOTE 2) Bun Welds in Plate & Fille Tubulars (mm) Welds (Note 6) “Thickness re=i25 } 1251040] 40 | 1<=100 1>40 op> 600 a age |e im | aT | orver | our UT ‘Traasverse Teasile a 2 2 NONE NONE ‘All Weld Tensile 1 1 1 NONE NONE IL Bend Tests zrace | sswe | «sie | non | woxe | None 2 ROOT Macro's & | Plate 1 1 1 2 NONE Hardness Tubular 2 2 2 2 4 4 cap | NONE 1 1 NONz | NONE 1 weld Metal Root | NONE 1 1 NONE 1 a HAZ | Note7 3 5 NONE NONE 3 ess Cap HAZ | Note?) NONE | NONE 3 NONE | NONE 3 Midst HAZ | Noe? | NONE | NOTES 3 None | NONE 3 Root ES-S.20 Page 80 REVISION1.0 2.0 3.0 6.0 7.0 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) NOTES FOR TABLE 6.8-1 Test plates for repair procedures shall be subjected to the same NDT and mechiaincal testing as that epplied to the original procedure test plate. As defined in clause 22? of this specification, Non Destreutive Test methods have been abbreviated to:- MPI - Magnetic Particle RT - Radiography UIT - Ultrasonics Post Weld Heat Treatment will not normally be specified for thicknesses less than 50mm ‘A complete set of root impact tests (WM, FL, FL+2, FL+5) are required for all single sided and double sided welds greater than 20mm thick. For double sided welds the rvot test shall be taken from the inter-fusion zone. Tubular Intersections (T, K and Y configurations) shall be qualified separately as shown in the table, Full mechanical tests shall be carried out on butt welds deposited in accordance with this specification. HAZ tests shall compri Fusion Line Fusion Line + 2mm Fusion Line + Smm ES-S-20 Page 81 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 8.8-1 - ACCEPTANCE LEVELS FOR NON DESTRUCTIVE TESTING BEreer ne MIFFED Magan Tir | Gast & LavetirFas Na Fee Bete = Lack of Root Fson wor Pei 12a S Se Pan Ek Since Pn Lasko Root Pein wo Pema Ghins | lcked Por ord oesns gow) |e < 08 tam ore apo ane cig st o 2 LSnm or ects Som ine tnd weg Tsun. | = Comm fre suerssnm Urol Biba Leis BS bane fore <5 Sets 3) Lina Poon Uses ian be hewn nko tao or pcm sce wi St nit rel ad be Seda lore goers gp Ted Wome 1 6mm,» < Bn ‘Aligned Wompole fs fo ine Pri cies Fes i fore Werni Iss | Tei wd Poco wed wi [= © € 30m NOTE incense hesopnied ne maar | wor be w0 © én we cary setae il sor peer as Selene ner te sf Mngint hc nchton ta cede so eld ine Tndasuly ons Rntons Ona oor ‘| a lar oe Fores proc we Non Liner Grup 1a for Lose Pry Tungsten Incl fed or ates Pores Grune ‘for Unity Laine Poretiy cope noe Na mined Frale | Undeea Sih ieee eG deh > Sm Bett Shrlage Graven Coney 1 forint, dh sos rot xe Sm Eten Peernon 1 < Sm, csr a aight aes awe Reoforemen Sige The efron shal end ancy wah ie pre mal tr resin roma rege pred espe es oo nrore weeps tn dei sing ony Ne Pei Lina rma See Chane 5.53 Page 82 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ABBREVIATIONS AND NOTES FOR TABLE 8.8-1 ¢ is the parent metal thickness. In the case of dissimilar thicknesses e applies to the thuuner part w is the width of the defect. 1is the length of the defect. hh is the height of the defect. @ is the diameter of the defect. NOTES: 1. The simultaneous prescence of more than one type of allowable def of weld is permitted end each type should be individually assessed 1 within @ given Jength 2. The area to be considered should be the Jength of the weld affected by porosity multiplied by the maximum width of the weld. ES-S.20 Page 83 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 10.3-1 - EXTENT OF No DESTRUCTIVE 1 hem Visual MPL ut Rel! 1.0 | EABRICATION YARDISHOP | A) | Pilesi¥acket Lees/Brecings Longitudinal & Circumferential But Welds 1 <= 10om 100% | 100% = 100% | 10 25mm 100% | 100% | 10% — ~ | Intersection of Longindinal & Circumferential | 100% | 100% 100% Bux Welds TK, ¥ Joins 100% | 100% | 10% = Boat Landing | |B) | Jacket Stub Bun Weds oom | 00% 100% | Tubular Bun Welds 100% | 100% 50% | Fillet Welds 100% 20% = | Anode sion ©) | Corettacket Fillet Weld 100% | 100% = _ Core/Doubler Fillet Weld 100% | 100% — Doubler/Jacket Fillet Weld 100% 100% _ Main Girders & Beams D) | Full Penetration Bu Welds t<= 10mm 100% 100% 100% 10 25mm 100% 100% 100% — Fillet & Partial Penetration Welds 100% tom | ores} — | T, K, Y Bunt Welds 100% 100% 100% ES-S-20 Page 84 REVISIO®QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 10.3-1 - EXTENT OF NON DESTRUCTIVE TESTING (cont'd) [ hem viwd | mpi | ut | Rt 5) Dec | All Bua Welds 100% 50% 20% NOTE 5 Fillet & Partia) Penetration Welds 100% 20% NOTE 4 a ar PadEves All Bun Welds 100% 100% 100% _ All Fillet Welds 100% 100% —_ G) | Anpuriances & Minor Steelwork All Butt Welds 100% 10% 10% —— All Fillet Welds 100% 10% | aa NOTES: 1, All SAW shell be 100% examined for transverse (chevron) cracking using ultrasonics with the probe positioned on the weld cap. el All full penetration welds in which part of the welding is by the GMAW process shall be 100% examined by ultrasonics. me All welds subject to repair shall be re-examined to the original method. 4. When the fillet weld leg length is greater tHan or equa] to 20mm, this shall be tested by ultrasonics. 5. Radiographic examination may be required by the EMPLOYER in liew of ultrasonics for butt welds less than 25mm. 6. For definition of percentage inspection refer to clause 10.3. 7. ‘All intersections of full penetration welds at tee or cross joints shall be radiographed or ultrasonically inspected and all copeholes shall be magnetic particle inspected. 8. Where joints are between two different inspection categories the requirements of the higher category governs. 9. The values given in the table are minimum requirements. The EMPLOYER reserves the right to increase the above values if deemed necessary. ES-S-20 Page 8 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) TABLE 10.3-1 - EXTENT OF NON DESTRUCTIVE TESTING (cout'd) CI em | ;~ | 2.0 | OFFSHORE INSTALLATION | | | | | | au son wees woos | 100s | we fo — Al Files Welds som | 20% _ ESS20 Page 86 REVISIONES-S.20 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) FIGURES Page 87 REVISION ( :QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) SECTION A-A (TYPICAL) (FROM WELD TOE) 400 min~ TYPICAL, NODE STUB LONGITUDINAL SEAM AND NODE BARREL CIRCUMFERENTIAL SEAMS SHALL NOT BE PERMITTED IN SHADED AREA. FIGURE 4.5-1 WELD SEAM LIMITATIONS [ESs20 Page 88 REVISIONo QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) pe _ NOT NECESSARILY ORTHOGONAL { Dn (mm) | Dmax - Dmin > + Dn <= 2000 | 0.75% Dn | Dn > 2000 | + 15mm TO BE CHECKED AT BOTH ENDS AND ALL CIRCUMFERENTIAL WELD SEAMS FIGURE 5.2-1 OVALITY TOLERANCE ES-S-20 Page 89 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) FOR Dn > 2000mm OR Dnj/tn > 65 awe / {/ Gauee——* : / : a yet \ See Js f \ / ss ° ee \\ ‘ oR \ \ oe \ \ "FLATSPOT" \ \ \Z "HIGHSPOT’ \ \ onr2 OOR1 = OOR2 = OOR / OOR > 0.2% Dn OR 25% tn (whichever is the lesser) Dn = Nominal External Diameter. tn = Nominal Wall Thickness. TO BE CHECKED AT BOTH ENDS AND ALL CIRCUMFERENTIAL WELD SEAMS FIGURE 5.2-2 OUT OF ROUNDNESS TOLERANCE ES-S-20 Page 90 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) Dn = Nominal External Diameter Zp > + 3mm for Dn <= 2000mm Z)P > + 5mm for Dn > 2000mm (Providing the Weld Gap Tolerance is not negated). FIGURE 5.2-3 END PERPENDICULARITY TOLERANCE [ESS-20 Page 91 REVISION3 ES-S.20 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) L<=13.5m As =0,001L L > 13.5m As = 12mm max.. FIGURE 5.2-4 PLATE GIRDER OUT OF STRAIGHTNESS TOLERANCE Page 92 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) FLANGE SURFACE TRUE POSITION «OF A\f = 0.01b OR 6mm (whichever the greater) except that abutting members shall be within the mismatch tolerances. | Aw = 0.008h or 6mm (whichever the lesser). Ae = 0.015b or 6mm (whichever the lesser) FIGURE 5.2-5 PLATE GIRDER CROSS SECTIONAL TOLERANCES oo 1 jESS-20 Page 93 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) esueeeeeeee td | SINGLE SIDED BUTT / REMEDIAL TREATMENT Ww | F Am | rT DOUBLE SIDED t <= 20mm | + 2mm t< 20mm | + 0.11 OR 3mm (whichever the lesser | SINGLE SIDED — ALL THICKNESSES| + 1.5mm FIGURE 5.2-6 JOINT MISALIGNMENT TOLERANCE ES-S-20 Page 94 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) ES-S-20 TUBULAR VERTICAL (EXCEPT SHOWN BELOW) FOR VARIATIONS OW WE! bi seine FAT 6) ] AND WELO PROFILE EVALUATION sn ACCORDANCE WITH CLAUSES 7 & | a4 E | Ee POSITIONS FOR WELDING PROCEDURE TESTS. FIGURE 6.7-1 QUALIFICATION TEST FOR TUBULAR INTERSECTIONS (SINGLE SIDED JOINTS) Page 95 REVISION 6QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) 9 a — 5 > BEND TEST (FACE OA SIDE) | ae HAZ CHARPY TEST (2 SETS OF 3) WELD METAL CHARPY TESTS (ROOT) BEND TEST (ROOT OR ) a ALL WELD METAL TENSILE TEST ROLLING DIRECTIO, (+17 MACROSECTION AND HARDNESS TEST i T Co TRANSVERSE TENSILE TEST L i 1 l DISCARD somm 1.Type & Quantity of Tests shail be as specified in Table 6.8-1 and Section 6.0. 2, Test Coupon Dimensions should allow for permiseable retests. 3. For position of Charpy V-Notch Test Spocimens see Figures 6.10-1 and £.10-2 FIGURE 6.8-1 TYPICAL LOCATION OF TEST SPECIMENS FOR PLATE TEST PIECES Page 96 REVISIONQATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) A. TUBULAR BUTT WELD TEST PIECE a B. FILLET WELD TEST PIECE | All dimensions are in millimeters. . Type and Quantity of tests shall be as specified in Table 6.8-1 and Section 6.0. |. Test Coupon dimensions should allow for permissable retests. . For position of Charpy V-Notch test specimens see Figures 6,19-1 and 6.10-2. FIGURE 6,8-2 LOCATION OF TEST SPECIMENS FOR TUBULARS AND FILLETS ES.S.20 Page 97 REVISIONa 1 TYPICAL INDENT LOCATION (ALL INDENTS SHALL BE CLEAR OF THE FUSION LINE) <—_—+ Type and Quantity of tests shail be 2s specified in Table 6.8-1 and Section 6.0. FIGURE 6.8-3 LOCATION OF HARDNESS INDENTATIONS Page 98 REVISION :QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) x z a. z ® a de ‘ 8 a y v = gg Hele az J =| -II Show. “ « aie + af fe > rhe : ; hail [AWN a [Le 1 re FIGURE 6.10-1 LOCATIONS AND NOTCH POSTIONS FOR WELD METAL AND HAZ V-NOTCH SPECIMENS ES-$.20 Page 99 REVISIONJ ES-S.20 QATAR GENERAL PETROLEUM CORPORATION (Oil & Gas Operations) LINE OF NOTCH EUSION LINE Nov WELD FUSION BOUNDARY ae a ~ ho of AN 1 LINE OF NOTCH FUSION LINE +2mm FUSION LINE +5mm FIGURE 6.10-2 _ NOTCH POSITIONS FOR HAZ CHARPY V-NOTCH SPECIMENS Page 100, REVISION (