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TABLE OF CONTENTS
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FOREWORD Nos.
3.0 APPLICATION
12.0 APPENDIX
FOREWORD
This document has been developed by Corporate Quality and Management Systems
Department, reviewed by User Departments and endorsed by concerned QP Management
for use as Corporate Standard.
This document is the replacement of the old version of the following documents: ES-L-22 and
ES.5.14.0010. This Standard will supersede the said standards and serve as technical
guidance for preparing project specification on the specific subject.
This document shall be used in conjunction with ASME B 31.3 2008, as Clauses 8.0 and 9.0
of this document are supplementary to chapter V and VI respectively of the said standard.
This document is published for the utilisation of project teams, business units, QP
Departments and Contractors / Consultants employed by them. It should be emphasised that
the document is to be used for QP operations / wherever applicable and appropriate.
The document in its present numbering, layout and format was prepared in accordance with
the standardization procedures (QP-PRC-A-001 & QP-PRC-A-003).
The document in its present form reflects as far as possible the current QP requirements
taking into account the known available industry practices and the applicable latest national
and international codes and standards.
The document is subjected to periodical review to re-affirm its adequacy or to conform to any
changes in the Corporate requirements or to include new developments on its subject.
It is recognised that there will be cases where addenda, data sheets, or other clarifications
need to be attached to the standard to suit a specific application or service environment. As
such, the content of the document shall not be changed or re-edited by any user (QP or its
contractors, suppliers, agents, etc.), but any addenda or clarifications entailing major
changes shall be brought to the attention of the Custodian Department.
The Custodian of this document is Corporate Quality and Management Systems Department.
Therefore, all technical comments, views, recommendations, etc on this document should be
forwarded to:
The Manager,
Corporate Quality and Management Systems Department Manager
1.0 OBJECTIVE
The objective of this standard is to state Qatar Petroleum's (QP) requirements for the
fabrication, welding, inspection and installation of carbon, carbon-manganese and low
alloy ferritic process and utility pipework.
2.0 SCOPE
2.1 This standard details QP‘s supplementary requirements to Chapters V and VI of ASME
B31.3, Process Piping.
2.2 The scope shall include all process, utility piping and in-line instrumentation piping. The
welding of riser pipe-work and transmission pipelines is outside the scope of this
standard.
2.3 Erection shall consist of complete installation of piping systems as defined by the piping
drawing documents. It includes the installation of all piping and piping components,
welding, related examinations, inspection and testing in both shop and field
environments.
3.0 APPLICATION
This standard shall be applied for projects on new and existing installations for all QP
Production Facilities, both onshore and offshore.
4.0 TERMINOLOGY
4.1 DEFINITIONS
The following definitions apply throughout this standard:
QP Shall mean QATAR PETROLEUM or appointed MANAGING
CONSULTANT.
CONTRACTOR The party which entered into contract with QP for the execution
of activities, as mentioned in a written agreement.
CERTIFYING The party which entered into contract with QP for the
AUTHORITY certification of the project.
THIRD PARTY The impartial body appointed by QP or Contractor possessing
INSPECTORATE the necessary competence to verify that the designs,
qualifications, procedure or fabrications satisfy the specified
requirements.
May Used where alternatives are equally acceptable.
Shall Used where the provision is an absolute requirement to be
followed strictly in order to conform to this standard.
ASME B31.3 – 2008 shall be utilized in conjunction with the amendments and additions
required by this Supplement plus any additional QP requirements specified in the Project
Contract Documents. In case of conflict between this standard and other Project
Specifications, the most stringent interpretation shall be adopted.
In clauses 8 and 9 of this standard, the titles and numbering of the main Clauses and
sub-clauses are the same as those of ASME B31.3. Additional Clauses and sub-clauses
to ASME B31.3 are indicated, but gaps in sub-clauses numbering of this standard
indicates that the related sub-clauses of ASME B31.3 do not require amendment.
5.2 NATIONAL, REGIONAL AND INTERNATIONAL STANDARDS
AWS A5.17/A5.17M Specification for Carbon Steel Electrodes and Fluxes for
Submerged Arc Welding
AWS A5.18/A5.18M Specification for Carbon Steel Electrodes and Rods for Gas
Shielded Arc Welding
NACE MR 0175- Petroleum and natural gas industries — Materials for use in
2001 H2S-containing environments in oil and gas production
API RP 2201 Safe Hot Tapping Practices in the Petroleum & Petrochemical
Industries‖.
API 570 Piping Inspection Code
5.3 QP STANDARDS/SPECIFICATIONS.
5.4 CONTRACTOR shall obtain the latest issues of all Specifications, codes and standards
referred to in this document and shall make them readily available to all personnel
involved with the work.
6.1 WORKMANSHIP
CONTRACTOR shall ensure that all materials, workmanship and inspection conform to
the requirements of this specification, and shall supply all labour, tools, consumables,
equipment and services necessary to accomplish his task as per contract requirements.
6.2 PERSONNEL
CONTRACTOR shall have fully experienced supervisory personnel in charge of all
aspects of the work, and shall employ only fully qualified tradesmen to carry out the
work. Personnel qualification requirements shall be as per ASME B31.3, ASME IX and
additional requirements as specified in the contract documents and referred standards &
specifications. Personnel curriculum vitae‘s shall be submitted to QP for prior approval.
6.3 MATERIALS
The checking, preparation, fabrication, inspection and non-destructive testing of all
materials to be used shall be the responsibility of CONTRACTOR, and shall be in
accordance with the requirements of this specification and contract requirements. All
such work shall be to Contractor‘s account.
6.4 SUBSTITUTIONS AND MODIFICATIONS
CONTRACTOR shall make no substitution of materials and/or modification of details,
without the prior approval of QP (and Third Party Inspectorate, where applicable).
CONTRACTOR shall submit, in writing, all such changes to QP for prior approval.
CONTRACTOR shall be responsible for all errors and omissions in the detailing, layout
and fabrication. It is an obligation of the Contractor to check QP‘s documents and
drawings and to notify QP of any errors or omissions.
7.0 MATERIALS
7.2.1 A quarantine store shall be established at the fabrication site to hold material awaiting
proof of compliance with specified requirements.
7.2.2 A secure store, for holding those materials, which after completion of site inspection are
proved to be satisfactory and to be complete with all necessary and identifiable
certification, shall be similarly established.
7.2.3 The CONTRACTOR shall establish both the quarantine and the secure stores and shall
submit details of design, layout and organisation to QP for approval. Special precautions
shall be taken to ensure that all material used for fabrication and installation of pipework
is fully documented and available prior to release to fabrication and installation.
7.2.4 CONTRACTOR shall adopt the colour coding system specified in QP-STD-R-001 to
identify different types of materials.
7.2.5 The CONTRACTOR shall establish procedures for the transfer of identification marks
(including heat number‘s) when pieces are cut from their parent pipe as required by the
quality plan. Pipe identification shall be completed prior to cutting.
7.3.1 CONTRACTOR shall ensure that adequate protection against damage is provided for all
components during any storage, loading and transportation activities, by providing
adequate timber bearers during the transport and the wrapping of lifting points.
7.3.2 Pipes, completed spools or component parts shall be stored above the ground on pallets,
timber blocking or other similar supports, so as to be kept above the level of any standing
water and be kept free from dirt, grease, paint sprays and any other harmful treatments
which in the opinion of QP could affect its ability to perform its intended function.
Note: CONTRACTOR shall protect all open ends pipes and flanges by the use of
plastic end caps and timber blinding respectively.
7.3.3 CONTRACTOR shall provide adequate certified safe lifting slings or similar equipment
during handling or lifting operations, which shall be according to Corporate Lifting
Regulations (QP-REG-Q-001 R4). The use of chains for lifting is not acceptable. When
pipes are lifted by their ends, soft faced hooks shall be used.
7.3.4 Damage to any part of the pipe-work or sub-assemblies, before, during or after
installation shall immediately be brought to the notice of QP.
7.3.5 All completed spools shall be transported by a method, which does not induce significant
deformations or stresses. Care shall be taken in the suitable placement of lifting lugs
and/or temporary attachments.
7.3.6 Particular care shall be taken in the storage and handling of coated and painted parts,
the damaged coating shall be restored to comply with the specified requirements by a
method approved by QP.
7.3.7 Different grades of material shall be clearly marked using an identification coding system
approved by QP in accordance with QP-STD-R-001. The steel types shall be stored in
dedicated locations to avoid inadvertent mixing.
7.3.8 The cutting of pipes and/or plates, the transferring of marks and where pertinent, the
particular identity of the piece shall be carried out in such a manner that a particular
grade of material can at any time be identified within a spool, installation. etc., If any
material is found without the appropriate reference CONTRACTOR shall prove the
identity of the material to the satisfaction of QP.
8.1 The following clauses are supplementary to Chapter V of ASME B31.3 - 2008 Edition.
They cover the requirements and procedures for the welding of process pipe-work in the
workshop, yard and offshore. For convenience the headings and numbering system used
within this section follow those of ASME B31.3.
8.2 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 CONTRACTOR shall observe and
follow current regulations concerning personnel safety, prevention of fire, explosions and
accidents. CONTRACTOR shall follow MoE regulations regarding radiation protection &
handling of radioactive sources and X ray units.
8.3 No exception to this section is allowed without the written authorisation of QP.
327 GENERAL
327.1 PROCESSES
All welding including tack welding, shall be accomplished with low hydrogen processes,
which shall deposit weld metal with a diffusible hydrogen content less than 5ml per
100gm of deposited weld metal. Tests to confirm the diffusible hydrogen level shall be
conducted to BS ISO 3690, if requested by QP. These tests shall be at the
CONTRACTOR'S expense.
Acceptable welding processes for the fabrication of pipe-work are SMAW, GTAW and
SAW.
(Addition)
Other welding processes shall not be used without the approval of QP. 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 CONTRACTORS past history of use. QP may refuse, or limit the use of an intended
process, and may specify additional testing and inspection requirements.
328 WELDING
(a) CONTRACTOR shall conduct the tests required to qualify the procedures and
these shall be witnessed by QP (and the CA/TPI if specified in the contract
documents).
The proposed WPS's shall be submitted for QP review and approval prior to
carrying out procedure qualification. Existing pre-qualified procedures may be
considered, subject to the submission of the supported PQR documentation to QP.
If pre-qualified procedures are accepted, QP reserves the right to re-qualify a
representative number of them.
Prior to qualifying the welding procedures, 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. Qualification
of repair procedures for sour service shall cover at least two repair scenarios;
Partial repair and through thickness repair. Original welding procedure shall be
used for re-welding the cut out weld joints.
A qualified welding procedure is one, which, has been tested to, and has
achieved the requirements of this specification and has been approved by QP.
Qualification of a welding procedure is restricted to the contractor who conducted
the welding procedure test.
Production welding shall not commence until the appropriate procedure tests,
PQRs and WPSs‘ have been approved by QP.
The use of plate qualifications to support a welding procedure for pipe-work is not
permitted. (Amendment)
(d) Impact testing shall be conducted for all materials where it is required for the
base material or where the minimum design temperature is below -10oC.
Impact tests shall be carried out at the minimum design temperature or at the
parent metal test temperature; whichever is more stringent.
If the minimum average impact value is not attained, and only one specimen
shows a value less than the minimum individual value, three additional
specimens shall be selected from a position similar to that from which the set of
specimens under consideration were taken. The value of each of these retest
specimens shall equal or exceed the required average value and the average of
all six specimens shall exceed the required average.
Sub-size specimens are only acceptable where full size specimens cannot be
extracted from the test welds. The largest possible sub-size specimen shall be
taken. The test temperature shall be as per subsection 323.3.4 of ASME B31.3
and The acceptance criteria shall be as per Table 323.3.5 of ASME B31.3.
(Amendment)
(f) P-Numbers.
The extension of a welding procedure specification from the material on the PQR
to a material of a different specification, even if it has the same P-Number, shall
only be permitted with prior approval of QP. (Addition)
(g) Changes which require a new welding procedure specification qualification are as
follows:
(j) Tubular butt joint test pieces shall be prepared to qualify all welding of pipework.
For impact tested procedures the test pieces shall be welded in the vertical (5G)
and horizontal positions (2G) and will qualify all positions and for non impact
tested procedures the test pieces shall be welded in the inclined 45° (6G)
position and will qualify all positions. (Addition)
(k) Welders and welding operators shall not qualify on production welds but shall
carry out performance tests. The welders shall be qualified for all passes, the use
of partially qualified welders is not permitted.
Existing qualifications may be considered provided that they relate to a similar
standard of work and use welding consumables having the same characteristics
as those to be used in production. Fully correlated documentation demonstrating
current qualifications endorsed by an acceptable CA, continuous experience with
the qualified process and satisfactory past performance shall be submitted to QP
for consideration. Acceptance of this documentation and existing qualifications
shall be entirely at the discretion of QP.
All welder and welding operator tests shall be witnessed by QP or a CA approved
by QP before the welder or welding operator is permitted to weld on any pipe-
work. The decision taken by QP regarding the qualification of any welder or
welding operator shall be final. (Addition)
(l) All welder performance tests for all positional welding shall be performed using
the same materials, P-number, consumable and in the 6G position to qualify all
positional welding in production. In the event that differing material groups are to
be welded or when special welding procedures are to be adopted to meet
unusual conditions, the welder shall be required to satisfactorily pass additional
qualification tests as directed by QP. (Addition)
(m) All welders shall be qualified by visual, magnetic particle and radiographic
examination. (Addition)
(n) All welding operators shall be qualified in the position to be used in production.
(Addition)
(o) The approval of a welder on a pipe of outside diameter ―O.D.‖ shall include
approval for diameters ranges according to Table 2-b in Appendix I of this
standard. (Addition)
(p) The use of qualification tests made on plate to qualify welders and/or welding
operators for pipe-work is not permitted. (Addition)
328.2.2 Procedure Qualification by Others
Ultrasonic lamination check shall be carried at the tie-in location before any
cut.
MPI shall be carried out on the bevel of the existing pipe.
Preheat shall be carried out as per table 4 in Appendix I of this standard for
the existing material.
The root pass shall be checked by MPI.
Preheat shall be carried out as specified above before depositing the hot
pass.
After weld completion the PWHT shall be carried out as per item 331 and
Table 5 of this standard.
The completed welds shall be subjected to 100% RT and MPI.
(Addition)
328.5.2 Fillet and Socket Welds
Whenever practicable, fillet welded joints should have a minimum of three weld
passes, two of which should be showing for visual inspection. Socket welding and
threaded connections are not allowed for process service.
(Addition)
328.5.3 Seal Welds
Joints to be seal welded shall be made up clean and without the use of tape or any
compound. A qualified welder shall perform welding in accordance with a qualified
welding procedure. The welding shall not cause damage to the threaded fitting and
the seal weld shall cover all exposed threads. (Amendment)
328.5.4 Welded Branch Connections
(i) For branch connections larger than NPS 2, wherever practical, a band centred
on the location of the proposed branch shall be ultrasonically examined to
confirm the quality of the parent pipe. (Addition)
328.5.5 Fabricated Laps
Not permitted. (Amendment)
328.5.6 Welding for Severe Cyclic Conditions
The weld reinforcement shall have an even finish and shall merge smoothly with the
parent material without abrupt irregularity or undercutting in order to minimize stress
raisers and generally be suitable for MPI. Surfaces of butt joints required to be flush
shall be finished so as not to reduce the thickness of the thinner base metal or weld
metal. (Addition)
328.5.7 Proximity of Welds
Unless noted otherwise on the drawings, all pipe to pipe joints shall be butt welds.
The distance between the toes of adjacent butt welds shall be at-least equal to the
pipe diameter or 100 mm whichever is higher. The distance between the toes of butt
weld and adjacent attachment weld shall be at-least four (4) times the nominal wall
thickness of the pipe but not less than 50 mm where these conditions are not
possible, the CONTRACTOR shall seek approval for the specific configuration from
QP.
Longitudinal welds shall be located so as to clear openings and external attachment
welds. Toe to toe distance between welds shall be a minimum of one pipe diameter
or 50 mm whichever is the greater. Adjacent longitudinally seam welded pipes shall
be located so that the seams are offset 90O or 250 mm whichever is the minimum.
Attachment of non-pressure parts by welds which cross existing main welds or for
which the minimum nominal distance between the toe of the attachment weld and
the toe of the existing main welds or branch welds is less than the smaller of twice
the thickness of the main pressure pipe or 40 mm should be avoided.
If unavoidable the area to be welded over shall be subject to 100% surface crack
detection and 100% ultrasonic examination prior to welding. After welding, the welds
and adjacent area shall be similarly examined. (Addition)
328.6 Weld Repairs
The repair rate shall be reported on a linear basis, submitted to QP on a weekly
basis and shall not exceed 3% during production. If this level is exceeded, the
CONTRACTOR shall investigate the reasons responsible for the increased repair
rate and report his findings to QP with a proposed method of rectification.
𝐃𝐞𝐟𝐞𝐜𝐭𝐢𝐯𝐞 𝐋𝐞𝐧𝐠𝐭𝐡 𝐑𝐞𝐩𝐚𝐢𝐫
𝐏𝐞𝐫𝐜𝐞𝐧𝐭𝐚𝐠𝐞 𝐑𝐞𝐩𝐚𝐢𝐫 𝐑𝐚𝐭𝐞 =
𝐓𝐨𝐭𝐚𝐥 𝐥𝐞𝐧𝐠𝐭𝐡 𝐨𝐟 𝐰𝐞𝐥𝐝𝐢𝐧𝐠 𝐜𝐨𝐦𝐩𝐥𝐞𝐭𝐞𝐝
No rectification, repair or modification may be made without QP approval.
Extent of cracks in welds or base metal shall be ascertained by use of non-
destructive inspection. The cause of cracking shall be identified prior to removal and
repair and full report issued on cause and corrective action.
Repairs to welds shall be limited to 30% of the weld length for a partial wall repair or
20% of the weld length for a full wall repair. When these criteria are exceeded the
weld shall be completely cut out and re-welded.
The removal of defective areas shall be done by machining, gouging, grinding and
any other method, which produces a clean, uncontaminated surface for re-welding.
The resulting excavation shall be ground to bright metal and have a contour to
permit ease of repair welding. Defect removal shall be assured by MPI.
Arc air gouging shall only be performed on material thickness exceeding 9.5 mm.
Prior to commencement a zone not less than 150 mm wide shall be preheated to the
temperature range indicated on the WPS.
Removal and repair of cracks in weld deposits or base metal shall be witnessed and
approved by QP and/or CA who re-serves the right to witness the repair.
Repair welding shall be performed in accordance with the approved qualified welding
procedure and the following:
(i) The crack and 50 mm of sound metal beyond each end of the crack shall be
removed by a method approved by QP.
(ii) The welding sequence and technique shall be selected to minimize distortion
and restraint.
330 PREHEATING
330.1 GENERAL
Preheating shall be carried out by electrical resistance or with gas burners
specifically made and shaped for the operation. Hand held torches shall not be used
for preheating purposes unless approved by QP.
NOTE : Electrical resistance pads are the preferred method of preheating.
(Addition)
330.1.3 Temperature Verification
Preheating methods shall ensure a satisfactory temperature distribution around and
through the material of the joint to be welded. Excessive local heating of pipe
surfaces shall be avoided. Preheat and inter-pass temperatures shall be measured
by digital thermometer, thermocouples, thermo-crayons or a combination of these
methods approved by QP. During welding, the inter-pass temperature shall be
monitored and unless otherwise established by procedure qualification, shall not
exceed 250oc. The minimum inter-pass is to be the minimum pre-heat temperature.
(Addition)
330.1.4 Preheat Zone
When preheat is specified the applicable temperature shall be maintained for a
minimum distance of 75 mm or 4t from the weld centre line, whichever is the greater.
(t = material thickness). Lagging shall be provided on adjacent areas, if necessary, to
maintain the required degree of preheat during welding. Recommended preheats for
cutting and welding are given in Table 4 in Appendix I of this standard.
(Amendment)
330.2 SPECIFIC REQUIREMENTS
330.2.4 Interrupted Welding
If welding is interrupted then the requirements of paragraph 328.5.1 (n) shall apply.
(Amendment)
331.1 GENERAL
All Post Weld Heat Treatment shall be carried out in accordance with this clause.
The CONTRACTOR shall submit for approval by QP, PWHT procedures detailing,
as a minimum, the following:
(i) Heat treatment method (furnace or local),
(ii) Heat treatment parameters,
(iii) Thermocouple location and attachment method,
(iv) Details of insulation etc.,
(v) The type, number and location of supports installed to prevent distortion etc.
PWHT should preferably be carried out in a stationary furnace, but where necessary,
local PWHT of circumferential welds using electrical pad type elements is permitted
subject to control of temperature gradients along the pipe length. The use of
manually operated gas torches to carry out PWHT is not permitted.
Any furnace being used for heat treatment shall have a current furnace
thermocouple calibration certificate. Thermocouples for both furnace and local heat
treatment shall be connected to a suitably calibrated chart recorder, and the charts
numbered with spool and weld numbers for scrutiny and endorsement by QP. These
charts shall become the property of QP after heat treatment.
The CONTRACTOR shall inform QP prior to any PWHT operation in order to permit
a full review and inspection to be made. All PWHT operations are subject to approval
by QP.
If a repair is to be performed after PWHT then further PWHT is required after the
repair is performed. A Welding Procedure Qualification Test will be required by QP
to demonstrate the effect of multiple PWHT on the design strength and notch
ductility of the material.
The CONTRACTOR shall ensure that adequate structural support is installed during
any PWHT operation to prevent any sagging, warp age or distortion during the
thermal cycle. (Addition)
331.1.3 Governing Thickness
(a) Figure 4, in Appendix II of this standard provides guidance on the heat
treatment of branch connections.
(Amendment)
331.1.4 Heating and Cooling
(i) If a furnace post weld heat treatment is used, the furnace temperature shall not
exceed 400 OC at the time of loading and unloading.
(ii) The maximum rate of heating from 400OC shall not exceed 220 OC per hour for
pipe wall thickness up to and including 25 mm and 5500/t OC OR 55 OC per
hour, whichever the greater, for pipe wall thickness greater than 25 mm.
(iii) The maximum rate of cooling from the holding temperature to 400OC shall not
exceed 275 OC per hour for pipe wall thickness up to and including 25 mm and
6875/t OC OR 55 OC per hour, whichever the greater, for pipe wall thickness
greater than 25 mm.
(iv) The CONTRACTOR shall consider the need for a slow heating rate for
complex fabrications
(v) The presences of low melting point materials in liquid phase in intimate contact
with the steel during heat treatment can generate detrimental effects such as
inter granular penetration, embrittlement or cracking. Metals or alloys of lead,
lead/tin solders, zinc, cadmium, aluminium and copper shall not come into
contact with the steels during PWHT.
(vi) For welds involving existing pipe-work in sour service a higher preheat is
required together with a post weld hydrogen release treatment and shall be as
given in Table 4 and Table 5 in Appendix I of this standard. For quenched and
tempered materials, the PWHT soaking temperature shall be less than the
tempering temperature by at least 25°C.
(Amendment)
331.1.6 Temperature Verification
For local PWHT, temperature measurement shall be made by thermocouples
attached directly to the pipe and shielded from direct radiation particularly the electric
pad type elements.
The thermocouples shall be welded to the pipes by the capacitance discharge
method.
The number and location of thermocouples shall be as per table 8, appendix I of this
standard.
For furnace heat treatment of several spools, thermocouples shall be attached to
sufficient spools including pipes at the centre and bottom of the heat treatment
charge to ensure uniform temperature distribution in the furnace. (Amendment)
331.2 SPECIFIC REQUIREMENTS
331.2.4 Delayed Heat Treatment
If a weld in material of P-No 3 through 5 is allowed to cool to ambient temperature
prior to final post weld heat treatment, intermediate post weld heat- treating shall be
required.
Upon completion of welding the joint shall be heat treated immediately by raising it‘s
temperature to 300OC and holding it there for one (1) hour per 25 mm of thickness,
with a minimum soak time of 30 minutes. Upon completion of the soak time the joint
shall be slow cooled under insulation.
When the welds are between materials that have greater than 4% Cr and a wall
thickness greater than 25 mm the weld shall be raised, immediately after welding, to
a temperature within the PWHT range for that material and held there for 30 minutes
after which it shall be slow cooled under insulation. (Amendment)
331.2.6 Local Heat Treatment
When heat treatment is applied locally, the weld shall be heated and insulated such
that the material temperature shall exceed half the heat treatment temperature over
a band of at least 2.5rt each side of the weld centre line, see Figure 5 in appendix II
of this standard, where ‗r‘ is the nominal bore radius and ‗t‘ is the nominal wall
thickness. (Amendment)
335.1 GENERAL
335.1.1 Alignment
(a) Piping Distortions. Removal of pipe distortion using either heating or
mechanical devices is not allowed. (Addition)
340 INSPECTION
340.1 GENERAL
QP shall have free access, at all times, to the fabrication and erection areas or any
other part of the CONTRACTOR'S yard that concerns the work.
QP may wish to inspect materials, equipment, testing facilities and fabrication at any
stage and to reject any part, which does not comply with this specification.
(Addition)
341 EXAMINATION
341.1 GENERAL
The CONTRACTOR shall formulate and implement a quality control plan complying
with the requirements of this specification.
341.3 EXAMINATION REQUIREMENTS
341.3.1 General
(a) For all materials, final examination shall be performed after completion of any
heat treatment. An initial (non acceptance) examination shall be performed
344.6.1 Method
The use of ultrasonic examination instead of radiographic examination may be
desirable under certain conditions of joint geometry or thickness. However its use
requires the specific approval of QP for each joint configuration and thickness and is
normally restricted to wall thickness greater than 10 mm.
QP may specify ultrasonic examination to supplement radiography where
radiographic interpretation is difficult.
The CONTRACTOR shall employ any additional NDT techniques necessary to
ensure full evaluation of welds or clarification of defect indications.
Ultrasonic examination procedures shall be qualified for:-
i) Set-in and set-on branch welds.
ii) Circumferential butt welds above 10 mm thick.
iii) Transitional welds of unequal thickness.
(Amendment)
344.8 HARDNESS TESTING
Hardness checks shall be carried out on all production welds in sour service piping
and heat treated welds to the following extent:
1) Hardness check per 10 m of weld or per 10 circumferential welds, whichever,
yields the greater number of tests (MINIMUM ONE TEST).
2) The cap of the weld at test location shall be removed and the surface ground
smooth. Three measurements shall be taken on the weld and HAZ and the
average of the three shall be taken as the result. (Addition)
344.9 ADDITIONAL EXAMINATION
If QP or the CA has reason to believe that a defect exists in any weld or pass,
including tack welds, then the CONTRACTOR when so directed, shall perform all
inspection and testing required by QP.
If percentage checking of welds reveals a defective weld, a further two (2) welds
completed by the welder in question shall be selected for inspection. If these prove
to be defective, the percentage shall be increased at QP‘S discretion. These
additional welds shall not be deemed part of the percentage inspection.
If the weld is deemed defective, it shall be repaired or replaced to the satisfaction of
QP.
Where QP deems it is necessary to increase the extent of testing other than for
reasons of defects, the CONTRACTOR shall comply with such increased
requirements and perform this work. (Addition)
345 TESTING
Contractor shall submit detailed testing procedure (including flushing and drying) for
QP prior approval for all new lines. However, Contractor shall include in their Test
Package the testing of existing lines also, wherever field welds are completed
between the old and new lines.
Where a new line is tied-in to an existing line, the existing line integrity shall be
assessed in accordance with API 570, Piping Inspection Code, and the remaining
available thickness at the tie-in point shall be checked by Ultrasonic. However,
contractor shall submit a detailed Tie-In procedure for QP prior approval.
In addition to testing of valves at factory, the valves shall be tested at site before
installation. The extent of testing shall be based on the criticality requirements
approved by QP. (Addition)
Contractor shall submit a Test Package for the lines to be tested. This Test Package
shall include and not limited to the following information:
a) Testing limits
b) Testing pressure
c) Testing media, applicable inhibitors, chlorine content.
d) Material traceability to the mill certificates.
e) Applied welding procedures, welders, date of welding NDT, repair...etc.
f) Release note, endorsed by QP/TPI for testing.
6.5 to 7.5 and the chloride content shall be 100 ppm maximum. After testing, the
tested piping system shall be dried as required by the service fluid.
(Amendment)
345.4.2 Test Pressure
(d) The test pressure shall be 1.5 times the design pressure or top of class rating
pressure, whichever is higher. When the design temperature is greater than the
test temperature, then the test pressure shall be calculated as per equation no
24 of ASME B 31.3. Pressurising of the system shall be carried out in
increments of 25% total pressure value or as designated by QP at the time of
testing up to the test pressure. There will be a hold for 15 minutes at each
increment. This is to ensure that the system is stabilised and to avoid over
pressurizing. The pressure shall be maintained at each incremental stage for a
minimum of two minutes or as specified by QP. Once the test pressure has
been attained it shall be maintained for a period of approximately one hour
before the detailed inspection takes place.
(e) Depressurising of the system shall be carried out at a maximum rate 200
psig/minute to avoid vacuum collapse of any part of the system while draining
the water after the test. However, depressurising shall be carried out in steps at
25% of total pressure value and there will be a hold for 15 minutes at each
step.
(f) Check valves shall be opened to ensure that water is completely drained.
(g) A record charts shall be made of the pressures and temperatures during
pressurizing/depressurising as well as during actual testing.
(Addition)
345.5 Pneumatic testing is not permitted without the specific approval by QP.
(Amendment)
345.10 Reinstatement Leak Test
After successful completion of the hydrostatic leak tests, piping Systems/subsystems
shall be subjected to leak test to check the reinstatement work.
The test medium shall be water or nitrogen. The water quality shall be as specified in
345.4.1.
The test pressure shall be 90% of the design pressure or 1.1 of the maximum
Operating pressure when the system/subsystem includes old existing piping.
The test duration shall be one hour.
Contractor shall submit a detailed procedure for the reinstatement leak test for QP
review and approval. (Addition)
10.1 The CONTRACTOR shall have a current and implemented QA system and QC
procedures for shop and field piping fabrication, erection, etc., in compliance with the
requirements of QP-STD-Q-004 and ISO 9000 for all works undertaken and shall meet
QP‘s specified requirements.
10.2 The CONTRACTOR shall, within two weeks of receipt of the order, submit for approval
a detailed quality Plan for fabrication, welding, installation and testing which complies
with the applicable clauses and elements of ISO 9000 standards and project
specifications.
10.3 It shall define the structure, welding, fabrication, installation and testing responsibilities,
authority levels and internal and/or external interface arrangements of personnel.
10.4 It shall identify the items and services to which this specification applies, the level of
control and verification.
10.5 It shall provide documents such as plans, procedures and instructions for the
accomplishment of welding, fabricating, installation and testing activities to provide the
required quality, taking into account the need for special controls, tests, tools, skills,
etc..
10.6 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 of inspections, tests, monitoring of work
performance, material and weld identification and related data such as qualifications of
personnel and procedures.
10.7 The CONTRACTOR shall provide all necessary certification and documents in
accordance with this Specification‘s requirements or any alternative specification
identified by QP.
10.8 The CONTRACTOR shall appoint only qualified and experienced personnel with the
necessary level of authority to ensure compliance with the requirements of this
specification.
11.0 DOCUMENTATION
11.1 GENERAL
11.1.1 All communication, both documentary and spoken shall be in the English Language
and all dimensions and weights shall be in SI (System International d' Unites) units.
11.1.2 The documents to be prepared by the CONTRACTOR to facilitate the fabrication and
installation of the piping shall provide full and complete information and instructions
including detailed methods and procedures. Approval or review of drawings by QP or
QP Representative shall not relieve the CONTRACTOR of his responsibility to
complete the work in accordance with the Contract Specification.
11.2 DOCUMENT SUBMISSION
The CONTRACTOR shall, as a minimum, submit the following documentation to QP
for approval at least two weeks prior to the commencement of work:
a) Fabrication, welding and installation procedures.
b) Detailed fabrication drawings including identification of material grades, weld
details and NDT requirements.
c) List of proposed welding consumables.
d) A Register of proposed welding procedures and their areas of application.
e) PQR'S and qualified WPS'S including those for weld repair, in accordance with
this specification for both permanent work and temporary attachments.
f) Certificates of welders and welding operators qualified in accordance with this
specification. Documents detailing qualifications and experience of engineers and
all QA and QC personnel.
g) Procedures for the receipt, storage, handling and issue of welding consumables.
h) Material identification (including welding consumables) and control procedures.
i) Certificates for all CONTRACTORS supplied material (including welding
consumables).
j) Procedures for Inspection, NDT, Examination and Testing, Format of the reports
and personnel qualifications.
k) Post Weld Heat Treatment procedures and instructions sheets.
l) Forming/Bending Procedures.
m) Hydrostatic Test Procedure.
12.0 APPENDIX
Thickness Range
Test Method
t 25 mm t > 25 mm
NDT Method MPI/RT MPI/RT
Transverse Tensile 2 2
Bend Tests (Note 1) 4 SIDE 4 SIDE
Macro & Hardness 2 2
Charpy V-Notch WM Cap NONE 1
Impact Tests WM Root 1 1
(Note 2) HAZ Cap NONE 3
HAZ Root 3 3
NOTE :
1) Face & Root Bends to be substituted for side bends when t 10 mm.
2) Sets of HAZ Charpy specimens to be taken at FL, FL + 2 and FL + 5.
12.1.3 Table 2-B Approval Diameter range for welders Qualification tests
These recommendations are based on matching the impact toughness, the tensile properties and the chemistry
of the weld deposit with the parent material. It is by no means exhaustive given the variety of possible
applications and so other electrodes may also be acceptable and shall be proven in the PQR testing before any
application.
O
C & C-Mn (-29 C) P-1 E70 XX ER70 S-3 F7 XX-EM12K
O
(-46 C) E70 XX-1 ER 70 S-3
or B6H
THERMAL CUTTING
O
Material Material Thickness Preheat ( C)
C-Steel All 15
C-Mo 12.5 mm 20
½ to 1¼ Cr-Mo 12.5 mm 120
2 to 3 Cr-Mo All 150
5 to 9 Cr-Mo All 200
WELDING (New Material)
O
Material P-Number Material Thickness (mm) Preheat ( C)
C-Steel P-1 25 15
25 100
C-Mo P-3 12.5 20
12.5 100
½ to 1¼ Cr-Mo P-4 12.5 100
12.5 150
2 to 3 Cr-Mo P-5A 12.5 150
12.5 200
5 to 9 Cr-Mo P-5B 200
WELDING (Existing Material)
O
Material P-Number Material Thickness (mm) Preheat ( C)
C-Steel P-1 19 100
19 150
C-Mo P-3 12.5 100
12.5 150
½ to 1¼ Cr-Mo P-4 12.5 100
12.5 150
2 to 3 Cr-Mo P-5A 12.5 150
12.5 200
5 to 9 Cr-Mo P-5B 200
The minimum level of NDT is given below. This minimum level may by increased (at any level up-to
100%) if the welds are questionable or the NDT indicates excessive defects.
Chilled Water
Closed drains of non-sour gas/liquid
D Halon System 5 5
Hot Oil (1)
Open Drains of non-sour gas/liquid
Sanitary Effluent
Slop Oil
Utility Water
Utility Nitrogen (Onshore)
Notes:
(1) 20% examination means 20 welds in 100 welds, which are examined 100%, similarly for 5%
examination. The given 5% and 20% examination shall be increased up to 100% if parts of
the tested welds are defective.
(2) QP may specify ultrasonic examination for thickness greater than 19mm.
WELD METAL
2 mm
FUSION LINE
FUSION LINE + 2 mm
FUSION LINE + 5 mm
FL +2 mm
FL +5 mm
xxxxxxxxxxxxxxxxxxxx
1 mm
xxxxxxxxxxxxxx
X X X X X X X X X X X X X X
1 mm 1 mm
Detail ‘A’
1
Shall conform with fit-up tolerances
qualified in Welding Procedure.
12.2.4 Figure 4 - Post Weld Heat Treatment Requirements for Set-On and Set-In Nozzles
Tb Tb
tc
tc Th
Th
Tb
0.5Tr Tb
0.5Tr
tc
Tc
Tr Tr
Th Th
2.5 r2t1
2.5 r2t2
Changes/Amendments Made:
Whole Document This standard has been revised to incorporate latest developments in
ASME B31.3 – Chapter V & VI (2008 Edition) and other standards
referenced in the document, the latest market research and QP
specific requirements.
Note:
The revision history log shall be updated with each revision of the document. It shall
contain a written audit trail of the reason why the changes/amendments have occurred,
what the changes/amendments were, and the date at which the changes/amendments
were made.