HIA Mid-Field Fuel Farm

Expansion - Welding of Steel

Structures
for

HIASC

Project Number 6415

31 January 2019

Authors: J Grantham/N Thompson

john.grantham@stopford.co.uk
Issue 00
Document Number: 00102-C5800-04-3PS-M-XXX0014

Certificate Number 5021

 Contents
Executive Summary ...................................................................................................................................... 3
1 GENERAL ......................................................................................................................................... 3
1.1 Summary ............................................................................................................................. 3
1.2 ABBREVIATIONS............................................................................................................. 3
1.3 CODES AND STANDARDS ........................................................................................ 4
1.4 SUBMITTALS..................................................................................................................... 4
1.5 WELDER QUALIFICATIONS....................................................................................... 5
1.6 QUALITY ASSURANCE ................................................................................................ 5
1.7 PERFORMANCE REQUIREMENTS ............................................................................ 6
1.8 SUSTAINABLE DEVELOPMENT ................................................................................. 6
1.9 CORROSION PROTECTION ..................................................................................... 6
2 PRODUCTS..................................................................................................................................... 7
2.1 WELDING AND BRAZING MATERIALS ................................................................. 7
2.2 STORAGE AND HANDLING...................................................................................... 7
3 EXECUTION ................................................................................................................................... 7
3.1 WELDING PROCESSES AND LIMITATIONS ......................................................... 7
3.2 WORKMANSHIP AND QUALITY REQUIREMENTS ........................................... 8
3.3 PREHEAT AND INTERPASS TEMPERATURES, AND POSTWELD HEAT
TREATMENT (PWHT) ................................................................................................. 10
3.4 WELDING OF STRUCTURAL STEEL, MISCELLANEOUS METALWORK
AND OTHER STEEL WORK ..................................................................................... 10
3.5 NON-DESTRUCTIVE EXAMINATION (NDE) ..................................................... 12
3.6 INSPECTION .................................................................................................................. 14
3.7 DOCUMENTATION .................................................................................................... 14
3.8 REPAIRS............................................................................................................................ 15
3.9 WELDING REINFORCING BARS ............................................................................ 16

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 Revision History
Issue Reviewed by (date) Approved by (date) Comments
00 L Whitbread L Whitbread Issued for Construction
(31/01/2019) (31/01/2019)

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 Executive Summary
The Purpose of this document is to provide detail on the welding of steel structures specification for
the Mid-Field Fuel Farm Expansion project. This project installs additional storage and pumping
facilities in-line with the original concept design for the facility. The detail of the installation will where
possible follow the existing installation, however the new installation should also be compliant with
current legislation.

1 GENERAL

1.1 Summary
The Hamad International Airport (HIA) fuel System provides on-site fuel storage and transfer to meet
aircraft fuelling demand. The type of fuel stored and dispensed at the fuel farm is Jet A1. Jet fuel is
supplied from the fuel farm through an underground distribution piping network and dispensed to the
aircraft via hydrant carts. Additional storage and pumping capacity is required to meet current and
future anticipated demand.

A. Work Included. Shop and field welding of all structures and equipment including: structural steel;
miscellaneous metal work; mechanical piping and fittings; pressure vessels; reinforcing bars; and field
erected storage tanks and silos.

1.2 ABBREVIATIONS
A. ECW: Electrogas Welding
B. ESW: Electroslag Welding
C. FCAW: Flux-Cored Arc Welding
D. GMAW: Gas Metal Arc Welding (also known as MIG welding)
E. GTAW: Gas Tungsten Arc Welding (also known as TIG welding)
F. MT: Magnetic Particle Testing
G. NDE: Non-Destructive Examination
H. PQR: Procedure Qualification Record
I. PT: Liquid Penetrant Testing
J. PWHT: Post-Weld Heat Treatment
K. RT: Radiographic testing
L. SAW: Submerged Arc Welding
M. SMAW: Shielded Metal Arc Welding (also known as stick welding)
N. UT: Ultrasonic Testing
O. WPS: Welding Procedure Specification

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 P. Refer to Section 01095 for other abbreviations.

1.3 CODES AND STANDARDS

Apply the following codes and standards as indicated. United States codes and standards are listed.
Equivalent international codes and standards may be proposed, subject to acceptance by the Engineer.

ACI 318 Building Code Requirements for Reinforced Concrete

AISC - Specification for Structural Steel Buildings – Allowable
Stress Design and Plastic design
AISI - North American Specification for the Design of Cold-
Formed Steel Structural Members
ANSI B31.1 Power Piping
ANSI B31.3 Process Piping
ANSI B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
ANSI B31.5 Refrigeration Piping
ANSI B31.9 Building Services Piping
API 650 Welded Steel Tanks for Oil Storage
ASME Sec.II Welding Rod, Electrodes and Filler Part C Metals
ASME Sec. VIII Boiler and Pressure Vessel Code Div. 1
ASME Sec. IX Welding and Brazing Qualifications
ASNT SNT-TC-1A Recommended Practice
AST A 370 Methods and Definition for Mechanical Testing of Steel Products
ASTM A 435 Straight Beam Ultrasonic Examination of Steel Plates for Pressure Vessels
ASTM B 32 Specification for Solder Metal
ASTM E 94 Recommend Practice for Radiographic Testing
ASTM E 142 Controlling Quality of Radiographic Testing
AWS A 5.8 Specification for Brazing Filler Metal
AWS D1.1 Structural Welding Code
AWS D1.3 Structural Welding Code – Sheet Steel
AWS D1.4 Structural Welding Code – Reinforcing Steel
AWWA C 206 Field Welding of Steel Water Pipe
IBC International Building Code

1.4 SUBMITTALS
Submit the following:

A. Weld Examination and Inspection Reports.

1. Submit detailed records showing evidence of the quality of welding. For each section of weld
inspected, furnish a report form which clearly identifies the work, the welder’s identification, the
area of inspection, the acceptance by the Contractor's Independent Testing and Inspection Agency of
the welds.
2. Furnish a complete set of report forms at the completion of work. For radiographic examination,
furnish a complete set of radiographs in addition to the report forms. Allow the Engineer to view any
or all of the examinations and to have access to all report forms and radiographs.

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 B. Fabrication and Examination Procedures.

1. Submit six copies of proposed welding or brazing procedures including qualification records where
applicable, welding sequence procedures, repair procedures, and welding rod control.
2. Provide a weld map or table identifying each weld joint (typical) and the assigned welding
procedure specifications, the parts being joined, the material thickness, and any requirements for
post weld heat treatment.
3. Use forms QW 482 and QW 483 for welding procedures and QB 482 and QB 483 for brazing
procedures qualified to ASME Section IX. Include full information on essential and non-essential
variables.
a. Similar forms may be used provided all of the equivalent information is stated.
4. Use forms found in AWS D1.1 Appendix E for welding procedures qualified to AWS.
a. Similar forms may be used provided all of the equivalent information is stated.
5. Submit Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) 60
days prior to use.
6. Do not perform welding prior to receiving Code 2 review notation on the welding procedure to be
used.

C. Qualification Certificates.

1. Make available qualification tests of welders and qualification records of the NDE personnel to the
Engineer upon request. Qualify NDE personnel to the standard applicable to the fabrication code
used.

D. Non-destructive Examination Procedures.

1. Sixty days prior to first examination, submit a schedule of non-destructive examination and
procedures for magnetic particle examination, liquid penetrant examination, radiographic
examination, and ultrasonic examination.

1.5 WELDER QUALIFICATIONS

A. Fully qualify all welders employed on HIA by testing in accordance with relevant codes. Arrange for
all welder testing to be witnessed and qualification certificates endorsed by Contractor's Independent
Testing and Inspection Agency.

B. All welders shall at all times carry welder ID, which shall include a photograph and details of the
welding procedures for which they are qualified.

1.6 QUALITY ASSURANCE

A. Unless accepted otherwise by the Engineer, use manufacturers and installers that employ a Quality
Management System complying with the program described in ISO 9001-2000, or similar system.

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 1.7 PERFORMANCE REQUIREMENTS
A. Comply with provisions of following, except as otherwise indicated:

The Contractor shall have to follow United States Codes, the International Building Code 2003 (IBC
2003) and the Standards listed in Design Basis Document No 25045-X-3DR-X1000-001 Section 3.0
Codes and Standard to establish minimum requirements for the design of all elements within the
airport. Other than stated above, the IBC 2003, and the Standards listed in the Bechtel Design Basis
Document No 25045-X-3DR-X1000-001, Section 3.0 will have precedence over Qatari Standards.

1.8 SUSTAINABLE DEVELOPMENT

A. To further compliance with LEED requirements (as defined in Division 1 Section "LEED
Requirements"), the Contractor shall employ the use of materials and products that optimize energy
performance (per ASHRAE recommendations), enable water use reduction in irrigation and building
facilities, promote ozone protection (no HCFC's), and promote high indoor air quality (IAQ) through
the use of low-emitting adhesives and sealants, paints and coatings, carpet, and composite wood. The
Contractor shall include where possible materials with recycled content, local/regional derivation,
and/or rapidly renewable constituents.

1.9 CORROSION PROTECTION

A The climate at the project site is particularly corrosive due to its proximity to the ocean, the resulting
saline atmosphere, and the high average temperatures. The intense solar radiation is also a cause of
accelerated aging of materials, as is the significant accumulation of fine sand and dust due to the
nature of local soils. The Contractor shall make all provisions necessary to propose, for the prior
approval of the Engineer, and then to install, non-corroding products and materials where appropriate
including aluminium, stainless steel, other non-corroding metals, and plastics. In the case where no
alternative to steel or other oxidizing metal is possible (or where the specifications specifically indicate
the use of steel), the steel or other material must be effectively protected against corrosion (by
galvanization and/or protective paint coatings, for example) with an anti-corrosion guarantee of 10
years. In all other cases, the Contractor will be asked to modify if necessary the proposed product
(even if a catalogue or manufactured item) and to replace the corroding-type materials by
noncorroding materials.

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 2 PRODUCTS

2.1 WELDING AND BRAZING MATERIALS

A. Welding and Brazing Filler Material.

1. Use welding and brazing filler material complying to the requirements of ASME Section II, Part C,
or corresponding AWS Specifications.
2. Select welding materials such that the deposited weld metal is similar in chemical composition,
and not significantly harder or stronger, than the base material.

B. Potable Water. For copper potable water piping, use lead free solder, 95-5 tin antimony to ASTM
B32, or proprietary equivalent.

2.2 STORAGE AND HANDLING

A. Control the receipt and dispersal of all welding filler materials and fluxes. Purchase all low-hydrogen
electrodes in sealed containers and use within 12 hours after removal from the container. Recondition
low-hydrogen electrodes not used within 12 hours in electrode storage ovens equipped with
temperature controls. Store, bake, and dry low hydrogen electrodes in accordance with the
manufacturers recommendations. Discard electrodes with wet or damaged coatings.

3 EXECUTION

3.1 WELDING PROCESSES AND LIMITATIONS

A. General.

1. Provide Welding Procedure Specifications (WPS) to each welder prior to the commencement of
the work, and make these available to the Engineer and Independent Testing and Inspection Agency
on request.
2. Welding processes listed in ASME Section IX, AWS D1 series, ANSI B31 series or AWWA C206 may
be used as specified, subject to the following limitations:

B. Submerged Arc Welding (SAW)

1. Do not use an alloying flux.

2. Individual beads shall not exceed 3/8 inch in thickness for joining material less than 1-1/4 inches
(32 mm) thick and shall not exceed ½-inch (13 mm) in thickness for joining materials 1-1/4 inches (32
mm) and greater in thickness.
3. Use removable starting and stopping tabs when practical.

C. Flux-Cored Arc Welding (FCAW). Use shielding gas for all pressure-retaining applications.

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 D. Gas Metal Arc Welding (GMAW). Use of short-circuiting transfer range is restricted to the following
applications:

1. All ferrite materials not exceeding ¼-inch (6.5 mm) nominal thickness.
2. Non-structural, non-pressure retaining attachments, such as, insulation clips and nameplates
where the material being attached does not exceed 3/16-inch nominal thickness.
3. Tack welds, temporary attachments, double-welded joints or other applications where weld metal
deposited by the GMAW short-circuiting process is subsequently removed.

E. Electroslag Welding (ESW) and Electrogas Welding (ECW). A grain refinement postweld heat
treatment is required.

F. Other specifications may include more specific or different welding and testing requirements than
this general welding specification. In the event of a conflict, follow the specific requirements of the
other specifications.

3.2 WORKMANSHIP AND QUALITY REQUIREMENTS

A. General.
1. In addition to conformance with the quality requirements set forth in the applicable code and/or
the specifications, meet the following requirements for workmanship and visual quality. Provide
access and space, as required, to enable shop or field inspection of all phases of work

B. Workmanship.

1. Protect all welding from wind, rain and other harmful weather conditions which may affect weld
quality.
2. Ensure all surfaces to be welded are dry and substantially free of mill scale, oil, grease, dirt, paint,
galvanizing, and other contaminants.
3. Where weld bevel preparations have been flame or arc cut, machine or grind back to bright metal
before welding.
4. Where full penetration joints are welded from both sides, backchip, grind or arc gouge the first
pass to sound metal before welding the second side. State this requirement on the WPS.
5. Ensure each layer is complete prior to starting the next one. (No block welding).
6. Make vertical welds in the ‘vertical up’ direction unless accepted otherwise by the Engineer for
each specific application.
7. Use weld extension tabs for groove welds. Remove after use.
8. Remove all temporary welds used for construction aids. Grind the removal area smooth and flush,
and inspect by the same methods required for fillet welds.
9. Use a minimum of two passes for all weld joints for pressure retaining applications
10. Peening is not permitted. The use of pneumatic tools for slag removal is not considered peening.
11. Ensure each layer of welding is smooth and essentially free of slag inclusions, porosity, and
excessive undercut. Cracks and lack of fusion are not permitted. In addition, ensure final weld layers
are essentially free of coarse ripples, nonuniform bead patterns, high crowns, and deep ridges.

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 Confine all arc strikes, starts, and stops to the welding groove or remove by grinding. Fill all weld
craters to the full cross-section of the weld.
12. Butt Welds. Make butt welds slightly convex, of uniform height, and with full penetration, unless
otherwise accepted. Make weld filler material reinforcement with a gradual transition (30 deg. max.)
to the plane of the base metal surfaces.
13. Groove Welds. Make groove welds flush, with full penetration.
14. Fillet Welds. Make fillet welds of specified size, with full throat and uniform leg length.
15. Undercutting. Ensure undercutting does not exceed the limits of the governing code and does not
encroach on the required section thickness.
16. Repairing Chipping or Grinding Welds. When repairing, chipping, or grinding welds, do not gouge,
groove, or reduce the base metal thickness.

C. Visual Inspection.

1. Perform visual inspection of welding operations including examination for internal alignment and
groove details prior to welding, examination for surface holes, cracks, and other defects during
welding, and examination for surface defects, undercuts and reinforcement heights after welding.
2. Perform visual examination after any required repair welding. Perform visual examination and
employ acceptance criteria in accordance with the applicable code requirements.

D. Non-Destructive Examination (NDE)

1. Perform radiographic inspection and magnetic particle or liquid penetrant inspection of welds
where required by the applicable Code, this specification, other referenced specifications, or as
shown.
2. Where used, seal-weld radiographic access plugs and stress-relieve with the adjacent butt weld,
when stress relieving is required. Use magnetic particle or liquid penetrant inspection on all
radiographic access hole plug seal welds and external plug surfaces.
3. Employ non-destructive examination methods and acceptance standards in accordance with the
applicable Code and this Specification.

E. Repairs.

1. Repair any unacceptable defect disclosed by visual, magnetic particle, radiographic, or other
inspection means by removing the material in the defective area until free of the defect, then
rewelding using an approved welding procedure, and re-inspecting, observing all of the requirements
of this specification for each operation performed.
2. Perform inspection of repairs by the same method and to the same acceptance standards as the
method which disclosed the defect. Establish the cause of all defects and show that such defects
have been corrected before further welding is performed. All repairs are to the Contractor’s account.

F. Stress-Relieving. Stress-relieve welded assemblies in accordance with the applicable code unless
otherwise approved. Do not perform additional welding after final stress relieving without prior
written acceptance by the Engineer.

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 3.3 PREHEAT AND INTERPASS TEMPERATURES, AND POSTWELD
HEAT TREATMENT (PWHT)
A. Preheat.

1. Employ minimum preheat temperature in accordance with the applicable codes except that
recommended code minimum preheat temperatures are considered mandatory under this
specification. These temperatures may not be satisfactory under all circumstances; the result of
qualification tests may indicate the need for higher preheat temperatures. When indicated, specify
such higher preheat temperatures in the welding procedures specification.
2. Preheat requirements also apply to tack welding and to the welding of temporary attachments.
3. Preheat requirements also apply to all thermal gouging and cutting except on P-1 steels.
4. Welds Between Austenitic Stainless Steels and Ferritic Steels. Make welds between austenitic
stainless steels and ferritic steels with preheat determined by the ferritic material.

B. Interpass Temperature.

1. Ensure the maximum interpass temperature for the welding of austenitic stainless steels does not
exceed 350° F (177° C).

C. Temperature Measurement.

1. Determine preheat and interpass temperatures by temperature-indicating crayons, contact

pyrometers or other equally suitable means.
2. Ensure temperature-indicating crayons used on austenitic stainless steels do not
cause corrosive effects or other harmful effects.
3. Select temperature-indicating crayons of brands and melting temperatures best
suited for the application. Make this information available to the Engineer on
request.

D. Postweld Heat Treatment.

1. Where required, perform post-weld heat treatment in accordance with the applicable code for
each item.

3.4 WELDING OF STRUCTURAL STEEL, MISCELLANEOUS

METALWORK AND OTHER STEEL WORK
A. Apply AWS codes noted in this clause for qualification of welding procedures, welds, and welders,
inspection and testing procedures, and selection of welding process and electrodes, and any additional
requirements as noted in the drawings and individual specifications.

B. Perform welding of structural steel and miscellaneous metalwork in accordance with AWS D 1.1.

C. Perform welding of Bored Piles, Post-Tensioning System, and heavy gauge Cold-Formed Metal
Framing in accordance with AWS D 1.1.

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 D. Welding procedures which conform in all respects to the provisions of Sections 2, 3, 4 and 8 of AWS
D1.1 are deemed as prequalified and exempt from qualification tests. Use forms shown in AWS D1.1
appendix E for documentation.

E. Perform welding of steel deck, metal sheet and light gauge cold formed metal framing
in accordance with AWS D1.3.

F. Visually examine all welds. Other non-destructive tests are required only as specified. Any weld
which is defective, as determined by the Contractor's Independent Testing and Inspection Agency,
will be rejected and must be repaired or removed as required.

G. Inspect welding prior to painting.

H. Perform non-destructive examination of welds in accordance with Article 6.7, AWS D1.1. Afford the
Engineer the opportunity to witness the NDE.

I. Use the following examination methods as and where specified. When a particular examination
method is specified for a joint and the method is impracticable to use, use the highest order method
that is practicable. The alternative method will be subject to acceptance by the Engineer.

1. Radiographic Method. In addition to the requirements of AWS D 1.1, comply with ASTM E 94.
2. Ultrasonic Method.
3. Magnetic Particle Method.
4. Liquid Penetrant Examination Method. Visible-dye, solvent-removable method only.

J. Structural Members Designated for Examination

1. Moment Connection Joints. Examine 100% of all flange-to-flange and web-to-web welding by the
ultrasonic method if full penetration groove welds, or by the magnetic particle method if fillet welds
or partial penetration groove welds.
a. Examine all weldments for moment connections by the ultrasonic method before welding to
detect any laminations. Repair laminations in accordance with the applicable code.
b. Examine all weldments for moment connections by the ultrasonic method after welding to detect
any laminar tearing. Replace any laminar tearing found in the weldments.
c. Examine 10% of each welder’s work for all web-to-flange welding by the ultrasonic method if full
penetration groove welds, or by the magnetic particle method if fillet welds or partial penetration
groove welds. If any weld does not meet the acceptance criteria, examine an additional 10%.
Continue until all welds in a 10% sample meet the acceptance criteria.
2. Beam and Girder Connections. Where beams or girders are to be connected to their supporting
members using clip angles welded to the web, completely examine at least one clip angle or 10% of
the clip angles welded by each welder by the magnetic particle method. If any weld does not meet
the acceptance criteria, examine an additional 10%. Continue until all welds in a 10% sample meet
the acceptance criteria.

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 3. Column Base Plates. Examine 100% of all welding of columns to base plates including associated
stiffeners, as shown, by the ultrasonic method if full penetration groove welds, or the magnetic
particle method if fillet welds or partial penetration grove welds.
4. Truss Connections. Examine 100% of all welding of truss member connections by the ultrasonic
method if full penetration groove welds, or the magnetic particle method if fillet welds or partial
penetration groove welds.
5. Diagonal Bracing Connections. Examine 100% of all welding for connection of diagonal bracing by
the ultrasonic method if groove welds, or by the magnetic particle method if fillet welds.

K. Shear Stud Welding

1. Method
a. Weld shear studs in accordance with the manufacturer’s recommendations for materials,
procedures and equipment. Make adequate return earth connections local to the area being stud
welded.
2. Trial welding
a. When specified by the Engineer and before production welding of studs commences, conduct
procedure trials. Make trials on samples of material and studs representative of those to be used in
the work.
b. At the start of each shift when stud welding is in progress, require each welder to perform the
fixing of at least two trial studs.
3. Tests and Inspection
a. Visually inspect all studs. Ensure all stud welds show a full 360-degree collar.
b. After a satisfactory visual inspection, make bend tests at locations agreed with the Contractor’s
Independent Testing and Inspection Agency. Test a minimum of 5% of the studs, but not less than
two studs per beam. Make the bend test by bending the head of the stud towards the nearer end of
the beam by means of a steel tube placed over the stud, until it is displaced laterally a distance of
one quarter of the height of the stud. Verify that the stud weld does not show any signs of cracking
or lack of fusion.
c. Do not straighten studs subjected to the bend test.
4. Defective Studs
a. Replaced and re-test studs with defective welding.
b. If removal of a defective stud is necessary, flame cut or arc-gouge at a point not less than 3mm
from the surface of the parent metal. Grind the residual material flush, and visually inspect the
affected area. When the parent metal thickness is greater than 20mm, also check the area by
magnetic particle inspection.

3.5 NON-DESTRUCTIVE EXAMINATION (NDE)

A. General.

1. Perform NDE examinations in accordance with the applicable code. In case none of the specified
codes are applicable for a particular test, submit a written and certified test procedure and
acceptance standard to the Engineer for acceptance.
2. Arrange and perform non-destructive examination at the Contractor’s expense, using an approved
Independent Testing and Inspection Agency.
3. Employ a fabrication and construction program that allows for examinations and inspections in
accordance with the Clause, Inspections

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 4. At least 60 days prior to radiographic, ultrasonic, liquid penetrant and magnetic particle
examinations, submit a complete, detailed and certified examination procedure for review and
permission to proceed.
5. Ensure NDE operators are fully qualified to do the NDE on which they are engaged. Upon request,
provide the Engineer with proof of such qualifications. The Engineer may have an operator replaced
if the results of that operator’s examination are found to be repeatedly unsatisfactory.

B. NDE for Castings.

1. Submit a drawing showing the areas proposed for inspection, for each type of casting, and a
proposed procedure and acceptance standard for all materials.
2. Where RT of castings is required or specified, perform examination of critical areas in accordance
with ASTM E94 and ASTM El42 except that the following shall apply:
a. Use radiographic film type II or finer grain with lead intensifying screens.
b. Use radiographic film with a minimum density of 1.8 for single film and 1.3 for each film of a
composite pair, and a maximum density of 4.0 in either case.
c. For each casting and material thickness, submit a proposed acceptance standard to the Engineer
for acceptance. Base the acceptance standard on ASTM E446, E186 or E280, whichever is applicable
for the material thickness being examined and Appendix 7 of ASME Boiler and Pressure Vessel Code,
Section VIII, where applicable. Indicate other standards of acceptance on the Contractor’s drawings.
These will be subject to the acceptance of the Engineer. Specify the proposed severity level for each
type of defect. Cracks are considered unacceptable in all castings.

C. NDE for Forgings.

1. Employ quality levels and test sensitivity in accordance with the ASME Boiler and Pressure Vessel
Code, Section V1 Article 23, Standard SA-388, and the following additional requirements:
2. Perform the examination for acceptance after final heat treatment.
3. Ensure the surface has a finish of 6.3 microns or better.
4. The forging shall be 100% ultrasonic examined. This includes a radial surface examination and an
axial examination, performed from both ends.
a. Adjust the equipment to display a ¾ to full screen back reflection. Ensure the back reflection is
visible on the face of the CRT during testing to allow continuous monitoring of the signal. Ensure
there is a minimum of 50 mm peak to peak distance of interface to back reflection signal.
b. Move the search unit in intimate contact with the test surface. Use sufficient couplant to permit
proper transmission of the sound waves. Move the search unit in a direct path over the entire
circumferential surface. Perform all examinations at a uniform rate not to exceed 150 mm/second
with the distance between passes not exceeding 90% of the width of the transducer.
c. Record all indications, expressed in percentage of back reflection, of 10% and greater, and areas in
which a 20% or greater loss in back reflection occur, on the forgoing and on a drawing. Record the
following information on the drawing:
1) location of indication;
2) indication of size with respect to percent back reflection and percent loss of back reflection;
3) depth indication;
4) width and length of indication;
5) orientation of defect;
6) direction of examination when noted (axial, radial and angular)
d. In addition, record sufficient data in order to reproduce the examination at a later date.
e. Acceptance standards are as follows:

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 1) Discontinuities which produce a complete loss of back reflection are unacceptable.
2) Forgings containing one or more discontinuities having an area which exceeds that of a 20 mm
diameter circle based on the calculated flaw size, are unacceptable.
3) Forgings are subject to rejection if they contain indications or recordable sizes which are clustered
(2 or more indications within 50mm) or aligned (3 or more indications in line within 150 mm).
4) Forgings which contain discontinuities, located on or near the outer fibre, bore, or critical areas,
which in the opinion of the Engineer are considered harmful defects, are subject to rejection.
Perform additional non-destructive examinations and, if possible, machining or trepanning. The costs
of these additional examinations are to the Contractor’s account.
5) Base flaw size calculation on examined data, corrected attenuation, beam dispersion and defect
orientation. Include the details for calculating the flaw sizes including applicable attenuation curves
and formulas as part of the procedure submitted to the Engineer for review.

3.6 INSPECTION
A. Perform inspection and examination in accordance with the applicable code. Employ acceptance
criteria in accordance with the applicable code. Engage an Independent Testing and Inspection agency
to perform tests and inspections. Make welding procedure sheets available to the welder prior to
commencement of the work and make available to the Engineer and Inspection Authority on request.

B. All welding and NDE is subject to inspection by the Engineer.

C. At least 60 days prior to performance of NDE examinations, submit a complete and detailed
examination schedule for Engineer’s review. Engineer will return the schedule indicating the NDE
examinations requiring inspection by Engineer. Inform Engineer of any changes in schedule at least 7
days prior to performance of the examination.

D. Waiving of inspection by the Engineer does not relieve the Contractor from the responsibility of
providing the material and workmanship in accordance with the Contract.

3.7 DOCUMENTATION
A. General.

1. During the work, ensure all welding and NDE data and records are properly referenced and kept in
an orderly manner. Make such data and records available to the Engineer upon request

B. Welds

1. During the course of the Work, keep records listing the following data for each individual weld,
including repair welds:

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 a. welding procedure number
b. welder(s) or welding operator(s)
c. welding current, voltage and travel speed when applicable
d. preheat temperature or interpass temperature control
e. date(s) welding was performed

C. NDE

1. RT: Maintain radiographic records for all radiography performed and submit to the Engineer on
completion of the work.
a. Keep such records in an orderly manner and include the job number, part identification, area
radiographed, exposure date, findings, disposition, radiographer’s name, and a record of
radiographic procedure, in sufficient detail that the radiography may be readily duplicated.
2. UT: Submit a copy of the Report of Examination required by Paragraph T-539 to the Engineer

D. Marking

1. Mark material and items as required by the material specifications and as necessary for correct
assembly or installation at the Site. Do not hard stamp ferritic materials.

E. Distribution of documents and records

1. Submit a copy of all required test and examination reports to the Engineer. Upon completion of
the Contract, submit 2 copies of the permanent record package, except radiographic films, to the
Engineer. Ship radiographic films along with the components to the Site. Submit any radiographs
taken at the Site to the Engineer on Contract completion.

F. Duration of files

1. Keep the original files at the manufacturer’s facility for 5 years. After that time the manufacturer
may either continue to maintain the records or, after offering them to the Employer and receiving a
rejection, the records may be destroyed.

3.8 REPAIRS
A. Repair defects to meet the requirements of these specifications and examine the repair by the same
method used to detect the original defect or as otherwise approved by the Engineer.

B. Repair local surface imperfections other than undercut at the edge of the weld with depths below
the surface of 1/16 inch (1.6 mm) or less by grinding to smooth contour with a curvature of not less
than 1/2 inch (13 mm) radius in either direction. Do not overheat the metal during grinding. Where
repair by welding is required, remove defective material by chipping or arc-air gouging, followed by
grinding to bright metal. To ensure that defects have been removed prior to depositing any weld metal,
examine prepared areas or cavities by a suitable non-destructive examination method.

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 C. Blend repair welds smoothly into the surrounding surface.

3.9 WELDING REINFORCING BARS

A. Perform all welding in conformance with AWS D1.4.

B. Reinforcing bars used in structural applications.

1. Welding is permitted only on reinforcing steel with properties conforming to the requirements of
AWS D1.4 or ASTM A706 for low-alloy steel reinforcing bars.
2. Welding is permitted only with prior written permission by the Engineer.
3. Tack welding of structural reinforcing bars is not permitted.
4. Ensure that the tensile strength of the splices equals or exceeds 125 percent of the minimum yield
strength for each grade of reinforcing steel as specified in Section 12.14.3 of ACI 318.

C. Repairs.

1. Welds which do not meet the visual quality acceptance standards of this specification will be
rejected and must be completely removed. Rejoin the bars with a new weld made in accordance with
these specifications.
2. All repairs and replacements are to the Contractor’s account.

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HIA Mid-Field Fuel Farm Expansion - Welding of
Steel Structures
for
HIASC
31 January 2019
Project 6415
Document Number: 00102-C5800-04-3PS-M-
XXX0014

Stopford Projects Ltd

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