ANSI/AWWA C206-11. é (Revision of ANSI/AWWA C206-03) American Water Works Association ‘Te Autnortatve Resource on Safe Water AWWA Standard Field Welding of Steel Water Pipe A STANDARD SESr | Since 1881 pet i, Effective date: March 1, 2011. First edition approved by AWWA Board of Directors Jan. 10, 1946, This edition approved Jan. 23, 2011. Approved by American National Standards Institute Jan. 4, 2011. £6666 West Quincy Avenue ‘vocacy Denver, C0 802383098 ‘Communeations 17800.926.7337 Conferences wanna. or8 sveation and Training Soienee and Technology Sections Copyright© 2011 American Water Works Assocation, Al Rights ReservedAWWA Standard ‘This document isan American Water Works Association (ANIWA) standard t's nat a specifeation, AWA standards describe ‘minimum requcements and donot contain a ofthe engneeting and administrative information normaly contained in speci Calls. The AWWA standards usualy contan options that must be evluated by the User of the standard, Uni each optional {eature is specie by the user, the product or service Is not fly defined. ANWA publication of @ standard doesnot constitute endorsement of any producto product type, cor does AWWA test, erty. or approve any product. The use of AAWA standards 's enbrey voluntary. Ths standard does nat supersede or take precedence ver or aisalace ary appicable law, regulation, oF codes of any governmental authority, AWWA standards are inended fo representa consensus ofthe water supply industry that the product described wil provide Satisfactory service. When ANIA revises or withdraws this standara, an oil naice of action wil be placed onthe fst page of te classed advertising section of Journal AWWA. The ation becomes effective on the fest day of he meth following the month of Journal AWWA pubiation of the oficial natice. American National Standard |an American Nationa Standar imple @ consensus of hose substantial concerned with its Scope and prisons. An American Natioral Standard is intended as guide to aid the manufacturer, th consumer, and the general publ. The existence of an ‘Amuriean Natonal Standard does ot in any respect preclude anyone, whether that person has approved the standard oF not ‘om manufacturing, marating, purchasing, 0 using products, processes, or procedures rat conforming tothe standard. Amer an National Standards are subject to pores review, and usors ae cautioned to obtan the latest etion. Producars of goods ‘mace in conformiy with an American National Standard are encouraged to stato onthe own roeponsibiyin advertising and ‘Promotional materials or on tags or labels thatthe goods are produced in conformity with particular American National Standards ‘Cauro Nonce: The American National Stangards Institute (ANS) approval date onthe front cover of ths standard indlestes| complation ofthe ANSI approval process, This Amarican National Standard may De revised or witrawn at any tm. ANSI procedures require that action be takan ts oatim, reuse or wtnéraw this standard no later than fve years fam the date of pbleaion.Purenasers of American National Standards may recowe curt information on all standards by calling or writing ‘he American Natonal Standards Institute, 25 West 42rd Stet, Fourth Foot, New York, NY 10036; (212) 642-4000, or maling info@ans.org. This AWWA content isthe product of thousands of hours of work by your fellow water professionals, Revenue from the sales of this AWWA material supports its ongoing development. Unauthorized distribution, either electronic or photocopied, is illegal and hinders AWWA's mission to support the water community. Al igs reserved. No part of tis publication may be reproduced or transmitted In ary form or by ary means, electronic of mechanical, eluding photocopy, cording. of any infermation of retrieval system, except inthe form of bie excerpts oF ‘Wotations Tor review purposes, without the witton permission ofthe publisher. ‘Copytight © 2023 by American Water Works Assocation Printed in USA. Copyright © 2011 American Water Works Associaton, Al Rights Reserved.Committee Personnel The task group for updating ANSIAWWA C206 had the following personnel: B. Nash Williams, Chair S.A. Arnaout, Hanson Pressure Pipe, Dallas, Texas H., Bardakjian, Manufacturer's Consultant, Glendale, Calif. B. Buchanan, Canusa-CPS, Toronto, Ont. J. Buratto, Lifelast Inc., Vancouver, Wash. B. Card, Manufacturer's Consultant, Sugarhill, Ga. D, Dechant, Manufacturer's Consultant, Aurora, Colo. B, Hansen, National Welding Corporation, Midvale, Utah B.D. Keil, Northwest Pipe Company, Portland, Ore. G. Kohibeck, Felker Brothers, Marshfield, Wis. J. Luka, American Spiral Weld Pipe Company, Columbia S.C. R. Mielke, Northwest Pipe Company, Raleigh, N.C. G. Ruchti, American Spiral Weld Pipe Company, Punta Gorda, Fla. RUN, Satyarthi, Baker Coupling Company, Los Angeles, Calif. H. Stoner, Consultant, North Plainfield, NJ. M.A. Vanderbosch, CAB Inc., Oakwood, Ga. D.R. Wagner, Wagner Consulting, St. Louis, Mo. BN. Williams, National Welding Corporation, Midvale, Utah (AWWA) (AWWA) (awwa) (awa) (awwa) (awwa) (awa) (awa) (awwa) (awa) (awwa) (awwa) (aww) (awwa) (awway (awwa) (awa) “The AWWA Standards Committee on Steel Pipe, which reviewed and approved this standard, had the following personnel at the time of approval: John H. Bambei Jr., Chair Dennis Dechant, Vice-Chair John L. Luka, Seeretary General Interest Members W.R. Brunzell, Brunzell Associates Led., Skokie, Il. RJ. Card, Lockwood Andrews & Newnam, Sugar Hill, Ga. RL. Coffey, HDR Engincering Inc,, Omaha, Neb, HLE. Dunham, MWH Inc., Bothell, Wash. CCopycght© 2011 American Water Works Assocation, Al Rights Reserved, (aWwWa) (AWWA) (AWWA) (AWWA)S\N. Foellmi, Black & Veatch Corporation, Irvine, Calif. MLB. Horsley,* Black & Veatch Corporation, Kansas City, Mo. J.K. Jeyapalan, Pipeline Consultant, New Milford, Conn. R.A. Kufaas, Norske Corrosion & Inspection Services Ltd., Surrey, B.C. J.L. Mattson, Corrosion Control Technologies, Sandy, Utah DLL. McPherson," MWH Americas Inc,, Cleveland, Ohio WJ. Moncrief” HDR Engineering Inc., San Diego, Calif. R. Ortega." Lockwood Andrews & Newnam, Houston, Texas Ralphyt Standards Engineer Liaison, AWWA, Denver, Colo. A.E, Romer, AECOM, Newport Beach, Calif, HLR. Stoner, Consultant, North Plainfield, NJ. CC. Sundberg, CH2M HILL Inc,, Issaquah, Wash. GJ. Tupac, GJ. Tupac & Associates Ine., Sun City West, Ariz. WAR. Whidden, Post Buckley Schuh & Jernigan, Orlando, Fla. K.E. Wilson, Standards Council ‘Tampa, Fla, jaison, Post Buckley Shuh & Jernigan Inc., Producer Members S.A. Arnaout, Hanson Pressure Pipe Inc., Dallas, Texas HLH, Bardakjian, Consultant, Glendale, Calif. M. Bauer, Tnemec Company Inc., North Kansas City, Mo. R.R. Carpenter, American SpiralWeld Pipe Company, Birmingham, Ala. D. Dechant, Dechant Infrastructure Service, Aurora, Colo. WE. Geyer, Steel Plate Fabricators Association, Lake Zurich, Il. B.D. Keil, Northwest Pipe Company, Pleasant Grove, Utah |J.L. Luka, * American SpiralWeld Pipe Company, Columbia, S.C. R. Mielke,* Northwest Pipe Company, Raleigh, N.C. J. Olmos, Ameron International, Rancho Cucamonga, Calif. J.A. Wise, Canus International Sales Inc., Langley, B.C. User Members G.A. Andersen, New York City Bureau of Water Supply, Little Neck, NY, JH. Bambei Jr, Denver Water, Denver, Colo, © Alternate + Liason, nonvoting Copyright© 2011 American Water Works Assocation. All Rights Reserved (AWWA) (AWWA) (AWWA) (AWWa) (AWWA) (AWWA) (AWWA) (AWWA) (AWWA) (aWwWa) (AWWA) (AWW) (awwa) (AWWA) (AWWA) (aww) (awwa) cawway (Mss) (awwa) (SEPA) (AWWA) (AWWA) (awway (awwa) (awa) (AWWA) (AWWA)B. Cheng, Metro Vancouver, Burnaby, B.C. DW. Coppes, Massachusetts Water Resources Authority, Southborough, Mass. RY. Frisz, US Bureau of Reclamation, Denver, Colo. G. George, Tacoma Water, Water Supply Section, Tacoma, Wash. TJ. Jordan, Metropolican Water District of Southern California, La Verne, Calif. ‘M. McReynolds,* Metropolitan Water Districe of Southern California, La Mirada, Calif. G. Oljaca* Metro Vancouver, Burnaby, B.C. GP. Stine, San Diego County Water Authority, San Diego, Calif. N.A. Wigner, Los Angeles Department of Water & Power, Los Angeles, Calif. JM. Young, City of Richmond, Richmond, B.C. “Alernate Copyright© 2011 American Water Works Assocation. Al Rights Reserve, (AWWA) (NEWWA) (BUREC) (AWWA) (AWWA) (AWWA) (AWWA) (AWWA) (AWWA) (AwWwa)This page intentionally blank, ‘Copyright® 2011 American Water Wocks Assocation, Al Rights ReservedContents All AWWA standards follow the general format indicated subsequently. Some variations from this format may be found in a particular standard. seo, PAGE Foreword 1 Introduction.. LA 1B 1c Tl Special Issues. IIL Use of This Standard... TILA Purchaser Options and Alternatives xi IILB Modification to Standard... xii IV Major Revisions... V_ Comments Standard 1 General LI Scope 1.2 Purpose 13° Application... 2 2 References. 3 Definitions... seo Pace, 4 Requirements 4.1 Materials . 3 4.2. General Requirements... 43° Joint Types. sennnnnnennne 5 44 Qualification of Welding Procedures, Welders, and ‘Welding Operator... 6 45 Welding Electrodes 4.6 Welding Procedure Details. 7 4.7 Repair of Welds 10 5 Verification 5.1 Inspection 10 5.2. Testing. 5.3. Rejection... 6 Delivery 6.1 Marking 12 6.2 Packaging and Shipping... 13 6.3. Affidavit of Compliance. Figure 1 Look-Box for Vacuum Testing of Circumferential Weld Seams..... Copyright © 201% American Water Works Assocation, Al Rights Reserved,This page intentionally blank. Copyright ©2011 American Water Werks Assocation. ll Rights Reserved.Foreword This foreword is for information only and is not a pare of ANSTIAWWA C206. I. Introduction. LA. Background. ‘The provisions of this standard describe the requirements ion and distribution lines. The for welding steel water pipe joints in water transmis purchaser for each project is responsible for determining if any unusual circumstances related to the project require additional provisions chat are not included in the standard. “The design of feld-welded joints is not discussed in this standard. Useful informa- tion on this subject may be found in AWWA Manual MII, Stee! Pipe—A Guide for Design and Installation and in Usefdl Information on the Design of Plate Structures After the welded field joint has been completed, if the pipe has been coated or lined, the joint shall be coated and lined with a coating system compatible with that on the body of che pipe, in accordance with the requirements for field repairs stated in the appropriate AWWA coating or lining standard. For lap-welded pipe with an inside diameter equal to o exceeding 48 in. (1,200 mm) and where the purchaser deems single welding to be acceptable, inside welding is recommended. Safety precautions shall be utilized in all pipe sizes, although when pipe with inside diameters less than 48 in. (1,200 mm) down to 27 in. (675 mm) are welded from the inside, additional safety precautions shall be observed. Interior welding on pipe diameters less than 27 in. (675 mm) is not recommended. Pipe requiring inside welds with limited access should be supplied with 3-in (75-mrm) diameter weld lead pass holes at approximately 400-ft (122-m) centers to allow passage of welding leads co the joint location. Shorter distances between pass holes may be required, depending on actual project conditions. Pass holes in the pipe will permic shorter welding leads and thus avoid erratic voltage drops caused by excessively long welding leads. The pass hole is fabricated using a weldable-grade, inside-chreaded pipe half coupling welded to a hole cut through the pipe wall. After using the pass hole, a weldable grade plug shall be threaded into the opening and seal-welded to secure, American National Standards Instcure, 25 West 43rd Street, Fourth Floor, New York, NY 10036. Steel Pipe—A Guide for Design and Intalation, AWWA Mangal MII, AWWA, Denver, Colo (2004) 4 Usefel Information on the Design of Plate Structures, Steal Place Engineering Data, Vol. 2, American Irom and Stel Insticute, 1101 17th St. NW, Ste. 1300, Washingeon, DC 20036, Copyright © 2011 American Water Works Association, Al Rights Reserve,LB. History, This standard was first approved as tentative by AWWA in January 1946 and by the American Welding Sociery (AWS) in October 1945. It was advanced to standard status by AWWA in 1950 and by AWS in 1951. The joint AWWA-AWS activity continued through revisions in 1957 (AWWA C206-57, AWS D7.0-57) and 1962 (AWWA €206-62, AWS D7.0-62a). The joine committee was dissolved in 1971, and the standard was assigned to the AWWA Standards Committee on Steel Pipe. Subsequent editions of the standard were published in 1975, 1982, 1988, 1991, 1997, and 2003. This edition was approved by the AWWA Board of Directors on Jan. 23, 2011 LC. Acceptance. In May 1985, the US Environmental Protection Agency (USEPA) entered into a cooperative agreement with a consortium led by NSF International (NSF*) to develop voluntary third-party consensus standards and a certification program for direct and indirect drinking water additives. Other members of the original consortium included che American Water Works Association Research Foundation (AwwaRF, now Water Research Foundation‘) and the Conference of State Health and Environmental Managers (COSHEM). The American Water Works Association (AWWA) and the Association of State Drinking Water Administrators (ASDWA) joined later. In the United States, authority to regulate products for use in, or in contact with, drinking water rests with individual states.* Local agencies may choose to impose requirements more stringent than those required by the state. ‘To evaluate the health effects of products and drinking water additives from such products, state and local agencies may use various references, including 1. An advisory program formerly administered by USEPA, Office of Drinking Water, discontinued on Apr. 7, 1990. 2. Specie policies of the state or local agency. 3. Two standards developed under che direction of NSF, NSF/ANSI 60, Drinking Water Treatment Chemicals—Health Effects, and NSF/ANSI 61, Drinking Water System Components—Health Effects 4, Other references, including AWWA standards, Food Chemicals Codex, Water Chemicals Codex and other standards considered appropriate by the state or local agency. “NGF Invernational, 789 N, Dixboro Road, Ann Arbos, MI 48105, ++ Water Research Foundation, 6666 W. Quincy Avenue, Denver, CO 80235. ‘Persons outside the United States should contact the appropriate authority having jurisdiction, ‘§Both publications available from National Academy of Sciences, $00 Fifth St. NW, Washington, DC. 20418. Copyright © 2011 American Wtor Works Association. Al Rights Reserve,Various certification organizations may be involved in certifying products in accor- dance with NSF/ANSI 61. Individual states or local agencies have authority to accept or accredit certification organizations within their jurisdiction. Accreditation of certi- fication organizations may vary from jurisdiction to jurisdiction Annex A, “Toxicology Review and Evaluation Procedures,” to NSF/ANSI 61 does not stipulate a maximum allowable level (MAL) ofa contaminant for substances not regulated by a USEPA final maximum contaminant level (MCL). The MALs of an unspecified lise of “unregulated contaminants” are based on toxicity testing guide- lines (noncarcinogens) and risk characterization methodology (carcinogens). Use of Annex A procedures may not always be identical, depending on the certifier. ANSU/AWWA C206 does nor address additives requirements. Users of this stan- dard should consult the appropriate state or local agency having jurisdiction in order to 1. Determine additives requirements, including applicable standards. 2. Determine the status of certifications by parties offering to certify products for contact with, or treatment of, drinking water. 3. Determine current information on product certification. IL, Special Issues. This standard has no applicable information for this section. TIL. Use of This Standard. It is the responsibility of the user of an AWWA standard to determine that the products described in that standard are suitable for use in the particular application being considered. TILA. Purchaser Options and Alternatives. "The following information should be provided by the purchaser. 1. Standard used—that is, ANSIAWWA C206, Field Welding of Steel Water Pipe, of latest revision. 2. Whether compliance with NSF/ANSI G1, Drinking Water Treatment Chemicals—Health Effects is required, 3. Derails of other federal, sate or provincial, and local requirements Sec. 4.1.1) Provisions for alleviation of thermal stresses (Sec. 4.2.6). ‘Type of joint (Sec. 4.3). Lap joint (See. 4.3.2) Butt joint (Sec. 4.3.3). Option regarding backing rings (Sec. 4.3.3.1). Seal weld of bute straps to facilitate an air test (Sec. 4.3.4). 10. Notch tough weld criteria, if required, temperature of test, and test values Gee, 4.6.10). 11, Weld inspection, if required (Sec. 5.1.3) eu ae Copyright © 2011 American Water Works Assocation, Al Rights Reserved.12, Testing methods, if required (Sec. 5.2) 13, Nondestructive testing of welded joints if substituted for hydrostatic tests (Gee. 5.2.2). 14, Affidavit of compliance (Sec. 6.3). TILB. Modification to Standard. Any modification of the provisions, definitions, or terminology in this standard must be provided by the purchaser. IV. Major Revisions. Major changes made to the standard in this revision include the following: 1. Information on inside welding of pipe with limited access was added to the foreword (Sec. L.A) 2. Definitions for procedure qualification record (PQR), weld-afver-backfill, welding procedure specification (WPS), and welder qualification record were added ection 2). 3. Deleted che permeation section since it is not applicable for welded steel pipe. 4, Added requirement for materials to comply with the Safe Drinking Water Actand other federal regulations (Sec. 4.1.1) 5. Added a section on double-welded lap joints and single-welded lap joints with air testing (Sec. 4.3.2.2 and Sec. 4.3.2.3) 6. Added a paragraph on butt joints without a backing ring (Sec. 4.3.3.1) 7. Revisions were made to Sec. 4.3.4, Butt-strap joints. 8. Revisions were made to Sec. 4.4, Qualification of Welding Procedures, Welders, and Welding Operators, including the addition of qualifications for ack welders. 9. The clearance between faying surfaces of lap joints was revised (Sec. 4.6.3). 10. A requirement for che fillet weld size was added (Sec. 4.6.3). 11. Anew section on weld-after-backiill was added (Sec. 4.6.4). 12. The permissible metal temperature of the pipe wall during welding was low- ered. (Sec. 4.6.5) 13. A requirement for repair of arc-strikes was added (Sec. 4.6.8.4). 14. A requirement for Charpy V-notch specimens was added (Sec. 4.6.10). 15. A section on visual inspection was added (Sec. 5.1.4) 16. The section on Ultrasonic testing without backing rings was deleted (old See, 5.2.2.2) and incorporated into a revised Sec. 5.2.2.1, Testing of feld-bute joints with or without backing rings. 17, The testing section on lap joints was renamed to Testing field filler weld joints, and was revised (new Sec. 5.2.2.2). 18, Information on marking of pipe segments was added to Sec. 6.1. Copyright© 2011 American Water Works Associaton. Al Rights Reserved,V. Comments. If you have any comments or questions about this standard, please call AWWA Engineering and ‘Technical Services at 303.794.7711, FAX at 303.795.7603, write to the department at 6666 West Quincy Avenue, Denver, CO 80235-3098, or e-mail at standards@awwa.org. CCopysght © 2011 American Water Works Assocation. Al Rights ReservedThis page intentionally blank, Copyright © 2011 American Water Works Assocation. Al Rights Reserved\. ANSI/AWWA C206-14 (Revision of ANSI/AWWA C206-03) American Water Works Association AWWA Standard Field Welding of Steel Water Pipe SECTION 1: _GENERAL Sec. LL Sec. 1.2 Scope “This standard describes manual, semiautomatic, and automatic field welding by the metal are-welding processes for steel water pipe manufactured in accordance wich ANSI*/AWWA C200, Scandard for Steel Water Pipe—6 In. (150 mm) and Larger. This standard describes field-performed, full circumferential welding of three types of pipe joints: (1) lap joints; (2) bute joints; and (3) butt-strap joints. ‘This standacd also applies to other welding required in field fabrication and instal- lation of specials and appurtenances. However, when possible, fabrications should be performed by the manufacturer at a manufacturing facility. The design of field- welded joints is nor covered within this standard. ‘his standard recognizes AWSt D1.1 as the supporting document. Welding of gasketed joints may require modification to the parameters of this welding standard, Purpose “The purpose of this standard is to provide minimum requirements for field welding and inspection of stel water pipe, including requirements and inspection, * American National Standards fnsitue, 25 West 43ed Street, Fourth Floor, New York, NY 10036. ‘tAmerican Welding Society, $50 N.W. LeJuene Road, Miami, FL 33126. 4 Copyright ©2011 American Water Works Assocation. All Rights Reserved,2 AWWA C206-11 Sec.1.3 Application This standard can be referenced in documents for field welding of steel warer pipe. The stipulations of this standard apply when this document has been refer- enced and then only to field welding of stecl water pipe. SECTION 2: _REFERENCES ‘This standard references the following documents. In their latest editions, they form a part of this standard to the excent specified within the standard. In any case of contlic, the requirements of this standard shall prev: ANSI/AWWA C200—Steel Water Pipe—6 In. (150 mm) and Larger. ASME* Sec. VIII Division 1—Boiler and Pressure Vessel Code, Rules for ‘Construction of Pressure Vessels. ASTMt A135—Standard Specification for Electric Resistance-Welded Stecl Pipe. ASTM A370—Standard Test Methods and Definitions for Mechanical Test- ing of Steel Products. AWS A2.4—Standard Symbols for Welding, Brazing, and Nondestructive Examination, AWS A3.0—Standard Welding Terms and Definitions Including Terms for Brazing, Soldering Thermal Spraying, and Thermal Cutting. AWS DI.1—Structural Welding Code—Steel. AWS QCI—Standard for AWS Certification of Welding Inspectors. Steel Pipe—A Guide for Design and Installation. AWWA Manual MU. AWWA, Denver, Colo. SECTION 3: _ DEFINITIONS ‘The following definitions shall apply in this standard: 1. GP: Complete joint penetration. 2. Constructor: The party that provides the work and materials for place- ment or installation, ‘ASME International, Three Park Avenue, New York, NY 10016, ASTM Incernational, 100 Barr Harbor Drive, West Conshohocken, PA 19428, CCopysght © 2011 American Water Works Assocation, Al Rights ReservedFIELD WELDING OF STEEL WATER PIPE 3 3. CWE Certified welding inspector. 4. Faying surfaces: “The mating surface of a member that isin contact with, or in close proximity to another member, to which ic isto be joined. 5. Full filler weld: A fillet weld with both legs of the weld equal in size co the thickness of the thinner member joined 6. Manufacturer: The party that manufactures, fabricates, or produces materials or products. 7. NDT: Nondestructive testing, 8. PQR: Procedure qualification record. A record of the welding variables used to produce an acceptable test weld and the results of the tests conducted on. the weld co qualify a welding procedure specification. 9. Purchaser: The person, company, or organization that purchases any materials or work to be performed. 10. WPS: Welding Procedure Specification. A document to describe the range of voltage, amperage, travel speed, and other parameters intended ro be uti- lized in the welding process. IL. WQR: Welder Qualification Record, The document to describe the welder testing and results of that testing that allows certification of a welder to perform welding. 12. Weld-after-backfill: The sequence of assembling a lap-welded joint, welding the outside weld (if required), applying the external joine pipe coating sys- tom, backfilling the pipe, then welding the inside joint ata later time (where inside welding is safe and practical) 13, Welder or welding operator: A person who performs a manual, semiauto- ‘matic, or automatic welding operation. 14, Welding symbols: Symbols used on documents to define weld type, size, location, and geometry. 15. Welding terms: Welding terms shall be interpreted in accordance with the definitions given in AWS A3.0, supplemented by Annex B of AWS D1. SECTION 4: _REQUIREMENTS Sec. 4.1 Materials 4.11 General, Mater requirements of this standard. provided and work completed shall meet the CCopycght© 2011 American Water Works Assocation. ll Rights Reserve,4 AWWAC206-14 Maxerials shall comply with the requirements of the Safe Drinking Water Act and other federal regulations for potable water, wastewater, and reclaimed water systems as applicable. See. 4.2 General Requirements 4.2.1 Construction drawings. Construction drawings shall be the pur chaser's drawings or approved constructor’ drawings. 4.2.2 Equipment. ‘The constructor’s equipment for welding shall be designed and maintained in such condition as to permit qualified welding opera- tors to follow the welding procedure details (Sec. 4.6) and obtain the results pre- scribed. 4.2.3. Welding proces. Welding shall be performed by any welding pro- cess that will (I) produce a joint meeting the minimum strength requirements of the base metals and (2) meet the welding procedure qualification required in See. 44 of this standard, excepe that the shore-circuiting transfer mode of the gas metal arc-welding process shall not be used for weld sizes greater than %isin. (4.8 mm).* 4.24 Safety and environmental considerations, Welding, cutting, and grinding operations will produce smoke and fumes. In confined spaces, the con- structor may be required to utilize exhaust ventilation systems, employ air moni- toring equipment, and take other actions to ensure meeting safety regulations. Interior pipe welding shall only be performed after safe and adequate access and gress is provided for the personnel. Federal state or provi tions shall also be followed. cial, and local regula- 4.25 Pipe condition. Prior co welding, ends of pipe to be welded shall be in conformance with the requirements for end preparation for field joints in accor- dance with ANSIAW WA C200. Any linings or coatings shall be held back in an amount that is appropriate for the type of joint. 4.2.6 Thermal-stress control, For welded joint pipelines, variations in pipe temperature at the time of installation, and the temperature difference between the pipeline and the temperature of the fluid being transported during operation, may induce thermal stresses. Anticipated thermal stresses should be evaluated by the purchaser. Various methods are available to reduce thermal stresses, such as shading the pipe in the trench, using backfill as insulation, making certain joint welds Mettic conversions given in this standard are direct conversions of US customary units and are not those specified in Inernational Organization for Standardization (ISO) standards Copyright© 2011 American Water Works Association. Al Rights ReservedFIELD WELDING OF STEEL WATER PIPE 5 (particularly when closure joints are made) at a time of day when the temperature is the lowest, or a combination of these methods. If specified by the purchaser, sleeve-rype couplings may be used in lieu of welded joints to control thermal stresses, as long as the movement in each joint is less than 0.375 in, (9.5 mm) or as recommended by the coupling manufacturer. Sec.4.3. Joint Types 43.1 General, Joints shall be lap joints, but joints, or bute-strap joints, as specified by the purchaser. 43.2 Lap joints, Lap joints shall be full-fillet single-welded unless other- wise specified by che purchaser. Field joints shall be assembled so that scams in adjacent pipe sections are offset from each other by at least five times the thickness of che thinner of the pipes being joined. 43.2.1 Single-welded lap joints. At the option of the constructor, and subject to the purchaser's approval, single-welded lap joints may be welded from either the outside of the pipe or from the inside of the pipe ifthe diameter is large enough. 43.2.2 Double-welded lap joints. If specified by the purchaser, double- welded lap joints with full-illee welds shall be required. 4 chaser, single-welded lap joints with air testing shall be completed by the addition 3 Single-welded lap joints with air testing. IF specified by the pur- ofa second weld to facilitate the air test described in Sec. 5.2.2.2. This second weld shall only be a seal weld. 4.3.3. Bust joints. Bute joints shall be single-groove with a backing ring or double-groove welded, at the option of the purchaser, and shall be CJP bute welds. Field joints shall be assembled so thac seams in adjacent pipe sections are offset from each other by atleast five times the thickness of the thinner of the pipes being joined. 4.3.3.1 Single-groove butt joints. At the option of the purchaser, single- groove bute joints may be welded from the outside of che pipe or from inside the pipe if che diameter is large enough. Backing rings will assist in proper alignment and may be used unless otherwise prohibited. The exterior backing ring should remain after welding unless otherwise required. The interior backing ring may remain after welding, subject to evaluation of possible interference with the interior lining, with agreement of the purchaser. Depending on the welding process used, the bute joint withoue a backing ring may require back grinding or gouging, then Copyright® 2011 American Water Works Association. Al Rights Reserved.6 AWWAC206-14 back welding on the opposite side of the bevel to achieve a CJP butt weld. Back grinding or gouging ensures complete removal of embedded slag. 4.34 Buer-strap joints, Bute straps shall receive complete circumferential single-welded full fillee welds, ether on the inside or outside of the butt strap. Tf specified by the purchaser, a double-welded butt scrap with full-fillec welds shall include welding both the inside and outside of the bute strap. Butt straps may be shop-attached by welding to one pipe end oF shipped loose for field attachment and welding. The bute straps shall have a minimum plate thickness equal to the thinnest member being joined and shall be fabricated from macerial of equivalent minimum physical properties and compatible chemical properties to the thinnest member being joined. Strap width shall be not less than 4 in. (102 mm) for pipe less than 36 in. (900 mm) in nominal diameter and 6 in. (152 mm) for pipe 36 in. (900 mm) nominal diamecer and larger. The minimum lap between pipe ends and the edge of the butt strap shall be 1 in. (25 mm) for pipe less than 36 in. (900 mm) in nominal diameter and 2 in. (51 mm) for pipe 36 in. (000 mm) nominal diam- ‘eter and larger. Longitudinal seams of bute straps shall be joined by CJP welded bute joints. See AWS DIL for various joint details. For butt-strap joints, the seams of adjacent pipe sections may be in alignment, provided the butestrap seams are office from the pipe seams by at least five times the thickness of the thinner member involved in the joint. At the option of the constructor and subject to the purchaser’ approval, the butt strap may be welded from the outside ofthe pipe, or from i the pipe ifthe diameter is large enough. ‘With the purchaser's approval, either the inside or the outside weld may be a seal weld co facilicate an air test as described in Sec. 5.2.2.2, if the other weld provides sufficient strengch to carry all loads anticipaced atthe joint Sec. 4.4 Qualification of Welding Procedures, Welders, and Welding Operators 44.1 General. Joinewelding procedures to be used for work under the provisions of this standard and welders, welding operators, and tack welders shall be qualified by tests, except procedures chat comply with Sec. 4.4.2, General requirements for qualification shall be in accordance with AWS D1.1, Qualifica- tion. (Nore: A pipeline is not “tubular construction” as defined in AWS DILL.) ‘Written procedures shall be prepared by the constructor and shall be made avail- able to the welders at the jobsite and co those authorized to examine the welds. 44.2 Welding procedure qualification record (PQR). The PQR docu- ment provides the verification that the welding method and operating, values provide the required metallurgical and mechanical characteristics. The WPS Copyright© 2011 American Water Werks Association, Al Rights Reserved,FIELD WELDING OF STEEL WATER PIPE 7 will provide the operating ranges (voltage, amperage, travel speed, etc.) allowed during the actual welding operations. Certain joint-welding procedures, as out- lined in AWS DI.1, Prequalification of Welding Procedure Specifications, are prequalified and are exempt from tests. Other procedures shall be qualified in accordance with AWS DIL" 443. Welder, welding-operator, and tack welder qualification. Welders and ‘welding operators shal be qualified by tests as prescribed in AWS DLLI* The WOR document provides cerifcation that the welder, welding operator, or tack welder is qualified to perform welding under this standard. The welder and welding-operator qualification will remain in effect indefinitely unless (I) the welder is nor engaged in a given process of welding for which the welder or welding operator is qualified for a period exceeding six months or unless (2) there is some specific reason to question a wwelder’s or welding operators ability. A tack welder who passes the tests as prescribed in AWS DILL shall be con- sidered eligible to perform tack welding indefinitely in che positions and with the process for which the tack welder is qualified unless there is some specific reason to ‘question the tack welder’ ability. 443.1 Records. Records ofthe test results shall be kept by the construc- tor and shall be available to the purchaser. Sec. 4.5 Welding Electrodes 45.1 General. Welding clectrodes shall be the same classification as those used for the welding-procedure qualification in Sec. 4.4.2. When low-hydrogen clectrodes are used for welding, the constructor shall control the storage and han- dling of clectrodes to maintain the low-hydrogen characteristics as recommended by the electrode manufacturer. Sec. 4.6 Welding Procedure Details 4.6.1 General. Welds in the pipe and the attachments shall be performed in strict accordance with the qualification procedures stated in Sec. 4.4, Weld sym- bols shall be as defined under AWS A2.4. Special welding conditions shall be fully explained by added notes or detail FAWS DIA, Table 47, sefers co qualification of welding procedures with 2 base metal included in group I and {group I of Table 3.1 in AWS DI.1. For the purposes of AWWA C206, group I and group II materials shall include pipe produced to ASTM A135, grades A and B. FAWS DI.1, Sec. 3.3, 4.7.3, and 5.2, sate that che base metal used in the qualification test shall comply wich Table 3.1 of the procedure described in AWS D.L.1 CCopyeght © 2011 American Water Werks Assocation. All Rights Reserved8 AWWAC206-11 46.2 Preparation of welding surfaces. Surfaces to be welded shall be free from moisture, scale, slag, heavy rust, grease, coatings, paint, primer, cement, or any other foreign material. Joint surfaces shall be smooth, uniform, and free from defects that adversely affect proper welding. After wire brushing, any residual light film of rust remaining on the cut or sheared edges to be welded need not be removed. Surfaces that were previously torch cut or aie-arc gouged shall be ground to remove slag and oxidation. 46.3 Lap-joint assembly, Clearance between faying surfaces of lap joints shall not exceed ¥e in, (3.2 mm) at any location for fillet welds on pipe having wall thicknesses less than or equal to %ic in. (7.9 mm), and clearance between faying, surfaces of lap joints shall not exceed 346 in, (4.8 mm) at any location for fillet (79 men). In che event the faying surfaces exceed these tolerances, verify if the pipe ends comply with the welds on pipe having wall chicknesses greater than % required manufacturing tolerances; ifso, the constructor shall fic the area to within the toleranecs stated in this section. The minimum overlap of the assembled bell- and-spigot sections of the joint shall be 1 in. (25 mm) or three times the thickness of the belled pipe, whichever is greater. No part of any field weld shall be closer than 1 in, (25 mm) co the nearest point of tangency to a bell radius. Joine fabrica- tion tolerances shall be in accordance with ANSVAWWA C200. “The filler weld size shall be the specified thickness plus the root opening between che two overlapping plates. The finished weld shall create a 45° angle rela- tive to the adjoining members. 4.6.4 Weld-after-backfill sequence. Welding inside feld joints after back- fill is an acceptable practice under this standard, provided the requirements of ANSUAWWA C205, C206, C209, C214, C215, C216, and other applicable AWWA standards are followed. Consult with the manufacturers subject to the above-referenced standards regarding recommended products, installation, and backfill procedures required for the weld-after-backfill sequence. Art the request of the purchaser, che manufacturer shall provide testing or historical information to verify that the exterior joint coating will comply with the applicable material stan- dard and the coating manufacturer's requirements after completion of the welding. Note: In all cases, the exterior coating manufacturer should be consulted to verify its product is intended for the weld-afier-backfill application with the project-specific conditions. The constructor shall adhere strietly to the specified stab depth minimum and joint gap tolerances. 4.6.5 Weather conditions. Welding shall not be performed when the ambient temperature is less than 0°F (18°C), or when surfaces are wet from rain, Copyright © 2011 American Water Works Association. Al Rights Reserved,FIELD WELDING OF STEEL WATER PIPE 9 condensation, snow, or ice, or during periods of high wind, unless the work is properly protected. Regardless of the ambient conditions, the metal temperature in the pipe wall shall nor be less than 32°F (0°C) at any of the point of welding or four times the pipe wall thickness, whichever is greater. 4.6.6 Preheating. Preheating of the joints to be welded shal be performed in accordance with AWS D1.1, Prequalified Minimum Preheat and Interpass Tem- int within 3 in. (76 mm) perature. When preheating is required, it shall extend ahead of the point of weld- ing a minimum distance of four times the plate thickness, but not less than 3 in. (76 mm), on each side of the seam. Proper preheat temperature shall be determined periodically during welding by checking the material ata point atleast four times she plate thickness, bur not ess than 3 in. (76 mm), on either side of the seam. 4.6.7 Tack welding. Small erection tack welds used in the assembly of joints rnced not be removed provided (I) they are sound and their size does not exceed the subsequently applied root pass: (2) they do not interfere with welding procedures required for closure joints to control thermal stresses (See. 4.2.6); (3) they do not prevent the proper distribution of the annular space to control the distance between faying surfaces in lap joints (ec. 4.6.3); (4) the electrodes used in making the rack ‘welds shall be the same as used in che final welds; and (5) welding is performed in strice accordance with the qualification procedures stated in Sec. 4.4. 46.8 Weld appearance and weld contour. "The welds shall be applied using continuous stringer beads, or a weave pattern meeting AWS DI.1, Visual Inspec- tion Acceptance Criteria for Scatically Loaded Nontubular Connections. Each bead shall be cleaned and descaled before the succeeding bead is applied. Welded joints shall not be covered or coated until after welding is completed and the weld accepted 4.6.8.1 Surface pass. ‘The surface pass on welds shall be central to the seam, and all surface passes shall be smooth and free from depression. The final ‘weld surface shall be free from weld slag and porosity. 4.6.8.2 Undercutting, overlapping, and finished fillet weld. Undercut- ting of the base metal in pipe and adjoining the weld, which exceeds AWS DI.1 requirements, is a defect and shall be repaired. Burning back the inside or outside corner during application of a fillet weld shall be permitted if the edge can be clearly defined. ‘The finished fillet weld shall be free of grooves, deep valleys, or ridges and shall contain no abrupt changes in the section at the toe. 4.6.8.3 Lap- or fillecweld legs and faces. Lap or fillet welds shall have . The faces of fillet welds may be legs of equal size, except when specified other flac to slightly convex, Copyright © 2011 Amarican Water Works Assocation, Al Rights Reserved.10 AWWA c206-11 4.6.84 Cracks, Pinholes, Porosity, and Arc Strikes. Cracks in welds and base metal, incomplete fusion, lack of complete joint penetration (including fillet welds that do not penetrate past the point of intersection of the members being joined), and weld overlap are unacceptable, Pinholes and porosity ate unacceptable and shall be repaired according to Sec. 47. Ate strikes outside the weld bound- ary are unacceptable and shall be ground flush with the base metal and shall be repaired according to Sec. 4.7 if additional weld metal is required. 4.6.9 Matching butt joints. Bust joints shall be accurately aligned and retained in position during the welding operation so that, in the finished joint, the abutting pipe sections shall not be misaligned by more than 20 percent of the pipe wall thickness or a maximum of Y4 in, (3.2 mm), whichever is less. 4.6.10 Notch tough welds, When required for the pipe material and requested by the purchaser, welding procedures shall be qualified to provide notch tough welds. Filler material shall meet the same toughness requirements as the base metal or as required by the purchaser's documents. If not otherwise specified, the minimum average value of absorbed energy shall be 20 felb (33:9 N-m) at 32°F (-0°C) or the lowest anticipated service temperature, whichever is lower. Charpy V-noch (CVN) transverse specimens shall be prepared in accordance with the requirements of ASTM. A370 and AWS DL.I Section 4, Pare D, Requirements for CVN Testing. Sec.4.7 Repair of Welds 41 Repair of defective welds. Welds that are defective shall be repaired to meet the requirements of Sec. 4.5 and 4.6. 471.1 Defects in welds. Defects in welds or defective welds shall be removed and that section of the joint shall then be rewelded. The amount of mate- rial removed shall be limited to that required to correct the defect. After the repair is made, the joint shall be checked by repeating the original test procedure. SECTION 5: _ VERIFICATION Sec. 5.1 Inspection Inspection ora lack of inspection shall not relieve the constructor ofthe respon- sibility for performing work in accordance with this standard. The constructor shall notify the purchaser before performing any work under the provisions of this stan- dard so that the purchaser can prepare for the inspection. S.LL Access. The purchaser shall have free access to chose areas of the proj- ect that are involved with the performance of any work pertaining to this standard. Copyright© 201 American Water Works Association, Al Rights Reserved,FIELD WELDING OF STEEL WATER PIPE 12 5.1.2 Facilities, The constructor shall provide the purchaser with rea- sonable facilities and space for inspection, testing, and obtaining the information required to determine the character of materials used, the progress and conditions of the work, and the results obtained. 5.13. Weld inspection. When requested by the purchaser, a full welding inspector shall be present whenever there is welding to be performed. The welding inspector shall have prior pipe-welding inspection experience and shall be a CWI in accordance with the provisions of AWS QCI or otherwise meet the qualification requirements stated in AWS DL.1. 5.14 Visual Inpection. Field welds shall be visually inspected by an indi- vidual who by training, experience, or both, in metals fabrication, inspection, and testing, is competent to perform che visual inspection. Any of the weld defects identified by visual inspection shall be cause for rejection, and the deficient weld shall be repaired or replaced. The acceptance criteria for field welds shall meet the requirements of AWS DI.1, Visual Inspection Acceptance Criteria for Statically Loaded Nontubular Connections, except as modified in Sec. 4.6.8. Sec. 5.2 Testing Inspection and testing for weld integrity shall be performed unless otherwise specified by the purchaser. All welds shall be visually inspected in accordance with Sec. 5.14, 5.2.1 Hydrostatic test. ‘Tests for leaks in all types of welded joinc pipelines shall be made by hydrostatically testing the entire pipeline, unless the procedures, frequency of tests, and standards for acceptance or rejection of an alternative non- destructive method are approved by the purchaser. If leakage exceeds the amount allowed in the purchaser's documents, the leaks shall be located and repaired in accordance with Sec. 47. 5.2.2 Alternative tes. In lieu of the hydrostatic test, the purchaser shall approve nondestructive testing of welded joints. 5.2.2.1 Testing field-butt joints with or wichout backing rings. Field-buct joints with or without a backing ring may be tested by 100 percent magnetic par- ticle testing using acceptance criteria as stated in AWS D1.1 or 100 percent ulea~ sonic testing of 10 percent of the joints, using methods and acceptance criteria in ASME Sec. VIII, Division 1. 5.2.2.2 Testing field filet weld joints. Field fillet weld joints used for single- ‘welded lap joints, double-welded lap joints, and bute-strap joints may be rested using testing procedures and acceptance criteria as stared in AW'S DI. Copyright © 2011 American Water Works Assocation. Al Rights Reserved,12 AWWA .C206-44 “Magnetic particle testing is not required for a scal weld used to facilitate air-tested joints, unless the seal weld isa structural element of the joint. Double-welded lap joints can also be tested by shop drilling and tapping a Yin, (6A-mam) 0: Apply 40 psi (276 kPa) of air, or other satisfactory gas, into the annular space becween the ewo fillet welds and maintain for a period of 5 min. al pipe thread hole into the spigot or bell end of the pipe. IF the pressure remains at 40 psi (276 kPa), the test is complete. If the test pressure drops below 40 psi (276 kPa), maintain the pressure at 40 psi (276 kPa) from an external source and paint the welds with a soap solution. Mark any leaks indicated by the escaping gas bubbles and repair leak indications per Sec. 47. Close the threaded openings with pipe plugs or by welding, Nore: Radiographic and ultrasonic testing of lap joints shall not be utilized because of the difficulty inherent in interpreting the results 5.2.2.3 Vacuum box test. Both butejoint welds and fillee welds may be tested using a vacuum box. In this tes, the weld is painted with a soap solution, a ‘lear plastic box with a foam perimeter is placed over the test section, and a vacuum is induced in the box (see Figure 1). Mark any leaks indicated by the escaping gas bubbles and repair according to Sec. 4.7.1. This test method may require additional hold-back for coatings and linings to allow a proper seal. Nore: The vacuum box should be constructed of a sealed clear plastic cover ‘with an open bottom. The open bottom is sealed against the pipe surface by a closed-cell foam rubber gasket. Vacuum gauges, valves, and vacuum pump or air ejector are attached. The gauge should register a partial vacuum of at least 10 in (250 mm) of mercury when testing the weld seam, Sec.5.3 Rejection Any work that is not in accordance with the requirements of this standard shall be rejected. The constructor has the option of either repairing an unaccept- able weld or removing and replacing the defective weld. SECTION 6: _ DELIVERY Sec. 6.1 Marking When required by the purchaser, pipe, fittings, and pipe specials shall have a serial number of other identification mark hat will reference the line diagram or laying schedule. ‘The welding operator and the subsequent inspections performed Copyright © 2011 American Water Works Association. Al Rights Reserved,FIELD WELDING OF STEEL WATER PIPE 13 Lo Acre Cover oH I Sra Raber ast of & Section Pe ‘cam 2a vane Suge xy | LAL | mene utvelded > Sree g se set A A 3 to Compressor Pn Figure 1 Look-box for vacuum testing of circumferential weld seams oon each joint shall reference these serial numbers or other identification numbers to document these tasks. 6.11 Exterior. The serial number or other identification mark shall be painted in a conspicuous location on the exterior of each section of pipe, fitting, or pipe special. 6.1.2 Interior. When joints require interior field welds, the serial number or other identification mark shall be transferred to the finished interior of each sec- tion of pipe, fitting, or pipe special. The requirement to transfer serial numbers or other identification marks to the interior shall be at the purchaser's option. Sec.6.2 Packaging and Shipping ‘This standard has no applicable information for this section. Sec.6.3 Affidavit of Compliance “The purchaser may require an affidavit from the constructor stipulating that all ficld welds on the pipe and attachments have been made in accordance with applicable provisions of this standard. Copyright© 2011 American Water Works Association. A Rights Reserved‘Ria isthe authortatv resource for Krowiede, formation, and advocacy to improve he gual ard ‘supply of marin North Amara and beyond. ANWA fs the largest organiation of water professionals iy the worl AWWA advances public Rea, safety, and welfare ty uniting the efforts ofthe ful spectrum ofthe entre water community, Trough eur caloctve strength me Become btter stewards of wate or te greatest food of people and the environment. ® 1P-2.4M-43206-2/11J Printed on Recycled Paper Copyright© 2011 American Water Works Association. Al Rights Reserved