Professional Documents
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SSP-87-M-002
1. Scope
This Specification covers the minimum requirements for welding of circumferential welds of
pipes, fittings or associated pipeline components performed on the construction Right-of-Way
or in BIDDER's field fabrication shop.
2. General Specification
All welding shall be carried out in accordance with API-1104 "Standard for Welding Pipelines
and Related Facilities", latest edition, except where amended here below.
3.1 BIDDER shall submit his proposed welding procedures in writing to COMPANY for
review and approval. These proposed WPS's shall be supported by proper Procedure
Qualification Records (PQR's). A test based on the approved procedures shall then be
carried out by BIDDER and witnessed by COMPANY and all the relevant data shall be
recorded. Thereafter, if satisfactory to COMPANY, the procedures shall be adopted on
all field welds.
3.2 In formulating his welding procedures BIDDER shall be guided by the following points
which shall be read in conjunction with Clause 2.3, API Standard 1104 (latest edition).
i) Process
2.3b All pipe and fittings to be supplied will be in accordance with the
specifications given in the list of PROJECT MATERIALS supplied by
COMPANY.
2.3c Material grade, diameter and wall thickness indication for which the
submitted procedure specification is being qualified. Changes require
new procedure qualifications.
2.3d The angle of bevel will be 30o plus 5o minus 0o. The root face will be
1.6 mm (1/6") plus or minus 0.8 mm (1/32").
For vertical downhill welding the root gap shall not be more than 2.4
mm (3/32") and not less than 0.8 mm (1/32"). For vertical upward
welding the root gap shall be not less than 2.4 mm (3/32") and not more
than 4.0 mm (5/32").
2.3e The size and classification numbers of filler metal and the minimum
number and sequence of beads shall be submitted in tabular form to
COMPANY for approval, prior to the welding procedure test.
v) Electrical Characteristics
2.3f The current, polarity, voltage and amperage for each size of electrode
shall be submitted to COMPANY in tabular form for approval, prior to
the welding procedure test.
vi) Positions
2.3i Downhill welding may be employed on off plot works and cross
country pipelines. The uphill method of welding may be used for
fittings, tie-in welds in the trench, small diameter pipe, and on plot
works. The welder carrying out this work shall be qualified for
downhill or uphill welding as appropriate.
2.3j The root bead shall be cleaned immediately after deposition and the
second pass carried out within the time period recorded and approved
in the procedure test.
Likewise the second bead shall be cleaned after deposition and the
third pass carried out within the time period recorded and approved in
the procedure test.
Any joint started shall be completed within the same working shift, i.e.
no partially completed welds shall be left overnight.
2.3k Internal line-up clamps shall be used except at tie-ins, fittings and other
points where their use is impracticable. Under these circumstances an
external line-up clamp shall be used.
2.3l Internal line-up clamps shall be removed after the root bead is 100%
completed. External clamps may be removed when the root bead is
50% complete and equally spaced around the circumference.
xi) Cleaning
2.3m Power operated rotary tools approved by COMPANY shall be used for
cleaning between weld passes.
xii) Preheat
2.3o If the downhill welding technique is employed the root bead and
second pass for 12" O.D. pipe and over shall be deposited by a
minimum of two welders working simultaneously one on either side
of the pipe, starting topside.
xv) Striking an arc on the pipe at any point other than the welding groove shall not
be permitted. Any section of pipe which has been arc burned shall be cut out
and replaced at CONTRACTOR's expense.
xvi) Where the use of double sided welding, internal sealing runs to correct
misalignment, local internal repairs or the use of fittings requiring backwelding,
etc., will result in untempered weld beads on the process side, BIDDER shall
3.3 Pipes of highest carbon equivalent shall be welded under full simulated conditions.
If the weld does not pass this examination, mechanical testing shall not be performed.
Test specimens of butt welded joints shall be cut from the joint at the locations shown
in API 1104 Specification. The number of specimens and the tests to which they are
subjected are given in API 1104 Specification. The performance of testing and the
cost involved shall be for BIDDER's account.
Qualification test pieces shall be retained until such time as the respective welders
may be requalified.
i. Tensile test specimens shall be machined so that the sides are smooth and
parallel as described in API 1104 Specification.
ii. Root, face, nick break and side bend tests shall be performed on specimens
and the preparation method and requirements shall be as stated in 2.6 of API
1104.
iii. Sets of three Charpy-V-Notch impact specimens (in accordance with ASTM
A 370-74 and E 23-72) are to be taken from four locations. Tests are to be
carried out at 0oC and results are to meet impact properties shown under
Article 1.7.9.
The hardness of the weld metal or heat-affected zone and the base material
shall not exceed 248 HV 10.
- Two additional tests of the type that failed shall be made, both of
which shall meet the said requirements.
4.1 A welder qualification test form shall be completed and submitted to COMPANY for
each welder, in accordance with the approved WPS's.
COMPANY or a designated qualified representative shall witness the test and judge
the specimens.
A welder may be disqualified at any time during the test, if his performance is judged
unsatisfactory.
4.2 A welder shall be qualified by visual, non-destructive and/or destructive testing of his
welds on all phases in accordance with the specifications.
BIDDER shall furnish all welding equipment and prepare all nipples to be used in the
testing of welders. COMPANY shall only furnish the pipe.
The BIDDER shall bear all costs in connection with the tests. COMPANY shall be
supplied by the BIDDER with a full radiographic film and report of each test weld.
Each welder will be required to make a position weld on a pipe nipple of the same
dimensions and specification to be used in the lines.
Downhill and uphill welders shall be qualified separately. The number and location
of destructive test specimens shall be as directed by COMPANY. In addition to these
tests a Vickers hardness test (HV 10) may be carried out.
Test methods to be used for these specimens are stated in Article 3.3 of these
specifications and API-standard 1104.
4.3 All welders employed on the WORKS shall be tested to the satisfaction of
COMPANY on pipe of the specification and dimensions to be used in the WORKS.
No welder shall be permitted to perform welding until written notification is given.
5.1 Pipe-ends when prepared for welding shall be regular and beveled to the correct
angle. No manual cutting will be allowed, and when pipe is cut by flame cutting
machine, it shall be dressed smooth by filing or grinding.
A zone at least 10 mm wide on the outside and inside surfaces of the pipe measured
from the welding edges shall be cleaned. If moisture is present, the joint shall be
dried by use of any oxy-fuel torch.
Otherwise the alignment and welding shall be made alongside the ditch with the pipe
supported on skids, pads or other suitable means at least fifty centimetres above the
ground and as approved by COMPANY.
5.2 Immediately prior to the line-up of the pipes the BIDDER shall inspect the uncoated
pipe ends internally and externally for nicks, dents, general damage, laminations or
other surface defects.
5.3 If materials of different thicknesses are to be welded together, the welding ends shall
be prepared to COMPANY satisfaction.
ii. The pipe shall be laid in such a way that the longitudinal seam is situated on
the 90o top sector of the pipeline, except in sag or overbend when the seam
will be situated at side of pipe, see Article 16 of these specifications. When
a new pipe is welded on, the longitudinal seam of this pipe shall be rotated
through at least 100 mm relative to the preceding pipe. A longitudinal joint
should pass an appurtenance of a structural element, at a distance of 50 mm
minimum. In this case the minimum distance between the staggered joints
should be 50 mm at least.
iii. The maximum "high low" allowed is 1.6 mm (1/16") and any greater misfit
shall be distributed about the periphery or swaged to fit with a bronze faced
hammer, 5 kg maximum or by any other methods as approved by
COMPANY. Cold dressing shall be held to an absolute minimum.
5.5 The use of internal line-up clamps for all nominal pipe sizes of 12 inches and larger is
mandatory.
For making tie-in welds, and special welds joining valves, flanges, fittings, etc.,
where an internal line-up clamp cannot be used, an external line-up clamp shall be
used. The adjoining lengths of pipe shall be accurately spaced before applying the
stringer bead.
Pipe ends shall be spaced according to Article 3.2 (iii). The internal line-up clamp
shall be held firmly in position until the root bead is completed and the pipe has been
supported properly. The hot pass shall be applied in accordance with Article 3.2
5.6 When an external line-up clamp is used, the total length of the first pass shall be at
least 50 percent of the total circumference and shall be equally distributed around the
circumference before the clamp is removed.
The pipe shall not be moved until both the first pass and the second pass have been
completed.
Damaged ends of pipe that are bent, cut or otherwise damaged to an extent where in
the opinion of COMPANY faulty alignment or unacceptable welding would result
shall be straightened, repaired or cut off and rebeveled with a beveling machine of
type approved by COMPANY. After cutting, bevels may be checked by ultrasonics if
required.
No extra compensation shall be paid to BIDDER for such required repair or cutting
and beveling, unless the damage has been reported by BIDDER prior to his
acceptance of PROJECT MATERIALS.
5.8 Pre-heating shall be carried out with prior approval of COMPANY and according to
the following guidelines:
ii. When the ambient temperature is more than 10oC (50oF), or when moisture
has condensed on the pipe, a hand warm preheat shall be applied.
iii. Preheat may be required when any condition exists which might affect
weldability. Examples of such conditions are:
In the case of winds or rain, the welding shall be performed under proper
shielding. Covering of the open pipe end at the start of the string is
required.
They shall work simultaneously on opposite sides of the pipe (see also
Article 3.2 (xiii).
- All slag and excessive weld build-up shall be removed before deposition of
each succeeding weld pass.
- The starts and stops of weld beads from weld pass to weld pass shall be
staggered. All slag and scale shall be removed by power tools from each
bead for visual inspection immediately after each bead.
- After completion of the finish weld pass, the completed weld shall be
thoroughly cleaned of all slag, weld spatter and rust over a distance of 7
times the wall thickness.
- The finish welds shall be built-up from 0.5 mm to 2 mm above the surface
of the pipe. The welds must extend or overlap the outside of the V-groove
not more than approximately 1.6 mm on each side.
- Should a section of the line, containing unfinished welds, fall from the
skids, BIDDER shall immediately report the same to COMPANY.
- Each welder shall be required to mark that section of the weld he has
worked on with his code number. Marking shall be done with weatherproof
chalk (crayon). The use of stamps for marking the welds is not allowed.
The welder who makes the root pass shall write his code at the top of the
pipe; if, however, more than one welder welds the root pass, each welder
shall mark the top of the pipe with his identification code on the side which
he has worked.
- Subsequent welders shall write their identification codes below the first
code in the sequence in which they work.
The identification marks may not be removed until after the welds have
been inspected both visually and non-destructively.
If any welder leaves the work his mark shall not be re-assigned to nor used by any
other welder. BIDDER shall prepare and maintain weld history sheets.
The total length of a pipeline shall be divided in sections. BIDDER shall give each
weld a number within the section and mark these numbers and sections on the
DRAWINGS and on the pipe adjacent to the weld. The pipe mill identification
number of pipe joints one either side of the weld shall also be recorded.
5.10 For the number of welders working simultaneously on a girth weld see Article 3.2
(xiii).
5.11 All filler metals shall conform to the relevant American Welding Society (AWS)
Specification and must be approved by COMPANY. Copies of the consumable
certificates shall be made available to COMPANY for each lot or batch.
The storage recommendations for low hydrogen electrodes shall follow manufacturer
instructions and containers, ovens, etc. shall be supplied by BIDDER
Unless otherwise specified by manufacturer, the following instructions shall apply for
cellulose coated electrodes:
The minimum length of matching pieces ("pups") shall not be less than 1000 mm or
two diameters, whichever is the larger.
5.13 Roll welding may be permitted for certain shop fabrications. All procedures and
welders shall be approved by COMPANY and by qualification testing.
6.1 The welds shall be visually inspected during welding and after the weld has been
completed. Non-destructive testing shall be carried out only on completed welds.
6.2 All circumferential welds joining pipes and appurtenances shall be fully
radiographically inspected unless otherwise stated or agreed upon in writing. If
necessary, COMPANY will determine when and in what way any further inspection
of the welds shall take place. Welds wherein the wall thicknesses at the welds differ
by more than 50 percent of the lesser wall thicknesses or are 30 mm or more may not
only be tested radiographically but also utrasonically.
Where pipe is cut out due to bad welding, damage to the pipe, buckles or faults
discovered in the pipe, the rebevelled ends will be examined by ultrasonics and wet
MPI to a minimum of 50 mm each side of the cut out.
Ultrasonic examination reports shall be made with a marked up sketch, indicating the
item or piece number, identification and qualification of the operator, device and
calibration and shall be signed and retained. All defects shall be noted.
6.4 The internal pipe surface at the location of welds of all joints which are accessible for
the purpose may be inspected throughout their circumference, full use being made of
suitable optical instruments, e.g. introscopes for quality acceptance.
7.2 Any individual instance of excessive stringer bead deposition shall not exceed 4 mm
and shall not be longer than 20 mm.
The total length of excessive stringer bead deposits in any 300 mm length of weld
shall be separated by at least 150 mm of sound weld metal.
7.6 Unrepaired burned through areas shall be unacceptable. Radiographs of the repaired
burn through shall show proper repair.
7.7 Tensile strength tests shall meet the minimum tensile requirements.
7.8 Root-, face-, side-, and nick break tests shall meet the requirements as set forth in 3.3
(ii).
7.9 The Charpy-V-notch impact test at 0oC shall result in a minimum average energy (of
3 specimens) of 53 joules; individual minimum of the specimen shall be used
preferably. If smaller specimens are used straight interpolation is permitted.
8.1 Prior to welding the BIDDER shall submit for COMPANY's approval full details of
the repair welding procedures to be adopted.
The repair procedure shall be qualified by making a repair procedure test weld, one
for downhill and one for uphill welding, if required.
The test weld shall be subjected to the same inspection, NDT and mechanical testing
as for the welding procedure qualification.
8.2 Production welds which do not comply with the Standards of Acceptability will be
rejected and cut out unless COMPANY approves repair of same.
8.3 All repairs shall be carried out the day after examination or earlier.
8.4 If grinding is performed the minimum grinding length shall be 100 mm.
8.5 After repair of a girth weld the whole circumference of the weld shall be re-
radiographed.
8.6 All costs for remedial work including radiography and any other NDT shall be for
BIDDER's account.
8.7 All rejected weld cut-outs shall be clearly identified and stored by the BIDDER until
COMPANY confirms in writing that same may be disposed of. A pup piece shall be
installed in place of the rejected weld at BIDDER's cost.
8.8 Re-repairs on the same area of a weld will not be allowed. That is, if the weld defect
is not remedied after the first attempt the entire weld shall be cut-out from the line
and rewelded at BIDDER's cost.