Specification For Welding

Engineering Services for
Abadan Petrochemical Plant
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Document No.: Rev.:00 Page 1 of 67
SPECIFICATION FOR
WELDING (PIPING)
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0 1400/05/23 Issued for Comment M.N. B.M.
Rev. Date Status Prepared. Checked. Approved AC
Prepared by: Approved by:

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1. TERMS AND DEFINITIONS…………. ..................................................................................................... 4

2. SCOPE…………………………………. ....................................................................................................... 4
3. REFERENCE STANDARDS…………… ................................................................................................... 4
4. WELDING REQUIREMENTS…………. ................................................................................................... 6
4.1 General .................................................................................................................................................... 6
4.2 Welding Consumables Requirements ..................................................................................................... 8
4.3 Welder Qualification & Records ............................................................................................................ 9
4.4 Preheating and Post Weld Heat Treatment ........................................................................................... 9
4.5 Welding Requirements for Crude Oil Line Pipe in Sour Gas Service ................................................. 10
5. WELDING OF PIPELINE……………. .................................................................................................... 11
5.1 Filler Metal for Pipe Lines .................................................................................................................... 11
5.2 Shielding & Purging Gas ...................................................................................................................... 13
5.3 Welding Process .................................................................................................................................... 13
5.4 Welding Techniques ............................................................................................................................. 14
5.5 Pipeline Welding Position ..................................................................................................................... 14
5.6 Welding Interruption............................................................................................................................ 14
5.7 Welding Qualification Requirements ................................................................................................... 15
5.8 Welding Requirements For Line Pipe in Sour Service acc. To NACE MR-01-75/ISO 15156............. 30
5.9 General Requirements for Pipeline Welding ....................................................................................... 31
5.10 Welding Inspection and Test .............................................................................................................. 37
5.11 Heat Treatment ................................................................................................................................... 40
5.12 Welding Equipment ............................................................................................................................ 44
6. WELDING OF PIPING………………. ..................................................................................................... 46
6.1 Welding Requirements ......................................................................................................................... 46
6.2 Welding Procedure ............................................................................................................................... 49
6.3 Welding Qualification Requirements ................................................................................................... 52
6.4 Welder Qualification & Records .......................................................................................................... 55
6.5 General Requirements .......................................................................................................................... 57
6.6 Inspection and Non-Destructive Testing (NDT) ................................................................................... 65
6.7 Repair and Removal of Defects ............................................................................................................ 66
7. CONFLICT AMONG REFERENCED DOCUMENTS .......................................................................... 67

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1. TERMS AND DEFINITIONS

• Owner/Client: Abadan Petrochemical Company
• EPC Contractor: Butane Procurement & Engeneering Services Company, Shall Mean
the Contractor Responsible For Engineering, Procurement & Construction of the Project.
• Vendor: The manufacturer /manufacturer's representative selected by the contractor &

approved by the client to supply equipment tools.
• Will: Is normally used in connection with the action by the "company" rather than by a
contractor, supplier or vendor.
• May: Is used where a provision is completely discretionary.
• Should: Is used where a provision is advisory only.
• Shall: Is used where a provision is mandatory.
2. SCOPE
This specification defines Buyer's minimum requirements for shop and field welding and heat
treatment of equipment and fabricated production systems.
All works should conform to the requirements of this specification, other Buyer specifications
referenced herein, and all other contract documents in conjunction with all applicable codes
and standards, sound engineering principles and good fabrication and construction practices.
3. REFERENCE STANDARDS
Throughout this specification the latest editions of following codes and Standards are referred
to:
ASME Section V Nondestructive Examination
ASME Section VIII Rules for Construction of Pressure Vessels

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ASME Section IX Welding and Brazing Qualifications
ASME B 31.1 Power Piping
ASME B 31.3 Chemical Plants and Petroleum Refinery Piping
ASME B 31.8 Gas Transmission and Distribution Piping Systems
ASME B 31.4 Liquid Transportation system
AWS D 1.1 American Welding Societies; Structural Welding Code-Steel
AWS 5.1 (5.29) Specifications for Welding Filler Materials
AWS A 3.0 Welding Terms and Definitions
IPS-C-PI-290 Construction Standard for Welding of Plant Piping Systems
IPS-C-PI-270 Construction Standard for Welding of Transportation Pipeline
IPS-G-SF-110 Radioactive Protection against Source
IPS-E-PI-221 Engineering Standard for Piping Material Selection
API 1104 Standard for Welding Pipelines and Related Facilities
API 5L Specifications for Line Pipe
ASNT-CP-189 Standard for Qualification & Certification of Non-Destructive

Testing Personnel
ASNT-TC-1A Recommended Practice for Non-Destructive Personnel
NACE MR-01-75/ISO 15156 Sulfide stress cracking resistant metallic materials
For oil field equipment”
AWS D 1.1 American Welding Societies; Structural Welding Code-Steel

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AWS 5.1 (5.29) Specifications for Welding Filler Materials
4. WELDING REQUIREMENTS
4.1 General
All welding and related activities shall satisfy the requirements of this
specification.
WPS’s shall be established for all welding which will be used in the fabrication of
piping systems.
WPS, PQR and WPQ should be qualified in accordance with the requirements of
ASME sec.IX
All Welders Shall be Qualified in Accordance with ASME SEC. IX
No welding shall be performed until the WPS’s have been reviewed by client and
qualified by PQR.
Contamination of weld bevels and surrounding areas with low melting point metals
such as copper, zinc, etc. are not acceptable.
Test required for qualification of WPS shall be organized by the executor taking
the followings into consideration:
Weld performance, preparation of test specimens, and conducting of the tests shall
be in the presence of the third party inspector and follow Inspection Test Plan.
After completion of mechanical test three copies of WPS and PQR (‘s) approved
by the inspector shall be submitted to the client.

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The executor shall submit to the third party inspector a list containing names of the
welders to be qualified at least one week before date of the test.
The surfaces to be welded shall be smooth, uniform, and free from laminations,
tears, scale, slag, grease, paint and other deleterious material.
The joint design and spacing between abutting ends shall be in accordance with the
procedure specification used.
The alignment of the abutting ends shall minimize the offset between surfaces. For
pipe ends of the same nominal wall thickness, the offset shall not exceed 1.59mm.
If a larger offset is caused by dimensional variations it shall be equally distributed
around the circumference of the pipe.
Hammering of the pipe to obtain proper lineup should be kept to a minimum.

Lineup clamps shall be used for butt welds in accordance with the procedure
specification.
When the pipe is welded above ground, the working clearance around the pipe at
the weld should not be less than 406mm.When it is welded in a trench; the bell hole
shall be large enough to provide the welder or welders with ready access to the
joint.
The procedure specification shall specify the pre and post heat treatment practices
to be followed when materials or weather conditions make either or both treatments
necessary.
Carbon equivalent (CE) is an effective method of controlling the HAZ

microstructure and hardness, determined by the formula given below:
Mn Cr + Mo + V Cu + Ni
+ +
C.E. = C+ 6 5 15
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The inter-pass temperature shall be measured within the joint bevel. The minimum
inter-pass temperature shall not be less than the specified preheat temperature. The
maximum inter-pass temperature shall not exceed the highest of maximum
qualified or 250 C for carbon steels.
All welding inside Site fence shall be performed per ASME B31.3, ASME Sec IX
and Pipeline welding shall be performed per API1104.
4.2 Welding Consumables Requirements

All filler metals shall conform to the relevant AWS standard; otherwise the welding
procedures shall qualify their usage.
All welding consumables shall have individual marking.
All extra low hydrogen consumables for carbon steels shall be delivered according
to manufacturer data sheets and with certification. Certificates should contain
chemical analysis of weld metal including C, Si, Mn, P, S and any other
intentionally added element, stated in the data sheet .Level of impurities maximized
in the data sheet or classification code should be stated, but may be given as
guaranteed maximum. The data sheets should contain guaranteed values on
mechanical and impact test results as long as the welding is carried out within the
recommended range. If the consumables shall be used for welds in PWHT
condition, then the properties shall also be documented in PWHT condition.
Filler metals and fluxes shall be stored and handled to avoid damage to them and
to the containers in which they are shipped. Filler metals and fluxes that show signs
of damage or deterioration shall not be used.
The shielding atmosphere to be used shall be qualified for the material and the
welding process.

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Shielding gases shall be kept in the containers in which they are supplied and
should be stored away from extremes of temperature.
4.3 Welder Qualification & Records

All welders shall be qualified in accordance with section 3 and 9 of API STD 1104.
The test records of all welders and welding operators shall be available at all times
at the work location for review by client/inspectors.
All welders shall be previously qualified by a Certifying Authority approved by

the Purchaser, in compliance with ASME BPVC Sect. IX or with any other Code
accepted by the Purchaser. When qualification tests are carried out on site,
Purchaser can authorize the Inspector to act as a certifying Authority. Anyway, the
Inspector is entitled to witness the welding performance qualification carried out
on site: therefore, he must be informed about the date of their performance. Upon
presentation of the qualification certificates to the Inspector, each welder will be
assigned an identification symbol (by numbers or letters) approved by the
Inspector. This symbol shall appear on a proper stamp, with which the welder shall
be equipped.
4.4 Preheating and Post Weld Heat Treatment

Preheating is essential under the following conditions according to relative
Standard and shall be mentioned in WPS:
• Carbon steel having a carbon equivalent in excess of 0.65 (Ladle analysis)

• Carbon steel having a specified carbon content in excess of 0.32% (Ladle
analysis)

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• Preheating may also be required for steel having lower carbon or carbon
equivalent when conditions exist that either limit the welding technique or
tend to adversely affect the quality of the weld.
• When the ambient temperature is below five degree Celsius
• When the risk of cracks exists in the HAZ
• For weld repair
• For completing an incomplete weld left at the end of the previous working
day
• For welding of various fitting/appurtenances to the pipe having different
wall thickness or of different types of material unless during the
establishment of the weld procedure, it is determined that the preheating is
not necessary.
Generally welds in carbon steels having carbon content in excess of 0.32% (Ladle
Analysis) or a CE in excess of 0.65% (Ladle analysis) shall be stress relieved as
prescribed in BPV Code, sec. VIII.
All welding inside Site fence shall be performed per IPS-C-PI-290, ASME B31.3,
ASME Sec IX and Pipeline welding shall be performed per IPS-C-PI-270,
API1104.
4.5 Welding Requirements for Crude Oil Line Pipe in Sour Gas Service
Welding procedure shall be used to produce weldments according to the NACE
MR0175/ISO15156
Welding procedure qualifications on carbon steels that use controls other than
thermal stress relieving to control the hardness of the weldment shall also include
a hardness traverse across the weld, HAZ, and base metal to ensure that the

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procedure is capable of producing a hardness of 22 HRC maximum in the condition

in which it is used.
Welding rods, electrodes, fluxes, filler metals and carbon and low alloy steel
welding consumables with more than 1% Ni shall not be used.
5. WELDING OF PIPELINE
5.1 Filler Metal for Pipe Lines

If low-hydrogen electrodes are selected the diffusible hydrogen content shall not
exceed 10 ml/100 g in the resulting deposited weld metal.
All welding consumables shall be defined in the proposed welding procedure

specifications (WPS).
Unopened electrode containers shall be stored in accordance with manufacturer’s

recommendations.
Basic welding consumables shall meet the requirements of the base material and
shall be selected such that the deposited weld metal exhibits mechanicals properties
equal to or in excess of the base material, as demonstrated in the welding procedure
qualifications.
As a minimum all welding consumables shall be stored and handled in accordance

with the manufacturer’s recommendations. All contaminated and/or damaged
consumables shall be removed from the works. A consumable handling procedure
shall be submitted to the Client for approval.
Each tin or packet of electrodes or reel of filler wire and bag of flux shall be clearly
marked with the respective batch number.

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Each manufacturer brand and type of consumable, to be used on the works. Shall
pass a welding procedure qualification test in accordance with this specification.
Sufficient quantities of each consumable brand and type should be purchased to

complete the Works, to avoid additional welding procedure qualifications.
Filler metals shall conform to the welding specifications for the various materials,
each lot of electrodes and wire should have certificates.
Electrodes shall be baked immediately before use at 300°C (± 30°C) for one hour
or in accordance with Manufacturers recommendations. This requirement may be
waived when the electrodes are removed from a hermetically sealed package
immediately before use. Plastic wrapped cartons are not considered to be
hermetically sealed. After drying as described.
Pipeline Consumables shall conform to one of the following specification:
· AWS A5.1
· AWS A5.5
· AWS A5.18
AWS classification carbon steel electrodes shall be used for welding pipes
manufactured according to API 5L.
Low hydrogen electrodes shall be used for repairing & welding tie-ins.
To maintain the low hydrogen content as specified above, electrodes shall be baked
immediately before use at 300°C (± 30°C) for one hour or in accordance with
Manufacturers recommendations. After drying as described above, electrodes may
be transferred to an intermediate storage cabinet maintained at approximately
150°C.
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For welding of API 5L Gr. X 42, API 5L Gr. B electrode E-6010(uphill) pass shall
be used for root & E-7010 (downhill) shall be used for another passes.
For welding of API 5L Gr. X 52 electrode E-6010(uphill) pass shall be used for
root & E-7010 (downhill) shall be used for another passes.
For welding of API 5L Gr. X 60 and upper grades electrode E-6010 for root pass
& E-8010 or equivalent for another passes shall be used.
5.2 Shielding & Purging Gas

The shielding atmosphere to be used shall be qualified for the material and the
welding process.
Shielding gases shall be kept in the containers in which they are supplied and
should be stored away from extremes of temperature.
Shielding and purging gases employed in welding shall have a normal composition
and purity according to the indications of the welding procedure specification.
5.3 Welding Process

All welding shall be carried out by using one or a combination of the following
processes. The welding processes to be used shall conform to the pipeline welding
requirements for the various materials according to here in after:
· Shielded Metal Arc Welding (SMAW)
· Manual and Automatic Inert Gas Tungsten Arc Welding (GTAW)
· A combination of the above processes
· For other processes, such as Gas Metal Arc Welding (GMAW)

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5.4 Welding Techniques

Upward & downward technique can be used for welding of pipes 2 inch and lesser.
For pipes, fittings and flanges 1 ½” and smaller, socket type & welded as fillet weld
is not acceptable and shall be butt-welded.
Where hydrostatic test performing is not possible (e.g. in tie in location) uphill
technique shall be performed.
Generally use of backing rings is not allowed, but in especial case Client
Engineer approval is necessary before use of back weld, where metallic backing
material is permitted, the P No. or its nominal chemical composition shall be
specified in WPS and or the applicable fabrication drawings. For joint between
similar materials the chemical composition of backing material shall much the
nominal base metal chemical composition.
5.5 Pipeline Welding Position

Following position can be used for pipeline welding:
· Flat Position (1G)
· Multiple Position (5G)
· Multiple Position (6G)
5.6 Welding Interruption

The deposition of each weld shall generally be a continuous operation. However,
in the case that welding must be discontinued, this shall not take place before at
least the root and hot passes are completed.

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Before resumption of welding, the joint shall be reheated to a temperature within

the inter-pass temperature. Interrupted welds shall be inspected by radiographic
examination.
5.7 Welding Qualification Requirements

5.7.1 General
Welding procedures for steel shall be qualified according to ASME IX.
The quality of the welds shall be determined by destructive testing as described in

proceeding paragraphs.
Any of the essential variables listed below are changed; welding procedure must
be completely prequalified. Essential variables according to IPS-C-PI-270 include:
· Welding Process
· Base material
· Joint Design
· Position
· Pipe diameter and Wall Thickness
· Filler Metal (Group, Brand, Yield...)
· Electric Characteristics
· Time between passes
· Direction of welding
· Shielding gas and flow rate
· Shielding Flux
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· Speed of travel
· Preheat and inter-pass
· Post weld heat treatment
· Number and sequence of weld beads
· Number of welders
· Type and removal of line-up clamp
Detail changes of above variables are according to API 1104.
Extension and Type of qualification test shall be finalized and approved by client
Inspection and shall be carried out under supervision of client’s inspection and in
laboratory approved by client.
The Contractor shall submit his recommended welding procedure for welding and
repair welding activity of the projects containing all essential variables as required
by API IPS-C-PI-270/API 1104 for pipeline. Before the qualification test, detailed
WPS shall be prepared and submitted to the Client Engineer for review and
approval.
No production welding shall be carried out before welding procedure specification

(WPS), procedure qualification record (PQR) and welding performance
qualification (WPQT) are qualified in accordance with requirements of IPS-C-PI-
270/API 1104.
The welding procedure specification proposed by the Contractor shall be submitted

to the Client Engineer for his review and approval at least one week before the date
of qualification test. Unless otherwise stated in the contract documents, for each

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contract all existing welding procedures shall be prequalified by the contractor, and
submitted for approval by the Client.
Test required for qualification of WPS shall be organized by the Contractor taking
the following in consideration.
All materials and equipments required for preparation of test piece and welding
including measuring instruments (Ampere/Volt meter), etc., shall be supplied by
the Contractor unless otherwise specified.
After completion of welding, The Contractor shall prepare test specimens for
delivery to an approved test center.
A change from one consumable manufacturer and/or trade name, or AWS

classification to another is essential variable and requires new PQR.
After completion of mechanical test, copies of WPS(S) and related PQR(S)

approved by the third party inspector shall be submitted to the Client Engineer.
Weld performance, preparation of test specimens and conducting of the NDT and
mechanical test shall be in the presence of the third party inspector and shall be
organized by the Contractor.
All expenses involved in preparation of test weld, test specimens and conducting
NDT and mechanical test shall be incurred by the Contractor unless otherwise
specified.
Test pieces to qualify the welder(s) shall be selected from pipe diameter, wall
thickness ranges and position of welding that will be involved in production
welding according to relevant standard.

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Records of the non-destructive and destructive tests that establish the qualification
of a welding procedure shall be signed by the Contractor and the
Client’s representative(s)/Engineer and be maintained as long as that procedure is

in use. Forms for such records shall include the details of each qualified procedure
together with its complete results of the qualification tests.
Radiographic examination for welder qualification shall be performed according

to IPS-C-PI-270/API 1104 and relevant standards. All tests shall be conducted in
the presence of the Client's representative/Engineer.
5.7.2 Welding of Test Joints
To weld the test joint for butt welds, two pipe nipples shall be joined, following all
the details of the procedure specification.
To weld the test joint for a fillet weld, a fillet weld shall be made to one of the
configurations shown in sec2 of API STD 1104, following all the details of the
procedure specification.
5.7.3 Testing Of Welded Joints
Preparation of test specimens for butt weld or fillet weld joint, should be according
to API 1104
The minimum number of test specimens and the tests to which they shall be
subjected are given in the Table 2 of API STD 1104.
5.7.4 Welding Procedure Qualification Tests
5.7.4.1 General

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SSC and HIC test is necessary for qualification of welding procedures in sour
services.
The Contractor shall arrange welding for welding procedure qualification tests at
least ten days before the commencement of such operation on Site.
The welding procedure qualification testing (WPQT) shall be witnessed by the

Client. Only qualified and approved welding procedures shall be used for
production welding.
The Contractor shall notify the Client’s representative(s)/Engineer, in writing, of

the data of performance of welding for procedure qualification at least one week in
advance.
Such welding shall be performed in the presence of the Client’s Representative(s)

/Engineer and according to the specified welding procedure with the approved
material and equipment under supervision of buy back supervisor and third party
inspector.
Note: Third party inspector is a person from a reputable agency who

entrusted by the Client with inspection and supervision.
Buy Back Contractor QC's responsibilities are remained and third party
duties does not withdraw buy back contractor responsibilities.
Qualified procedures shall be recorded by the Contractor and submitted to the

Client. The contract materials to which the procedure applies shall be identified on
the WPS. Grouping of materials of different pipe manufacturers, supply condition,
diameter, wall thickness or steel specification/grade shall not be done unless agreed
by the Authorized Client’s Representative.

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Where contract materials have been supplied in the same dimensions by more than
one manufacturer, a qualification test shall be performed based on Authorized
Client’s Representative order using two pipes form different manufacturers. This
may be used to qualify the procedure for use on the pipes from each manufacturer
provided the specified range and number of tests in the heat affected zone are taken
from both sides of the weld.
Procedures shall be qualified for each combination of diameter and nominal wall
thickness of contract materials according to essential variable of relevant standard.
Details of the filler metal sizes, classification and manufacturer/brand identity shall
be given together with a sketch showing the location, minimum number, deposition
sequence and characteristics (stringer or weave) of each weld bead.
The ranges of voltage and amperage shall not vary from the aim values by more
than + 10 percent.
For pipeline butt welds Time between passes is 5 minutes or less.
Similar measures shall be taken to specify and monitor weld inter-pass

temperatures.
Non-destructive testing personnel shall be certified in accordance with ASNT

Recommended Practice SNT-TC-IA for the test method used or an equivalent
certification scheme approved by the Client. Only level II or III personnel shall
interpret the test results.
5.7.4.2 Non-Destructive Testing
On completion of welding, all procedure qualification test pieces shall be left cold
for at least 24 hours and shall then be subjected to NDT, this shall be carried out
prior to sectioning for mechanical testing.
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Prior to sectioning for destructive testing, all test welds shall be inspected by
radiography according to NDT specification. Only test welds passing radiographic
examinations shall be taken for destructive testing.
Post-weld heat treatment, if required, shall be performed after 24 hours has elapsed,
but before & after PWHT, NDT shall be performed.
The NDT shall consist of:
· Visual examination, with the aid of optical instruments where necessary, to

determine the dimensions of indications.
· Penetration testing as specified.
· Radiographic testing, supplemented, if specified by the Client, by Phased Array

testing.
· The supplementary Phased Array testing shall always be carried out for test welds
made in whole or in part by the GMAW, GTAW processes.
Acceptance criteria for the NDT shall be as stated in IPS-C-PI-270/API 1104

standard. If a test weld is found to be unsatisfactory following NDT it shall be
rejected and not be submitted for destructive/mechanical testing.
5.7.4.3 Destructive Testing
An approved institution according to the IPS-C-PI-270/API 1104 Standards for

pipeline and this specification shall conduct destructive testing of the radio
graphically accepted test welds.
Followings are the additional requirements for such tests for API 5L grade B and
above (or its equivalent) are to be utilized in this Project.

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· Tensile Test
If any tensile strength-test specimen breaks outside the weld or fusion zone in the
parent metal at a stress level less than the minimum specified tensile strength of
the pipe metal, the reason for this shall be established before the qualification tests
are repeated.
The tensile strength of the weld, including the fusion zone of each specimen, shall
be greater than or equal to the specified minimum tensile strength of the pipe
material but need not be greater than or equal to the actual tensile strength of the
material. If the specimen breaks outside the weld and fusion zone (that is, in the
parent pipe material) and meets the minimum tensile-strength requirements of the
specification, the weld shall be accepted as meeting the requirements.
· Nick-break Test
The Nick-break test specimens shall be approximately 9 in. (230 mm) long and
approximately 1 in. (25 mm) wide and may be machine cut or oxygen cut. They
shall be notched with a hacksaw on each side at the center of the weld, and each
notch shall be approximately 1/8 in. (3 mm) deep. Nick-break specimens prepared
in this manner from welds made with certain mechanized and semiautomatic
processes may fail through the pipe instead of the weld. When previous testing
experience indicates that failures through the pipe can be expected, the external
reinforcement may be notched to a depth of not more than 1/16 in. (1.6 mm),
measured from the original weld surface. At the company’s option, Nick-break
specimens for qualification of a procedure using a semiautomatic or mechanized
welding process may be macro-etched prior to being nicked.
The Nick-break specimens shall be broken by pulling in a tensile machine, by

supporting the ends and striking the center, or by supporting one end and striking
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the other end with a hammer. The exposed area of the fracture shall be at least 3/4
in. (19 mm) wide.
The exposed surfaces of each Nick-break specimen shall show complete

penetration and fusion. The greatest dimension of any gas pocket shall not exceed
1/16 in. (1.6 mm), and the combined area of all gas pockets shall not exceed 2% of
the exposed surface area. Slag inclusions shall not be more than 1/32 in. (0.8 mm)
in depth and shall not be more than 1/8 in. (3mm) or one-half the nominal wall
thickness in length, whichever is smaller. There shall be at least 1/2 in. (13 mm)
separation between adjacent slag inclusions. Fisheyes, as defined in AWS A3.0,
are not cause for rejection.
· Bend test
Root- and Face-bend Test
The root- and face-bend test specimens shall be approximately 9 in. (230mm) long
and approximately 1 in. (25 mm) wide, and their long edges shall be rounded. They
may be machine cut or oxygen cut. The cover and root-bead reinforcements shall
be removed flush with the surfaces of the specimen. These surfaces shall be
smooth, and any scratches that exist shall be light and transverse to the weld.
The root- and face-bend specimens shall be bent in a guided-bend test jig. Each
specimen shall be placed on the die with the weld at mid span. Face-bend
specimens shall be placed with the face of the weld toward the gap, and root-bend
specimens shall be placed with the root of the weld toward the gap. The plunger
shall be forced into the gap until the curvature of the speci-men is approximately
U-shaped.

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The bend test shall be considered acceptable if no crack or other imperfection

exceeding 1/8 in. (3 mm) or one-half the nominal wall thickness, whichever is
smaller, in any direction is present in the weld or between the weld and the fusion
zone after bending. Cracks that originate on the outer radius of the bend along the
edges of the specimen during testing and that are less than 1/4 in. (6mm), measured
in any direction, and shall not be considered unless obvious imperfections are
observed. Each specimen subjected to the bend test shall meet these requirements.
Side-bend Test
The side-bend test specimens shall be approximately 9 in. (230 mm) long and
approximately 1/2 in. (13 mm) wide, and their long edges shall be rounded. They
shall be machine cut, or they may be oxygen cut to approximately a 3/4 in. (19 mm)
width and then machined or ground to the 1/2 in. (13 mm) width. The sides shall
be smooth and parallel. The cover and root-bead reinforcements shall be removed
flush with the surfaces of the specimen.
The side-bend specimens shall be bent in a guided-bend test jig. Each specimen
shall be placed on the die with the weld at mid span and with the face of the weld
perpendicular to the gap. The plunger shall be forced into the gap until the
curvature of the specimen is approximately U-shaped.
Each side-bend specimen shall meet the root and face-bend test requirements
specified in above mentioned requirements for root and face bend test.
· Hardness Test
One test specimen after being polished and etched for macro examination shall
undergo a Vickers hardness test.

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For vertical- down welding, the specimen shall be taken from the 3 o’clock
position. The test to be carried out in accordance with ASTM E92 standard with a
10 kg load, although a 5 kg load will often be necessary for the narrow heat affected
zones. Make two zone traverses, one across the root and one across the cap region
of the weld. For pipe 16 millimeter or over in thickness, make an additional traverse
midway between the other two. Each traverse shall consist of at least eight
impressions: Two in each heat-affected zone (H.A.Z), two in the weld metal and
one in the parent metal each side of the weld.
Carbon steel welds subject to sour service shall have a maximum Brinell hardness
of 200 HRB. Hardness profile and metallographic test result shall be prepared.
Macroscopic examination shall be performed according to IPS-C-PI-270
TABLE 6-MAXIMUM ALLOWABLE HARDNESS VALUES (HV10)
ITEM LOCATION SWEET SERVICE

Weld Metal Root 275
Weld Metal Cap 250
H.A.Z Root 250
H.A.Z Cap 250
Toughness Test
A sample shall be cut from the completed joint at approximately the 3 o’clock
position for Charpy V-Notch impact test of the weld metal and the Heat-Affected
Zone. Three specimens shall be prepared from the sample and notched. Charpy V-
notch tests shall be carried out in accordance with the latest edition of ASTM A370.
Impact testing shall be carried out when the nominal pipe wall thickness exceeds 5
mm. Three values shall be obtained from each of the weld centre line, fusion line

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and the fusion line +2 mm. The specimens shall be taken from the mid-thickness
with the notch in a radial orientation. When the pipe dimensions preclude the
preparation of a rectangular (5 mm x 10 mm) cross- section specimen a rectangular
cross-section specimen shall be prepared with the maximum feasible thickness.
In each case the impact energy shall satisfy the requirements specified for a 5 x 10
mm specimen. When the wall thickness is over 20 mm a test series at the same
locations shall also be made at the root side of the weld. Testing shall be carried
out at a temperature determined in accordance with Table 7.
TABLE 7-CHARPY V-NOTCH TEST TEMPERATURE
Nominal Wall Thickness(mm) Test

Temperature(°C)
t ≤ 16 T
25 ≥ t > 16 T-10
t > 25 T-20
Note: "T" is the minimum design temperature.
Testing Records
Records of the non-destructive and destructive tests that establish the qualification
of a welding procedure shall be signed by the Contractor and the Authorized
Client’s representative(s)/Engineer and be maintained as long as that procedure is
in use. Forms for such records shall include the details of each qualified procedure
together with its complete results of the qualification tests.
These forms shall not contain information less than those that appear on our
proposed formats as attached to this specification.
Welder Performance Qualification

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The purpose of the welder qualification test is to determine the ability of welders
to make sound butt or fillet welds using previously qualified procedures.
Each welder shall be qualified in accordance with the requirements of API 1104
and IPS-C-PI-270
Requirements of this specification before commencement of production welding.

Shall be approved by Client. Only Single Qualification is accepted.
In certain particular situations, Multiple Qualification may be permitted. Then, the

qualification tests shall be fully detailed (pipe diameters, wall thicknesses, material
type, welding positions, etc...) by Contractor and specifically approved by Client
The Contractor shall use only skilled workmen for welding. Each welder employed
by the Contractor shall be required to pass a welding test for the type and methods
of welding he will do including attachment welds. No welder shall do any phase of
welding on the pipeline for which he has not been tested and previously approved
by Client.
Pre-qualified manual or semi-automatic welders are not permitted.
With previous approval of Client, the qualification of a welding machine operator

may be accepted without further testing provided Contractor submits satisfactory
proof concerning the operator's professional skills (apprenticeship or advanced
training, previous work in using similar welding procedures and equipment,
previous qualification certificate dated of less than 6 months, etc.)
The CONTRACTOR shall furnish welding materials and equipment the same as
those to be used on the line. He shall also furnish coupon cutting machine and
testing equipment, and the pipe for test nipples of the same size and grade as to be
used on the line. Contractor shall prepare all test nipples. The welder shall make a
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test weld under simulated field conditions or on the lay barge as appropriate. The
weld shall be examined and tested by Contractor and witnessed and approved by
Client.
Full size pipe nipples shall be used. Grouping on pipe diameter and/or wall
thickness according to IPS-C-PI-270/API 1104 is acceptable.
Manual welders shall be separately qualified for each welding position encountered
on the job, in a same way as for the welding procedure qualification test.
When testing manual or semi-automatic welders for execution of a weld without

back pass, the pipe nipple ends shall be closed so that internal check of the weld
root cannot be made by welders during performance of welding.
For butt welds, all welders, including welders for automatic welding, shall be
qualified by nondestructive tests. Finished coupons shall be visually examined,
fully radio graphed and, then in the case of automatic (except SAW) or
semiautomatic welds, ultrasonically tested.
Welders for mechanized welding shall be approved for all parts of the welding
operation.
For fillet welds, welders shall be qualified as per API 1104.
Test welds shall meet the acceptance standards stated in this Specification.
Welders having participated in the execution of the welding joints for successful
qualification of the welding procedure in accordance with section 8 shall be
considered as qualified.
For manual metal arc welding, a change in electrode trade name requires welder
re-approval for butt welds, unless specific approval is obtained from Client.

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Each welder/operator shall be given a unique identification number which he shall

mark in paint against all welds produced by him. A list of qualified personnel (with
photographs) is to be kept up to date and available for inspection.
Any welder found responsible for a high level of defects/repairs in production shall
be removed from production. At the discretion of Client the welder in question may
be retested after an agreed period of retraining.
Requalification of welders or operators is required if any change is made to the

welding procedure which necessitates requalification of the welding procedure.
Requalification of welders or operators will be required where established
tolerances on weld procedures are exceeded.
Arc-air gouging shall be carried out by personnel who have previously satisfied
Client that they are competent to do so and in accordance with an approved
procedure.
The welder shall perform the qualification test welding in accordance with
approved WPS. A pipeline welder shall qualify for welding by performing a test
on contract material. He will be qualified to weld only in the same position as the
test weld. All tests shall be conducted in the presence of the third party inspector,
Client Engineer. A welder qualification shall be valid for a period of six months.
Each qualified welder shall be assigned an identification number by the Contractor

to be used for identification of each weld performed by welder. Other welders shall
not be used his identification number.
The Contractor shall submit a list of qualified welders to the Authorized Client’s
Representative /Engineer and right of welding shall be restricted to the enlisted
welders only.

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Records of welder's qualification tests shall be signed by the Contractor and

Authorized Client’s Representative/Engineer. Such records shall be maintained as
long as the welder is engaged with the specific welding procedure for which he was
qualified.
All welders shall be re-qualified if there is some specific reason to question a

welder’s ability by the welding third party inspector/weld engineer.
The welding third party inspector may remove any welder and disqualify him from
any welding activity if in his opinion:
· The welder’s workmanship is constantly below the required standards.
· The welder has intentionally changed the essential variables of a welding

procedure such as polarity, direction, filler material, etc.
· A record of qualified welders, showing the date and results of the tests shall be
retained during the construction involved.
5.8 Welding Requirements For Line Pipe in Sour Service acc. To NACE
MR-01-75/ISO 15156
Welding procedure shall be used to produce weldments with hardness below
22HRC
Welding procedure qualifications on carbon steels that use controls other than
thermal stress relieving to control the hardness of the weldment shall also include
a hardness traverse across the weld, HAZ, and base metal to ensure that the
procedure is capable of producing a hardness of 22 HRC maximum in the condition
in which it is used.

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Welding rods, electrodes, fluxes, filler metals and carbon and low alloy steel
welding consumables with more than 1% Ni shall not be used.
5.9 General Requirements for Pipeline Welding

5.9.1 General
All welding operations shall be performed upon the third party inspector, /Client
Engineer approval.
All welding operations shall be performed according to established and qualified

welding procedures.
All welding operations shall be performed according to heat treatment

requirements of the pertinent qualified welding procedures or this specification.
The Contractor shall make all necessary provisions for the supervision personnel
for the inspection of welding operations before, during and after such operations,
in a safe and convenient manner.
Before any production welding is started, a detailed WPS and PQR shall be
qualified and/or established related to intended specific project.
All essential variables shall be listed.
All welds shall be completed by qualified welder.
Joint preparation shall be made according to ANSI B31.8, ANSI B 31.4 and WPS
as applicable.
Material to be welded shall be cut to the required size and shaped for welding pipe
such as thermal, cold and plasma cutting. The cut edges shall be dressed back by
machining or grinding. Before welding, all foreign matter shall be removed from
the beveled ends. If any of the ends of the pipe joints are damaged to the extent that
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satisfactory welding contact cannot be obtained, the damaged pipe ends shall be
cut and beveled to the satisfaction of the third party inspector with a beveling
machine.
Preheat and post weld heat treatment (if required) shall be performed if
specified in the relevant WPS.
The surfaces to be welded shall be smooth, uniform and free from laminations,
tears, scale, slag, grease, paint and other deleterious material that might adversely
affect the welding.
If work is to be carried out in the vicinity of equipment already installed, before

any welding commences adequate protection shall be provided to prevent damage
from weld spatter, flame cutting droplets, etc. Care shall be taken to avoid
overloading or damaging any of the pipeline components at all stages of the work.
Current return cables of welding equipment shall be connected directly to the pipe
on which the welding is to be done.
If the pipe size exceeds 10 inches at least two welders shall weld simultaneously
around the pipe circumference
Arcs shall be struck only on fusion faces or on striking plates provided as an aid to
arc starting.
Stray arc strikes shall be removed by grinding away all material which has been
affected by the arc heat. Where this results in the minimum thickness being below
tolerance, the section of pipe containing the arc strike shall be removed. Weld
repairs or build-up shall not be made on the base pipe.

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A circular cap to prevent entry of foreign material, of a design which will not
damage pipe ends, shall be used to cover the open ends of the pipe and shall be
placed on the line during interruptions in the work expected to last more than two
hours. Caps shall not be removed until recommencement of the work. All open
ends of pipe strings shall be capped off and sealed when welding is completed.
After arc strike removing, suitable NDT (PT) shall be performed.
5.9.2 Environmental Conditions
Welding shall not be performed under the following weather conditions:
- In the rain
- In winds of 10 m/s or more (3 m/s or more for GTAW)
- When the relative humidity is 90% or more
- In snow or sleet
When the item to be welded is wet with rain or dew, or covered with snow, frost,
or ice shall be removed and the surface dried completely prior to beginning
welding.
No welding shall be performed on wet pipes or at ambient temperature of 5°C and

below and In case of rain, airborne moisture, high winds, and blowing sands.
The third party inspector shall decide if weather conditions despite all precautions
and proper arrangement are suitable for welding operations, or not.
Shelters and windshields to the satisfaction of third party inspector shall be used.
5.9.3 Alignment

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The alignment of abutting ends shall minimize the offset between surfaces. For
pipe ends of the same nominal thickness, the offset should not exceed 1/8 in. (3
mm). Larger variations are permissible provided the variation is caused by
variations of the pipe end dimensions within the pipe purchase specification
tolerances, and such variations have been distributed essentially uniformly around
the circumference of the pipe. Hammering of the pipe to obtain proper lineup
should be kept to a minimum.
5.9.4 Matching
For pipes having different wall thicknesses, the inside or outside offset shall not
exceed 1.5 mm.
5.9.5 Proximity of Seam Welds
5.9.5.1 Minimum Seam Welds Staggering Distance
The minimum allowable distance between girth welds shall be the external
diameter of the pipe or 500 mm, whichever is the larger.
In case of pipes of different wall thickness, the pipe with the higher wall thickness
shall govern.
5.9.6 Clearance
When the pipe is welded above ground, the working clearance around the pipe at
the weld should not be less than 16 in.(400 mm)
When the pipe is welded in a trench, the bell hole shall be large enough to provide
the welder or welders with ready access to the joint.
5.9.7 Pipe Movement

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During position welding, the pipe shall be kept perfectly still and free from
vibration.
Welded sections of the pipe shall not be moved until all welds are completed and
are cooled.
5.9.8 Use of Line-Up Clamp for Butt Welds
Line-up clamps, holding devices, etc. shall be used for butt welds to avoid tack
welding in the groove and to optimize alignment. Internal line-up clamps of a type
acceptable to the Client shall be used for pipe sizes of 8 inches and larger. External
line-up clamps may be used for pipe sizes 6 inches and smaller. For tie-in welds,
external line-up clamps may be used for all pipe sizes.
Internal line-up clamps shall remain in place at least until the root pass is completed
around the full circumference.
External line-up clamps shall not be removed until a minimum of 50% of the root
pass, uniformly spaced around the circumference, has been completed.
Root bead segments used with external line-up clamps shall be cleaned, ground
down to a feather edge at both ends and visually inspected prior to completion of
the root pass. Any such segment which is not in accordance with the
acceptance standards shall be removed before completion of the root pass .
The pipe joint shall not be moved until after the second weld pass (hot pass) has
been made.
5.9.9 Removal of the Line-Up Clamps
5.9.9.1 Internal Line-Up Clamps

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An internal line-up clamp shall be held firmly in position at least to the end of the
root bead completion.
Under no circumstances shall the internal line-up clamp be removed before the
completion of the root bead.
Any movement of the joint and/or removal of the internal line-up clamp during the
welding of the root bead shall be the cause for rejection of the weld.
5.9.9.2 External Line-Up Clamps
External line-up clamps shall not be removed until a minimum of 50% of the root
pass, uniformly spaced around the circumference, has been completed.
5.9.10 Partition Distance between Welding Groups
The Contractor shall preferably keep the partition distance between the line
welding groups such that a welding joint does not exercise any thermal shock. The
maximum distance between root-bead-team & the finish bead-team shall be such
that all the welds, which have started, are finished by the end of the same working
day. Second pass shall be performed maximum 5 minutes after root pass.
5.9.11 Skids and Supports
The Contractor shall supply suitable skids in sufficient number as approved by the
third party inspector to support the pipe for safe welding.
If the pipe is to be supported over the trench, the skids shall be of sufficient length
to prevent the trench from collapsing.
The Contractor shall repair or replace the defective parts to the third party inspector
Approval.

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5.9.12 Tie-In Welds
A tie-in weld shall be considered as a weld connecting.
In welding basic low hydrogen electrodes shall be used for hot, fill and finish
beads; all passes shall be of Up-Hill direction.
Tie-ins of all kinds shall be started and finished in the same working day.
The third party inspector presence at all Tie-Ins is mandatory, therefore the
Contractor shall notify the third party inspector with at least 48 hours before the
operation of the exact place and starting time of tie-in activity.
The absence or delay of third party inspector during Tie-In operation will be the
cause of stand-by claim for the Contractor. The Contractor shall never
Start/Complete the tie-in operation in the absence of third party inspector unless
otherwise a different procedure is mutually agreed between all parties involved
(Client, third party inspector, Contractor)
5.9.13 Cause of Rejection for the Tie-In Welds
Lack of compliance with welding procedure
Absence of third party inspector.
Use of artificial objects and/or application of heat for proper adjustment of the root-
gap in the abutting joints.
Misalignment and where inherent stresses are set up after completion of weld.
5.10 Welding Inspection and Test

5.10.1 General

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Visual inspection of welds must be conducted by a person qualified by

appropriate training and experience.
All welds that are inspected must either meet the standards of acceptability of IPS-
C-PI-270/API 1104 or be appropriately repaired and re-inspected. The results of
the inspection shall be used to control the quality of welds.
When radiographic examination is employed, a procedure meeting the

requirements of IPS-C-PI-270/API 1104 shall be followed.
Defective welds shall be repaired or removed. If a repair is made, it shall be in

accordance with IPS-C-PI-270/API 1104.
Client has the right to request destructive tests for each production weld (Maximum
1% of weld joints) which all cutting, tests and re-joining costs are in contractor
responsibilities.
5.10.2 Extent of Inspection for Pipeline
5.10.2.1 Pre-Welding Inspection
All materials to be welded shall be subjected to visual inspection for surface

defects, laminations, etc. for compliance with the requirements in the relevant line
pipe or fitting specification.
All weld preparations and repaired preparations shall be inspected visually.
Edge preparations for tie-in welds shall also receive magnetic particle examination.
5.10.2.2 Inspection during Welding
During production welding the welding parameters shall be checked against the
WPS.

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5.10.2.3 Inspection after Welding
All welds shall be visually inspected and cracks, craters, pinholes, weld spatter,
residual slag or arc strikes shall not be acceptable.
Butt welds shall be inspected radio graphically, and where appropriate inspected
by phased area testing. All fillet welds shall be tested using wet magnetic particle
inspection.
Category 1
For normal production, as a minimum 30% of welds shall be radio-graphed. In

addition to the nondestructive inspection requirements outlined above, the quality
of welds shall be continually controlled by qualified personnel.
Category 2
For special cases in production welds 100% of welds shall be radio-graphed:
• For tie-ins, similar welds and welds performed in bell holes.

• For complete or partial welds (excluding of cap repair)
• For welds performed on pipeline sections intended for crossings (Freeways,
rail, road and river crossing)
• For welds between pipes of different grades and for joints of pipes having
same outside diameter and different wall thickness.
• For welds performed on insertion into line. When there is a change in
welding team.
• When the Client considers that performance conditions have changed,
either because of the location or because of climatic conditions (for
example wind or sand storm)

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• For lines subjected to sour services initial period of construction (minimum

100 number of weld) When the percentage of repair welding (except crack)
reach to below 6% during 48 hours, RT % could returned to normal
condition. In terms of crack defect, RT% in shall be increased to 100 % at
least for 48 hours
5.11 Heat Treatment

5.11.1 Preheating
Preheating of the parent metal prior any welding, tack welding and thermal cutting
may be necessary to avoid cold cracking of certain Ferritic steels in the weld and
HAZ.
Pre-heating shall be accomplished by methods as stated in welding procedure and

approved by the third party inspector, provided that it is uniform and that the
temperature does not fall below the prescribed minimum level during the actual
welding or thermal cutting operation.
The preheating temperature shall cover an area of at least 75 mm width on either

side of the weld and shall be maintained over the full length of the weld until the
weld is completed.
The weld area shall be protected from draughts, and insulation shall be provided
on adjacent areas where this is necessary to maintain the required temperature of
preheating during welding.
In all cases a minimum preheat of 50°C shall be used. The inter-pass temperature
shall not be permitted to drop below the minimum preheat temperature. The inter-
pass temperature shall not be allowed to exceed 300°C.

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Ovens or storage cabinets with automatic heat controls and temperature read out
equipment shall be provided to maintain low hydrogen welding electrodes and
welding flux at the required temperature.
After removal from an oven, all low-hydrogen electrodes shall be kept in a storage
cabinet or quiver.
No electrodes shall be left exposed to the atmosphere. Issue of low-hydrogen

electrodes from the storage cabinet shall be controlled so that all electrodes are
used within four hours of issue.
To maintain the low hydrogen content, electrodes shall be baked immediately

before use at 300°C (± 30°C) for one hour or in accordance with Manufacturers
recommendations. This requirement may be waived when the electrodes are
removed from a hermetically sealed package immediately before use. Plastic
wrapped cartons are not considered to be hermetically sealed.
After drying as described above, electrodes may be transferred to an intermediate

storage cabinet maintained at approximately 150°C. Upon removal from such
drying or storage the electrodes shall be transferred in small numbers to heated ~
quivers with a minimum temperature of 70°C and used within 4 hours.
Electrodes not used within 4 hours, or for some reason exposed to adverse
atmospheric conditions, shall be baked again in accordance with the above
conditions. Electrodes may be baked twice only. If these electrodes are not used
within four hours after the second baking treatment, they shall be discarded.
Pre-heating shall be applied by any of the following means:
• Gas Ring
• Electric Resistance
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• Induction Heating
• Gas Torch
The choice of above method is dependent on local conditions. The procedure used
shall ensure an even temperature distribution around and through the joint to the
satisfaction of third party inspector but shall not nevertheless, interfere with access
for welding. Where using gas torch, care to be taken to avoid excessive local
heating of the pipe surface, hence a skilled labor is to be employed to the
satisfaction of third party inspector.
Where induction heating is proposed for the application of either preheat or post-
weld heat treatment, the equipment and the procedure to be used shall be approved
by the Authorized Client’s Representative. In particular, the Contractor shall
demonstrate to the satisfaction of the Authorized Client’s Representative that
heating rates and required temperatures can be properly controlled and that
adequate precautions have been taken against overheating.
Further to the requirements of this specification, preheating shall be proceeded in

the following cases:
• When the ambient temperature is less than 5°C.

• When there is condensate moisture on the welding area.
• When completing an in-completed weld.
• When repairing a weld.
• When doing a Tie-in or connection.
• When the risk of crack exists in the heat affected zone.
• When welding carbon steel having a carbon content in excess of 0.32%
(ladle analysis)

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• When welding of various fittings to the pipe having different wall

thicknesses or different type of material unless during the establishment of
the welding procedure, it is determined that the preheating is not necessary.
Preheating temperature shall be checked using temperature – indicating crayons,

thermocouples or other methods approved by the third party inspector.
• In special cases thermocouple parameters or other suitable method, as

decided by the engineer shall be used to assure that the required temperature
is obtained prior to and maintained during the welding operation.
• The thermocouple (if used) shall be located in positions within 5 times wall
thickness or 50mm from the outside edge of the fusion faces whichever is
the greater.
5.11.2 Post Weld Heat Treatment (If Required)
Post weld heat treatment procedures shall be submitted to the Client for approval
along with the WPS and WPQT record, prior to the commencement of work.
Pipe ends shall be covered. When stress-relieving welds, to avoid draughts inside
the pipe. Threads and gasket surfaces shall be protected from oxidation during heat
treatment, if there is no subsequent machining operation which will remove any
damage.
All machined surfaces shall be protected from scaling during PWHT using a
suitable protective coating.
PWHT is mandatory for wall thickness equal or greater than 19 mm except sour
service. For sour service post weld heat treatment (PWHT) is required for the
pipeline sections in wall thickness equal to or greater than 12.7 mm. for thickness

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less than 12.7 mm if HIC and SSC tests in relevant PQR would be accepted, PWHT
is not required, otherwise it is mandatory.
For field welding if the service is sour the extent of hardness test is as below:
If PWHT is mandatory the extend of hardness test is 100% for cap(Weld metal and
HAZ)
If PWHT is not mandatory the extend of hardness test is 10% for cap(Weld metal
and HAZ)
A sufficient number of thermocouples shall be used in order to give a reliable

temperature measurement. On pipe with a diameter of 8 inches to 20 inches shall
have at least two at 180 degrees between each other. In no circumstance shall the
distance between two thermocouples be greater than 800 mm, measured around the
pipe circumference.
The procedure shall specify whether preheating or post weld heat treatment (if any)
must be performed when materials welding consumables, thickness, weather
condition & mechanical resistant’s make either or both of them necessary .all
welding procedures specifying PWHT must indicate the following cycle:
• Heating rate (maximum)

• Holding temperature (maximum & minimum)
• Holding time
• Cooling rate (maximum)
5.12 Welding Equipment

5.12.1 Welding Machines

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Welding machines shall be of suitable size and type for the work and shall be
maintained in such condition as to ensure acceptable welds, continuity of operation
and safety of personnel.
The Contractor shall take necessary precautions to ensure that no arcing occurs
between the ground leads of the welding machines and the pipe.
Welding machines shall be operated within the amperage, and voltage specified in
the qualified welding procedures. A welding machine which does not meet the
requirements shall be repaired or replaced by the Contractor. All welding machines
shall be calibrated prior to commencement of fabrication.
5.12.2 Welding Filler Material
All filler materials used in welding operations shall conform to those specified by
the relevant welding procedure.
Welding electrodes shall be so stored and handled as to prevent damage to them

and the container in which they are shipped. These containers shall be opened only
when their use is needed.
The uncovered parts of welding electrodes shall be free from corrosion.
Electrodes’ coating shall show no cracking and sticking marks. If so, the whole
batch of the defective electrodes shall be rejected by QC of Contractor/ third party
inspector Cellulose-base electrodes shall not have moisture content higher than the
maximum value specified by the manufacturers or the third party inspector. This
type of electrodes shall not be kept in high temperature ovens for losing their
minimum required moisture content as specified by the manufacturer or the third
party inspector.

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Low hydrogen electrodes, upon opening their containers, shall be transferred to

proper ovens set at a constant temperature specified by the manufacturer or the
third party inspector; these electrodes shall be kept in proper portable electrical
ovens set at the same specified temperature during the course of welding
operations.
All welding consumable shall be selected to produce welds with yield strength
exceeding that specified for the parent material where steels with different
specified properties are joined .
The weld metal yield strength shall match or exceed that of the higher strength
grade.
5.12.3 Welding Electrodes Storage
Electrodes shall be supplied fully sealed packages and stored in a dry storage room
with a maximum relative humidity of 50%. All manual types of electrodes shall be
properly identifiable up to the time of usage, each electrode being distinguishable
by proper coding. If the coding is destroyed by baking, handling, or other causes,
the electrodes shall not be used.
The weld metal yield strength shall match or exceed that of the higher strength
grade.
6. WELDING OF PIPING
6.1 Welding Requirements

6.1.1 Welding Consumables Requirements

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The covered electrodes used shall be 2.4mm, 3.2mm, 4.0 mm, or 5.0mm in dia.
However, diameters more than 2.4mm or 3.2 mm dia. Size shall not be used for the
root pass.
When joining similar materials, the deposited metal shall match the chemical and
mechanical properties of the base metal as far as possible. However, AISI Type
347 filler metal shall be used for welding Type 321 material.
When joining dissimilar carbon and low-alloy steels of P-Numbers 1, 3, 4 and 5,

the filler metals may match the lesser chemical composition (Cr, Mo , etc.) of
either base metal.
When joining dissimilar austenitic stainless steels, the filler metal may match either
base metal.
When joining austenitic stainless steels to Ferritic steel, the filler metal shall be
selected as follows:
Type 309/309L (E 309/309L, ER 309/309L) for design temperatures 343°C and

below.
ENiCrFe-3 and ERNiCr-3, or an equivalent combination for design temperatures

higher than 343°C, or where post welds heat treatment is to be performed.
6.1.2 Shielding & Purging Gas
Argon gas used in GTAW process for shielding purposes shall be 99.995% pure.
The purity of the gas shall be certified by the manufacturer. The rate of flow for
shielding purposes shall be established through procedure qualification tests. This
rate may be 0.34-0.57 M3/H (12-20 ft3/h).
Argon gas with a purity level of 99.995% shall be used for purging.

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When GTAW process alone or a combination of GTAW and SMAW processes is

recommended for the production of a particular joint, the purging shall be
maintained during the root pass and for the first filling pass to minimize oxidation
on the inner side of the pipe, unless otherwise specified in WPS.
Initial purging shall be maintained for sufficient period of time so that at least 4-5
times the volume between the dams is displaced, in order to completely remove the
entrapped air. In no case should the initial purging period be less than 10 minutes.
High gas pressure should be avoided.
After initial purging, the flow of the backing gas should be reduced to a point where
only a slight positive pressure prevails. For systems which have a small volume up
to 0.014 m3 (½ cubic foot) to be purged, a gas flow rate of 0.17 M3/H (6 ft3/h) is
usually adequate. Systems of larger volume may require higher flow rates and these
should be established during procedure qualification tests.
Gas backing (purging) is not required for socket type of welded joints.
Dams, used for conserving inert gas during purging, shall be removed after
completion of the welding. Wherever, removal of dams is not possible after
welding, use of water soluble dams should be made.
6.1.3 Acceptable Welding Processes
All welding shall be carried out by using one or a combination of the following
processes:
• Shielded Metal Arc Welding (SMAW)

• Manual and Automatic Inert Gas Tungsten Arc Welding (GTAW)
• A combination of the above processes

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• For other processes, such as Gas Metal Arc Welding (GMAW),

Construction Sub-contractor shall submit all of the pertinent data and
application of said process for evaluation and approval by Client.
For the root pass on 1¼ Cr and higher low alloy steel pipe, or an austenitic stainless
steel pipe, GTAW shall be performed with back shielding, such as Aragon gas in
the pipe, except when the flux cored welding electrodes are used for the austenitic
stainless steel pipe.
6.2 Welding Procedure

6.2.1 General
The Construction Sub-contractor who will do the actual welding work for piping
shall prepare the detailed Welding Procedure Specifications (WPS) and Procedure
Qualification Records (PQR) in accordance with ASME BPV Code section IX and
requirements of this specification for Client's review and approval, upon request.
6.2.2 Welding Procedure for Carbon Steel Pipe
• This metal group includes carbon steel pipe, ASTM A53, A106 Gr. B,
A134, API 5L-B, API 5L X60 and other weld able carbon steel materials.
• All pressure retaining welds and attachment welds to the pressure retaining
parts shall be made by Shielded Metal Arc Welding (SMAW) using Low
Hydrogen Type Electrode (AWS E7016/E7018)
• E6010 electrodes may be used for welding the root pass and the subsequent
pass in all carbon steel butt welds, except:
- Butt welds in pipe NPS 2 and smaller.
- For welding galvanized structural attachments to carbon steel pressure

containing components
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• Sour services
Other uses of E6010 electrodes require advance written approval from the
Client.
• Root pass of girth butt weld and branch connection weld , where the
complete penetration is required , shall be made by GTAW using AWS ER-
70S- 6 or ER70S-G .
• Filler pass and cover pass shall be made by GTAW or SMAW for smaller
• All weld areas must be cleaned of all foreign substances to avoid the
adverse effects caused by such contamination. (on galvanized pipe work,
the zinc in the area of the joint must be removed for 40 mm each side of the
welding groove prior to the welding operation. If welding requirements is
specified)
• Welding Procedure of Carbon Steel Pipe for Low Temperature Service
• This metal group includes low temperature carbon steel and low alloy steel
pipe, ASTM A333 Grade 3, 6, 7 and other carbon/low alloy steel pipe
qualified for service to -100 °C.
• The specifications given for metal group in Paragraph 5.2 (Carbon Steel
Pipe) shall also apply to this metal group and, in addition, the Charpy
impact tests shall be included in the welding procedure qualification.
• Consideration should be given to the use of low hydrogen type to produce
welds with the necessary impact properties.
• Root pass of girth butt weld and branch connection weld, where the
complete penetration is required, shall be made by GTAW process.
• Filler pass and cover pass shall be made by GTAW or SMAW. For smaller
diameter piping (2" and smaller), all GTAW process shall be done.

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6.2.3 Welding Procedure for Austenitic Stainless Steel Pipe
• This metal group includes austenitic stainless steels ASTM A182, A312,
A358, A403 and other similar materials used in the fabrication of piping
systems.
• Root pass of girth butt weld and branch connection weld, where the
complete penetration Is required, shall be made by GTAW process, with
the underside of the weld purged with argon gas. Other methods and
processes may be used only when approved by Client.
• Filler pass and cover pass shall be made by GTAW or SMAW. For smaller
• Weld Metal:
- The deposited weld metal shall have chemical & Physical properties at least
equal to that of the base metal.
- For welding of dissimilar stainless steel (for example Type 316 to 304), the
deposited weld metal shall be according to proper filler metal based on
AWS classification like as E-316 / ER-316 or E-308 / ER-308.
- For welding of stainless steel to carbon steel, a high alloy electrode shall be
used which will produce a sound ductile weld. AWS Classification E309-
16 /E-309L-16 or ER309 / E-309L Electrode must be used.
- Stainless steel shall not be welded to galvanized steel for any purpose.
• Internal back shielding with pure Argon gas (min. 99.9%) shall be required
during the welding. Back shielding with Nitrogen gas shall not be
permitted.
• Maximum inter-pass temperature during welding shall be 150°C.
• The welding joints shall not utilize a backing strip

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• All requirements for low temperature toughness test for metals shall be
according to table 323.2.2 of ASMEB 31.3
6.2.4 Welding Procedure for Dissimilar Metal
Root pass of girth butt weld and branch connection weld, where the complete
penetration is required, shall be made by GTAW process. Other methods and
processes may be used only when approved by Client.
Filler pass and cover pass shall be made by GTAW or SMAW. For smaller
Internal back shielding with Argon gas (min. 99.9%) shall be required during
the welding. Back shielding with Nitrogen gas shall not be permitted.
The welding joints shall not utilize a backing strip.
6.3 Welding Qualification Requirements

6.3.1 General
All welding procedure used for the piping work shall be qualified before
production welding, Construction Subcontractor shall carry out the welding
procedure qualification test and shall submit the complete document as WPS
and PQR to Client's review and approval. Also unless otherwise stated in the
contract documents, for each contract all existing welding procedures shall be
re-qualified by the contractor, and submitted for approval by the Client.
Welding sampling testing for PQR shall be at "H" level in inspection state.
The welding procedure specification proposed by the Contractor shall be

submitted to the Client Engineer for his review and approval before the
qualification test.

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All equipment, tools, test materials and labors required to carry out procedure
qualification test shall be supplied and prepared by the Construction consultant.
The base metal may consist of plate, pipe or other product forms. Qualification
in plate also qualifies for pipe welding and vice versa.
The welding process and electrodes shall be suitable for use in the positions
permitted by the WPS. A welder or welding operator making and passing the
WPS qualification test is qualified for the position tested.
WPS qualified on groove welds shall be applicable for weld repairs to groove
and fillet welds and for weld buildup under the following provisions:
- No limitation on the thickness of base metal or deposited weld metal

for fillet welds.
- For other than fillet welds the thickness range for base metal and
deposited weld metal for each welding process shall be in
accordance with QW-451 of ASME Section IX.
6.3.2 Tests
The Construction subcontractor shall supply all test specimens as follows.

Material and base material thickness to be qualified shall be determined prior
to test:
6.3.2.1 Tension Test Specimen
Tension test specimens shall conform to one of the types illustrated in QW-
462.1 (a) through QW-462.1 (e) and shall meet the requirements of QW-153 in
ASME Sec. IX. Tension test procedure and acceptance criteria shall be in
accordance with QW-152 and QW-153 of ASME Sec. IX respectively.
6.3.2.2 Guided-Bend Test Specimen

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Test specimens shall conform to one of the types illustrated in QW-462.2, QW-
462.3 (a) and QW-462.3 (b) and shall meet the requirements of QW-163 in
ASME Section IX. Guided-bend test procedure shall be in accordance with
QW- 162 of ASME Section IX.
6.3.2.3 Impact Test Specimen
The impact test specimens shall be prepared only when required by WPS and
concerned code for the material.
The test procedure and apparatus shall conform the requirements of ASME
SA370
The Acceptance Criteria shall be in accordance with Table 323.3.5 of ASME

B31.3.
6.3.2.4 Macroscopic Examination and Hardness Tests
Hardness requirements for welds shall be as per the WPS. Hardness testing
shall be carried out by Vickers hardness tester during welding procedure
qualification. In all other cases, hardness testing may be carried out by Vickers,
Brinell, or Rockwell hardness tester as agreed by Client.
On production welds for P5 and P6 group material, a Brinell hardness test shall
be taken on ten percent of the butt-welds in each P-groups material for all air
hardening filler metal. If less than ten welds are made per P-group, one weld
shall be tested. Brinell hardness shall not exceed 225 BHN (20 HRC).
Carbon steel welds subject to sour service shall have a maximum Brinell
hardness of 200 HRB. Hardness profile and metallographic test result shall be
prepared.

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The Brinell hardness testing shall be limited to piping greater than nominal pipe
size of 4" and a wall thickness over 6.35 mm.
Post weld heat treatment shall be repeated, if the Brinell hardness after PWHT
exceeds the maximum limits specified. Take repeating of PWHT for carbon
steel shall be maximum two times and more than two times is not permitted.
Specimens for hardness testing from test pieces in the 5G and 6G positions
shall be taken from the weld area of weld representing the minimum heat input
Hardness test results and locations shall be recorded. The third party inspector
shall be permitted to witness hardness testing and shall have access to test
results.
6.3.2.5 SSC and HIC Test
SSC and HIC test is necessary for qualification of welding procedures in sour
services.
6.4 Welder Qualification & Records

All welders and welding operators engaged in this project are required pass the
performance qualification test in accordance with ASME BPV Code Section IX
under the witness of buy back supervisor and third party inspector, even though
they have been previously qualified by other organization unless previous
qualifications approved by the Client.
The test records of all welders and welding operators shall be available at all times
at the work location for review by buy back supervisor and third party inspector
Each welder or operator shall be identified by means of a stamp. The stamp shall
be applied 100mm maximum near the weld. It is forbidden to mark the internal part

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of pipes in case of design temperature -10°C and below and for thickness 5 mm
and below. Other means than stamp shall be used to identify the welders. The
symbol assigned to each welder, shall be marked clearly visible on the welder's
helmet, or on the working clothes, to identify each welder without asking his
identification documents.
Construction consultant shall keep a record of welders working at shop and at field,
and to be submitted to Client for review. If the qualification of any welder or
welding operator is found expired all affected welds shall be traced and examined
to the satisfaction of Client.
During welding the maximum heat input in each pass shall be the same one used
during the relevant procedure qualification record.
Each welder performing welds for which preheating is required, shall have
availability to the equipment for heating and for temperature checking.
When GTAW process is used, the arc shall be extinguished on the edge of the
bevel, keeping the molten pool under gas shielding until it solidifies.
Marking of the joint shall be performed utilizing proper tools as follows:
• Carbon steel: Metallic punch

• Killed carbon steel for low temperature:
• Low stressed punch for Thk.>6 mm
• Paint or electric pencil for Thk <6mm
• Low and intermediate alloy steel: Low stressed punch
• Austenitic Stainless Steel: Paint without Zn, Pb, Cu& Halogen

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6.5 General Requirements

6.5.1 General
All welding shall conform to the requirements of Section IX of ASME Boiler and
Pressure Vessel Code.
Welding procedure specifications and procedure qualification records shall be

submitted and approved prior to start of any welding work.
Procedure qualifications for material subjected to low temperature service shall

include impact tests.
If reinforced branch connections are employed the branch-to-header welds must be

complete, inspected and tested prior to pad installation
Stress relieving according to the applied code and approved procedure shall be
carried out.
Welders shall be equipped with clean gloves (especially for S/S materials), safety
glasses & safety shoes.
6.5.2 Environmental Conditions
Welding shall not be performed under the following weather conditions:
• In the rain
• In winds of 10 m/s or more (3 m/s or more for GTAW)
• When the relative humidity is 90% or more
• In snow or sleet
However, where necessary protection from the weather is provided, welding may
be performed.

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ALL requirements of standards ASME B 31.3 IPS-C-PI-290 shall be considered in

undesirable climatic condition
When the item to be welded is wet with rain or dew, or covered with snow, frost,
or ice shall be removed and the surface dried completely prior to beginning
welding.
If the ambient temperature is less than 5°C, the recommended preheating

temperature shall be in accordance with ASME B31.3.
Welding of austenitic materials (stainless steel and nickel-alloy steel) shall be

performed with great care and as follows:
When the welding, cutting, or grinding of galvanized steels is performed near

austenitic materials, the austenitic materials shall be strictly protected from any
adhesion of the zinc or zinc fumes and carbon steel material.
When paint materials with zinc dust are used for painting near the austenitic
materials, the painting shall be performed after completion of welding and heat
treatment of austenitic materials. If these types of work must be performed in
parallel, the austenitic materials shall be strictly protected from any adhesion of the
paint or mist.
6.5.3 Preparation of Weld Joint
Machining, grinding or thermal cutting shall make weld bevels. The surfaces shall
be reasonably smooth and true for good fit-up. Materials that require preheat for
welding shall be preheated in the same manner for tack welding, thermal cutting or
gouging. Weld bevel’s preparation shall be in accordance with ASME B31.3.
Double-welded butt joints are preferred and shall be used whenever possible and
for all pipe of 30" OD and larger, where accessible.
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Peening is not allowed
During the welding operation, edges of the plates or pipes shall match accurately
and retained in constant distance all around the joint. “Gap Gauge" shall be used
for measurement.
In austenitic stainless steel and nickel alloy the cutting for the edge preparation
shall be performed by machining, or grinding, or by plasma-arc with subsequent
light grinding. The grind wheels shall be of a suitable type for stainless steel and
shall not have been previously used for carbon steel. The brushes (both manual and
mechanical) shall have chromium nickel austenitic stainless steel wires.
6.5.4 Alignment & Spacing
Components to be welded shall be aligned and spaced as per the requirements laid
down in applicable code. Special care must be taken to ensure proper fitting and
alignment when the welding is performed by GTAW process. Flame heating for
adjustment and correction of ends is not permitted unless specifically approved
by Client.
Consumable backing inserts are not permitted unless in the inevitable situations.
At this condition all qualification requirements shall be considered based on
paragraph 328.2 of ASME B31.3
A wire spacer of suitable diameter may be used for maintaining the weld root
opening while tacking, but it must be removed after tack welding and before laying
the root bead.
For pipes of wall thickness 5 mm and above, the ends to be welded shall be secured
in position with the aid of couplers, yokes and “C” clamps, to maintain perfect
alignment. Yokes shall be detached after the completion of weld, without causing
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any surface irregularity. Any irregularity caused on the pipe surface must be
suitably repaired to the satisfaction of Client.
Tack welds, for maintaining the alignment, of pipe joints shall be made only by
qualified welders. They shall be made with same type of electrode which is used
for the root pass, executed carefully and shall be free from defects. All defective
tack welds must be removed prior to the actual welding of the joints.
Tack welds should preferably not touch the root of the weld preparation to avoid
damage to the root area. The use of bridge pieces is recommended.
Tacks should be equally spaced. Minimum number of tacks shall be:
· 2 tacks for: "2 and smaller diameter pipes
· 4 tacks for: "3 to 12" diameter pipes
· 6 tacks for: "14 and larger diameter pipes
6.5.5 Cleaning Requirement
All surfaces to be welded shall be cleaned thoroughly and any paint, oil, rust, dirt,
scale moisture, or any other foreign matter that would be detrimental shall be
removed from at least 10 mm from the groove end prior to the welding.
Flux, weld spatter and slag shall be removed from weld beads before starting to
deposit a succeeding pass
Compressor piping requiring special cleaning as indicated on piping drawings shall

have the root pass deposited with the gas tungsten arc process.
6.5.6 Welding

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Tack-welds shall be made with the same type of electrode that is used for the root
pass. Permanent back-up rings are not permitted. If back-up rings are used and then
removed, the weld area shall be dressed and examined for cracks by the magnetic
particle method or by the liquid penetrate method if the base material is non-
ferromagnetic.
The striking of the arc must not be performed on the pipe wall outside the bevel (a
suitable plate may be used for this purpose)
Once the welding has been started and until the joint has been completed, care shall
be taken to avoid displacements, shocks, vibration or stresses, which could damage
the weld.
On butt welds, the weld reinforcement shall be in accordance with applicable code
requirements. The width of the weld face shall cover completely the groove of the
joint. On fillet welds, the weld profile shall be regular, at about 45°.
For socket welds and for slip-on flanges at least two passes shall be performed.
As a rule, the filling passes shall be performed immediately after completion of

root pass. Should this, in particular cases, be impossible , post heating shall be
performed and then any displacement or shocks shall be carefully avoided on pipe,
until the completion of welding is performed.
The inter-pass temperature of the joint during execution shall not be decreased
below the minimum required preheating temperature and the completion of the
weld should be carried out without interruption.
For GTAW technique, the purity of the gas shall be monitored continuously.

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Volume and the width of each pass shall be limited, using low current and stringer
bead technique whenever possible; anyway the bead width shall not be larger than
three times the electrodes size.
On-plot lines welding of all passes shall be performed in up-hill position
On-plot use of low hydrogen electrodes for root (where are access to root pass) and
filling passes shall be considered when SMAW process is subjected.
6.5.7 Repairs of Welds
Defects ascertained through the inspection methods, which are beyond acceptable
limits shall be removed after the joint is completely radio graphed, by the process
of chipping and grinding.
When the entire joint is judged unacceptable, the welding and HAZ shall be
completely cut and the edges are suitably prepared as per required alignment
tolerances. The re-welded joint shall again be examined following standard
practices.
No repair shall be carried out without prior permission of Client
6.5.8 Weld Contour and Finish
Weld beads shall be properly contoured to permit complete fusion at the sides of
the bevel, and to minimize slag inclusions.
Internal and external weld reinforcement and finish shall be as required by the
applicable code.
Welds, which are to be examined by nondestructive methods, shall be finished as

required for the applicable inspection method.

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6.5.9 Preheating and Post Weld Heat Treatment
Preheating is essential under the following conditions:
• Carbon steel having a specified carbon content in excess of 0.32% (Ladle

analysis)
• Preheating may also be required for steel having lower carbon or carbon
equivalent when conditions exist that either limit the welding technique or
tend to adversely affect the quality of the weld
• When the ambient temperature is below five degree Celsius.
• When the risk of cracks exists in the HAZ
• For weld repair.
• For completing an incomplete weld left at the end of the previous working
day.
• For welding of various fitting/appurtenances to the pipe having different
wall thickness or of different types of material unless during the
establishment of the weld procedure, it is determined that the preheating is
not necessary.
• PWHT is mandatory for wall thickness equal or greater than 19 mm for
sweet service.
• For field welding if the service is sour the extent of hardness test is as
below:
- If PWHT is mandatory (based on item d) the extend of hardness test is
100% for cap(Weld metal and HAZ)
- If PWHT is not mandatory (based on item d) the extend of hardness test is
10% for cap(Weld metal and HAZ)
6.5.10 Storage and Control of Electrodes

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Electrodes shall be stored indoors free from moisture as far as possible.
The packages of welding materials shall not be opened prior to their use or to
drying.
Covered arc welding electrodes (except for high cellulose) shall be dried in a
heating oven in accordance with the manufacturer's recommendation prior to use.
Immediately after drying, these electrodes shall be stored either in a portable dryer
or in a keeping oven.
Electrodes coated with high cellulose and flux cored welding electrodes used for
GTAW are not required to be dried. However, wet electrodes coated with high
cellulose shall be annulled.
During welding, all covered arc welding electrodes shall be kept in a quiver or its
equivalent. The electrodes shall not be laid directly on the ground or on any other
damp place.
Electrodes (except for electrodes coated with high cellulose, and flux cored
welding electrodes) exposed to the atmosphere for more than 4 hours shall be re-
dried.
When the day's work has been completed, the electrodes shall be collected and
stored in a heating cabinet. This process shall be done only for twice, remaining
electrodes are not acceptable for using.
The issue of electrodes shall be controlled by the assigned person.
Electrodes and filler wires shall be kept clean, dry, and properly stored according
to the manufacturer’s recommendation. No electrodes or filler wires may be used
which are damp, greasy, or oxidized. Repacking of electrodes are not normally
allowed and if in certain cases required, the Construction consultant shall get prior
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approval of the Client. Electrode shall be stored in a sheltered area and ventilated
during storage namely in electrode room. The electrode room shall be shelved.
6.6 Inspection and Non-Destructive Testing (NDT)

6.6.1 General
The buy back supervisor third party inspector shall have the right to inspect all
welds by nondestructive means or by removing welds and subjecting them to
mechanical tests.
The inspection should be made before, during and after welding. The frequency of
inspection shall be specified.
Nondestructive testing personnel shall be certified in accordance with the

recommendation of ASNT RP SNT-TC-1A or have qualifications and experience
acceptable to the client.
Only level II or III personnel shall interpret test results. Level I and II
nondestructive testing personnel shall be recertified at least every three years. Level
III Nondestructive personnel shall be recertified at least every five years.
All nondestructive testing shall be performed in accordance with the requirements

and methods specified in ASME sec. V
For RT testing of seam welds with sweet services, AGFA D7 type and for those
with sour services AGFA D4 type shall be used as radiograph.
Examination of welds shall be in accordance with the procedures and

acceptance standards of the applicable ASME codes, the Project specifications,
this Specification, and the references given hereafter in below Table.

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Weld examination procedures and

acceptance standards
Examination method Applicable standard(s)
Visual ASME Sect. V, Article 9
Radiography ASME Sect. VIII, Div. 1 Par. UW 51

ASME Sect. VIII, Div. 2, Art. 1-5
ANSI B31.3, (Piping only)
Magnetic particle ASME Sect. VIII, Div. 1 App. 6

ASME Sect. VIII, Div. 2 App. 9-1
6.6.2 Extent of Visual Inspection and NDT
Extent of RT for wellhead shall be 100% and just for burn pit it could be 10%.
Extent of visual inspection and NDT other than RT for piping systems, the shall be
in accordance with ASME B31.3 standard.
6.7 Repair and Removal of Defects

Defects, other than cracks, in the root and filler beads may be repaired with prior
third party inspector authorization. Defects other than cracks, in the cover pass may
be repaired without permission.
Repair welds shall be made using a welding procedure qualified.

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Before repairs are made, injurious defects shall be entirely removed to sound metal.
All slag and scale shall be removed.
Repaired area shall be radiographed or inspected by the same means

previously used.
The same area on a weld shall not be repaired more than twice.
Minor surface flaws may be removed by grinding, provided the pipes minimum
wall thickness is not violated.
Repair of porosity found in flash butt welds is not permitted.
Damage to the base metal or welds, including dimensional changes caused by

external forces requires special repair and inspection procedures be submitted to
client for review and approval prior under taking the repairs.
7. CONFLICT AMONG REFERENCED DOCUMENTS

If there are any conflicts between this requisition, data sheets, specifications, codes and
standards, the order of priority shall be as follows:
• Specification For Welding

• IPS Standard Specifications
• International Codes and Standards (latest version) However, should there be any
conflicts between the information supplied in the documents listed above, vendor shall
notify Purchaser and obtain written clarifications of the points in question.

Date: Date:
Sign: Sign:

Specification For Welding

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Specification For Welding

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Engineering Services for

Abadan Petrochemical Plant

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1. TERMS AND DEFINITIONS…………. ..................................................................................................... 4

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1. TERMS AND DEFINITIONS

• Vendor: The manufacturer /manufacturer's representative selected by the contractor &

• May: Is used where a provision is completely discretionary.

• Should: Is used where a provision is advisory only.

• Shall: Is used where a provision is mandatory.

ASME Section V Nondestructive Examination

ASME Section VIII Rules for Construction of Pressure Vessels

ASME Section IX Welding and Brazing Qualifications

ASME B 31.1 Power Piping

ASME B 31.3 Chemical Plants and Petroleum Refinery Piping

ASME B 31.8 Gas Transmission and Distribution Piping Systems

ASME B 31.4 Liquid Transportation system

AWS D 1.1 American Welding Societies; Structural Welding Code-Steel

AWS 5.1 (5.29) Specifications for Welding Filler Materials

AWS A 3.0 Welding Terms and Definitions

IPS-C-PI-290 Construction Standard for Welding of Plant Piping Systems

IPS-C-PI-270 Construction Standard for Welding of Transportation Pipeline

IPS-G-SF-110 Radioactive Protection against Source

IPS-E-PI-221 Engineering Standard for Piping Material Selection

API 1104 Standard for Welding Pipelines and Related Facilities

API 5L Specifications for Line Pipe

ASNT-CP-189 Standard for Qualification & Certification of Non-Destructive

ASNT-TC-1A Recommended Practice for Non-Destructive Personnel

NACE MR-01-75/ISO 15156 Sulfide stress cracking resistant metallic materials

For oil field equipment”

AWS D 1.1 American Welding Societies; Structural Welding Code-Steel

AWS 5.1 (5.29) Specifications for Welding Filler Materials

All Welders Shall be Qualified in Accordance with ASME SEC. IX

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Hammering of the pipe to obtain proper lineup should be kept to a minimum.

Carbon equivalent (CE) is an effective method of controlling the HAZ

4.2 Welding Consumables Requirements

All welding consumables shall have individual marking.

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4.3 Welder Qualification & Records

All welders shall be previously qualified by a Certifying Authority approved by

4.4 Preheating and Post Weld Heat Treatment

• Carbon steel having a carbon equivalent in excess of 0.65 (Ladle analysis)

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procedure is capable of producing a hardness of 22 HRC maximum in the condition

5.1 Filler Metal for Pipe Lines

All welding consumables shall be defined in the proposed welding procedure

Unopened electrode containers shall be stored in accordance with manufacturer’s

As a minimum all welding consumables shall be stored and handled in accordance

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Sufficient quantities of each consumable brand and type should be purchased to

Pipeline Consumables shall conform to one of the following specification:

5.2 Shielding & Purging Gas

5.3 Welding Process

· Shielded Metal Arc Welding (SMAW)

· Manual and Automatic Inert Gas Tungsten Arc Welding (GTAW)

· A combination of the above processes

· For other processes, such as Gas Metal Arc Welding (GMAW)

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5.4 Welding Techniques