000 GPP GCX 00029 Welding and NDT Matrix

Al Taweelah Alumina
PROJECT PROCEDURE
WELDING & NDE MATRIX – Project Form 167
25875-000-GPP-GCX-00029
Bechtel Petrofac JV
000 Jan 7 2016 Issue for Construction S.M. Yee C. Cannell R Johnson M Barnham M Crosse
REASON FOR
REV DATE BY CHECK EGS PEM OWNER OWNER
REVISION
JOB NO. 25875 Page 1 of 18
DOCUMENT No.
25875-000-GPP-GCX-00029
Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to the electronic documents in the project electronic database for current revisions.
Confidential
Confidential © 2016 Joint Venture between International Bechtel Co. Ltd (Abu Dhabi Branch) and Petrofac Emirates L.L.C. (BPJV).
This document, prepared under Contract EGA/SH-EPCM/27-016 between BPJV and Emirates Global Aluminium PJSC (EGA),
contains information confidential and/or proprietary to BPJV that is not to be used, disclosed, or reproduced in any form by any
person or entity other than BPJV or EGA without BPJV’s prior written permission. All rights reserved.
25875-000-GPP-GCX-00029 Page 1 of 18
SCOPE
This procedure summarizes the welding, post weld heat treatment, non destructive examination (NDE)
and other project specific requirements for all piping systems fabricated and installed for Al Taweelah
Alumina Refinery located in the Khalifa Industrial Zone Abu Dhabi (KIZAD). It also provides a method for
shop fabricators and field installation contractors to list their weld procedures by types of materials and
fluid types. Shop fabricators and field installation contractors shall use this procedure as outlined in the
general notes, the piping class matrices, and attachment A. This procedure shall be used in addition to
technical specifications to meet project requirements.
GENERAL NOTES
(A) Welding Procedure Specification – For subcontracted work, the supplier is required to fill in their
own WPS numbers for each applicable line under the "Welding Procedure Specification" column on
the applicable pages. A copy of the completed Form 167 shall be submitted for review along with the
supplier's WPS/PQRs prior to the start of fabrication. WPS/PQR review will not proceed until
completed copies of the Form 167 are submitted.
(B) For submittal of procedures see Attachment A.
(C) Min Preheat and Post Weld Heat Treatment for non-pressure attachments to pressure containing
parts shall be the same as for pressure containing welds. Preheat shall apply to all welding
including, tack welding and temporary attachments.
(D) Socket Welds - A minimum of 2 weld layers is mandatory. Maximum electrode diameter of
2.4mm(3/32inch) applies to SMAW on DN 13(NPS ½ inch) thru DN 50 (NPS 2 inch) joints. Socket to
pipe end gap shall be 1.5mm (1/16inch) to 3.2mm (1/8 inch) prior to welding.
(E) Alignment of Girth Butt Welds - Where ends of piping components to be joined by girth butt welds
have internal misalignment exceeding 1/16 inch (1.5mm), the inside diameters of the components
shall be trimmed so that internal surfaces are approximately flush. Code minimum thickness shall be
measured and verified.
(F) Zinc Coatings -Zinc-Coated (galvanized or painted) components shall not be welded to stainless
steel (e.g. 304SS) even if the coatings have been removed. Galvanizing in weld regions shall be
removed by grinding prior to welding.
(G) Pipe Welds - All DN 40 (NPS 1½inch) and smaller full penetration groove welds shall be welded
using the GTAW process. Backing strips or rings shall not be used. When back purge is required it
shall be maintained for 2 layers minimum.
(H) Non-Destructive Examination–Acceptance criteria for NDE shall be per Table 341.3.2 (ASME B
31.3). Normal Fluid Service or as specified in the notes associated with an individual pipe class in this
document.
(I) O'lets - shall be visually inspected after fit-up and on completion of Root Pass to ensure correct fit-up
with full root fusion. This inspection shall be performed before the branch pipe is welded to the weld-
O’let.
(J) GTAW - shall be used for branch connections and weld-O-let Root Pass.
(K) Pipe Class data within this document is based on pipe classes in Technical specification 25875-000-
3PS-P000-00001, Rev 001.
(L) Exceptions to the basic Code mandated PWHT requirements are not permitted. PWHT holding time
for P1 shall be 1 Hr. minimum.
(M) Form 167 takes precedence over other documents for percent NDE except for open ended lines
where NDE requirments shall be govern by the shop fabrication specification.
All rights reserved.
Refer to the electronic documents in the project electronic database for current revisions. Page 2 of 18
25875-000-GPP-GCX-00029
(N) Filler Metals – All filler metals for CVN applications shall be impact tested at the minimum design
temperature or lower, and purchased with actual CMTR’s. When required by this form 167, stainless
steel pressure boundary and load bearing welds shall have a minimum delta ferrite content of 5FN
based upon actual chemical analysis and the WRC ferrite diagram.
(O) “Rev bar” indicates change from previous revision.
(P) Field welding shall not be carried out when the pipe surfaces are moist or during periods of wind in
excess of 5km/hr. unless protective enclosures are provided. Weather enclosures and their suitability
for protection shall be subject to prior approval by OWNER.
(Q) All welds on the project site require full traceability. This includes all non-pressure retaining
components such as pipe supports which are welded directly to the pipe. Weld mapping of isometrics
is required and welds will also be tracked.
(R) Where random radiography percentages are specified, each welder is required to have that specified
percentage of their welds examined by radiographic or ultrasonic test.
(S) All Stainless steel pipe welds including non-pressure attachments, shall have all surfaces thoroughly
cleaned and passivated. The method or process shall be approved by the OWNER
(T) ASME B31.3 Fluid category shall be as specified in the Form 167 for each pipe class. Normal fluid
service requires a minimum random 5% radiography (RT). Category D fluid service requires visual
examination (VT) and no RT. The category of fluid service shall be as specified on each Isometric
drawing. When available, the project line list design conditions may be checked to verify the design
temperatures and the design pressures.
(U) All attachments (to piping including pipe supports, lifting lugs etc.) requiring PWHT shall have PWHT
carried out after welding.
(V) For both shop and field welds, the required NDE for Normal Fluids - CL300, CL600 & CL900 (NDE
Class 1) require 10% random radiography for butt welds and 10% MT or PT for branch, socket and
fillet welds.
25875-000-GPP-GCX-00029
WPS Index: Enter WPS name/number below and use the index numbers to fill in the WPS(s) on following forms.
1 31 61
2 32 62
3 33 63
4 34 64
5 35 65
6 36 66
7 37 67
8 38 68
9 39 69
10 40 70
11 41 71
12 42 72
13 43 73
14 44 74
15 45 75
16 46 76
17 47 77
18 48 78
19 49 79
20 50 80
21 51 81
22 52 82
23 53 83
24 54 84
25 55 85
26 56 86
27 57 87
28 58 88
29 59 89
Confidential
Confidential © 2016 Joint Venture between International Bechtel Co. Ltd (Abu Dhabi Branch) and Petrofac Emirates L.L.C. (BPJV). This document, prepared under Contract EGA/SH-
EPCM/27-016 between BPJV and Emirates Global Aluminium PJSC (EGA), contains information confidential and/or proprietary to BPJV that is not to be used, disclosed, or reproduced in any
form by any person or entity other than BPJV or EGA without BPJV’s prior written permission. All rights reserved.
25875-000-GPP-GCX-00029 Page 4 of 18
Piping Classes
Design Code: ASME B31.3 Category: See Below (Note 2)
Pipe Class(es): Line Services: Design Pressure (kpag) Design Temperature (ºC)
A2 AP, AX, FA, LF, WC, WF, WG, WP, FL Normal DS Category D 1400 100
B2 SB, WT Normal AI, WT Category D 1000 65
B3 SB Normal DS Category D 1400 80
C1 FV Normal AB, DX, PV Category D 120 140
Q2 --- --- AL Category D 600 110
Piping Material Type: Carbon Steel P Number: 1 Hardness Requirements: NA

CVN Requirements: No PMI Requirements: No Ferrite Requirements: NA
Heat Treatment NDE (%)
Pipe Max W.T. Weld PRE POST Welding Procedure RT MT PT VT Other
Pipe Class
Size (DN) (mm) Type (ºC) (ºC) Specification(s)
15-40 5.08 THR NA NA --- --- --- 100
A2 5
50-1050 9.52 BW 10 None --- --- 100 Note 1
(Note 1)
15-40 5.08 THR NA NA --- --- --- 100
B2
50-300 9.52 BW 10 None 5 --- --- 100
15-40 5.08 THR NA NA --- --- --- 100
B3
50-300 9.52 BW 10 None 5 --- --- 100
15-40 5.08 THR NA NA --- --- --- 100
C1
50-1800 12 BW 10 None 5 --- --- 100
15-40 5.08 THR NA NA --- --- --- 100
Q2
50-150 12 BW 10 None --- --- --- 100
Fillet, attachments, & seal

All All FW 10 None --- --- --- 100
welds
Branch Welds All All BR 10 None --- --- --- 100
Notes:
1) Butt welds located U/G shall be subject to 10% random radiography to their full circumference.
2) The following Line Services are specified as Normal fluid service however may be Category D based on the design parameters.
The Line Services are: AP, AX, FL, WC, WF, WG, WP
25875-000-GPP-GCX-00029
Piping Classes
B4 --- --- WK Category D 1000 50
F1 AS, FL, HL Normal --- --- 1000 50
F2 DA, NH, PS Normal --- --- 14475 65
F3 FL Normal --- --- 10000 60
S1 XY Normal --- --- 8875 65
P1W --- --- WK Category D 1000 35
P8 WF Normal --- --- 1030 50
P9 WP Normal --- --- 900 55
Piping Material Type: Stainless Steel (316L) P Number: 8 Hardness Requirements: NA

CVN Requirements: No PMI Requirements: Yes, 100%. Ferrite Requirements:
Pipe Class
20 - 50 2.77 PFit NA NA --- --- --- 100
B4 (316L)
80 - 150 3.4 BW 10 None --- --- --- 100
F1 (316L) 15 - 400 4.78 BW 10 None 5 --- --- 100 Note 1
10
F2 15 - 50 5.54 BW 10 None
(Note 1)
--- --- 100 Note V
F3 15 - 40 3.68 SW 10 None --- --- --- 100 Note 1

15 - 20 2.87 SW 10 None --- --- --- 100
S1
25-50 3.91 BW 10 None 10 --- --- 100
P1W (316) 50-200 8.18 BW 10 None --- --- --- 100
P8 (316) 50-350 9.52 BW 10 None 5 --- --- 100
P9 (316) 50-400 9.52 BW 10 None 5 --- --- 100
All All FW 10 None --- Note V Note V 100 Note V
welds
Branch Welds All All BR 10 None --- Note V Note V 100 Note V
Notes:
1) All welds including original pipe to be descaled and passivated.
The Line Services are: FL, NH, PS, WF, WP
25875-000-GPP-GCX-00029
Piping Classes
Design Code: ASME B31.3 Category: Normal Fluid Service
D2 LC, LS, LP Normal --- --- 1500 130
E2 CA, LC Normal --- --- 1900 40
E3 CA Normal --- --- 5010 50
J2 LD, LH, LJ, LP, LS, SD, SO Normal --- --- 1500 150
J3 LC, LS, SB, SD Normal --- --- 1960 200
J4 SD, SL Normal --- --- 15320 350
Piping Material Type: Carbon Steel (Caustic) P Number: 1 Hardness Requirements: NA

Pipe Class
15-40 5.08 SW 10 621-649 --- --- --- 100
D2
50-750 9.52 BW 10 621-649 5 --- --- 100
15-40 5.08 SW 10 621-649 --- --- --- 100
E2
50-450 9.52 BW 10 621-649 5 --- --- 100
15-40 5.08 SW 10 621-649 --- --- --- 100
E3 10
50-400 12.7 BW 10 621-649 --- --- 100 Note V
(Note 2,3)
15-40 5.08 SW 10 621-649 --- --- --- 100
J2
50-600 9.52 BW 10 621-649 5 --- --- 100
15-40 5.08 SW 10 621-649 --- --- --- 100
J3
50-750 9.52 BW 10 621-649 5 --- --- 100
15-40 5.08 SW 10 621-649 --- --- --- 100
J4 50-200 18.26 BW 10 621-649 10 --- --- 100 Note V
250-750 50.8 BW 80 621-649 10 --- --- 100 Note V
All All FW 10 621-649 --- Note V Note V 100 Note V
welds
Branch Welds All All BR 10 621-649 --- Note V Note V 100 Note V
Notes:
1) Stress relieved welds shall be painted over white for identification.
2) All butt welds located U/G shall be 100% radiographed to their full circumference.
3) All butt welds located A/G piping requirements via conveyor galleries shall be 100% radiographed to their full circumference.
25875-000-GPP-GCX-00029
Piping Classes
F4 --- --- WS Category D 1200 35
F5 AS Normal --- --- 2000 80
Piping Material Type: Duplex Stainless Steel P Number: 10H Hardness Requirements: NA
CVN Requirements: No PMI Requirements: Yes, 100%. Ferrite Requirements:
Pipe Class
15 - 40 3.68 SW 10 None --- --- --- 100
F4
50 - 750 6.35 BW 10 None --- --- --- 100
F5 15 - 600 6.35 BW 10 None 5 --- --- 100 Note 1

All All FW 10 None --- --- --- 100
welds
Branch Welds All All BR 10 None --- --- --- 100
Notes:
1) All welded joints shall be pickled and passivated as per the specification for shop pipe spool fabrication 25875-000-3PS-PS02-00001 and field piping installation 25875-000-3PS-
P000-00005.
25875-000-GPP-GCX-00029
Piping Classes
H2 GN, NT Normal --- --- 11000 75
H3 GN Normal --- --- 5110 80
L2 SL Normal --- --- 1600 100
M2 FR Normal --- --- 1600 80

Pipe Class
15-40 5.08 SW 10 None --- --- --- 100
H2 10
50-300 9.52 BW 10 None --- --- 100
(Note 1)
15-40 5.08 SW 10 None --- --- --- 100
H3 5
50-250 9.52 BW 10 None --- --- 100 Note V
(Note 1,2)
15-40 5.08 SW 10 None --- --- --- 100
L2
50-300 9.52 BW 10 None 5 --- --- 100
15-40 5.08 THR NA NA --- --- --- 100
M2
50-250 9.52 BW 10 None 5 --- --- 100

All All FW 10 None --- Note V Note V 100 Note V
welds
Branch Welds All All BR 10 None --- Note V Note V 100 Note V
Notes:
2) All girth butt welds to above ground sections of piping shall be 100% radiographed to their full circumference. Remaining welds shall be subject to 100 % MPI.
25875-000-GPP-GCX-00029
Piping Classes
FA, LC, LD, LH, LJ, LP, LS, LW, SA,
K1
SB, SC, SD, SH, SM, SO, CR, QL Normal ED Category D 1500 110
K2 SB, SD, LS, SL, LD Normal --- --- 1960 210
K3 LS, LW, SB, SD, SH, SM Normal --- --- 5110 265
K4 SD, SL Normal --- --- 10210 300

Pipe Class
15-40 5.08 SW 10 None --- --- --- 100
K1
50-1800 12.7 BW 10 None 5 --- --- 100 Note 1
15-40 5.08 SW 10 None --- --- --- 100
K2
50-900 12.7 BW 10 None 5 --- --- 100
15-40 5.08 SW 10 None --- --- --- 100
K3
50-600 17.48 BW 10 None 10 --- --- 100 Note V
15-40 5.08 SW 10 None --- --- --- 100
K4 50-350 19.05 BW 10 None 10 --- --- 100 Note V
400-600 30.96 BW 80 593-649 10 --- --- 100 Note V

All All FW 10 Note 3 --- Note V Note V 100 Note V
welds
Branch Welds All All BR 10 Note 3 --- Note V Note V 100 Note V
Notes:
1) Spent Liquor pipework operating at above 85ºC requires stress relieving and shall be Spec D2.
The Line Services are: SA, CR,
3) See Preheat and PWHT requirement for each pipe class where applicable.
25875-000-GPP-GCX-00029
Piping Classes
K5 SD, SL Normal --- --- 10210 300
K6 SB Normal --- --- 3400 60
K7 SM Normal --- --- 3400 60
FA, LD, LH, LJ, LP, LS, LW, SB, SC,
K8
SD, SH, SM, SO Normal ED, WT, WK Category D 1950 90

Pipe Class
15-40 5.08 SW 10 593-649 --- --- --- 100
K5 50-350 19.05 BW 10 593-649 10 --- --- 100 Note V
400-600 30.96 BW 80 593-649 10 --- --- 100 Note V
15-40 5.08 SW 10 None --- --- --- 100
K6
50-900 9.52 BW 10 None 10 --- --- 100 Note V
15-40 5.08 SW 10 None --- --- --- 100
K7
50-750 16 BW 10 None 10 --- --- 100 Note V
15-40 5.08 SW 10 None --- --- --- 100
K8 None 5
50-750 9.52 BW 10 --- --- 100
(Note 1)

welds
Notes:
1) Spent Liquor pipework operating at above 90 C requires stress relieving and shall be D2.
25875-000-GPP-GCX-00029
Piping Classes
N2 CL, CP, CR,CW, FV, ST Normal --- --- 1960 210
N3 ST, FV, CL, CP, WG, WP Normal --- --- 5110 265
N4 ST, FV, CL, CP, WG Normal --- --- 10210 325
N5 ST, CP, CL, NT, FL, FV, AD, WG Normal --- --- 15320 350
N7 NT Normal --- --- 8875 65

Pipe Class
15-40 5.08 SW 10 None --- --- --- 100
N2
50-2100 12.7 BW 10 None 5 --- --- 100
15-40 5.08 SW 10 None --- --- --- 100
N3
50-600 12.7 BW 10 None 10 --- --- 100 Note V
15-40 5.08 SW 10 None --- --- --- 100
N4 50-350 19.05 BW 10 None 10 --- --- 100 Note V
400-600 30.96 BW 80 593-649 10 --- --- 100 Note V
15-80 7.62 SW 10 None --- --- --- 100
N5 100-200 18.26 BW 10 None 10 --- --- 100 Note V
250-600 46.02 BW 80 593-649 10 --- --- 100 Note V
15-40 5.08 SW 10 None --- --- --- 100
N7 10
50-100 8.56 BW 10 None --- --- 100 Note V
(Note 1)

welds
Notes:
The Line Services are: CL, CP, CR, CW, FL, WG, WP.
25875-000-GPP-GCX-00029
Piping Classes
P1 LD, SA Normal WS, ED Category D 1050 35
P1W --- --- WK Category D 1000 35
P2 SM Normal WS Category D 940 50
P3 SM Normal WS Category D 640 35
P5 --- --- WS Category D 292 40
P7 --- --- WS Category D 765 40
P8 WF Normal --- --- 1030 55
P9 WP Normal --- --- 900 55
Piping Material Type: HDPE P Number: NA Hardness Requirements: NA

Pipe Class
P1 63-1000 PN16 BF 10 None --- --- --- 100
P1W 63-200 40S BF 10 None --- --- --- 100
P2 25-500 SDR11 BF 10 None --- --- --- 100
P3 63-800 SDR17 BF 10 None --- --- --- 100
P5 50-630 SDR41 BF 10 None --- --- --- 100
P7 110-800 SDR17 BF 10 None --- --- --- 100
P8 110-355 CL250 BF 10 None --- --- --- 100
P9 63-400 PN20 BF 10 None --- --- --- 100
Notes:
25875-000-GPP-GCX-00029
Attachment A
1. SUBMITTAL OF PROCEDURES
1.1 Subcontract Fabrication Supplier’s procedures for fabrication, examination, and testing shall be
submitted to the Buyer for review and acceptance.
As a minimum, the following Subcontract Supplier procedures shall be submitted:
 Welding Procedures, comprising Welding Procedure Specifications (WPS’s) associated
Procedure Qualification Records (PQR’s), as well as any associated general welding procedure
documents.
 Post Weld Heat Treatment (PWHT) and other heat treatments (see paragraph 3.0)
 Control, issue, and storage of welding consumable procedures (see paragraph 4.0 )
 Nondestructive Examination (NDE) procedures (see paragraph 2.0)
 The “Supplier” completed “Form 167”
 Positive Material Identification (PMI) .
 Hardness testing procedure
1.2 Subcontract and Field suppliers are responsible for transmitting relevant and applicable Project
Specifications to each of their Sub-suppliers, prior to start of the Sub-suppliers’ work.
The Supplier is also responsible for submittal of Sub-supplier procedures (including NDE,
welding procedures, weld procedure application information and/or weld/NDE maps) to the
Buyer. Submittal requirements stated in clause 3.3 shall be transmitted by the supplier to its sub-
suppliers. Supplier shall review Sub-suppliers’ procedures verifying that Code and project
specification requirements have been met. Supplier shall then submit the sub-supplier procedures
to the Buyer for review and acceptance.
1.3 A review status of "Work May Proceed" must be obtained for each submitted procedure, prior to
its use or implementation.
1.4 The Buyer issued Form 167 identifies piping classes or suppliers’ Pipe Material Specifications,
fluid commodities, pipe diameters, wall thicknesses, applicable Code of Construction, and project
technical requirements. Buyer will supply the Form 167 to the Supplier. The Form 167 shall be
completed by the Supplier, and then returned to the Buyer to allow verification of qualification
thickness and suitability for use. Application of a weld procedure to pipe joint(s) may be
referenced by means of typical pipe spool drawings and/or Weld Procedure Application Lists.
These drawings/documents shall be referenced in the Form 167, and submitted at the same time as
the Form 167.
Confidential
Confidential © 2016 Joint Venture between International Bechtel Co. Ltd (Abu Dhabi Branch) and Petrofac Emirates L.L.C. (BPJV). This
document, prepared under Contract EGA/SH-EPCM/27-016 between BPJV and Emirates Global Aluminium PJSC (EGA), contains information
confidential and/or proprietary to BPJV that is not to be used, disclosed, or reproduced in any form by any person or entity other than BPJV or
EGA without BPJV’s prior written permission. All rights reserved.
25875-000-GPP-GCX-00029 Page 14 of 18
Form 167 is also a tool used to consolidate and communicate Buyer’s Welding, Heat Treatment,
and NDE requirements for the Project Pipe Classes or suppliers’ Pipe Material Specifications.
However, the Form 167 is not a design document and does not relieve the Supplier/fabricator of
the responsibility to follow the requirements of the Purchase Order. As with other Purchase Order
documents, real or perceived conflicts shall be brought to the Buyer’s attention for written
resolution.
2.0 SUBMITTAL OF WELDING PROCEDURES
2.1 WPS/PQR’s, NDE procedures, or fabrication procedures SHALL NOT be submitted as a group or
booklet with a single cover sheet. NOTE: Each single WPS shall have the associated PQR(s)
submitted with it as a single package.
After the individual Supplier procedures have been accepted by the Buyer, the accepted WPS/PQR
submittals, NDE procedures, or fabrication procedures may be assembled in booklet form for
submittal as part of the Final Document Package/Manufacturer’s Record Book/Vessel Dossier.
2.2 Submitted weld procedures shall be qualified in accordance with the requirements of the
applicable Code of Construction, ASME Section IX, additional requirements stated in the Form
167, or by other purchase documents. Procedure Qualification Records (PQR’s) shall be submitted
with the Welding Procedure Specifications (WPS’s) and the completed Form 167 to the Buyer for
review and comment. WPS(s) will NOT be reviewed without a corresponding review of the
supporting PQR(s) and application data (Form 167 and supplementary information).
Individual Welder/Welding Operator Performance Qualifications (WPQ’s) will be verified by the
Buyer’s representative at the Supplier’s work location and SHALL NOT be submitted through the
Buyer’s Document Management System, unless specifically stated otherwise in the Purchase
Order.
2.3 It is not the Buyer's intent to require revisions to Supplier's qualified WPS’s to meet the additional
requirements of this Specification. However, amendments or addenda to their standard qualified
WPS's shall be issued to satisfy the project requirements. Amendments or addenda shall become
part of the WPS for the Purchase Order, and the additional or modified requirements shall be
communicated to the welders employed in the work.
2.4 At the Buyer’s option, new welding procedure qualification(s) required for execution of this
Purchase Order may be witnessed by the Buyer’s representative(s). During the Supplier’s
engineering work, the Supplier shall identify procedures that will require qualification or re-
qualification for this Purchase Order. Adequate notice, prior to beginning actual welding
procedure qualification, shall be provided to the Buyer to allow the Buyer sufficient time to make
reasonable travel arrangements.
2.5 For repair of weld metal defects discovered during final NDE, either the original WPS or one
specifically submitted and accepted by the Buyer that is qualified to make the repair shall be used.
25875-000-GPP-GCX-00029
3.0 SUBMITTAL OF NONDESTRUCTIVE EXAMINATION PROCEDURES
3.1 NDE procedures shall be submitted to Buyer for review and permission to proceed.
3.1.1 Employers written practice shall be submitted to Buyer for review and permission to proceed.
3.1.2 Minimum requirements to be addressed in the NDE procedures shall be those specified in the
applicable Article in ASME Section V. Article 1 is mandatory for all methods.
3.1.3 UT in lieu of RT is prohibited.
3.1.4 The following additional variables shall be documented:
 Scope - type of material or weld, type of component, area(s) to be examined, amount (100%,
entire surface, etc.)
 Surface preparation applied prior to examination (grit blasting, grinding, brushing, solvent
cleaning, etc.).
 Point in time/Fabrication Stage when performed (e.g. after welding, after repair, after PWHT,
after machining, after leak testing).
 Acceptance criteria - criteria shall be contained within the procedure by incorporation,
reference to applicable code is unacceptable.
 Reporting Format – A blank copy of the NDE report form shall be included as part of the
procedure.
 Minimum personnel qualifications/certifications of personnel performing/interpreting NDE
examinations. Personnel who interpret and report NDE shall be Certified Level II ASNT
SNT-TC-1A (2006) minimum.
3.1.5 Examination and inspection reports, including radiographic film, shall be available to Buyer's
representative(s) at all times. The examination(s) and results shall be documented and submitted as
part of the Final Data Package.
3.1.6 NDE procedures shall meet the requirements of ASME Section V, Article 1, the
acceptance/rejection criteria of the applicable Code of Construction, and the requirements in
Section 14.0 of this specification. NDE procedures shall be submitted to Buyer for review and
acceptance prior to fabrication.
Each NDE procedure proposed shall be signed off by a responsible Supplier or NDE Sub-contractor
employee, showing a review to, and compliance with, the latest edition of the relevant Code. Each
NDE procedure shall state the specific acceptance criteria to be used, and not merely a reference to
criteria stated in another standard or Code.
3.2 NDE Methods

3.2.1 Radiographic Examination (RT) Procedure Requirements
The following RT variables, as a minimum, shall be addressed in Supplier Procedures:
 Source type (gamma, x-ray, Iridium etc.)

 Material thickness to be examined and pipe/nozzle diameter as applicable
25875-000-GPP-GCX-00029
 Maximum focal spot size
 Minimum source to film distance
 Type and thickness of intensifying screens (fluorescent screens shall not be used)
 IQI Type and pattern
 Technique (single wall, double wall, double wall single image)
 Sensitivity and film density
 Viewing conditions
 Backscatter checks
 Marking and identification of film
 Film overlap limits
 Digital RT
3.2.2 Magnetic Particle Testing (MT)

For MT examination the following additional variables, as a minimum, shall be addressed:
 Magnetizing technique (AC Yoke etc.)

 Type of equipment to be used
 Frequency of calibration of the equipment to be used
 Measurement of field strength
 Media application technique (bulb, sprayer etc.)
3.2.3 Liquid Penetrant Testing (PT)

For PT examination the following additional variables, as a minimum, shall be addressed:
 Surface cleaning and drying methodology

 Specific temperature limitations
 Specific penetrant application method(s) to be employed (spray, brush, flush etc.)
 Penetrant dwell time
 Specific method of penetrant removal (water wash, wipe, solvent, etc.)
 Specific drying method(s) (still air, forced air, heated air, blotting, etc.) to be employed
 Development time(s)
4.0 STORAGE AND CONTROL OF WELDING CONSUMABLES

Procedure for the storage and control of weld filler material shall describe in detail the following:
 Marking of containers (filler metal manufacturer’s marking, Supplier’s additional marking,
MTR marking or control marking)
 Heat and Lot Number Identification on the containers
 Marking of bare electrodes
 Receiving Inspection and disposition of damaged containers
 Description of storage area: Description of how unopened and opened containers covered
electrodes, flux, etc.)
 Identification, storage, and segregation of low-hydrogen electrodes
 Electrode oven marking to identify weld filler material classifications
 How weld filler material issuance is controlled and traceability to the fabricated items
 Moisture control of low-hydrogen electrodes and SAW flux
25875-000-GPP-GCX-00029
 Disposition of unused and returned material
 Protection of spooled wire left on the wire directed unit between and after shifts
25875-000-GPP-GCX-00029

000 GPP GCX 00029 Welding and NDT Matrix

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000 GPP GCX 00029 Welding and NDT Matrix

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Al Taweelah Alumina

WELDING & NDE MATRIX – Project Form 167

Piping Material Type: Carbon Steel P Number: 1 Hardness Requirements: NA

Fillet, attachments, & seal

Piping Material Type: Stainless Steel (316L) P Number: 8 Hardness Requirements: NA

F3 15 - 40 3.68 SW 10 None --- --- --- 100 Note 1

Piping Material Type: Carbon Steel (Caustic) P Number: 1 Hardness Requirements: NA

Fillet, attachments, & seal

Piping Material Type: Carbon Steel P Number: 1 Hardness Requirements: NA

Fillet, attachments, & seal

Piping Material Type: Carbon Steel P Number: 1 Hardness Requirements: NA

Fillet, attachments, & seal

Piping Material Type: Carbon Steel P Number: 1 Hardness Requirements: NA

Fillet, attachments, & seal

Piping Material Type: Carbon Steel P Number: 1 Hardness Requirements: NA

Fillet, attachments, & seal

Piping Material Type: HDPE P Number: NA Hardness Requirements: NA

3.2 NDE Methods

The following RT variables, as a minimum, shall be addressed in Supplier Procedures:

 Source type (gamma, x-ray, Iridium etc.)

3.2.2 Magnetic Particle Testing (MT)

 Magnetizing technique (AC Yoke etc.)

3.2.3 Liquid Penetrant Testing (PT)

 Surface cleaning and drying methodology

4.0 STORAGE AND CONTROL OF WELDING CONSUMABLES

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