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Gis 43-331
Gis 43-331
GIS 43-331
Applicability Group
Date 21 April 2006
GIS 43-331
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GIS 43-331. This Guidance on
Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as
follows:
British Petroleum
GS 118-9 Welding of Transmission Pipelines (Supplementary to API 1104).
GS 118-10 Welding of Transmission Pipelines (Supplementary to BS 4515).
AMOCO
A PN-OFS-WLD-C Piping—Offshore—Welding Pipelines—Construction.
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Copyright © 2006, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of the Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
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Table of Contents
Page
Foreword............................................................................................................................................2
Introduction ........................................................................................................................................3
1 General .....................................................................................................................................3
1.1 Scope ............................................................................................................................3
1.2 Welding process restrictions..........................................................................................3
1.3 HSSE for pipeline welding operations ...........................................................................3
1.4 Pre-production consultation...........................................................................................3
1.5 General duties of the contractor ....................................................................................3
1.6 Quality assurance..........................................................................................................3
1.7 Records .........................................................................................................................3
1.8 Contractor’s personnel ..................................................................................................3
1.9 Abbreviations and acronyms .........................................................................................3
2 Referenced publications ...........................................................................................................3
3 Definitions of terms ...................................................................................................................3
3.2 Definitions......................................................................................................................3
4 Specifications............................................................................................................................3
4.1 Equipment .....................................................................................................................3
4.2 Materials ........................................................................................................................3
4.3 Minimum design temperature (MDT) .............................................................................3
5 Qualification of welding procedures for welds containing filler-metal additives ........................3
5.1 Procedure qualification ..................................................................................................3
5.2 Record ...........................................................................................................................3
5.3 Procedure specification .................................................................................................3
5.4 Essential variables.........................................................................................................3
5.5 Welding of test joint—butt welds ...................................................................................3
5.6 Testing of welded joints—butt welds .............................................................................3
5.7 Welding of test joints—fillet welds .................................................................................3
5.8 Testing of welded joints—fillet welds .............................................................................3
6 Qualification of welders.............................................................................................................3
6.1 General..........................................................................................................................3
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6.2
6.3
6.4
6.6
Single qualification.........................................................................................................3
Multiple qualification ......................................................................................................3
Visual examination ........................................................................................................3
Radiography—butt welds only.......................................................................................3
7 Design and preparation of a joint for production welding..........................................................3
7.1 General..........................................................................................................................3
7.2 Alignment.......................................................................................................................3
7.3 Use of line-up clamp for butt welds ...............................................................................3
7.4 Bevel..............................................................................................................................3
7.5 Weather conditions........................................................................................................3
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Appendix B – In-service welding........................................................................................................3
B.1
C.1
General..........................................................................................................................3
Appendix C – Additional requirements for pipelines subject to high strain levels ..............................3
Introduction....................................................................................................................3
C.2 General..........................................................................................................................3
C.3 Weld procedure qualification testing..............................................................................3
C.4 Production welding ........................................................................................................3
Appendix D—CTOD testing ...............................................................................................................3
Appendix E—Pin brazing and aluminothermic welding of anode leads .............................................3
E.1 Joining technique...........................................................................................................3
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List of Tables
List of Figures
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Guidance on Industry Standard for API 1104 Pipeline Welding
Introduction
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1 General
1.1 Scope
Add
The scope includes the off-line fabrication of items such as welding nipples to valve bodies or
other fittings and the fabrication welding of branches. The following items are outside the scope
of this GIS:
- Corrosion resistant alloy (CRA) clad linepipe
- Solid CRA linepipe
- The welding of process piping in terminals, pump or compressor stations, or in refineries
- Hyperbaric welding
- Wet welding
- Overlay welding
- Steel catenary risers (SCRs)
Additional requirements for high strain pipelines are given in Appendix C.
Requirements for pin brazing and aluminothermic welding of anode leads are given in
Appendix E
Add
1.3
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Radiography operations shall conform to local regulations regarding the dangers of ionizing
radiation, e.g. in the UK radiography should be undertaken in accordance with the Ionising
Radiation Regulations 1999 (SI 1999 No. 3232) and The Approved Code of Practice and
Guidance – Working with Ionising Radiation: Ionising Regulations 1999.
Environmental guidance shall be taken from EN 14717 when undertaking welding and its
associated processes.
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1.7
fabrication.
Records
Documentation shall be collated, indexed, stored safely, and presented to BP.
A log identifying, by number, each pipe or fitting and identifying the weld numbers joining
them to other items, shall be compiled. Each circumferential weld (whether a field joint or shop-
made weld) shall be allocated a unique number, which shall be used for reference to the weld in
reports, radiographs, and test documents.
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-
-
BGAS-CSWIP (TWI, UK) – Welding Inspector
PCN (BINDT, UK) – Weld Inspection Level 2
AWS QC1 (1996 or later edition) – Certified Welding Inspector (CWI)
Alternative Welding Inspector certification is unacceptable unless approved by BP.
A Senior Welding Inspector shall be employed to coordinate and supervise the work of the
welding inspectors. The role of Senior Welding Inspector requires at least 10 years relevant
experience and sound knowledge of welding processes and their application. Formal
engineering training through apprenticeship and technical college education are required.
Senior Welding Inspectors shall hold current certification to any of the following standards as a
minimum:
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BGAS-CSWIP British Gas Approval Scheme – Certification Scheme for Welding and Inspection
Personnel
CP Cathodic protection
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CRA
CSWIP
Corrosion resistant alloy
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HV Vickers hardness
ID Internal diameter
MT Magnetic testing
OD Outside diameter
PT Penetrant testing
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RT
SAW
SCR
Radiographic testing
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UT Ultrasonic testing
VT Visual testing
2 Referenced publications
Add
The following standards contain requirements that, through reference in this text, constitute
requirements of this GIS. For references below that are dated, subsequent amendments to, or
revisions of, any of these publications do not apply, although parties to agreements based on this
GIS are encouraged to investigate the possibility of applying the most recent editions of the
standards indicated below. For references below that are undated, the latest edition of the
referenced standards applies.
API
Add
Q1 Specification for Quality Programs for the Petroleum, Petrochemical and
Natural Gas Industry
ASTM
Add
A370 Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
E23 Standard Test Methods for Notched Bar Impact Testing of Metallic
Materials
E92 Standard Test Methods for Vickers Hardness of Metallic Materials
E1815 Standard Test Method for Classification of Film Systems for Industrial
Radiography
AWS
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Add
D1.1/D1.1M Steel Structural Welding Code
A4.3 Determination of Hydrogen Content Produced by Arc Welding
C5.3 Recommended Practices for Air Carbon Arc Gouging and Cutting
A5.32 Specification for Welding Shielding Gases
BSI
Add
BS 4515-1 Specification for Welding of Steel Pipelines on Land and Offshore –
Part 1: Carbon and Carbon Manganese Steel Pipelines
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BS 7448-1 Fracture mechanics toughness tests. Part 1. Method for the determination
of KIC, critical CTOD and critical J values of metallic materials
BS 7910 Guide on methods for assessing the acceptability of flaws in metallic
structures
Add
BP
GIS 43-311 Guidance on Industry Standard for Manufacture of Longitudinal or
Helical Seam Submerged Arc Welded Linepipe in Grades up to X80
GIS 43-312 Guidance on Industry Standard for Manufacture of High Frequency
Induction (HFI) or Electric Resistance Welded (ERW) Linepipe in
Grades up to X70
GIS 43-313 Guidance on Industry Standard for Manufacture of Seamless Linepipe in
Grades up to X80
GIS 43-317 Guidance on Industry Standard for Bends, Fittings, Flanges, and Wyes
GP 18-02 Guidance on Practice for the Storage and Control of Welding
Consumables
GP 43-34 Guidance on Practice for Automatic Ultrasonic Testing of Pipeline Girth
Welds
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EN 10208-2 Steel pipes for pipelines for combustible fluids. Technical delivery
conditions. Pipes of requirement class B
EN 14717 Welding and allied processes – Environmental check list
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UK regulations
SI 1999 No. 3232 Ionising Radiation Regulations 1999 Statutory Instrument 1999 No. 3232
Work with ionising radiation - Ionising Radiations Regulations 1999
Approved code of practice and guidance (UK HSE)
3 Definitions of terms
3.2 Definitions
3.2.3 Company
Modify to Read
BP plc or its authorised representative
3.2.4 Contractor
Modify to Read
A contractor responsible to BP for construction (including welding) of the pipeline
Add
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Note: Heat input requires an efficiency factor dependant on the
welding process.
3.2.22 BP
BP plc, an associate or subsidiary of BP, or other organisation as defined in the Conditions of
Contract on a project.
3.2.23 Lot
A single heat of filler wire, a single blend of flux, or for covered electrodes or cored wire, the
combination of a single heat of cored wire with a single dry blend of flux cover or core.
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4 Specifications
4.1 Equipment
Add
Welding power supply voltage and amperage meters shall be calibrated. Independent calibrated
instrumentation shall be provided to measure relevant parameters during production. NDT
equipment shall also be calibrated. Certificates showing that equipment calibration is valid for
the period of use shall be available.
The manufacturer, model and type of equipment shall be identified in the Procedure
Qualification Record (PQR).
SMAW electrode holders shall be fully insulated.
Welding return cables connections shall be of sufficient cross-sectional area to prevent
concentration of current and shall be securely attached to prevent arc burns.
4.2 Materials
Add
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(a,b)
Pipe Grade Pipe Grade Maximum Wall Thickness
(API 5L) (ISO 3183)
(EN 10208)
(CSA Z.245)
< X65 < L450 3/4” (approx 19 mm)
X70 L485 5/8” (approx 16 mm) with E8010 fill passes
3/8” (approx 10 mm) with E9010 fill passes
X80 L555 Root & hot pass only
> X80 > L555 Not permitted
a. E6010 or E6011 electrodes may be used for root pass welding provided sufficient overall weld strength and
toughness is obtained.
b. Preheat shall be applied to cellulosic welds (see 5.3.2.13 and 7.11.1).
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Add
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For low hydrogen SMAW consumables, manufacturer’s certificates shall include average-
diffusible-hydrogen level as determined and reported in accordance with ISO 3690 or
ANSI/AWS A4.3.
Certificates shall comply with BP GP 18-02 and EN 10204 type 3.1.b.
SAW wire shall be tested in combination with the same brand and classification of flux as that
to be used during production welding.
The consumable certificates shall be examined to verify that the same weld properties can be
expected for the production welds as those obtained during weld procedure testing.
Add
4.2.3.3 Compliance
Shielding gases shall meet BS EN 439 or AWS A5.32. They shall be pre-mixed and bottled by
the supplier and shall have certificates of compliance. The certificates shall show the
composition and dew point. Subject to BP approval, Ar/CO2 gases may be mixed at site.
Add
5 DO NOT COPY Unless otherwise specified in the contract, the MDT shall be 0°C (32°F).
Add
5.1.1 General
Preliminary Welding Procedure Specifications (pWPSs) shall be submitted for BP agreement
before commencement of the Welding Procedure Qualification Tests (WPQTs).
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Welding procedures, including fillet welds and repair procedures, shall be qualified by visual
examination, NDT, and mechanical testing as specified in this GIS.
Welding, NDT and mechanical testing of the WPQT welds shall be witnessed by BP or an
approved third party. The witnessing of mechanical tests shall include the positioning of the
notches for Charpy and CTOD tests.
A WPS written with more than one supporting Procedure Qualification Record (PQR) shall not
permit optional processes, but shall uniquely specify the process for each pass.
5.2 Record
Modify First Sentence to Read
The details of each procedure shall be recorded
Add
Forms used to record WPS and WPQT details shall contain the relevant information. The format
shall be subject to approval by BP.
DO NOT COPY The PQR documentation package for each WPS shall comprise:
a.
b.
c.
As-run records
NDT results
Mechanical test results and macrographs
d. Consumable certification
e. Parent material certification
The following data shall also be available if requested by the BP Welding Engineer:
f. Calibration certificates for equipment and measuring devices
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5.3.1 General
Add
The relevant BP approved WPSs shall be displayed at each work location and shall be readily
available to each welder.
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5.3.2.4 Joint design
Add
The use of permanent or consumable backing rings is not permitted. An exception is the outer
pipe welds in a pipe-in-pipe system. Non-consumable temporary backing as an integral
permanent feature on an internal clamp will be permitted subject to satisfactory demonstration
of the process.
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5.3.2.8 Position
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Add
The welding position shall be stated on the WPS and PQR documents.
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The preheat temperature shall not be lower than that recorded during WPQT welding.
The interpass temperature shall not be less than the preheat temperature and shall not exceed the
highest value recorded during WPQT. In no case shall the interpass temperature exceed 300°C
(572°F).
The preheat and interpass temperatures shall be measured in accordance with 7.11.1.
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If any form of post-weld heat treatment or delayed cooling of the weld is to be used, it shall be
specified in the WPS.
If the weld is to be cooled rapidly to allow immediate AUT, then this shall be simulated during
WPQT. Assisted cooling shall not commence until the weld temperature has cooled without
interference to below 400°C (750ºF).
Add
5.4.1 General
Add
An approval of a WPS obtained by a contractor is valid in workshops or sites of that contractor
under identical or equivalent technical and quality control. The validity shall be subject to the
approval of the BP Welding Engineer. Welding procedures shall not be transferred from one
contractor or sub-contractor to another without requalification.
Add
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Removal of a line-up clamp at an earlier stage than qualified in the WPQT constitutes an
essential variable.
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5.4.2.4 Position
Add
A change of welding position shall constitute an essential variable. Welding positions 5G and
2G shall be qualified separately. 6G qualification shall be required if the angle of the pipe is
between 25° and 65° to the horizontal.
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5.4.2.8
g.
h.
Diameter of electrodes or welding wires
For semi-automatic and mechanised (automatic) welding, the welding unit, power supply
type, manufacturer, model number and software version number
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5.4.2.13 Preheat
Add
Any change in the preheat application method shall constitute an essential variable.
Add
Add
DO NOT COPY If an internal line-up clamp will be used in production welding, the length of the nipples used in
the WPQT shall be sufficient to accommodate the full length of the clamp. The minimum length
of any nipple piece used during qualification should be 1 m (3.3 ft) or 1.5 pipe diameters
whichever is the greater.
The minimum length of test rings for the WPQT of fittings and flanges shall be subject to
agreement with BP.
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5.6.1 Preparation
Add
Reference Figure 3 and Table 2, in accordance with this GIS
The blanks from which the mechanical test pieces are machined may be cut from the
qualification weld using oxy-fuel gas cutting, but its dimensions shall be sufficient to allow the
material of the final machined test piece to remain unaffected by the heat from the cutting
operation.
Test specimens shall not be subjected to any elevated temperature degassing treatment.
Add
Table D - Specified minimum delay time before NDT for WPQT welds
WPQT Welds in API/ISO Pipe Grades Welding Process Minimum Delay Before NDT
< API X70 / ISO L485 Any process except cellulosic SMAW 24 hours
a
< API X70 / ISO L485 Cellulosic SMAW 48 hours
> API X70 / ISO L485 Any welding process 72 hours
a
Welds made with cellulosic root/hot pass only may be inspected after 24 hours.
Acceptance by BP shall be required before sectioning of WPQT welds for mechanical testing.
The NDT procedures for WPQT welds shall be qualified and subject to approval by BP.
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position around the weld where spare material is available, but the exact locations should be
agreed in each instance with the BP Welding Engineer. More than one weld may be required to
provide sufficient material for testing. Table 2 shows the type and number of test specimens
required.
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5.6.2.1 Preparation
Add
Preparation of the tensile test piece shall be as per Figure 4, except that internal and external
weld reinforcement shall be removed before testing.
The position of failure shall be recorded, i.e. weld metal, HAZ or base metal.
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5 6
1 2 6 5
3 4
4
2
4 3
2 1
5
5 6
3
2 4
3 1
4 4
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2 2
1 3 Key:
1) Face or side bend
5
2) Transverse tensile
3) Root or side bend
4) Nick-break
5) Macrosection
6) Charpy V-Notch
NOTE: Test specimens not shown in Figure-3, e.g. CTOD test pieces, may be taken from any position around the weld where
spare material is available. More than one weld may be required to provide sufficient material for testing.
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Table 2 - Type and number of test specimens (a) for procedure qualification test
NOTES:
a Specimen locations shall be in accordance with 5.6 and Figure 3.
b One nick-break and one root-bend specimen shall be taken from each of two test welds, or for pipe less than or equal to 34 mm
(1.315 in) diameter, two full section tensile strength specimens shall be taken.
c If an ECA is to be used for defect acceptance levels, three all-weld metal tensile specimens shall be taken.
d. Nick breaks are not required for mechanised (automatic) welding.
e Charpy impact tests shall comprise weld metal and fusion line specimens machined from the pipe outside diameter. Pipes with
wall thickness > 20 mm shall have additional specimens machined from the ID .Additional sets of Charpy Impact specimens may
be required by the BP welding engineer, e.g. if very thick pipe is to be utilised or the combination of processes or consumables
have not been adequately sampled by the specified locations.
f CTOD tests shall comprise a minimum of one set of weld metal and two sets of HAZ samples (see paragraph D.4 of
Appendix D).
g CTOD tests are only required for pipelines with ECA based acceptance criteria or if required by the pipeline designer.
5.6.2.3 Requirements
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Add
5.6.6.1 Scope
WPQT butt welds shall be subjected to Charpy V notch impact testing.
5.6.6.2 Preparation
The test pieces shall be prepared and tested in accordance with ISO 148, EN 10045-1 and
EN 875 or ASTM A370 and E23.
A set of Charpy impacts shall comprise three specimens. Sets of Charpy specimens shall be
taken from the locations shown in Figure 3.
Specimens shall be notched with the axis of the notch perpendicular to the pipe surface. The
position of the notch for each set shall be as depicted in Figure A.
Full size specimens shall be used if possible.
5.6.6.3 Method
The impact test temperature shall be the minimum design temperature when the following
conditions apply:
- The minimum design temperature is minus 10°C (14°F) or higher
- The wall thickness is 25 mm (1 in) or lower
- The material SMYS is 555 N/mm2 (80 ksi) or lower
In addition to the above, for gas pipelines the impact test temperature shall be no higher than
minus 10°C (14°F).
Test temperatures for welds outside of the above conditions shall be advised by BP.
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A(ii) Fusion Line
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NOTES:
1 Specimens shall be positioned between 1 – 2 mm from the pipe outer surface. Additional specimens for thicknesses greater than
20 mm shall be positioned within 1 – 2 mm from the inner surface.
2 Fusion line Charpy specimens shall sample 50% weld metal and 50% HAZ.
5.6.6.4 Requirements
The Charpy impact values shall meet or exceed the values given in Table E.
For specimens below 10 mm in thickness, the energy requirement shall be reduced pro rata, e.g.
a 7.5 mm specimen shall achieve 75% of the required full size value.
The ductile shear area shall exceed 50%.
Individual samples may be replaced if there is evidence of a weld defect on the fracture surface.
Re-testing may be allowed following discussion with the BP Welding Engineer.
Test results, including percentage ductile shear area, shall be recorded.
5.6.7 Macro-section
5.6.7.1 Method
Macro-sections shall be extracted from procedure qualification test welds at three locations
approximately 90° apart. For welds containing any pass made in the 5G position, macro-
sections shall be extracted as close as practicable to the 12 o’clock, 3 o’clock and 6 o’clock
positions.
When girth welding seam-welded linepipe, an additional macro-section shall be extracted from
the girth-weld at the T-intersection region between the girth weld and seam weld.
Macro-sections shall be polished to a metallographic (1 µm) finish and etched in a 2-10% Nital
solution, or other suitable BP approved etchant. The etched specimens shall be thoroughly
examined at 10 times magnification.
Original photo-macrographs of macro-sections at approximately 3 to 5 times magnification shall
be included in the PQR documentation.
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5.6.7.2 Acceptance criteria
When examined at 10 times magnification, the macro-section shall reveal:
a.
b.
No cracks
Complete fusion between adjacent layers of weld metal and between weld metal and base
metal
c. Complete fusion at the root
d. No lack of cross penetration
e. No undercut (unless weld surfaces are to be ground smooth). If weld surfaces are to be
ground smooth, minor undercut may be removed by the surface grinding operation. If the
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undercut is of such depth that its removal would result in encroachment of the minimum
specified thickness of the pipe, it shall be deemed unacceptable.
f. No excess cap reinforcement exceeding 1.6 mm (1/16 in) above the base metal surfaces for
weld surfaces not specified to be ground smooth
g. Weld reinforcement shall blend smoothly into the adjacent base metal
h. No penetration of the root bead into the bore exceeding 3 mm (1/8 in). For pipe diameters
less than 60 mm (2-3/8 in) this penetration shall not exceed 1.5 mm (1/16 in).
i. At no point shall the weld surface, ID or OD, lie below the adjacent base metal
Any observed defects shall be within the limits given in Section 9.
5.6.8.1 Preparation
The hardness testing technique shall be the Vickers method with an applied load of 10 kg in
accordance with ISO 6507-1 or ASTM E92.
The hardness surveys shall be undertaken on each of the macro-section specimens specified in
5.6.7. For non-sour pipelines, surveys on the 12 o’clock and 6 o’clock macro-sections may be
omitted.
5.6.8.2 Method
Each survey shall consist of three rows of indents. One traverse shall be located below the cap,
one above the root (or internal surface) and one at mid-thickness. The positions are shown in
Figure B. The mid-thickness traverse may be waived for single sided welds below 12.7 mm.
The BP Welding Engineer may require additional hardness indent positions, e.g. if a
consumable type has not been sampled by the specified three traverses.
1 - 2mm
t/2
1 - 2mm
NOTES:
DO NOT COPY
1. Parent material indentations shall be at least 20 mm from the fusion line.
2. The first HAZ indentation shall be placed as close to the fusion line as possible. Further indentations into the HAZ shall
be separated by approximately 0.5 mm, however the minimum centre-to-centre separation requirement of 2.5 or 3 times
the mean diagonal of the nearest indentation shall be maintained (ref. ISO 6507-1 and ASTM E92).
3. The same survey pattern shall be applied to double-sided welds.
The macrophotographs shall show the position of each hardness indent and shall be included in
the PQR along with a tabulation or diagram showing the result and location of each indent. The
maximum and minimum values shall be identified.
5.6.8.3 Requirements
The individual hardness values shall not exceed the values given in Table F.
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The parent material hardness values shall not exceed the values permitted in the relevant
material specification.
Non-Sour
Grade Location Sour a
SMAW Cellulosic Other Processes
< X80 < L555 Inside Surface & Weld 248 275 275
Mid-Thickness HAZ 248 275 275
b
Outside Surface Weld 275 275 275
HAZ 275 325 350
> X80 > L555 To be advised
NOTES:
a Use of cellulosic electrodes is limited to the applications shown in 4.2.2.1.1
b For grade X80 (L555), outside surface weld metal hardness levels up to 300HV10 are permitted
DO NOT COPY
5.8.1 Preparation
Add
Two macro-sections shall be taken from the test weld at locations agreed with the BP Welding
Engineer. The specimens shall be prepared and examined in accordance with 5.6.7.
5.8.2 Method
Add
One of the macro-sections shall be subject to hardness testing. The test method shall be Vickers
with an applied load of 10 kg in accordance with ISO 6507-1 or ASTM E92. The survey shall
consist of two traverses with indentations as shown in Figure C.
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1 – 2 mm
A macrophotograph shall show the position of each hardness indent and shall be included in the
PQR along with a tabulation or diagram showing the result and location of each indent. The
maximum and minimum values shall be identified.
5.8.3 Requirements
Add
If the fillet weld is on the outside of the pipe wall and, therefore, not in contact with the process
fluids, then the criteria given in Table F for outside surface shall apply.
6 Qualification of welders
6.1 General
Add
Welder qualification tests shall be carried out on full diameter project pipe nipples. Test welds
shall be visually sealed at each end until at least the root bead and hot pass have been completed
around the full circumference. Testing shall be witnessed by a BP representative or a BP
approved third party inspector.
Welders shall be qualified for each welding process that they will use in production. Welders
shall complete at least 50% of the circumference for the passes they are being qualified for. For
automatic, mechanised or semi-automatic welding, each welder shall be qualified for each type,
manufacturer, and model number of the welding unit(s) and power supply to be used in
production welding or for weld repair.
Welders shall be qualified before welding on the pipeline.
A welder who has satisfactorily completed a procedure qualification test is automatically
qualified for that procedure.
DO NOT COPY Previous welder qualification tests may be accepted by BP provided they are fully documented,
supported by production records demonstrating satisfactory welder performance, and are less
than 6 months old. These tests shall have been conducted utilizing a WPS substantially the same
as that for the current work and, for automatic, mechanised or semi-automatic welding
procedures, utilizing the same type, manufacturer, and model number of welding unit and power
supply. Additionally, these tests shall have been conducted by the same fabrication contractor
and witnessed by BP, or have been conducted by a BP approved independent testing laboratory.
In addition to the practical welding test and before the commencement of production welding,
welders shall be required to attend a briefing session arranged jointly with the BP Welding
Engineer. This briefing shall detail the elements of good welding practice and the specification
requirements applicable to production welding. These requirements shall be further emphasized
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during regular tool-box sessions and each welder shall be issued a card or booklet summarising
these requirements. This card or booklet shall be available for reference at all times when
welding.
Any welder who, in the opinion of BP, is either consistently ignoring good welding practice or
specification requirements or is responsible for a high level of repairs during production shall be
removed from the work, and shall undergo a re-training programme approved by BP before a
retest may be considered.
6.2.1 General
Add
Qualification welds shall be assessed by VT and shall also be subject to RT. The agreed NDT
regime shall reflect production NDT and shall examine the full weld circumference.
Qualification of welders using GMAW (solid or cored wire) shall be by VT, RT, MUT, and
mechanical testing to include face and root bends or side bends. In the case of manual welds,
nick break tests are also required.
If the application of AUT for the inspection of production girth welds has been agreed by BP, it
may be used for assessment of the welder qualification welds in place of RT. However, the
acceptance criterion used shall be Section 9 rather than an ECA based criterion.
The position of the pipe used in the test shall determine the extent of qualification as follows:
a. Horizontal pipes shall be used to qualify for welds between pipes positioned within 25° of
the horizontal.
b. Vertical pipes shall be used to qualify for welds between pipes positioned within 25° of the
vertical.
c. Pipes at 45° to the horizontal shall be used to qualify for welds between pipes positioned at
intermediate angles between 25° and 65° to the horizontal.
6.2.2 Scope
Modify c. to Read
For SMAW, a change of electrode manufacturer and brand name
DO NOT COPY
6.6
Modify Paragraph 2 to Read
Filler wire protruding into the pipe bore shall not be permitted.
6.6.1 General
Modify to Read
RT (or AUT: see 6.2.1 above) shall be performed on the qualification welds using the same RT
(AUT) procedure as to be used in production.
Testing procedures and acceptance criteria shall be subject to approval by BP.
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7.1 General
Add
Any protective coating on the end bevel shall be removed before welding by a BP approved
method.
Before welding, the pipe end shall be cleaned inside and out using power driven wire brushes,
grinders or other method approved by BP, for a minimum distance of 40 mm (1½ in) from the
edge of the weld bevel.
If AUT is to be used, a reference line at a specified distance from the root face shall be scribed
onto the pipe surface to allow the AUT equipment to identify the exact location of the root bead.
Arc burns outside of the weld groove shall not be permitted. Remedial action on arc burns shall
be in accordance with 10.6.
Attachment of welding return cables by welding shall not be permitted. Arc burns caused by a
faulty attachment shall be removed in accordance with 10.6.
Repair of the pipe body by welding shall not be permitted.
Add
7.2 Alignment
Modify to Read
Pipe ends shall be aligned by rotating pipes, avoiding pipe end bevel damage, thereby achieving
accurate fit up for welding.
The misalignment between the internal surfaces shall not exceed the lesser of 3.0 mm (1/8 in.)
or 1% of the pipe internal diameter at any point.
The longitudinal (or spiral) weld ends shall be separated, at the circumferential weld, by 90º or a
circumferential distance of 250 mm (10 in), whichever is the smaller.
DO NOT COPY
Longitudinal welds shall lie within the top half of the pipe circumference.
If abutting pipes have the same outside diameter with different nominal bores, the smaller bore
shall be machined, ground or filed, to produce an internal taper no steeper than 1 in 4;
alternatively, a transition piece may be inserted. Internal tapering shall be subject to BP
approval if the taper will interfere with ultrasonic inspection. Internal tapering may not be used
with AUT.
Any misalignment in pipe to fitting girth weld set-ups, which exceeds 3.0 mm (1/8 in.) at any
point on the internal surface, shall be subject to corrective action agreed with BP.
Slight misalignment may be corrected using a bronze-headed or other soft-faced hammer of
mass not exceeding 5 kg (11 lb). Hammering must not impinge on the weld area.
Heat shall not be used to correct excessive misalignment.
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For some pipeline applications, e.g. pipelines subject to high strain, strain based
design pipelines, or pipelines carrying corrosive fluid streams, a more stringent
maximum limit for internal offset may need to be specified. In such instances, it is
necessary to take this into account when ordering the line pipe as more stringent
tolerances on diameter, wall thickness, and out-of-roundness need to be specified. In
the case of seamless pipes, the ends may require match boring.
7.3.1 General
Internal alignment clamps shall be used for pipe-to-pipe butt welds and shall not be released
until 100% of the root pass is completed. If access does not permit the use of an internal clamp
for pipe-to-pipe welds, e.g. on tie-in welds, an external clamp shall be used. For short pipelines
and small diameters (< 150 mm (6 in)), the use of an external clamp may be proposed for BP
approval. A welding sequence that distributes the stress as evenly as possible shall be used, e.g.
two welders working diametrically opposite each other. At least 50% of the root pass shall be
completed before the external clamp is released.
DO NOT COPY
tacks may be required for diameters greater than 300 mm (12 in).
f. Welding shall be confined to the weld preparation.
g. Tacks shall be removed by grinding as root welding progresses around the butt.
h. Tacking shall be incorporated in the WPQT if it is to be used in production.
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7.4 Bevel
Add
DO NOT COPY
If necessary, measures shall be taken, e.g. by covering the pipe ends, to prevent water or other
extraneous matter being channelled into the weld region.
7.6 Clearance
Add
Full and adequate clearance to the joint shall be provided for the welders so that the full
circumference is readily accessible without hindrance to the welding operation. This may
require staging, pipe lifting, or further excavation.
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Add
DO NOT COPY
be maintained throughout the welding of the joint.
The preheat temperature shall be measured at a minimum distance of 75 mm (3 in) from each
edge of the weld bevel at four circumferential locations, each approximately 90° apart. Preheat
temperature measurement shall be made on the heated face of the pipe after a time interval
following the removal of the heat source to allow for temperature equalisation. The time interval
shall be 1 minute per 12.7 mm (½ in) of wall thickness, e.g. 2 minutes for 25 mm (1 in) thick
material. The preheat temperature should be confirmed immediately before the commencement
of welding and around the whole joint whilst welding is taking place.
The preheat temperature shall not exceed the minimum preheat temperature given in the
approved WPS by more than 50ºC (90ºF).
Interpass temperature shall be measured on the parent material at the edge of the weld bevel
near the weld start location. The temperature shall be measured immediately before the passage
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of the arc. The maximum specified interpass temperature shall not be exceeded. Interpass
temperature checks shall be made during welding.
For continuous 1G rotated or 5G welding, interpass temperature shall be measured once per
complete revolution around the weld circumference.
Temperature indicating crayons which melt on attaining the specific temperature may be used to
check preheat and interpass temperature, but shall not be marked on weld bevels, weld beads, or
surfaces to be welded. Temperature indicating crayons or paints, which indicate temperature by
colour change, shall not be used. Alternatively, suitably attached (and calibrated) thermocouples
or calibrated contact or optical pyrometers may be used to check preheat and interpass
temperatures.
If pipe-to-pipe joints are to be left partly completed, the joint shall be wrapped in dry insulating,
heat-resisting material with a waterproof backing and shall be cooled at a slow uniform rate.
Preheat shall be re-applied and the specified temperature attained before recommencement of
welding.
Add
DO NOT COPY
allowed to cool below preheat temperature before the completion of four full circumferential
passes.
For pipe-to-pipe welds for onshore pipelines being constructed on steep gradients (> 10%), the
welds shall not be left partially completed for longer than four hours.
7.13 Branches
7.13.1 General
Procedures for cutting, joint preparation, setting up, welding and NDT shall be subject to
approval by BP.
Forged fittings shall be used for branch and other pressure containing attachments, unless
otherwise approved by BP.
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Branch welds shall be sited away from other welds on the pipeline (see 7.1.1).
The pipe area surrounding a branch weld shall be tested for laminations using UT up to a
distance of 100 mm (4 in) surrounding the projected locations of the weld toes. Any laminations
found (individual or cluster) shall not exceed a total area of 500 mm2 (3/4 in2). No lamination,
regardless of size, shall be permitted within 25 mm (1 in) of the projected weld toes.
8.1
DO NOT COPY Inspection and testing of production welds
Rights of inspection
Add
The right of inspection includes NDT undertaken by BP personnel in addition to any NDT
undertaken by the contractor. For instance, BP may choose to inspect welds by MUT.
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Add
DO NOT COPY
Inspectors shall be qualified in accordance with 1.8.2.
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9.1 General
Modify to Read
The acceptance standards defined in Section 9 shall be the minimum requirements for BP
pipelines in which RT is the primary NDT method. If the use of AUT has been approved by BP,
the requirements of Section 9 shall be augmented by an ECA to determine flaw dimensions and
acceptance levels, which shall be subject to BP approval (see Appendix A).
If unacceptable flaws occur in more than five consecutive welds, or if in the opinion of BP a
particular flaw type becomes repetitive in terms of its size and/or location, the cause of the flaws
will be investigated by the BP welding engineer. If necessary, welding shall be terminated until
the cause of unacceptable flaws has been established and satisfactorily resolved.
For off-line fabrication, e.g. risers or welding of nipples to valve bodies, the pipeline
designer may wish to specify acceptance criteria that do not permit defects such as
lack of fusion or lack of penetration, e.g. ASME B31.3 [2] Table 341.3.2 severe
cyclic conditions.
More onerous acceptance criteria than those in Section 9 may be required for
surface breaking root flaws for some pipeline duties. These acceptance criteria are
specified on a project by project basis.
Add
DO NOT COPY
9.3.7
of the radiographic image of the IC does not exceed that of the thinnest adjacent base metal.
Burn-through
Delete 9.3.7.2
Modify First Paragraph of 9.3.7.3 to Read
For all pipe diameters, a burn-through (BT) shall be considered a defect if any of the following
conditions exists:
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9.3.9 Porosity
Add
The total area, when projected radially through the weld, shall not exceed 2% of the projected
weld area in the radiograph. The area shall be the length of the weld affected by the porosity
(with a minimum length of 150 mm (6 in)) times the maximum width of the weld.
9.3.10 Cracks
Modify to Read
Any form of crack or suspected crack shall be unacceptable.
9.3.11 Undercutting
Add
The aggregate length of internal undercut (IU) exceeds 25 mm (1 in) in any continuous 300 mm
(12 in) of weld length.
Add
DO NOT COPY
Add
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10.1.1 Cracks
Modify to Read
Welds with cracks (other than small crater cracks < 4 mm (5/32 in) in length) shall be removed
from the pipeline. The welding procedure shall be suspended until the cause is identified and
remedial measures implemented to prevent further occurrence. Production welding with the
suspended WPS shall only recommence following approval from the BP Welding Engineer.
Small crater cracks shall be removed by local grinding and repaired.
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DO NOT COPY
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Table G - Type and number of test specimens for repair weld procedure qualification test
Tensile
Charpy
Strength All-Weld
Impact Macro/ CTOD
Type of Repair (Cross Metal Bend f
Tests HV10 (set of 3)b
Weld Tensileb c
(set of 3)
Tensile)
a
Single Pass 0 0 0 0 1 0
Multi Pass – d
2 1 2 5 1 2
Partial
Multi Pass – e
2 1 2 3 1 2
Full Penetration
NOTES:
a If the strength of the weld may be significantly affected (e.g. low strength repair electrode on thin wall pipe)
then transverse tensile testing shall be undertaken.
b CTOD and Weld Tensile testing shall be undertaken if the acceptance criterion is based on an ECA. One set of
CTOD specimens shall be notched in the weld metal and one in the HAZ.
c One set of Charpy impacts specimens shall be located in the repair weld metal and associated parent material
HAZ at the fusion line and fusion line +2 mm.
d For partial penetration repair welds, a further two sets of Charpy specimens shall be notched to sample the
repair weld metal and associated original weld metal HAZ at the fusion line and fusion line +2 mm.
e For welds greater than 20 mm, additional sets of weld metal and fusion line Charpys shall be located at the
outer surface for full penetration repair welds.
f The bend specimen type shall be selected in line with 5.6 based upon the thickness and diameter of the weld.
Add
DO NOT COPY
11.1.1 General
Add
Radiographic testing shall be conducted using X-ray equipment. If the use of X-ray equipment
is impracticable, Iridium 192, Ytterbium 169 or Selenium 75 may be used subject to approval
by BP; other sources of gamma rays are not permitted.
Radiographic practice shall be in accordance with this GIS and ISO 17636.
Radiographic procedures shall be qualified and approved by BP before use.
As part of the radiographic procedure qualification, test radiographs shall be produced using
each radiographic procedure. These shall be made on the welding procedure qualification welds
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or welds made with the production WPS. The full circumference of each test weld shall be
radiographed.
For radiographic procedure qualification, wire type IQIs, meeting the requirements of ISO 2504,
ASTM E747 or BP approved equivalent, shall be placed across the weld on both the source side
and the film side of the area being examined. The sensitivity level, obtained using the film side
IQI, shall be no worse than that given in Table H. The corresponding sensitivity for the source
side IQI shall be recorded. If any test radiograph shows more than one visible wire of the film
side IQI, compared to the source side IQI image, BP has the option to reject the radiographic
procedure.
The procedure test radiographs shall be submitted to BP for approval before the start of
production. New procedure test radiographs may be requested, at the discretion of BP, whenever
any change is made in operating technique, or whenever production radiographs differ
appreciably from the detail, contrast, definition or density of the qualifying radiographs.
Procedure test radiographs shall be readily available for comparison purposes in each darkroom
used for radiographic viewing.
Film type shall be ISO 11699-1 Class T2 or ASTM E1815 Class I, e.g. Agfa Structurix D5 or
Kodak Industrex T200, or finer grain (slower) film. If it is shown that exposure times would
exceed 2 minutes using X-ray equipment with this film, the use of ISO 11699-1 Class T3 or
ASTM E1815 Class II may be permitted at the discretion of BP.
Lead (Pb) intensifying screens shall be used. BP may approve the use of fluorometallic screens
as an alternative, if it can be demonstrated that test procedures and results are of a standard
acceptable to BP.
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DO NOT COPY
11.1.9
11.1.9.1
h. WPS
Film
Add
Radiographs shall be stored in an environment that will not detrimentally affect the radiographs.
Boxes shall be used to store radiographs in multiples of 25, 50, or 100 welds. The weld numbers
that apply to the stored radiographs that each box contains shall be clearly visible on each box.
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DO NOT COPY
11.4.1 General
Add
Manual ultrasonic testing shall comply with ISO 17640 or ASTM E164.
UT procedures shall be approved by BP before use.
If the use of AUT is proposed, qualification of the AUT procedures and production testing shall
comply with the requirements of BP document GP 43-34.
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Add
If mechanised or automatic processes for main line welding, tie-in welding or for multiple
jointing of pipeline sub-assemblies are proposed, the bid proposal shall include full details of
the processes to be used, the associated welding equipment, and the proposed area of
application.
For mainline welding applications, the proposal shall list the number of welding stations (root
pass to final capping pass) on a spread by spread basis and detail the equipment and number of
welders and other personnel required to operate each station. Full details of the welding shelters
shall also be provided.
A similar level of detail shall be provided for tie in welding and multiple jointing.
Mechanised (automatic) 2G or 5G welding equipment should be operated in-conjunction with
data logging facilities capable of recording the essential variables associated with the arc
including wire feed speeds and travel speeds. The equipment shall record all parameters for
each pass of every weld at a minimum rate of once per 10 degrees of angular rotation and shall
indicate the angular position of each measurement. This data shall be readily retrievable for
monitoring purposes and shall form part of the pipeline construction data package. Data logging
is mandatory if welding with either multi torch or multi wire systems and for girth welds made
in ≥ X80 grade linepipe.
Each mechanised (automatic) welding station shall be demonstrated to be fully operational
before it is employed to weld any joints that will be incorporated into the pipeline. For example,
for a spread of welding stations this demonstration may consist of two full girth welds made
consecutively, each weld being required to meet the production acceptance criteria without the
need for any repair. NDT shall utilise the agreed pipeline NDT techniques and equipment.
Internal welding equipment shall also require operational demonstration. Each of these pre-
construction welds shall be uniquely identified and reserved for possible mechanical evaluation
by BP.
This operational demonstration shall be repeated as agreed with BP, but should as a minimum
be repeated after interruptions ≥ 7 days in pipeline welding and when a welding spread is
disassembled and transferred from one section of the line to another.
The proposal shall also detail the intended level of technician support for equipment
maintenance and list the principal spares that will be available in order to maintain equipment
serviceability for the duration of the pipelay.
The proposal shall also advise if a manual welding procedure is to be qualified for production or
repair welding.
DO NOT COPY
12.3
Modify to Read
The requirements for the qualification and testing of procedures for mechanised (automatic)
welding shall be as per Section 5.
Record
Add
Additional requirements for mechanised (automatic) welding have been incorporated in
Section 5.
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Delete
Add
The use of alternative acceptance standards for girth welds shall be subject to BP approval
before contract award. The ECA method and testing shall be proposed for BP approval before
the commencement of WPQT. The ECA method may be that described in API 1104 or other
recognised codes (i.e. BS 7910, EPRG Guidelines or CSA Z662). If API 1104 is used then
consideration against plastic collapse shall also form part of the ECA.
The output of the ECA shall be used to develop the weld NDT acceptance standard. The weld
acceptance standard shall include an appropriate NDT sizing allowance (see GP 43-34) which
shall be clearly documented. In addition to the limits derived from the ECA, the following
restrictions on defect size shall apply:
• Individual defects with a height greater than 4 mm (5/32 in) (before interaction
assessment) shall not be permitted.
Defects with a height greater than 4 mm (5/32 in) are unusual and their occurrence
indicates abnormal welding. No acceptance of these defects is permitted even
though the ECA may show safe defect heights in excess of 4 mm (5/32 in).
• Irrespective of defect height, defects with a length greater than 7 times wall thickness (after
interaction assessment) shall not be permitted.
DO NOT COPY
Appendix B – In-service welding
B.1 General
Add
Welding onto in-service “live” pipelines is usually an individual operation for each application
and may only be undertaken under BP guidance. The in-service welding operation shall be
subject to detailed planning and approval by BP in each instance.
Although Appendix B gives useful guidance on this subject, the techniques employed
for welding on to in-service pipelines and the fundamental technical issues to be
addressed are different from those of new construction pipeline welding.
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Add
C.1 Introduction
This appendix applies to pipelines subject to plastic deformation during installation, e.g.
installation by reeling. High strains may also be generated in operation and the effects on the
welds should be assessed if operational strains are deemed to be significant.
When evaluating the amount of strain at the weld expected during installation, the effects of
misalignment, pipe strength variation, and coating stiffness shall be considered.
C.2 General
C.2.1 Linepipe
The requirements for materials to be used for high strain installation are more onerous than
those for conventional pipe installation. The pipeline is required to have sufficient strain
capacity to withstand multiple strain cycles, and uniform mechanical and dimensional properties
are required to prevent excessive strain localisation. The BP GISs for linepipe give additional
requirements for linepipe subject to high strain. Pipelines welded in accordance with this
appendix shall use linepipe that complies with these additional GIS linepipe requirements.
The linepipe GISs are GIS 43-311 GIS 43-312, GIS 43-313, and GIS 43-317.
DO NOT COPY
C.3
C.3.1
Weld procedure qualification testing
Simulation
The weld procedure qualification welds shall be subjected to full scale bending at the maximum
strain predicted during installation. The number of cycles shall be determined from the number
of cycles required for installation plus any contingency operations and agreed with BP. Weld
repair procedures shall be included in the full scale trial and shall be located to undergo
maximum strain.
A procedure shall be provided for BP approval detailing the test string and test method. The
following points shall be addressed:
- The type and number of welds. Each qualified WPS shall be included in the trial testpiece.
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- The length of the test string and the spacing of the welds.
- The bending frame dimensions and materials.
- The calculated maximum strain (based on the carousel & pipe diameters).
- A step-by-step description of the test.
- The proposed strain rate.
- Trial report proforma.
If a successful track record can be demonstrated using the same vessel to install pipe of similar
properties with similar welding procedures then, at BP’s discretion, the full scale trial may be
omitted. The spool base, the time between cycles, and the temperature shall be considered when
evaluating existing data.
DO NOT COPY
C.4
The testing shall be undertaken in accordance with Section 5 and the results shall meet the
requirements of Section 5; however any large deterioration of properties compared with the
unstrained specimens shall be cause for investigation.
Production welding
The maximum permitted pipe misalignment at the weld shall be 1.5 mm (1/16 in) unless larger
misalignments are demonstrated to be tolerable and are agreed by BP.
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D.1 CTOD testing shall be undertaken in accordance with BS 7448 Parts 1 & 2 by a testing
laboratory specifically approved for CTOD testing by BP.
D.2 Testing shall be based on the use of through thickness notched, single edge notched bend
(SENB) specimens (BS 7448 Part 1 paragraph 5.1) in the NP orientation, unless agreed
otherwise by BP.
D.3 Test specimens shall be notched and fatigue cracked to sample the microstructures at the weld
centre line and in the coarse grained HAZ adjacent to the fusion line.
D.4 The number of valid test results employed to determine the characteristic CTOD of the weld
metal and HAZ microstructures shall comply with BS 7910 paragraphs K.2.3 and 7.1.5.5. This
may require a greater number of CTOD specimens than listed in Table 2.
D.5 The test temperature shall be MDT unless otherwise advised.
D.6 Post test metallography shall be used to identify the initiation point and the associated
microstructure on a minimum of three HAZ specimens selected by BP. The initiation point of
all brittle events shall be identified by metallography.
D.7 Any specific requirement for the achievement of a minimum CTOD will be specified on a
project by project basis.
E.2.1 General
A procedure specification shall be submitted for BP approval.
Before qualification, the parameters and information to be recorded and shown on the final
WPS shall be proposed for BP approval. Relevant details of the test, including serial or
catalogue numbers of the components and tools used, shall be recorded. For brazing, this shall
include the electrical settings of the power supply.
The procedure should be qualified by making three consecutive test joints, in the presence of
BP, on material to be used in production. The test material should be selected by BP to represent
the upper quartile of the carbon equivalent range.
The electrical resistance of each weld should be measured and should not exceed 0.1Ω. The
DO NOT COPY mechanical strength of the weld should be tested by means of a sharp blow from a 1 kg (2.2 lb)
hammer.
The test welds should be sectioned and prepared for metallographic examination. The following
tests should be performed on the sections:
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Add
Bibliography
DO NOT COPY
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