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GENERAL SPECIFICATION FOR WELDING

AND WELD INSPECTION
PROJECT : DEVELOPMENT OF WO-16 CLUSTER AND
SB-14 WELLHEAD PLATFORMS PROJECT
(TENDER-1)

OWNER : OIL & NATURAL GAS CORPORATION

CONSULTANT : ENGINEERS INDIA LIMITED

JOB NO. : A108

1 28.01.11 Revised and issued for bid

0 05.01.2011 Issued for bid

Rev. Prepared Checked Approved
Date Purpose
No by by by

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CONTENTS

CLAUSE TITLE PAGE NO.

1.0 SCOPE 3

2.0 CODES AND STANDARDS 3

3.0 WELDING PROCESSES 3

4.0 MATERIAL 3

5.0 QUALIFICATION 4

6.0 WELDING PRACTICES AND REQUIREMENTS 6

7.0 INSPECTION AND TESTING OF WELDS 14

8.0 REPAIR DEFECTS 19

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1.0 SCOPE

This specification modifies and/or supplements the referenced codes, which

apply to all piping, pressure vessels, skid, and structural welding. These
requirements cover welding done at Supplier’s fabrication plants,
Contractor’s yards, or field installations, either onshore or offshore.

The company shall review the adequacy of all welding procedures to assure
compatibility with the accepted offshore structural fabrication practices and
the service requirements. The company reserves the right to reject all such
procedures which, in its opinion, conflicts with sound fabrication practices or
pose a hazard to good service performance.

2.0 CODES AND STANDARDS

The following codes and standards shall be the minimum acceptable

standards for welding and inspection. The latest editions, addenda, and
supplements available at the time of bidding will be used. Any part of any
other non-listed code referred to in these listed codes as augmentation is to
be considered applicable.

Structural

- AWS Code D1.1.

- ASTM E 94
- ASTM E 142.
- ASME BPV Code
Sections V, VIII and IX
- API RP 2X

Pressure Vessels

- ASME BPV Code

Section VIII-division I, Section IX, Section V

Piping on Platforms or Skid Mounted Assemblies

- ANSI B 31.3.

3.0 WELDING PROCESSES

3.1 All welding required in the fabrication of the offshore structures and on the
deck shall be carried out by low-hydrogen processes.

3.2 In general, Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding
(FCAW), Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding
(GMAW) and Submerged Arc Welding (SAW) are acceptable in the
fabrication of structure, vessels, and piping coming under the scope of this
specification.

4.0 MATERIAL

4.1 Welding Consumables

a) All welding consumables will be suitable for the position and for the
conditions of its intended use and be suitable for use with the
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particular base metal to which they are applied and shall be bought
from reputed approved manufacturer. All welding consumables like
welding electrodes, filler wires and fluxes shall be individually
approved by the Company.

b) All electrodes and filler wires shall be bought in hermetically sealed

containers and stored in suitably heated humidity controlled storage
ovens until issued for use. Temperature of storage shall be to
manufacturer’s recommendations. After removal from storage ovens,
the electrodes shall be transferred to portable holding ovens kept at
about 100°C and shall be drawn one at a time for immediate use.
These materials shall be identifiable by means of their original colour
coding (or factory labelling, in the case of wire) until the time of use.

c) If Submerged Arc Welding (SAW) is utilized, the flux shall be the

neutral type. It shall be kept on humidity controlled storage and used
in accordance with the manufacturer’s recommendations regarding
the temperature and humidity limitations. Flux shall be screened and
filtered before re-use. The wire flux combinations used in SAW shall
be specifically approved by the Company.

d) Electrodes and filler wire showing signs of damages or deterioration

shall not be used.

4.2 Inspection of Welding Materials

a) All welding materials furnished by the Contractor shall be subject to

inspection and test at the site by the Company. Inspection and tests
of materials will be conducted without expense to Contractor only
when such inspections and/or tests are in addition to those required
by these specifications.

b) Inspection at the mill, shop, and/or fabricating sites will not relieve
the Contractor of the responsibility of furnishing welding materials
satisfactory to the specification requirements. In the event that these
materials do not perform on site to the requirements of these
specifications Company reserves the right to reject such materials at
any time.

5.0 QUALIFICATION

5.1 Welding Inspectors

Irrespective of any stipulations in the Codes, the Company’s inspectors shall

be the Qualified Welding Inspectors for the contract resulting from these bid
documents.

5.2 Procedures

a) Prior to commencing welding work, Contractor shall submit the

proposed welding procedures, including the repair welding procedure
specification, for the Company’s approval, in accordance with ASME
section IX. Test results of procedures previously qualified should be
submitted and if satisfactory will form the basis for approval of these
procedures without further testing.

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b) Any procedures not previously qualified, and any pre-qualified

procedure whose test results are not satisfactory, shall be qualified
as required by the particular code applicable to the work for which
the fabrication or assembly of structural members will have these
requirements for qualification in addition to the requirements of AWS
D1.1. “Structural Welding Code” and ASME section IX.

1. Impact Testing

If AWS standard and code do not require minimum Charpy V-Notch

impact properties for the electrodes and fluxes,that are to be used for
procedure qualification, then Charpy V-Notch test specimens shall
be obtained and tested according to ASTM A 370 and ASTM E 23.
The as-deposited weld metal is required to have a minimum impact
energy value of 27 Joules or 2.75 kgm. (20 ft–lb) at -18°C (0°F) for
welds in tubular joints and other key points.

2. Radiography

In addition to the above requirements, the welding procedure

qualification testing must include the provision for the radiography
examination, by the reputed testing agency. Radiography
examination of complete penetration groove tests welds shall be
carried out prior to the removal of impact test specimens.

3. Hardness Testing

Hardness testing shall be carried out with acceptance criteria as set

forth in DNV Rules (1977) and with procedure as given in Appendix
C.8.3.6 of DNV rules.

4. Fabrication of Welded Tubular Members (Structural)

For qualifying procedures for fabricating welded tubular members,

the transverse tensile strength of the welds shall be determined by
tests on weld specimens conforming to the requirements of ASTM A
370 “Mechanical Testing of Steel Products, Supplement II, Steel
Tubular Products”. Weld tensile test specimens shall be taken 90
degrees to the weld, with the weld at the centre as shown in Fig. 23
(tensile test specimen) of ASTM A 370. The bend test specimen as
shown in Fig. 31(a) of ASTM A 370 shall withstand being bent 180
degrees in the jig and for guided bend test, substantially in
accordance with Fig. 32 of ASTM A 370. A bend specimen shall be
considered acceptable if no crack or other open defect exceeding 3
mm (1/8 inch) measured in any direction is present in the weld metal
or between the weld and base metal after bending. The position and
number of test specimens shall be subject to the approval by the
Company or its representative.

5. Stress Relieving

Contractors desire to use ultrasonic or other mechanical stress

relieving arrangement, they shall completely define their method of
application in the welding procedures submitted. This definition will
be complete with proof of the effectiveness of the arrangement and
its effect on weldments produced during its usage.
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5.3 Welders and Welding Operators

a) Welders and Welding Operators must be qualified as required by the

ASME section IX or any other code covering the work they are to
perform, by passing a Welder/operator qualification test. This
qualification shall be at the Contractor’s expense.

b) Prior to commencement of work, Contractor must submit records of

welder/operator qualifications to the Company. If the work turned out
by a welder or welding operator shows repetitive defects, Company
reserves the right to ask for the retesting of the welder or welding
operator at any time. The decision of the Company regarding the
qualification and requirement of qualification of the welder shall be
final. Retesting of the welder shall be at Contractor’s expense.
Qualification based on solely radiography shall not be permitted
unless specifically permitted by the Company’s representative in
exceptional cases.

c) All welders shall be qualified for the type of weldment and grade of
steel they are employed to weld. Welders qualified to weld only part
of materials utilized shall be restricted to welding on only that portion
of the work for which they are qualified.

d) All welders working on the project shall wear identification cards

made at Contractor’s cost, which shall contain the photograph and
name of the welder, procedure qualified and Company’s or
representative’s signature.

6.0 WELDING PRACTICES AND REQUIREMENTS

6.1 Pressure Vessels

6.1.1 Welding

i) Only welders and procedures qualified as per ASME section IX shall

be used for fabrication. Qualification papers for these welders shall
be made available on request.

ii) Non-consumable backing rings shall be used only with Company’s

approval.

iii) Temporary attachment welds shall be removed. The affected surface

shall be restored by adding weld metal.

6.1.2 Heat Treatment

i) Minimum preheat temperature for thermal cutting, welding and tack

welding shall be as specified in ASME section VIII, division 1,
appendix R except as follows:

a) Materials in the P-1 group shall be preheated to 80°C (175°F)

and maintained during welding when (i) under a high degree of
restraint (such as closely spaced nozzles), or (ii) when any one
of the following conditions exist :

i) The specified carbon content is 0.25% or more.

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ii) Minimum specified tensile strength exceeds 60 Ksi

(414 Mpa).

iii) Metal thickness at the joint exceeds 25 mm (1.0 inch).

b) All other P-1 group materials, other than those included above,
shall be preheated to maintain a minimum temperature of 10°C
(50°F).

ii) All welding including internal and external structural attachments

shall be completed prior to Post Weld Heat Treatment (PWHT).

iii) P-1 group materials requiring PWHT heat treatment, which contain
lining or internals of non-stabilized austenitic stainless steels such as
AISI type 304, 316 shall be heat treated at 510° ± 10°C (950°F ±
50°F) for a period of 10 hours per 25 mm (1.0 inch) of thickness.

iv) Machined surfaces shall be protected against scaling during heat

treatment.

v) Cold-formed dished ends i.e. formed below the normalization

temperature range shall be stress relieved.

6.1.3 Cleaning

i) Prior to testing, vessels shall be cleaned of all weld spatter, loose

scale and foreign matter. Liquid used for testing shall be completely
drained.

ii) Vessels of thickness greater than 20 mm (0.75 inch) shall be cleaned

externally by the No.6 “Commercial blast, SSPC-SP 6-63”, to ensure
freedom from embedded foreign matter. Any defects discovered shall
be repaired.

6.2 Piping and Pipelines

a) No chill rings or backup rings are to be used.

b) All welds shall be allowed to air cool to a temperature of not over
52°C (125°F) prior to being placed in the water and to a temperature
below 204°C (400°F) prior to pipe tensioning.

6.3 Structural Welding

6.3.1 General

a) All structural welding shall conform to the Company approved

welding procedures. The Contractor shall post copies of the
procedures in a conspicuous location in each fabrication area and
shall provide adequate supervision to ensure strict adherence to the
qualified procedures.

b) All member intersections including those between floor grating or

deck plate and its supporting structural members shall be seal
welded in all areas where strength welds are not required. Steel
doubler plates shall be completely seal welded.
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c) Preheating of the base metal prior to welding shall be in accordance

with the AWS D1.1 “Structural Welding Code” for those materials not
having been heat treated during their manufacture for the purpose of
increased strength or notch ductility. Such heating should be
accomplished by devices that produce uniform heating of all the
critical zones around the entire welded zone, such as resistance
heating flexible pads. When materials intended for joining by welding
have been heat treated in manufacture, Contractor shall strictly
adhere to heating requirements to the qualified welding procedures
pertinent to the specific type of material used and to their thickness.

d) It is extremely important that the finished structure be as free from

distortion as possible. The Contractor shall be responsible for
preventing or for correcting distortion and maintaining perfect
alignment as per the detailed approved drawings. The Company will
have the right to stop the work should excessive distortion become
evident. Stiffener plate edges and bevels shall be ground smooth
prior to installation.

e) Welders shall be supplied Tempil sticks–Thermal Crayons or contact

thermocouple instruments, so that welders and inspectors can
accurately check and control the preheat temperatures at the
weldments.

f) Circumferential butt welds joining pipes of the same diameter shall

be welded by the automatic submerged arc process wherever
possible. If the joint preparation is such that welding is done from
both sides of the welding groove, the inside weld shall be deposited
first excepting the case of clad pipes. The depth of the weld
deposited from the inside shall not constitute more than 1/3 of the
thickness of the members being joined. The backside of the first pass
of the inside welding shall be gouged, ground, or chipped to clean
weld metal before deposition of any of the outside weld metal. The
inside weld may be deposited by the manual arc-welding process if
desired.

g) Butt welds in jacket legs, piles, braces and conductor pipes shall be
background and re-welded from both sides. Welding backup rings
shall not be used for butt-welded joints of structural tubular members.
In joints where welding is possible from only one side, the members
shall be carefully contour fitted and bevelled to achieve complete
weld penetration.

h) If pipe contains longitudinal weld seams, the longitudinal seams shall

be staggered a minimum of 90 degrees at the circumferential butt-
weld joints. Longitudinal seams shall not be placed within 50 mm.
(2.0 inch) of any point on the intersection seams between members
at tubular joints.

i) Grooves shall be beveled to give an included angle of 60°. The

groove shall be of single-`V’ or double-`V’ type root openings shall be
not less than 1.5 mm (1/16 inch) and not greater than 3.2 mm (1/8
inch). Root face shall not be greater than 1.5 mm (1/16 inch).

j) The covered electrodes for manual welding shall only be used in the
positions recommended by the manufacturer. The Submerged Arc
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Welding shall be done in a flat position. If Submerged Arc Welding is

required on tubular, the tube shall be rotated. A multiple pass
technique shall be used.

k) No fit-ups and associated joint intersection placement operation for

major structural joints, especially tubular ones, shall be permitted to
occur before one hour after sunrise and after one hour before
sunset, unless otherwise specially authorized by company. All such
joining operations, to include placement of at least the root pass weld
can occur at night, provided the operating conditions and preheats
are satisfactory to the Company.

l) All fitted members shall conform to the straightness and alignment

specified in the bid specification and approved drawings. Correction
of improperly fitted parts shall be accomplished by disassembly and
refitting. Thermal straightening shall not be permitted unless
specifically approved in writing by the company as an exception.

6.3.2 Structural Plates, Shapes, and Stiffeners

a) All welded fabrication involving structural shapes and/or plates shall be

joined in the manner designated on the drawings and may require
shop drawings. Weld sizes and notes on drawings shall be strictly
adhered to, or if not specified shall joint section in such a manner as to
develop not less than the net area of the sections joined. Where full
penetration welds are specified, the backside of the first pass of
welding on double butt welds shall be gauged and ground smooth to
sound metal before depositing weld metal to the opposite side.
Company shall have the right to non-destructively test the root of this
weld before deposition of weld filler metal. Where welding can only be
done from one side, the joining member shall be prepared with proper
angle of bevel and shall not contain a root face.

b) Where strength welds are required by the drawings, or otherwise, to

extend only partially around a member of plate joint, a 6.0 mm (1/4
inch) fillet seal weld shall be deposited continuously throughout the
remaining distance around the member or plate. Company places
special emphasis on the complete seal welding of all intersections
(where there is no strength welds) between steel members. Special
attention shall be taken for the beam-to-deck plate and the beam-to-
beam intersections on the superstructure.

c) Sections of beams with the same cross section may be splice welded
in the interest of material economy. The number of splices welds and
their locations, with respect to beam-ends, shall be dictated by the
design function of the beam(s) under consideration. Generally, in
cantilever beams, there shall be no splice weld located closer to the
point of support than one-half of the cantilevered length. For beams
employed in any span between supports, there shall be no splice weld
in the center one-fourth of the span distance and in one-eighth
segment of the beam nearest any support. No two splice welds shall
be located closer together than two times the beam depth, or a
minimum of three feet whichever is smaller.

d) Joints between deck plate and bar grating sections shall be fully
strength welded.
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e) Stiffeners shall be accurately located and neatly fitted between the

flanges of the beam or the girders when full surface contact is
required. The ends of stiffeners shall be milled or smoothly ground to
conform to the geometry of the member to which it is being attached,
or beveled in such a manner as to assure 100 percent fusion in the
root of the attachment weld, as dictated by the drawings, and/or by the
Company or its representative.

f) When members are slotted to receive gusset plates, the slot must be
300 mm (12 inches) or 12 times the member wall thickness, whichever
is greater, from any circumferential weld. The slotted member shall be
drilled at the end of slot with a drill diameter at least 3 mm (1/8 inch)
greater than the width of the slot. Where a gusset plate passes through
a slot, the edge of the gusset plate shall be ground to an approximately
half round shape to provide better fit-up and welding conditions. Slots
shall be at least 12 inches away from longitudinal seam welds.

6.3.3 Finishing of Surfaces

a) The completed structures shall be free of all scars, grooves, random

arc striker, burrs, and any other imperfections introduced by handling,
scaffolding, lugs, dogs, or other welding aids. Fillet welds attaching
lugs, dogs, scaffold supports or other temporary attachments shall be
so located that their removal can be accomplished without the removal
of parent metal. These attachments must be removed by cutting with
a flame torch, then by power grinding them to the original plate
surface. Removal of these attachments by arc gouging will not be
allowed. Repair welds shall not be less than 50 mm. (2 inch) in length.

b) If, in the opinion of the Company’s Representative, welded joints

contain geometric irregularities contributing to stress concentrations or
notch effect, Contractor shall eliminate the condition by grinding. Over-
welding will not be permitted to correct such conditions. If additional
welding will assist in correction, it shall be done with the Company s
approval.

6.4 General Welding Requirement

a) No weld is to be cooled by quenching or by any means other than

natural convection by air.

b) No weld is to be coated before it has been inspected and accepted.

c) Welders’ identification stamping for piping and pressure vessels shall

be done using low-stress type dies. This identification on all structural
and pipeline welding shall be done by a paint marking or a tagging
system, which will avoid die stamping. The system is to be submitted
to the Company for approval.

d) Proper grounding of all welding machines is necessary to prevent

underwater corrosion damage. The welding machine should be located
on and grounded to the structure whenever possible. If this is not
possible, the welding machine should be insulated from the barge and
the vessel and an adequately sized cable should be used to ground

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the structure to the welding machine. Ground clamp connection to the

component shall be steel not brass.

e) All surfaces or joint faces to be welded shall be free of loose scale,

paint, oil or other foreign material. Cleaning shall be accomplished by
grinding, power wire brushing, or by sandblasting.

f) Components may be cut and shaped by machining, grinding, chipping,

flame or plasma-arc cutting or shearing. Mechanically guided
equipment shall be used wherever practical. Sheared edges not
subsequently fused by welding shall be trimmed by grinding or
machining to a minimum depth of 3 mm (1/8 inch) to ensure complete
removal of cracked or cold work metal. Components may generally be
flame or plasma-arc cut without preheat.

g) All plate edges or pipe wall ends to be welded shall be examined for
laminations before assembly into the structure.

h) The entire area to be welded shall be warmed before welding is started

to a minimum temperature of 21°C (72°F). Preheat and interpass
temperatures shall conform to those given in AWS D1.1, or Contractor
s qualified welding procedure.

i) Welding shall not be done when the quality of the completed weld
would be impaired by the prevailing weather conditions including,
without limitation airborne moisture, blowing sands, or high winds.
Windshields may be used when practical. Company Representative
shall decide if weather conditions are suitable for welding.

j) No welding shall be performed in any area when the base metal

temperature is above 260 ° C (500 ° F).

k) Arc-air gouging shall be an acceptable method for random metal

removal and back gouging only when followed by grinding to bright
metal. The temperature and weather limitations specified above for
welding shall apply to all arc-air gouging.

l) All low hydrogen flux coated electrodes shall be heated before use by
holding in a drying oven for a minimum period of 24 hours at a
temperature of 149°C minimum to 204°C (400°F) maximum, or strictly
as per the electrode manufacturers recommendations. They shall then
be stored in heating quivers at about 70°C (158°F) till use. All low
hydrogen flux coated electrodes shall be used within 4 hours after
removal from the oven. Welding materials left unnecessarily exposed
to moisture contamination shall be discarded.

m) The root (or second) side of all joints to be back welded shall be back
gouged to clean, sound metal. The back gouged weld root shall be
subject to inspection (for porosity, unfused metal and cracks) by
magnetic particle methods, until the gouging operation has been
demonstrated to be capable of consistently producing a sound weld
surface for subsequent weld passes.

n) Weld detail, for fillet weld contour and reinforcement of butt-welded

joints, shall conform to the requirements given in AWS D1.1. Full or
partial penetration groove-welded tee joints shall be contoured
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smoothly into the upstanding member by building up a filler

reinforcement in the inner corner with a minimum transition radius
equal to 1/2 the thickness of the thinner member joined, but not more
than 3/16 inches unless otherwise specified for joint strength.

o) Partial or deep penetration welding joints are not generally acceptable.

However, if such joints are unavoidable and permitted by the Company
representative, then the root pass of all partial penetration groove
welds shall be visually inspected for adequate penetration into the joint
before the welding is continued.

p) Root openings in the welding joint wider than permitted by AWS D1.1
and as qualified but not greater than the thickness of the thinner
member shall be built up by welding to the specified groove
dimensions before the parts are joined.

q) Root openings in the welding joint less wide than that permitted by
AWS D1.1 shall be chipped or gouged in a manner as to maintain the
specified groove dimensions.

r) All welding shall be accomplished by an approved bead deposit

sequence. Weave passes in a excess of 2.5 times the electrode
diameter shall not be acceptable.

s) Care shall be exercised to keep arc-strikes and Weld Scars to a

minimum. Temporary fit-up and erection attachments shall be welded
with the same care and the same procedures as applicable for the
structural connections.
t) Radiographic or other inspection operations shall be maintained
concurrent with weld completions. All general clean up surface repairs
shall be completed before final inspection.

u) Welding on primary strength members shall not be permitted on any

galvanized surfaces or any surface coated with a lead or zinc bearing
paint, unless otherwise specified.

v) Unless otherwise indicated on the Contract Drawings, the weld joint

groove preparation for joining members less than 50 mm. (2 inch)
thickness through the centerline of the weld shall be AISC type B-L2.
Weld in excess of 50 mm (2 inch) throat thickness shall be welded with
AISC type BU-3B or B-1. 3-S joint preparation whenever possible. If a
single groove preparation is employed for welds in excess of 50 mm.
(2 inch) thickness, qualification of a welding procedure is required as
proof that the welding groove is satisfactory.

w) Electric ovens shall be provided at job sites for baking of electrodes.

The bake electrodes shall be transferred to a portable holding oven
kept at about 100°C, and shall be drawn one at a time for immediate
use on the job. Any welder shall draw electrodes from oven not more
than one at a time for use in immediate welding works.

x) With the exception of manually welded root runs for submerged arc
welding, interruptions shall not take place until at least half of the final
weld thickness is achieved all around the joint. In the event of
interruptions, controlled cooling of the weld area shall be ensured.
Before resumption of welding, the weld shall be inspected visually for
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cracks and, if required by Company, shall be tested by MPI or liquid

penetrant examination.

y) Contractor shall develop and submit for Company’s approval welding

sequences to control warping, creeping, or build up of excessive
residual stresses in the structure. Contractor shall ensure that these
planned sequences are fully adhered to during fabrication.

z) All seal welding shall be done using minimum 6 mm. size fillet welds.

6.5 Pipe Welding

a. Piping joints shall be butt-welded or filet welded using the appropriate

qualified welding procedures by qualified welders.

b. GTAW or P- GMAW is preferred for the root welding. Fill and cap
passes can be by GTAW or GMAW or SMAW or FCAW process. For
shop welding of longitudinal joints and circumferential joints, SAW
using an approved wire/flux combination may be used with the
approval from the Company.

c. The weld area and the neighbourhood shall be cleaned both by

mechanical and solvent cleaning procedures to remove any adherent
paint, oil, grease, oxides and other contaminants.

d. All beveled edges shall be checked for cleanliness and accuracy of

dimension as per the approved drawing before fit up.

e. The proposed edges shall be inspected for laminations at the ends on

a band of 50mm. All defective ends shall be cut and removed to
prepare fresh edges. The discarded ends shall not be used anywhere.

6.6 VESSEL WELDING

a) Welding on vessels could be carried out by SMAW, SAW or FCAW

process. The rest could be welded with GTAW process or Pulsed-
GMAW process.

b) All pressure containing welds such as longitudinal welds,

circumferential welds and nozzle attachment welds shall be full
penetration welds. Wherever approach exists from both sides, the
welding shall be done by using a double `V’ groove edge preparation,
the weld detail employed shall be such that it ensures a full penetration
joints.

c) Back up strips shall not be used, even in closure joints in heads.

d) All nozzles, couplings and manholes shall be attached to the vessel

wall with full penetration butt welds through the vessel walls.

e) All beveled edges shall be mechanically prepared by grinding smooth

to sound material and shall be cleaned by mechanical and solvent
cleaning procedures to remove oily/greasy substances, paints and
other oxide scales.

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f) All longitudinal seams shall clear nozzles, clips and other external
attachments by a minimum of 6” distance. Longitudinal seams for the
vertical vessels shall be located 180° approximately from each other.
Longitudinal seams for horizontal vessels shall be located 80° apart
and shall be minimum of 30° above the horizontal plane through the
centerline of the vessel.

g) All welds in the vessels shall be ground flush with the neighbourhood
on the inside of the vessel to facilitate easy installation of trays and
baffles. Remelting of the weld metal to impart smooth finish shall not
be permitted.

h) All external attachments to the vessels, both in the shell as well as in

the head, shall be made by continuous seal welding, unless prohibited
by the ASME code or the approved drawings.

i) The welded vessels shall be stress relieved in accordance with the

requirements of the codes and approved welding procedures. The
heat treatment procedures, including the schemes for the heating
arrangements, thermocouple placements and insulation, shall be
specifically qualified and approved by the Company prior to their
deployment on the job. Flange facings shall be protected against
oxidation during heat treatment. No welding shall be permitted after
the stress relieving, unless specifically permitted in writing in
exceptional cases.

6.7 Temporary Welds

Temporary welds (for temporary handling attachments, lugs etc.) shall be

minimized. When a temporary weld is necessary, the welding will be
performed with the same care, materials, electrodes, preheat, and procedures
as for the permanent weld installations with a doublers plate whenever
possible. However temporary attachments to permanent members like sea
fastenings shall be through a doublers plate.

The temporary welds shall subsequently be removed with an oxy-acetylene

torch by severing the attachment slightly above the surface of the structural
member and by grinding the remainder of the weld deposits flush with the
member. Temporary welding shall not be removed by arc-air gouging,
hammering or other mechanical means.

7.0 INSPECTION AND TESTING OF WELDS

7.1 Pressure Vessel

7.1.1 Company reserves the right to inspect vessels at any stage during fabrication
and testing to assure compliance with this specification, the vessel
specification and the ASME Code. Adequate advance notice shall be given
for the inspection prior to start of fabrication and scheduled time of hydrostatic
testing.

7.1.2 All examination methods shall be ASME Code, Section VIII. Division 1 with
the following additional requirements:

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(a) Radiograph film shall be equivalent to Type 1 or 2 per ASTM

E94. Type 1 film shall be used on steel less than 20 mm (3/4
inch) thick.
(b) Company reserves the right to approve the radiographic
method employed.
(c) Ultrasonic examination and acceptance Criteria shall be per
ASME Code Section VIII, Division 1, Appendix 12.

7.1.3 For fully radiographed vessels greater than 20 mm (3/4 inch) thickness, in
addition to Code requirements, the followings examinations shall be
performed:

(a) All circumferential and longitudinal butt welds joining heads, shells,
and nozzles shall be radiographed.

(b) All welds attaching nozzle necks to shell or reinforcing pads (Category
D, other than butt welds shall be examined by one of the following
methods:

(i) Radiography
(ii) Liquid penetrant examination of every 10 mm (3/8 inch)
of weld build up.
(iii) Magnetic particle examination of every 10 mm (3/8 inch)
of weld build up by both the prod and coil methods.
(iv) Ultrasonic examination.

7.1.4 For spot radiographed vessels, a minimum of 10% spot radiography on all
main weld seams and 100% at all tee junctions of welds shall be carried out.
The film length for each spot shall be 250 mm minimum. At least 10% length
of welds other than the main circumferential and longitudinal seams shall, in
addition be examined by magnetic particle or liquid penetrant, method. For
cylindrical vessels, one spot shall be examined at each shell seam
intersection.

7.1.5 All reinforcing pads shall be air tested to 1.05 kg/cm2g (15 psig) prior to Post
Weld Heat Treating (PWHT) and/or hydrostatic test and all welds inside and
outside inspected during the test. Test holes shall be open during the
hydrostatic test and plugged with a non-hardening sealant or heavy grease
after the hydrostatic test.

7.1.6 Pressure Testing

A shop hydrostatic test shall be applied as per paragraph UG-99C ASME

Code Section VIII, Division I, Test requirements are :

(a) No testing shall be performed before post weld heat treatment.

(b) No pre-testing shall be performed before the code hydrostatic test.

(c) Time period of testing shall be 1 hr. per 25 mm (1 inch) of the greatest
thickness with a minimum of 4 hour.

(d) Minimum test water temperature and metal temperature shall be 16°C
(60°F) except if the design temperature is below 16°C (60°F), the
minimum water temperature may be equal to the design temperature.

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(e) Test fluid shall contain no more than 500 ppm chlorides. However, for
stainless steel vessels it shall not contain more than 25 ppm chlorides.

(f) All cover plate hinge pins shall be in place during the test and shall not
bind on the hinges.

(g) Service bolting and ring joint gaskets to be finished with the assembly
may be used for shop tests. Any materials damaged during testing and
all types of gaskets other than ring joints shall be replaced by
fabricator with new material. Gaskets used for tests shall be of the
same material and design as those to be furnished with the vessel.

7.2 Piping

7.2.1 Random radiography shall be performed on one weld in each 10 welds for each
welder on the following:

Water (in case of carbon steel)

Air
Chemicals
Diesel
Closed drain
Relief
Hydraulic oil
Oily water
Slops

7.2.2 25% radiography shall be performed on the following:

Glycol and Therminol

Vent gas
Lube oil & Seal oil

7.2.3 100% radiography shall be performed on size 2” and above and 25% on sizes
below 2” for the following:

a) Crude oil
b) Jet fuel
c) Fuel gas/Instrument gas
d) Process gas
e) Production flow lines (well fluid)
f) Injection water
g) Hydrocarbons (Process)
h) Water (in case of 90/10 Cu-Ni)
i) H.P. and LP Flare lines

7.2.4 For fillet welds and brazed joints where carrying out radiography is not possible,
magnetic particle test or dye penetrant test shall be carried out. The extent of
inspection shall remain same as for radiography.

7.2.5 All the lines which are stress relieved or have design pressure more than 50
kg/cm2 shall be fully radiographed (100%) even if not required as per 5.1 to 5.3.

7.2.6 Radiography Procedure shall be as per ANSI B31.3.

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7.2.7 Acceptance Criteria based on visual, radiography and other types of examination
shall be as per ANSI B31.3 with the following modifications:

i) The internal weld protrusion on “pigged lines” shall not exceed 1.6mm
(1/16 inch).

ii) Orifice flange butt welds shall be internally ground smooth and flush.

iii) For 90-10 Cu-Ni Piping, radiographic examination of welds shall be as

per ASME Section VIII, UW 51.

7.2.8 Hydrostatic Testing is not required for shop-fabricated piping where the pipe is to
be field-tested. Hydrostatic testing is required on skid mounted assemblies or if
called for on an individual specification. Pressure tests shall be performed per
ANSI B31.3 and the appropriate piping material specification class chart.

7.2.9 Those field welded joints, which cannot be leak-tested due to unavoidable
reasons, shall always be 100% radiographed.

7.3 Structural

a) All welds will be visually inspected as instructed in Section-6 of AWS

D1.1. The Company will be vitally concerned with welds relative to
quality, geometry, fit-up, and size, and will impose the use of gauges
and/or non-destructive test procedures when and where they deem
necessary. It shall not be construed as unreasonable for the Company
to request proper repair of any defects in welds or materials that they
consider to be detrimental to the strength and usefulness of the facility.

If random NDT, as specified in this specification, indicates non-

acceptable defects in a weld, the identification of the weld to the
respective welder(s) shall be established and testing of other welds
made by the same welder(s) shall be extended to the discretion of the
Company, up to 100% at no extra cost to the Company.

b) Radiography examination shall be performed in accordance with

ASTM E94 and E142 at the following weld areas:

1. 100% of all girth welds in tubular.

2. At the intersection of all tubular member girth and longitudinal

seams, minimum 6 inches on either side of seam.

3. In addition to clause 7.3(b2) above, 10% of each longitudinal

seam of all tubular.

4. Any questionable weld defect.

5. 100% of all beam splices in skid beams, main truss beams and
deck beams.

6. 20% of all full section splices in minor beams.

7. 100% for all pad-eyes to main structural attachment welds.

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AWS D1.1 shall be the standard of acceptance for all the welds
inspected by radiography.

c) All longitudinal seams of factory manufactured welded pipes shall be

examined by 100% ultrasonic inspection during production, as directed
in ASTM E-273, “Ultrasonic Inspection of longitudinal Welds of Welded
Pipe and Tubing” or ASTM E164, “Ultrasonic Contact Inspection of
Weldments”.

d) 100% Ultrasonic Testing and Magnetic Particle Testing of following

weld areas shall also be performed:

1. All T, K & Y, X and TK joint welds of jacket legs, skirt sleeves

and deck frame work including truss chord to brace joints
(beam to pipe).

2. Welds and areas upto 100mm all around the weld of 10% of all
remaining joints (Location of joints to be decided by Company’s
representative).

3. All pad eyes to main structural member attachment welds deck

leg to girder welds, deck leg to ring stiffeners or diaphragm
welds and inter-costal deck beam to truss chord butt welds.

e) 100% Ultrasonic Testing and Magnetic Particle Testing shall be carried

out on all welds in built-up girders.

f) Rejection criteria for UT specified in 6.3.d above, shall be as per the

“Rejection Criteria Level C” of API RP 2X. Rejection criteria for UT as
in 6.3.c shall be as per the “Rejection Criteria Level A” of API RP 2X.
Acceptance criteria for MPI shall be in accordance with ASME Section-
VIII Div. I.

g) The area of structural steel plates where attachments like paddies,

temporary supports, etc. are to be welded, shall be ultrasonically
tested for laminations upto a distance of 100mm from the weld areas
on all sides, prior to welding.

7.4 Inspection (General)

a. The mandatory inspection methods specified in Paragraph 6.1 through

6.3 above shall be at the Contractor’s expense, Company shall have
the right to ask for the inspection of any weld (not previously accepted)
by either non-destructive or destructive methods.

This optional inspection can be for the purpose of routine quality

control or to further investigate apparent defects detected visually.
Defective welds found during a Company-optional inspection shall be
repaired and the cost of removal, repairs, and re-inspection shall be at
the Contractor’s expense. Welds found to be satisfactory shall be
repaired and the cost of removal and repairs shall be at the Company’s
expense under the provisions of the “Extra Work” clause in the Articles
of Agreement. Company shall not be held liable by the Contractor for
loss of time during these tests.

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b. Contractor will provide complete facilities for radiographic inspection of

welds, including the equipment for development of films and full time
services of a qualified technician familiar with radiographic inspection
techniques, who will be competent to operate the above equipment.

c. Contractor is responsible for rendering the surface of all welds clean

and satisfactory for non-destructive testing.

d. The Company retains the final right to determine the acceptability of

any weld. Interpretation of test results will be in accordance with the
guidelines set forth in the applicable codes.

8.0 REPAIR OF DEFECTS

8.1 Method

a. Defects shall be repaired as specified in the code governing the type of

weld involved, in accordance with an approved repair welding
procedure duly qualified along with the production welding procedures.

b. Repaired defects shall be re-inspected by the same criterion as used

for the original inspection.

8.2 Notification

a. The Company shall be notified before repairs are made on defective

material and/or welds. Repairs made without a reasonable notice shall
be subject to any form of testing (both destructive and non-destructive)
to assure adequacy of the repair, and all removal, repair, and retesting
deemed necessary by Company shall be at the Contractor’s expense.

b. Welding Procedures shall be developed by vendor based on broad

guidelines provided in the AWS Welding Specification Charts.

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AA DESIGN BASIS
A The system shall be adequately designed to protect all bare external submerged steel
jacket. Following components shall be protected by this protection system.
1 Jacket steel works, including such items as mud mats/subsea template, piling etc.
2 Boat landings and riser protectors
3 Well conductor
4 All sumps and caissons

B Details of areas to be protected (Refer 'Note-1')

2
1 Steel surface area in sea water (Bare) *m
2 Steel surface area in sea water (Painted) * NA
2
3 Steel surface area below mud line *m
4 Number of wells on the platforrm NA
Note: Contractor shall forward the final areas alongwith jacket drawing to the vendor.

C Design life
1 C.P System for jacket As per structural design criteria
2 C.P System for SBM NA
(Including PLEM)
3 Sea water temperature Refer Specification-' Site Condition
& Climate'
BB COMPONENT DETAILS
A Details of sacrificial anodes
1 Anode output * AH/kg
AH/k
2 Anode Potential (Closed ckt) * mV
3 Performance characteristics
and test procedure
4 Anode material & composition
in percentage

B Details of monitored Anodes

1 Anodes to be identical to (Vendor to furnish the difference, if any)
sacrificial anodes
CC MONITORING SYSTEM
1 Type of monitoring system Hard wired
2 HARD WIRED SYSTEM
a Details of monitoring panel
Size
Enclosure IP-51
Weight and overall dimension
Basic component details
Mounting details and fixing
arrangement
Electrical power requirement Watts
at 24V D.C (Nominal)
b Details of reference Electrode
Material of Electrode
Material composition in
percentage
Percent purity
Electrode potential
Weight of complete electrode

1 31.01.2011 REVISED AND ISSUED WITH BID SD RC RC

Rev. Date Purpose Prepared Checked Approved

Format No: 1650-2017 Rev.3 Copyrights EIL - All rights reserved

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DATASHEET FOR CATHODIC A108-01-06-42-SP-DS-01
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PROTECTION SYSTEM
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c Cables
Make and type
Construction
Applicable standards
Cross section area and
overall diameter
d Conduits
Make and type
Size
Material
Details of thickness and thread
Details of accessories
e Junction boxes
Make and type
Construction details
Enclosure protection
Weight and overall dimensions
Details of filling compound
Details of entry Conduit entry from sea side, armoured cable with double
compression nickel/chromium plated brass cable gland
on platform side

N t
Notes:
1 The contractor shall calculate the surface area based on the structural drawings. An allowance of 10%
shall be added to the calculated area by the contractor.
2 Contractor shall fill in the information marked '*'.
3 Data left blank is to be filled up by vendor alongwith bids.
4 For hard wired monitoring system, Power supply system (24V D.C) may be either floating
or negative earthed.
5 Monitoring panel shall include DC/DC converter if considered necessary by vendor to ensure compatibility
with above power supply system in case of process platform.

Format No: 1650-2017 Rev.3 Copyrights EIL - All rights reserved