Ly001-Let-Bon-Fial-0007

Head Office BONATTI - Società per Azioni
Via Nobel, 2/A Capital Stock € 50,696,792.28 wholly paid-up

43122 Parma Bus. Reg. Parma No. 02188130153
Italy R.E.A. No.130274
Tel. +39 0521 6091 N. Meccanografico PR 008484
Fax +39 0521 607700 VAT No. IT00765080346
Email: info@bonatti.it Tax Code No. 02188130153
Certified email: bonattispa@pec.bonatti-group.com
www.bonatti.it
Libyan Branch
Sidi Abdul Jalil
Zanzour – Tripoli
Libya
Tel. +218 (91) 2200051
______________________________
References to quote in any reply
FERROSTAL INDUSTRIENLAGEN
Réf. n. LY0001-LET-BNT-FIAL-0008 LIBYEN LTD
______________________________
LIBYA BRANCH
Al Nasreen Street nearby Ben Nabee
Tripoli, ………………. Mosque
Al Mansoura
(Tripoli – Libya)
Att.n. Mr. Gregory Zajaczkowski
Subject: SUBCONTRACT AGREEMENT N° OC/22000005

QUALITY DOCUMENTATION SUBMITTAL (ref. FPO22001-FIA-BON-L-CS-2200004)
QUALITY DOCUMENTATIONPROCEDURES – SUBMITTAL (ref. FPO22001-FIA-
BON-L-CS-2200009)
Dear Sir,
CONTRACTOR refers to the SUBCONTRACTOR’s letters ref. FPO22001-FIA-BON-L-CS-

22000004 dated 25 September 2022 and FPO22001-FIA-BON-L-CS-22000009 dated 2
October 2022 in connection with the subject.
Please find attached CONTRACTOR’s comments to the following procedures:
Doc. 22001-QAPR-705 “General Procedure for Welding Activities”
Doc. 22001-QAPR-706 “Welder & Welding Procedure Qualification Procedure”
As a general remark, and in addition to the comments individually made on the referenced
documents, CONTRACTOR reminds that the SUBCONTRACTOR’s document shall be
aligned to the documents submitted to COMPANY by CONTRACTOR.
To this extent, CONTRACTOR is hereby attaching its document LY0001-000-ZH-11023

“Technical Specification for Welding & NDT”.
Regarding the documentation submitted on 25 September 2022, CONTRACTOR deems it
very preliminary and largely incomplete.
For example, the following documents were missing:
- Pipeline Site survey procedure.

- Right of way construction procedure.
- Minor Road and wadi crossing procedure.
- National road crossing procedure( if any on the project).
- Pipe crossing procedure.
- Piping Spooling procedure.
- Piping prefabrication procedure.
- Piping erection procedure.
- Cathodic protection installation procedure.
- Fiber optical cable installation and splicing procedure.
- Cable termination procedure.
- Solar panel installation procedure.
- RTU installation procedure.
SUBCONTRACTOR is kindly requested to speed up the preparation of these basic

documentation for CONTRACTOR’s final approval.
Best Regards
Paolo Destro Cappellano
____________________
Project Manager
Attachments:
Doc. 22001-QAPR-705 “General Procedure for Welding Activities” commented BNT
Doc. 22001-QAPR-706 “Welder & Welding Procedure Qualification Procedure” commented

BNT
LY0001-000-ZH-11023 “Technical Specification for Welding & NDT”.

Ferrostaal Industrieanlagen Libyen Ltd
NORTH HAMADA (AREA47) DEVELOPMENT
Gathering Network and Oil Export Pipeline
GENERAL PROCEDURE FOR WELDING ACTIVITIES
Grégory
00 29-09-2022 Yousab Bassili Joaquim Lima Zajaczkowski Issue of document.
Rev. Date Issued Reviewed Approved Revision Description
Owner/Company:
BONATTI Job No.: FIAL Job No.: Formatted: Italian (Italy)
NAFUSAH OIL OPERATIONS B.V.
Contractor: C-001-PRO-2019 FPO-22001
BONATTI S.P.A.
Document Number: Revision: Department/Doc: IDM Ref. No.: Contractor Doc. No.: Supplier Doc. No.:
Formatted: Portuguese (Portugal)
Project QA/QC FIA2101215 N/A N/A
22001-QAPR-705 0 Procedure
This document is processed digitally and does not require signatures.

General Procedure for Welding Activities
Table of Contents
1. PURPOSE .................................................................................................... 3
2. SCOPE......................................................................................................... 3
3. DEFINITIONS AND ABBREVIATIONS ......................................................... 3
3.1 Definitions .................................................................................... 3
3.2 Abbreviations................................................................................ 4
4. REFERENCES DOCUMENTS ........................................................................ 4
5. RESPONSIBILITIES ........................................................................................... 5
6. REQUIREMENTS ................................................................................................. 5
6.1 General Requirements .................................................................... 5
6.2 Weld ........................................................................................... 6
6.2.1 General .................................................................................................... 6
6.3 Welding Procedures ....................................................................... 6
6.3.1 General .................................................................................................... 6
6.3.2 Application Method .................................................................................... 6
6.3.3 Joint Design .............................................................................................. 6
6.3.4 Materials .................................................................................................. 7
6.4 Welding Procedure Qualifications ...................................................... 7
6.5 Welder Qualification ....................................................................... 7
6.5.1 General .................................................................................................... 7
6.5.2 API 1104 .......................................................................................................... 8
6.5.3 ASME Section IX ....................................................................................... 8
6.5.1 Records of Qualified Welders and Welding Operators ............................................. 8
6.6 Weld Execution. ............................................................................ 9
6.6.1 General .................................................................................................... 9
6.6.2 Compliance with Specifications .................................................................... 9
6.6.1 Weld Preparations..................................................................................... 9
6.7 Inspection and Nondestructive Examination of Welds .............................. 14
6.7.1 General ...................................................................................................14
6.7.1 Disposition of Defective Welds ........................................................................... 14
6.7.2 NDE Records ............................................................................................14
6.7.3 Standards of Acceptability .......................................................................... 15
6.7.4 Repair of Welds Containing Defects .................................................................... 15
7. RECORDS AND DOCUMENTATION ........................................................... 15

8. APPLICABLE DOCUMENTS AND TOOLS .................................................... 15
8.1 Procedures ................................................................................. 15
8.2 Forms. ............................................................................................. 15
Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 2 of 15

© Property of Ferrostaal, Ltd. ● All rights reserved This document when printed is a non-controlled copy
1. PURPOSE
The Purpose of this Procedure is to present all the welding work methodology and requirements
as laid down in the project specifications and referenced codes, standards, and management
procedures.
2. SCOPE
This Procedure applies to all welding works to be performed on the fabrication and erection of
equipment, structures, and piping, to be executed on the Ferrostaal Industrieanlagen Libya
Limited (FIAL) projects.
3. DEFINITIONS AND ABBREVIATIONS
3.1 Definitions Commented [DG1]: Put the definition in

alphabetical order
Welding Procedure Specification (WPS)
A formal written document provides the required welding variables for a specific application, as
per the code requirements, which provides direction to the welder or welding operators for
making sound and quality production welds.
Welder Performance Qualification Record (WPQR) Formatted: Font: (Intl) Tahoma, Strikethrough
A record of performance qualification variables, test results and range, qualified that certifies the
Welder is qualified to weld in the range specified, according to the reference code.
Welding Procedure Qualification Record (WPQR)
A record of welding variables is used to produce an acceptable test weldment and the result of
tests conducted on the weldment to qualify a welding procedure specification according to the
reference code.
A PQR demonstrates that the Company has the ability to produce welds possessing the correct
mechanical and metallurgical properties.
Preheat
The act of applying the heat to the workpiece(s) on the base material in the volume surrounding
the joint to attain and maintain the specified preheat temperature immediately before starting
welding.
Post-weld Heat Treatment (PWHT)
It is a controlled process in which a material that has been welded around a welding joint is
reheated to a specified temperature, and then it is held at that temperature for a specified
amount of time and cooled as specified, according to the applicable standards.
A post weld heat treatment is performed to alleviate residual stresses, increase the strength,
increase or decrease the hardness, and reduce the risk of cracking.
Welding Supervision
This is the function for supervising and coordinating welding activities, which has to guarantee
that welding execution fully meets relevant specifications.

Welding Inspection
This is the function for monitoring all welding activities for acceptance, verifying the weld
preparation, including documentation as WPS, PQR and welders/operators’ qualification, the
welding material according to the WPS, an inspection of fit-ups before welding, checking correct
parameters during the welding process, and inspect the completed welds for acceptance.
Following and verifying all the welding register, Welding log, NDE reports and others as required.
Inspection Authority / 3rt Party
The independent organisation represents the Owner that verifies that the equipment and facilities
have been designed, constructed, inspected and tested in accordance with the requirements
and specifications of the Purchase Order/Contract.
QA/QC Inspector
A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection
Authority verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the specifications, applicable code, standards and the
requirements of the Purchase Order/Contract.
Records
Its written elements to provide evidence that the realisation processes and resulting products
meet requirements.
Welding Consumables
Any material used for making or protecting a weld, such as a Coated electrode, rods,
solid/tubular wires, fluxes or shielding gases.
3.2 Abbreviations
FIAL Ferrostaal Industrieanlagen Libyen, Ltd.
API American Petroleum Institute
ASME American Society of Mechanical Engineers
GES General Engineering Specification
NDE Non-Destructive Examination
PQR Procedure Qualification Record
QA/QC Quality Assurance / Quality Control SQM Site Quality Manager
SM Site Manager
WI Welding Inspector
WPS Weld Procedure Specification
WS Welding Supervisor
4. REFERENCES DOCUMENTS
ASME B31.3 Process Piping

ASME B31.4 Flowline Piping
ASME Section IX Boiler and Pressure Vessel Code- Welding, Brazing, Fusing Qualifications
ASME SEC II C Standard for Material and Consumable of Welding
ASME Section V Non-destructive Testing Formatted: French (France)

Formatted: French (France)
API 1104 Welding of Pipelines and Related Facilities

AWS A5.1to A5.24 Filler Metal Specifications
AWS D1.1 Structural Welding Code
GES W01 Welding Procedure and Welder Qualification
GES W06 Storage and Control of Welding Consumable
GES W07 Non-Destructive Testing
Welder and Welding Procedure Qualification Procedure
Welding Consumable Handling Procedure Commented [DG2]: To be implemented also
Pipeline Welding Procedure by Bonatti LY0001-
000-ZH-11023
5. RESPONSIBILITIES
Project Manager
The Project Manager is responsible for providing all human and material resources for properly
executing the welding works according to the Project's requirements.
Site Quality Manager /Welding Engineer
The SQM Is responsible for ensuring that all required documentation is available and that field
personnel possess the latest revision. Ensure all required information is reviewed, approved,
recorded, and completed documentation.
Ensure that any requests to deviate from the standards and/or specifications are thoroughly
reviewed and approved by the client or their representative.
Welding Inspector
The Welding Inspector is responsible for ensuring that all the welds are carried by the Welder with
valid certification, according to the correct welding parameters of applied WPS, covered by a
qualified procedure (PQR). Ensure that all required NDE are performed according to the
Inspection and Test Plan and that the reports are confirmed and approved.
Ensure all weld elements are correctly recorded in the Weld Map and Weld Log, including the
NDE log.
Welding Supervisor
The WS is responsible for ensuring that all welding activities are carried out according to the
project requirements and the applicable code, standards, and procedures.
Welder
The Welder is responsible for ensuring that he has all the materials and welding equipment in good
condition and has in hispossession all the referenced documentation up to date, such as the
Performance Certificate and corresponding WPS, and that he understands and follows.and he
should have the ability to perform a sound weld as per certified WPQ
All directives from the WS are understood and followed.
6. REQUIREMENTS
6.1 General Requirements

Wherein the Manufacturer's literature, governmental or regulatory requirements conflict with this
Procedure, the more stringent requirement shall govern.
Unless specified, all statements in this Procedure shall be considered as requirements.

6.2 Weld
6.2.1 General
Perform all welding, including tack welds, temporary welds, and utility piping welds, using qualified
welding procedures approved for use by Quality Department.
Use welders who are qualified for the welding procedure specification to be used.
Ensure a qualified Welding Inspector witnesses all welding of process piping, gas transmission,
hazardous liquid, or other types of pressurised piping, including temporary welds.
The Welding Inspector checks the validity of certification records for each Welder.
Engineering to assure that proper and current qualification data is on file and is appropriate for
the welding to be performed.
6.3 Welding Procedures
6.3.1 General
Use the following processes, or combinations thereof, for welding procedures:
 Shielded metal arc welding (SMAW)
 Gas tungsten arc welding (GTAW)
Other welding processes may be used if approved by the Company.
6.3.2 Application Method

GTAW Weld deposition can be manual, mechanised, or semi-automatic.
SMAW process shall be manual
6.3.3 Joint Design

Butt Welds
Ensure bevels angles are either 30° -0/+5° or 37.5° ±2.5°, unless otherwise specified, and all field
cuts are 90° to the pipe axis.
Between pipes of unequal nominal wall thickness, make butt welds using a transition designed in
accordance with the design code requirements andof Company Specification.
Do not make mitre joints. A deflection up to 3° caused by misalignment is not considered to be a
mitre joint.
Do not use permanent backing rings or backing welds.
Fillet Welds
Except where specified by the design, do not use fillet welds to join piping larger than NPS 2 (60.3
mm OD).
Tack Welds
A qualified welder or welding operator makes tack welds (using appropriate, approved welding
procedure) within the weld bevel area. Place a minimum of four tack welds equidistant around
the pipe circumference. The Contractor/Fabricator assesses the weight and size of the fabricated
assembly to determine the appropriate length of tacks required to move and support it safely.
Make tack welds at the root using filler metal with equivalent mechanical properties to that of the
root pass, and then either fuse it with the root pass weld or remove it ahead of welding the root.
Remove bridge tacks (above the root) ahead of welding the root pass. Tack
welds follow the preheat requirements outlined in the applicable WPS.
6.3.4 Materials
Pipe and Components Base Metal
Weld materials according to their P-Number and Group Number, as given in ASME Section IX, or
the base material groupings as given in API 1104. Materials that do not conform to the P-Number
and Group Numbers specified above are considered to be unassigned. Do not use unassigned
base metals, as described in ASME BPVC Section IX, Clause QW-424.
Filler Metals
Select filler metals to match the deposited tensile strength appropriate for the welded materials.
Evaluate consumables listed in vendor/contractor welding procedures to ensure they are
appropriate for the welded materials. All consumables must be according to the WPS that
requires Company approval prior to use.
Store and handle properly filler metals and fluxes to avoid damaging them and their shipping
containers. Protect consumables in opened containers from deterioration and protect coated
filler metals from excessive moisture changes. Discard filler metals and fluxes that show signs of
damage or deterioration. Commented [DG3]: Low Hydrogen consumable
Store low-hydrogen type covered electrodes in hermetically sealed, moisture proof containers. shall be purchased with vacuum pack
After opening, store low-hydrogen electrodes in appropriate holding ovens at a temperature of
350°F + 50°F (175°C + 27°C) degrees or the Manufacturer's recommended holding temperature.
Do not store other electrode types (e.g., cellulosic) in holding ovens with low-hydrogen Commented [DG4]: Please to replace all the
electrodes. wording “do not” with the wording “shall not”,
as well as, “do” with “shall”.
Welding Consumables materials are managed according to the specified Welding Consumable
Procedure
6.4 Welding Procedure Qualifications

Welding works are carried out respecting the Welding Procedure Specifications (WPS) covered
by the Approved Procedure Qualification Record (PQR), in accordance with the requirements of
API 1104 or ASME Section IX, and Company/Contractor Welding Specification along with additional
requirements of GES.
Welding Procedure Qualifications are performed according to the specific Welder and Welding
Procedure Qualification Procedure and approved by a recognised international organisation
following the required referenced code.
No welding work start before the WPS and PQR have the Company's approval.
Repair welding doesn’t require a specific procedure; repair shall be used original Procedure
Qualified.
In accordance with ASME BPV Code Section IX, WPS and welding procedure qualifications are
the sole ownership of the entity that develops the procedures and employs the welders. This weld
documentation is non-transferable between companies when allowed by fabrication code and
approved by Company ..
6.5 Welder Qualification
6.5.1 General
Assign welders a unique symbol for the purpose of identification on all welds. Once a symbol is
assigned to a welder, do not reassign it to another welder during the Project.
Conduct qualification of welders in the presence of a Company representative.

Repair welder qualifications are determined according to the applicable code of Construction.
No welder repair separate qualification is required. Commented [DG5]: Repair Welder require
Welder qualifications performed for non-Company affiliated companies are notshall not be separate qualification according to welding
procedure specification.
considered.
A welder who has successfully completed an approval test, qualified in accordance with this
procedure, shall be qualified within the limits of the essential variables described in API 1104 or
ASME Section IX ,where applicable. If any specified variables are changed, the Welder using
the new Procedure shall be qualified.
Where the contracting parties agree that the failure of a welder to pass the test was because of
conditions beyond his control, the Welder may be given a second opportunity to gain approval.
No further retests shall be permitted until the Vendor/Contractor has submitted proof of
subsequent Welder training acceptable to the Company.
If a welder is responsible for a high level of repairs in production, he shall be removed from the
work and shall undergo a retraining programme approved by the Company before being
retested.
Welder Qualification shall be performed following the specific Welder and Welding Procedure
Qualification Procedure.
6.5.2 API 1104

All welder qualification testing shall be carried out in accordance with Section 6.0 of API 1104.
Welders who can produce proof of current qualification by the Company in accordance with
the requirements of API 1104 for a given process may be exempted from re-qualification,
provided that within the preceding six calendar months, they have engaged in welding with that
process and had one weld tested and found acceptable under API 1104, Section 9.
 Document such tests using Welder Qualification Form –API 1104
 Ensure radiographic inspection reports clearly identify the Welder, date of welding, and
disposition to API 1104. Commented [DG6]: For pipeline purposes, new
Welder Performance Qualification shall be held.
6.5.3 ASME Section IX
All welder qualification testing shall be carried out in accordance with Article III of ASME Section
IX.
For welder performance qualification, the requirements for visual inspection of welded joints shall
be as specified in the applicable fabrication code. At a minimum, the weld shall be uniform and
free from excessive profile defects, e.g. excessive cap height and/or root penetration. There shall
be a smooth transition between the weld metal and parent material, and the weld shall be free
from undercut, pinholes or any other visible defect.
For welder performance qualification, a radiographic inspection of butt-weld joints can
alternatively replace the mechanical test as per ASME Code, Section IX.
6.5.1 Records of Qualified Welders and Welding Operators

Quality Department reviews all welder/welder operator qualification reports before the start of
production welding and develops and maintains a list of qualified welders for the Project.
Quality Department makes welder/welder operator qualification records available to the
Company and submits them as part of Project documentation. The Company reserves the right
to request a re-qualification if there is any reason to question the welder/welder operator's ability.

Following satisfactory welder qualification, a welder qualification test report (WQTR) shall be
prepared to show the actual test results and the range of material diameters, if pipe, and
thicknesses for which the Welder is qualified. This report shall also show the WPS number to which
the Welder is qualified.
A welder qualification index shall be prepared showing, as a minimum, the welders name,
identification number, which welding procedure specifications the Welder is qualified to, the date
of qualification for each WPS and the date when revalidation of qualification is due for each
Procedure.
6.6 Weld Execution
6.6.1 General
During construction, ensure copies of the welding specifications are available for reference at the
local work site where the welding is performed.
6.6.2 Compliance with Specifications

Random monitoring and maintaining records of welding parameters (e.g., amps, volts, and travel
speed) are used for production welding to demonstrate compliance with the parameter range
requirements of the WPS. Ensure such records are available to the Company upon request.
The Company reserves the right to measure welding parameters on any production weld. When
parameters measured on a weld do not comply with the specified values, the Company reserves
the right to reject such weld and any weld made after the last compliant record unless the party
responsible for the work can demonstrate that such welds are in full compliance with the WPS.
Non-compliance with the requirements of API 1104 or ASME IX (as appropriate), this Specification,
or the WPS is cause for weld rejection.
If the Company identifies an unacceptable weld repair rate, submit a remedial plan that includes
quality checks such as welder retraining, root cause analysis of weld defects, and welding process
improvement.
6.6.1 Weld Preparations

6.6.1.1 Cleaning of Pipe Ends
The WPS shall detail the method used for cleaning the weld preparation before starting welding.
Clean areas to be welded (including the weld bevel and both internal and external pipe surface
in the vicinity of the weld) to a minimum distance of 1 in. (25 mm) from the ends of the pipe, so
they are free of oxides or other extraneous matter.
Grind flame-cut bevels prior to welding. Ensure bevel surfaces are smooth and free of irregularities
that could adversely affect the welder's ability to produce high-quality welds.
6.6.1.2 Pipe Identification
Where a pipe needs to be cut, transfer pipe identification (such as pipe number, grade, heat
number) to both ends of the pipe with the Welding Inspector's witness.
Do not die to stamp the pipe or weld for pipe identification or any other purpose.
6.6.1.3 Laminations
When tie-ins are made to existing pipe or facilities, check the pipe for laminations over the entire
360º circumference over a 12 in. (305 mm) width, centred at the proposed weld location using
straight beam ultrasonic testing. An ultrasonic thickness gauge is acceptable for lamination

check, with preference given to an ultrasonic flaw detector with an "A" scan display. Determine
the weld location before cutting the pipe.
Examine the prepared weld bevel using magnetic particle inspection. Lamination or other
conditions that could affect the completed weld found on the bevel with a circumferential length
greater than 0.25 in. (6 mm) are classified as defects. Cut back the pipe until no lamination or
other deleterious condition is present at the pipe end.
6.6.1.4 Grinding of Seam Welds
For welds subject to NDE using radiography, grind the pipe seam welds flush (-0, +1/64in.) for a
minimum distance of 1 in. (25 mm) from the bevel edge (internally and externally), with a gradual
transition to the weld reinforcement.
For welds subject to NDE using ultrasonic examination, grind the pipe seam welds flush (-0, +1/64
in.) for a minimum distance of 4 in. (100 mm) from the bevel edge (internally and externally), with
a gradual transition to the weld reinforcement.
6.6.1.5 Alignment and Fit-Up
Do not use mitre joints. (Deflections up to 3° caused by misalignment are not considered mitre
joints.)
Minimise external forces required to align pipes. If pipes to be joined are in place:
 Below grade, expose a sufficient length of each end of the pipes so they can be moved
without imposing detrimental external stresses on the joint.
 Below or above grade, and there is insufficient length to allow free movement, cut and
reinstall the pipes to bring the misalignment within the allowable tolerance.
 For buried piping, except in the case of bends, stagger longitudinal seam welds on the
adjacent pipe at approximately the 10 o'clock and 2 o'clock positions.
 On longitudinal seam welded pipe, place the seam at right angles ±10° to the bending
plane.
 For above-grade piping, locate the seams welds to not interfere with possible branch
connections at the 12, 3, 6, or 9 o'clock positions.
 Where two-seam welds on adjacent pipes meet at a common girth weld, offset the two
seams by a minimum distance of 2 in. (50 mm) from each weld toe.
 Do not locate pipe seam welds on top of any pipe support (i.e., beam or concrete
support).
 Do not hammer pipe. (Use of small hard plastic or steel hammer to signal the release of
internal clamps is acceptable as long as there is no damage to the pipe surface or
adjacent coating). Where external line-up clamps are used, correct minor out-of-
roundness and misalignment using wedges.
 On new mainline construction, use internal line-up clamps for all welds. External clamps
may be used for tie-ins, facility construction, NPS 4 (114 mm OD) or smaller pipe, and
specific situations approved by the Company.
 For pipe-to-pipe welds of the same nominal wall thickness, do not exceed 1/8 in. (3.2 mm)
maximum offset or misalignment of the abutting pipe ends.
 For pipe to component joints of equal nominal wall thickness, do not exceed 1/8 in.
(3.2mm) external offset. Ensure internal offsets exceeding 3/32 in. (2.4 mm) conform to
the conditions specified in Section 2.42 of this Specification.

 Do not fully insert the pipe into socket fittings using the Manufacturer's recommended
gap.
Gapolets are an acceptable means of maintaining the gap requirements.
6.6.1.6 Pipe Support
Do not weld supports, bracing bars or counterbalance weights to pressure piping and
components.
Ensure the pipe is supported in accordance with standard industry practice. Report any
occurrence of a section of line falling from its support to the Company, together with any tests,
inspections, and remedial work performed as a result of the fall. The Company determines
whether or not the piping is acceptable for use.
6.6.1.7 Weather Conditions
Protect welds during welding from weather conditions considered detrimental to weld quality.
Portable enclosures may be used to make conditions satisfactory for welding.
Wrap the completed weld in a clean, dry welding blanket when the ambient temperature at
the time of welding is below 50°F (10°C). Remove the blanket once the weld area reaches
ambient temperature.
6.6.1.8 Grounding and Cables
Securely attach grounding devices in a manner to prevent arc burns. Do not weld grounding
devices to the pipe or place them on the pipe body. Preferably make contact within the weld
groove, and ensure it is large enough to prevent local overheating or arcing (i.e., minimum 0.5 in.
(12.7 mm) wide and 1/8 in. (3.2 mm) thick). Ensure devices grounding in the bevel area are made
of steel. Do not use copper or bronze tips for such a purpose.
Ensure welding cables, ground clamps, and connections are insulated to prevent arcing to the
pipe surface. Avoid ground paths through valves.
6.6.1.9 Protection of Coatings
Protect existing coatings on piping to minimise the damage that may result from the welding
operations.
6.6.1.10 Preheating, Inter-pass
The WPS shall specify the minimum preheat and maximum inter-pass temperatures in accordance
with the following:
 Preheat
Where the material surface is wet or the metal temperature is below 50°F (10°C), preheat shall
be employed to dry the surfaceas per applicable WPS.
Preheat shall be applied, where necessary, to avoid cracking or undesirable hardening of
weldments as per WPS requirements.
For carbon steels, this shall take into account joint design, heat input, presence of diffusible
hydrogen and the base metal composition, including the effects of higher carbon and alloy
content. Unless specifically agreed otherwise, minimum preheats shall be in accordance with
ASME Code, Section VIII, Table UCS-56 and UCS-56.1.
Apply preheat for a minimum distance of:
 4 in. (102 mm) to each side of the weld for the full circumference; in the case of girth
welds
 6 in. (152 mm) from any point of the area to be repaired, in the case of repairs.

Maintain mMinimum preheat temperatures shall be maintained for completing all welding.
Check to preheat and inter-pass temperatures at the top, bottom, and both sides of the
pipe using temperature-indicating crayons or contact thermocouple probes in areas 0.5 to
1 in. (12.7 to 25 mm) from the edge of the bevel. Ensure temperatures are within the
specified limits after each pass. Do not use Infrared pyrometers. Crayons which indicate
temperature by colourcolor change shall not be used.
Temperatures shall be measured immediately prior to the commencement of welding and
around the whole of the joint during the welding operation.
Whenever possible, the temperature shall be measured on the side opposite to that on which
the heat has been applied. Otherwise, the temperature shall be measured on the heated
side following removal of the heat source and allowing a time-lapse for temperature
equalisation. Up to 1" (25 mm) thickness, this time-lapse shall be 2 minutes. For each additional
½" (12 mm) above that thickness, 1 minute shall be added.
Do not cool passes of a weld at a rate greater than that provided by natural air cooling.
Preheat may be applied by either gas or electrical means. The method used shall be that
used during welding procedure qualification and shall be approved by the Company stated
in the applicable WPS.
Preheat shall be applied in such a manner as to avoid damage to any coating.
The minimum preheat temperature shall be as specified in the WPS, and the maximum shall Formatted: Strikethrough
not exceed it by more than 50°C.
 Inter‐pass Temperature. Formatted: Font: Tahoma, 10 pt, (Intl) Verdana,

Before each subsequent pass, the weld shall cool sufficiently to ensure the maximum inter- Character scale: 95%
pass temperature, which shall be specified on the WPS, shall not be exceeded. Formatted: Font: (Default) Cambria Math, 10 pt,
Character scale: 95%
For any weld, the inter-pass temperature shall not be allowed to fall below the specified
preheat temperature until the completion of not less than 30% of the final weld depth in the Formatted: Font: Tahoma, 10 pt, (Intl) Verdana,
case of P1 material. For other `P' numbers, the weld must not be allowed to drop below the Character scale: 95%
preheat temperature until all the hydrogen diffuses.The relevant WPS shall specify the preheat Formatted: Font: Tahoma, 10 pt, (Intl) Verdana,
maintenance and Dehydrogenation Heat treatment as necessary Character scale: 95%, Not Expanded by / Condensed by
Where the inter-pass temperature falls below the specified preheat temperature, the Formatted: Indent: Left: 0.41", No bullets or
preheat level shall always be restored before welding is resumed. numbering
6.6.1.11 Number of Welders Formatted: Font: Tahoma, 10 pt, (Intl) Verdana,

Use a minimum of two welders for welds on piping equal to or greater than NPS 14 (356 mm OD),
except that only one Welder is required for roll welds of any diameter. Formatted: Font: Tahoma, 10 pt, Bold, (Intl) Verdana,
6.6.1.12 Start of Welding
Do not commence welding until all parts to be joined are secured against movement.
6.6.1.13 Release of Line-Up Clamp
When using internal line-up clamps, complete the root pass for 100% of the circumference prior
to release. In case of use cellulosic electrode for root pass, it shall be executed hot pass
before to release internal line up clamp.
For external line-up clamps, ensure the root pass is at least 50% complete before removal of the
clamp unless stated otherwise in the welding procedure. Ensure there is no pipe movement until
the root pass is 100% complete.
Note: To minimise the risk of cracking of mainline manual welds (i.e., manual welds completed
with an internal line-up clamp), it may be necessary to weld the hot pass for an approximate
length of 1 ft. (305 mm), in the area of highest anticipated stresses, prior to moving the pipe. This
area would typically be on the bottom of the pipe but could be on the top of the pipe in an
overbend situation or on the sides of the pipe in a side bend situation.

6.6.1.14 Cleaning between Passes

Remove clusters of surface porosity, weld bead starts, high points, and slag by grinding prior to
depositing weld metal in subsequent passes. Clean between passes as necessary for all welding
processes to ensure weld quality.
6.6.1.15 Interruptions in Welding
Continue welding a production weld without interruption is preferred.
Unless otherwise specified by the construction code or WPS, the weld must be without interruption
and m maintain weld temperature above the minimum inter-pass temperature until at least two
passesare completed, or 21/3 of the weld thickness is filled . If welding is interrupted at this point,
preheat the weld to a minimum preheat temperature before recommencing welding.
Unless otherwise specified in the WPS, the maximum time delay between weld passes is:
 Root to hot pass—15 minutes (to be qualified and stated in The WPQR)
 Hot pass and first fill—60 minutes Complete
final tie-in welds the day they are started.
6.6.1.16 Bead Sequence, Width, and Capping
For SMAW, ensure the maximum bead width is no more than three times the electrode diameter
being used.
Overlap the circumferential start locations of consecutive beads by at least 1 in. (25.4mm).
Ensure the face of the completed weld is no more than 1/8 in. (3.2 mm) beyond the edge of the
original groove.
For split weld caps and multi-pass weld caps, avoid having the edge of any bead along the weld
centerline.
6.6.1.17 Back Welding
Back welding using low-hydrogen consumables is permitted in any area where the internal
misalignment exceeds 3/32 in. (2.4 mm).
Ensure welding produces a gradual transition in material thickness.
Remove root pass metal reinforcement in areas to be back welded by grinding before welding.
6.6.1.18 In-Process Repairs
In-process repairs to welds made using temper bead welding are permitted. In-process repairs
are defined as repairs in which a flaw is mechanically removed, and a repair weld is made before
welding of a joint is presented for final visual inspection. Examples of such repairs are areas of
removal of porosity, incomplete fusion, etc., where sufficient metal has been mechanically
removed that localised addition of weld metal is necessary in order to make the surface geometry
suitable for continuation of normal welding. In any case it is shall not be possible to execute
welding beads with parameters outside the WPS’s qualified range and it shall not be possible
to insist with the in process repair if it has not been possible to remove the open to surface
defect.
6.6.1.19 Transition Welds
There shall be a smooth transition between the weld metal and parent material, and the weld
shall be free from undercut, pinholes or any other visible defect.
6.6.1.20 Identification of Welds and Welders
Mark welds with unique identification on the top quadrant of the pipe adjacent to each weld.
Welders are responsible for marking their unique welder number/letter on the top quadrant of the
pipe adjacent to each weld they have worked on using a permanent marker (the use of low-
stress stamps is acceptable for pressure piping).

Record the welder identification number/letter on the weld log, NDE inspection record, and
relevant drawing/spool sheets.
Should any welder leave the Project, do not reassign their unique identification to another welder.
6.6.1.21 Closure Welds
Submit welds that are not hydrostatically tested to in-process examination as outlined in Weld-
Tie-In.
6.6.1.22 Weld Clean-up
Completely remove weld spatter, coating, or loose debris s from the joint's surface for a
minimum distance of 4 in. (100 mm) on each side of the weld, as required for NDE inspection.
6.7 Inspection and Nondestructive Examination of Welds
6.7.1 General
Inspect completed welds for 100% of their lengths and assess any imperfection using the
applicable standard of acceptability ASME IX ASME B31.3 for piping as well asand API 1104 for Formatted: Strikethrough
pipeline. Fully document all inspections.
Perform a visual inspection. At a minimum, ensure the completed weld is uniform appearance,
free from excessive profile defects, cracks, inadequate penetration, and burn-through, and
presents a neat workman-like appearance. Ensure the undercut meets the requirements of API
1104.
Document the visual inspection of each weld on the appropriate form along with the disposition
(Acceptable or Non-Acceptable to API Welding of Pipelines and Facilities and ASME B31.3 for
pipingand ASMEIX). Formatted: Strikethrough
Do not submit welds that do not pass visual inspection in accordance with this Procedure and API
1104 to NDE until the discrepancy has been rectified or repaired according to WPS to the
satisfaction of the Company.
Use radiographic inspection according to API 1104 of Welds or ultrasonic inspection methods, or
a combination of such methods, for butt weld NDE. For welds having a wall thickness difference
shall be taken into consideration to choose the appropriate NDE technique.
Do not use the manual ultrasonic inspection as girth welds' primary method.
For buried service, unequal wall thickness pipe to pipe field welds (NPS 12 and greater) with one
side having a back-bevel transition, an ultrasonic inspection shall be performed when cellulosic
consumables are used. This shall be a secondary inspection to screen for lack of fusion in the root
or cracking. This ultrasonic inspection should be performed at least 24 hours after the weld has
been completed where other delayed hydrogen cracking mitigations have not been
implemented.
Use magnetic particle inspection on ferromagnetic materials and use liquid penetrant inspection
on non-ferromagnetic materials for fillet weld NDE in accordance with API 1104 and ASME V.
Inspect repair welds with the same NDE method originally used to identify the defect.
6.7.1 Disposition of Defective Welds

Remove welds that are found to be unacceptable or repair them using the original WPS and
qualified welders.
6.7.2 NDE Records

Prepare inspection records showing milepost, the number of girth welds made, the number non-
destructively tested, the number rejected, and the disposition of the welds.

Provide the inspection records to the Company. Keep these records for the life of the pipeline.
6.7.3 Standards of Acceptability

Refer to the NDE procedures and ASME B31.3 ASME IX, API 1104 or other construction codes for Formatted: Strikethrough
acceptability for production welding.
6.7.4 Repair of Welds Containing Defects

Welding Procedures for repairs in accordance with API 1104. ASME Section IX states that the
original WPS may be used for repairing welds.
Ensure repair welding of defects in production welds meets the following requirements:
 Obtain approval from the Company Welding Inspector
 Qualified welders approved by the Company perform welding using applicable WPS
and approved by the Company.
 Record repair welding on the inspection reports.
7. RECORDS AND DOCUMENTATION
Submit a Contractor Turnover Package to the Company at the completion of the Project that
includes, but is not limited to, the following:
 Purchase order number, Project number
 Filler Material Certificates
 Weld Map and Weld Log, including NDE log
 List of welding procedures, consumable welding documentation, welding parameter
reports, and welder identification used for field installation
 NDE reports (i.e., visual inspection records, radiographic film, and ultrasonic testing
records) identify the procedure method and technique used for the inspection.
8. APPLICABLE DOCUMENTS AND TOOLS
8.1 Procedures
Welding Consumable Procedure
Non-Destructive Examination Procedures
Welder and Welding Procedure Qualification Procedure
Mechanical Completion & Pre-commissioning
Any other documentation required in project specification
requirement
8.2 Forms
Welding Daily Visual Inspection Report
Inspection Report
Non-Destructive Examination Reports
Piping Logbook (In-Plant Piping)
Piping Logbook (Flowline/Pipeline Piping)
Any other documentation required in project specification
requirement

Ferrostaal Industrieanlagen Libyen Ltd
NORTH HAMADA (AREA47) DEVELOPMENT
WELDER AND WELDING PROCEDURE QUALIFICATION

PROCEDURE
Grégory
00 29-09-2022 Yousab Bassili Joaquim Lima
Zajaczkowski
Issue of document.
Rev. Date Issued Reviewed Approved Revision Description
Owner/Company:
BONATTI Job No.: FIAL Job No.: Formatted: Italian (Italy)
NAFUSAH OIL OPERATIONS B.V.
Contractor: C-001-PRO-2019 FPO-22001
BONATTI S.P.A.
Document Number: Revision: Department/Doc: IDM Ref. No.: Contractor Doc. No.: Supplier Doc. No.:
Formatted: Portuguese (Portugal)
Project QA/QC FIA1900616 N/A N/A
22001-QAPR-706 0 Procedure
This document is processed digitally and does not require signatures.

Welder and Welding Procedure
Qualification Procedure
Table of Contents
1. PURPOSE ...................................................................................................... 3
2. SCOPE........................................................................................................... 3
3. TERMS, DEFINITIONS ....................................................................................... 3
4. STANDARD AND DOCUMENT REFERENCES ....................................................... 4
5. RESPONSIBILITIES ......................................................................................... 4
6. EVALUATION OF REQUIREMENTS ..................................................................... 4
7. REQUIRED RESOURCES .................................................................................... 5
7.2 Test Piece ....................................................................................... 6
7.3 Consumables .................................................................................. 6
7.4 Human Resources ............................................................................. 6
7.5 Physical Resources ............................................................................ 6
8. WELDING PROCEDURE QUALIFICATION ......................................................... 87
8.1 Welding Procedure QUALIFICATION .................................................... 87
8.2 Non-destructive Testing (NDT) ............................................................ 87
8.3 Post Welding Heat Treatment (PWHT) .................................................... 87
8.4 Destructive Testing .......................................................................... 87
8.5 Procedure Qualification Record (PQR) .................................................. 87
8.6 PQR Re-Testing .............................................................................. 98
8.7 PQR Approval ................................................................................ 98
9. WELDER PERFORMANCE QUALIFICATION (WPQ) ............................................ 98
9.1 Welder Performance Qualification Test (WPQT). ...................................... 98
9.2 WPQT Validity ................................................................................. 98
10. ANNEXES .................................................................................................... 98

1. PURPOSE
The purpose of this procedure is to define the methods for performing the required Welding
Procedures Qualification Record (WPQR) and Welder Performance Qualifications (WPQ) to be Commented [DG1]:
applied on the welding activities.
2. SCOPE
This procedure applies to all construction sites under the authority of Ferrostaal Industrieanlagen
Libyen Ltd. for all welding activities.
3. TERMS, DEFINITIONS Commented [DG2]: Put in alphabetical order

terms and definitions
FIAL Ferrostaal Industrieanlagen Libya, Lda.
CWI Certification Welding Inspection Personnel.
Examiner The person who has been appointed to verify compliance with the
(Inspector) applicable standard or requirement.
NDT Non-destructive Testing is a method to evaluate the quality of a component

by assessing its internal and/or external integrity, but without destroying it.
PQR Procedure Qualification Record shall document the essential variables of
the specific welding process or processes and the test results.
Preheating The act of applying the heat to the workpiece(s) on the base material in the
volume surrounding the joint to attain and maintain the specified preheat
temperature immediately before starting welding.
PWHT Is a controlled process in which a material that has been welded around a
welding joint is reheated to a specified temperature, and then it is held at
that temperature for a specified amount of time and cooled as specified,
according to the applicable standards.
A post weld heat treatment is performed to alleviate residual stresses,
increase the strength, increase or decrease the hardness, and reduce the
risk of cracking.
PWPS Preliminary Welding Procedure Specification is a document containing the
required variables of the welding procedure to be qualified.
Records Its written Elements provide evidence that the realization processes and
resulting products meet requirements.
Welding Any material used for making or protecting a weld, such as a Coated
Consumables electrode, rods, solid/tubular wires, fluxes, or shielding gases.
WPS A formal written document provides the required welding variables for a
specific application, as per the code requirements, which provides direction
to the welder or welding operators for making sound and quality production
welds.
WPQ A Welder Performance Qualification is a test certificate that shows that the
welder is qualified to weld in the range specified, according to the
reference code.
4. STANDARD AND DOCUMENT REFERENCES
The governing codes and standards for the above work procedure are listed here, which will be
strictly implemented, and work will be carried out in compliance with such codes or standards:
ASME IX ASME Boiler and Pressure Vessel Code - Welding, Brazing, and Fusing
Qualifications
ASME SEC II C Standard for Material and Consumable of Welding
API 1104 Standard for welding Pipelines and Related Facilities
ASME B31.4 Pipeline Transportation Method for Liquid and Formatted: English (United States)
Slurries
AWS D1.1 Structural Welding Code - Steel

ISO/TR 15608 Welding – Guidelines for a metallic material grouping system.
ISO 2560 Welding Consumables – Covered electrodes for manual metal arc
welding of non-alloy and fine grain steels – Classification.
General Procedure for Welding Activities (later)
Welding Consumable Handling Procedure (later) Commented [DG3]: Also insert Bonatti
specification references:
- LY0001-000-ZH-11023 - PIPELINE WELDING
SPECIFICATION
-LY0001-000-ZH-11002 – WELDING
SPECIFICATION FOR PIPING
5. RESPONSIBILITIES
Quality Manager (QM) Is responsible for ensuring that this procedure is followed and giving support
to the WE in the evaluation of the needs for the execution of the welding works, specifically the
processes to be applied, considering the applicable codes, the base materials, diameters and
thickness to be welded, including the necessity of qualifying new welding procedures and/or
welders.
Welding Engineer (WE) is responsible with the QM for drawing up the proposed WPS, pre-qualify
WPS for producing PQR, and approved WPS. Further, he is responsible for maintaining records of
all submitted WPSs and their relevant PQRs.
Maintaining all records related to PQR, WQT, WPS. Including, but not limited to:
Updating Welders Qualification Test Record Summary, with the WPSs for which are qualified.
Certified Welding Inspector (CWI) is responsible for supervising the WQTs and WPQTs and shall
witness the qualification tests, perform random inspections and Testing, and sign the test results.
Other responsibilities of CWI include but are not limited to:
 Inform Client and Third-Party Welding Inspector about place and time and facilitation of
WQT & WPQT exams.
 Cross-checking Non-destructive test and destructive test results of WQTs and WPQTs.
6. EVALUATION OF REQUIREMENTS
When the technical information for the project is placed available, i.e., Tender Documents,
Project Specifications, Drawings, Isometrics, etc., the Quality Department perform a detailed
analysis of the welding needs for the project.
The Welding Engineer (WE) with Quality Manager (QM) evaluate the needs for the execution of
the welding works, specifically the processes to be applied, considering the design codes, the
base materials, diameters, and thickness to be welded, including the necessity of qualifying new
welding procedures and/or welders according to project code.
With all previous elements, all Welding Procedure Specifications (WPS) covering all welding
activities planned for the project will be prepared. All WPS need to be covered by the approved
ProcedureWelding Procedure Qualification Record (WPQR). In the fault of a WPQR to validate
any of the WPS identified, a revised or new Preliminary Welding Procedure Specification
(PWPS) will be prepared to perform the needed WPQR.
WE and/or QM give the elements to the Project Manager to provide resources to perform the WPQR
and the need for Welders Performance Qualification.
In accordance with ASME BPV Code Section IX and API 1104, WPS and welding procedure
qualifications are the sole ownership of the company or entity that develops the procedures
and employs the welders. This welding documentation is non-transferable between companies
without Company approval and when considered by fabrication code (e.g. ASME B31.3 PAR. 328.2.2)
7. REQUIRED RESOURCES
To perform Welder and Welding Procedure Qualifications, it is necessary to organize the following
resources:
7.1 Equipment Commented [DG4]: Please to do reference to

Bonatti specification and its requirement LY0001-
Welding Machines 000-ZH-11023 for this paragraph
The welding machine is adequate for the welding process, and the machine shall present the
internal setting.
Available welding equipment, including all accessories, shall be in proper working order with the
necessary maintenance and a valid Calibration Certificate as applicable.
Ovens
Welders, during qualification, for the materials that require, must have individual portable ovens
for storing welding electrodes in a temperature setting per the manufacturer's recommendations
or the specific procedure.
The portable holding ovens used should be verified with a thermometer calibrated and identified
with a valid label.
Vacuum pack electrodes can be used without the portable oven.
They shall be placed in a clean container in the quantity needed for the test. The remaining
electrodes shall be re-baked or scraped.
Heat Treatment Machine
When the test piece to be welded requires PWHT, the equipment shall be suitable for the heat
treatment requested. It shall enable the temperature within the component to be controlled with
adequate accuracy and uniformity, especially for materials that have a small permissible heat
treatment temperature range. The equipment must have a valid Calibration Certificate as
applicable.
Preheating device
Electrical equipment or open flame devices can be used according to requirements. The device
chosen must be suitable for the application and to reach the required temperatures and
parameters according to the specific procedure and WPS.
Thermometer
To control the preheat and inter pass temperatures required as per applicable WPS, must be
available suitable thermometer with valid calibration. For some applications can be used
temperature-indicating crayons with a specific temperature. Infrared pyrometers and crayons
which indicate temperature by colour change shall not be used.
Working tool
A set of working tools must be prepared in good condition, as grinder, wire brush, gloves, welder
helmet, clamps, supports, etc.
7.2 Test Piece

The base material shall be in accordance with the defined in the applicable WPS. The base
material certificate shall be available to verify conformity with the applicable standards/codes,
i.e., heat number, material grade, chemical composition, mechanical properties, etc.
The length and the number of test pieces shall be enough to comply with the necessary tests
required by the applicable standards/codes.
No welding shall begin without first checking that the groove is in accordance with the sketch
included in the preliminary WPS, the parts to be welded are aligned, and the grooves are free of
mill scale,rust, oil, fat, or any other foreign matter.
Machined grooves already executed must be properly protected after machining to avoid
contamination with humidity, oil or grease during storage and handling in the workshops before
the qualification.
Pipe or plate position for procedure qualification shall be specified in the WPS in accordance with
the applicable requirements and standards/codes.
7.3 Consumables
All welding consumables shall be in accordance with the WPS, namely the standard designation,
dimensions of the filler metals, and, if required manufacturer and trade name, etc.
During qualification, the welding consumables shall be stored and used in accordance with
specific Welding Consumables Procedure and manufacturer recommendations in a way that
avoids proprieties deterioration or physical damage to them and their packages. Consumables
that show any kind of deterioration or visible damage shall be destroyed to avoid being used.
Humidity resistant package (Vacuum pack or equivalent) shall be purchased for electrodes
packaging.
7.4 Human Resources

Welder Performance Qualifications shall be performed by welders with proven experience or proven
training in the material, positions, and dimensions to be welded.
Welding Procedures Qualifications shall be preferably performed by a qualified welder in the
material, positions, and dimensions to be welded.
A welding inspector (examiner) must shall be present before starting the welding activities to
checkthe conformity of the preparation and the resources available and materials with the
requirements of the WPS, the code and the project.
7.5 Physical Resources

The area for the qualification works shall be presented in good and safe conditions, as adequate

space, protected from rain or wind, protections for all workers, etc.

8. WELDING PROCEDURE QUALIFICATION
8.1 Welding Procedure QUALIFICATION

The Welding Engineer shall prepare a Preliminary Welding Procedure Specification (PWPS) for use
on the welding of the sample test to obtain the Procedure Qualification.
In the presence of a Welding Inspector certified and with a qualified welder, the Test Sample will
be welded following the specified WPS and all working parameters registered according to the
requirements.
When the weld is finished, testing shall be done, including but not limited to non-destructive and
destructive testing, following the applicable standards/code requirements and project specification.
8.2 Non-destructive Testing (NDT)

When After the test piece is accepted by visually Visual Testing by the examiner, the NDT
applicable could be executedonshall be executed in the shop/site where the test piece is welded
or on in the NDT entity LAB.
8.3 Post Welding Heat Treatment (PWHT)

If the PWPS requires PWHT, this is made by a heat treatment qualified technician. The parameters
to be used in a PWHT are defined in the applicable PWPS and according to the desired objectives
and supported on WPS. The heat treatment records shall be provided, which indicate the
temperature, the rate of heating, holding and cooling times.
When the heat treatment is completed, the Welding Engineer analyses the results, and when
accepted, the chart will be duly stamped, signed and dated. The accepted PHWT chart is part
of the qualification process documentation.
8.4 Destructive Testing

The welds' coupons quality shall also be determinedbe examined by destructive Testing to
demonstrate that welds have suitable mechanical properties (such as strength, ductility, and
hardness). These procedures shall be adhered to except where a change is specifically authorized
by the Client. Destructive Testing will shall be carried out only for those welded joints which have
passed the NDT. Destructive Testing will be carried out for the specimen taken from welded joints of
WPQT.
The mechanical tests are to be executed by an accredited LAB as per ISO/IEC 17025 requirements
or equivalent.
The LAB shall indicate the type and extension of tests that will be performed on each piece
welded, according to the different applicable standards/codes.
8.5 Welding Procedure Qualification Record (WPQR)

The PQR combines all the information of the PWPS and adds the WQPT Inspection reports and Test
results to provide a complete document that certifies the procedure. The main information are
weld joint design, welding electrodes, sequence of welding passes, welding parameters,
method of clamping, grinding, cleanings, etc.
All PQR-related records, i.e., a personal identification of the welder, PWPS, NDT records, PWHT
charts when applicable, base material and welding material certificates, or any other record
pertaining relevant.

8.6 PQR Re-Testing

If the mechanical tests fail for whatever reason. The Contractor shall immediately investigate the
causes of the failure and take all necessary actions including but not limited to retesting and/or
re-evaluation of PQR parameters.
For Re-Testing, the COUPON shall be re-welded and Inspection and Testing mentioned above shall
be carried out again.
If, after retesting as described below, the qualification weld again fails to meet the minimum
requirements, a new (or revised) PWPS proposal shall be established, and a new qualification
welding and testing performed.
8.7 PQR Approval

After satisfactory completion of the required test, the PQR shall be prepared and certified
according to the applicable standards/codes or contractual specification, and submitted to
Company for Approval.
9. WELDER PERFORMANCE QUALIFICATION (WPQ)
Welders that will be deployed for welding work on pipelines or piping shall have a WPQ for the
applicable WPS by successfully completing the Welder Qualification Test (WPQT) according with
code requirements and applicable project specification.
9.1 Welder Performance Qualification Test (WPQT).

A Welder Performance Qualification Test is a weld demonstration for the qualification of the welder,
whereby the weld shall be performed in accordance with a specific WPS and is subsequently
subjected to NDT.and mechanical test as required by the code..
The WPQT must be supervised by Welding Inspector, and the Client or Client’s representative shall
witness the WQT to ensure that qualification tests are done in accordance with applicable Codes
/ Standards and Client Specifications.
WPQ shall be certified by Welding Inspector in accordance with the specific procedure and the
applied code.
9.2 WPQT Validity

The performance qualification of a welder or welding operator shall remain valid, provided
no greater than 6 months have passed since the qualified welding process was last used under
the supervision and control of the qualifying or participating organization(s)
Within this scope,a dedicated welders register shall be issued to record the date of
qualification and the date of successfully NDT
The NDT examination shall be performed at least within 6 month form qualification date and
then periodically each 6 month.
In case of NDT failure or not data recording, the involved WPQT shall be revoked
10. ANNEXES
Not applicable.

PROJECT AND LOCATION DOCUMENT NR.
LY0001-000-QA-11023
North Hamada (Area 47) Field
Development – Gathering Network and JOB NUMBER REV. SHEETS / OF
Oil Export Pipeline (EPCC) C-001-PRO-2019 0 1 / 29
CONTRACTOR DOCUMENT NUMBER
LY0001-000-ZH-11023
PIPELINE WELDING SPECIFICATION
Rev. 0
September 2022
0 15-09-22 Issue for Approval G. Dambrosio M. Musti N. Pompili

Rev. Date Description Prepared Verified Approved
LY0001-000-QA-11023
LY0001-000-ZH-11023
SUMMARY
1 INTRODUCTION ................................................................................................................... 5
1.1 DEFINITIONS ......................................................................................................................................... 6
1.2 ABBREVIATIONS ................................................................................................................................... 7
2 REFERENCE STANDARD AND SPECIFICATIONS............................................................. 9
1.3 GENERAL ............................................................................................................................................. 9
1.4 PROJECT’S SPECIFICATIONS ................................................................................................................. 9
1.5 INTERNATIONAL CODES AND STANDARDS .............................................................................................. 9
1.6 LANGUAGE......................................................................................................................................... 11
1.7 UNITS OF MEASUREMENT ................................................................................................................... 11
1.8 WELDING TERMS ........................................................................................................................... 11
3 SCOPE ................................................................................................................................ 13
4 GENERAL REQUIREMENTS.............................................................................................. 14
4.1 WELDING PROCESS ............................................................................................................................ 14
4.2 JOINT DESIGN .................................................................................................................................... 14
4.3 EQUIPMENT ........................................................................................................................................ 15
4.4 MATERIALS ........................................................................................................................................ 15
5 WELDING PROCEDURE SPECIFICATION ........................................................................ 16
5.1 GENERAL ........................................................................................................................................... 16
5.2 QUALIFICATION OF WELDING PROCEDURE ............................................................................. 17
5.3 ADDITIONAL ESSENTIAL CHANGES ...................................................................................................... 17
5.4 TEST WELD ACCEPTABILITY FOR DESTRUCTIVE TESTING..................................................................... 18
5.5 DESTRUCTIVE TESTING ....................................................................................................................... 18
5.6 TRANSVERSE TENSILE TEST ............................................................................................................... 18
5.7 IMPACT TOUGHNESS TESTING ............................................................................................................. 18
5.8 HARDNESS TESTING ........................................................................................................................... 19
5.9 BEND TESTING ................................................................................................................................... 19
5.10 MACROSCOPIC EXAMINATION .............................................................................................................. 19
5.11 REPAIR WELDING ............................................................................................................................... 19
6 QUALIFICATION OF WELDERS ........................................................................................ 20
6.1 GENERAL ........................................................................................................................................... 20
6.2 QUALIFICATION TEST PERFORMANCE................................................................................................... 20
6.3 REPAIR WELDER QUALIFICATION ........................................................................................................ 20
6.4 TEST WELD ACCEPTABILITY FOR WELDER QUALIFICATION .................................................................. 20
LY0001-000-QA-11023
LY0001-000-ZH-11023
6.5 RECORDS OF QUALIFIED WELDERS ..................................................................................................... 21

7 PRODUCTION WELDING ................................................................................................... 21
7.1 RECORD OF WELDING PROCEDURE QUALIFICATIONS AND WELDING SPECIFICATIONS ........................... 21
7.2 CLEANING OF PIPE ENDS .................................................................................................................... 21
7.3 PIPE IDENTIFICATION .......................................................................................................................... 21
7.4 LAMINATIONS ..................................................................................................................................... 21
7.5 GRINDING OF LONGITUDINAL SEAM WELDS ......................................................................................... 22
7.6 BEVELLING ........................................................................................................................................ 22
7.7 ALIGNMENT AND FIT-UP ...................................................................................................................... 22
7.8 WEATHER CONDITIONS ....................................................................................................................... 22
7.9 GROUNDING AND CABLES................................................................................................................... 23
7.10 PROTECTION OF COATINGS................................................................................................................. 23
7.11 PREHEATING AND INTERPASS TEMPERATURE....................................................................................... 23
7.12 START OF WELDING ........................................................................................................................... 23
7.13 RELEASE OF LINE-UP CLAMP .............................................................................................................. 23
7.14 CLEANING BETWEEN PASSES ............................................................................................................. 23
7.15 INTERRUPTIONS IN WELDING ............................................................................................................... 23
7.16 FILLER AND FINISH BEADS.................................................................................................................. 24
7.17 IDENTIFICATION OF WELDS AND WELDERS .......................................................................................... 24
7.18 CLEAN-UP OF THE WELD .................................................................................................................... 24
8 INSPECTION AND TESTING OF PRODUCTION WELDS.................................................. 25
8.1 GENERAL ........................................................................................................................................... 25
8.2 PERSONNEL ....................................................................................................................................... 25
8.3 VISUAL INSPECTION ............................................................................................................................ 25
8.4 RADIOGRAPHIC TEST ................................................................................................................... 25
8.5 MAGNETIC PARTICLE (MPI) ................................................................................................................ 26
8.6 ULTRASONIC INSPECTION ................................................................................................................... 27
 MANUAL ULTRASONIC INSPECTION (MUT) ........................................................................................... 27
 SEMIAUTOMATIC ULTRASONIC INSPECTION (PAUT) ............................................................................. 27
 AUTOMATIC ULTRASONIC INSPECTION (AUT)....................................................................................... 27
8.7 ACCEPTANCE CRITERIA FOR GIRTH WELDS .......................................................................................... 28
9 REPAIR OF WELDS CONTAINING DEFECTS................................................................... 28
9.1 CRACKS ............................................................................................................................................. 28
9.2 REPAIR PROCEDURE .......................................................................................................................... 28
9.3 REMOVAL OF DEFECTS ....................................................................................................................... 28
9.4 START AND STOP OF REPAIR WELDS .................................................................................................. 28
9.5 MINIMUM LENGTH OF REPAIR.............................................................................................................. 29
LY0001-000-QA-11023
LY0001-000-ZH-11023
9.6 INSPECTION OF REPAIRS..................................................................................................................... 29

9.7 FURTHER REPAIR ATTEMPTS .............................................................................................................. 29
LY0001-000-QA-11023
LY0001-000-ZH-11023
1 INTRODUCTION
The operator, Nafusah Oil Operations B.V. was established in 2013 to develop A/47 commercially declared
discoveries. North Hamada field is an onshore oil field consists of several hydrocarbon bearing structures.
It is located in the northern part of the prolific Ghadames Basin, NW Libya, 250km SW Tripoli within the
contract Block-47 awarded in ESPA IV round of 2005 to MEDCO-VERNEX consortium.
In 2014 MEDCO conducted comprehensive 3D-Reservoir simulation study led to a full development plan
(FDP) OF North-Hamada Field consisted of drilling 23 infill producers, 50.000 BOPD production capacity.
A FEED study executed the full scale development project through 3 main packages:
Package “A” Gathering system and exports pipelines.
Package “B” central processing facilities (CPF)
Package “C” Field Infrastructures.
Following the drop in Oil prices and instability in Libya, due to internal civil conflict, have raised the risks
associated to the FDP. The Management committee (MC) decided to pursue a phased-out development
strategy, an approach that considers an implementation of fast-track-development plan to reduce CAPEX,
expedite first oil and generate early cash flow to offset cost and enhance second party economics.
In 2018 phased out fast-track concept is envisioned, starting by an initial development phase, called fast-
track-early production period (FTEPF); for 3 years, 10000BOPD plateau, using 25000BOPD production train,
initially flaring the remaining associated raw gas and differing gas processing to the follow up phase.
The adopted Fast-track phased out development plan, is to be less costly, maintains integrity of
standards/quality and mitigate associated risks; thus achieves the objectives of expediting first oil to
generate early cash flow to offset cost, minimize high capital investment exposure, hence relaxes financial
obligations and evaluate reservoir performance to cater for future production optimization.
The Package “A” Gathering system and Oil Exportline” object of this Contract has been awarded to Bonatti
SpA in May 2022 and is relevant to the EPCC of the Pipeline Gathering Network and the Oil Exportline as
described in the following scheme.
The package “B” Central Processing Facility (CPF) will be substitute by a new Early Production Facility
(EPF) out of this Contract scope of work.
Gathering Facilities
9 Oil Production Wells
2 Water Wells
1 Remote Manifold Station (RMS)
2 Temporary RMS
1 EPF Manifold
Oil Exportline Facilities
1 Oil Exp. Tie-in Station
1 Block Valve Station
Pipelines
9 Oil Prod. Flowlines (4’’ & 6’’) 30 km
1 Trunkline 16’’ – 23 Km
1 Oil Exportline 12’’ – 50 Km
1 Water Flowline 4’’ - 1.5 km
LY0001-000-QA-11023
LY0001-000-ZH-11023
Figure 1 - Project Scheme
1.1 DEFINITIONS
COMPANY: Nafusah Oil Operations B.V.
CONTRACTOR: Bonatti Spa
PROJECT: North Hamada (Area 47) Field Development – Gathering Network and Oil
Export Pipeline (EPCC)
LY0001-000-QA-11023
LY0001-000-ZH-11023
SUPPLIER: Part selected by CONTRACTOR, which is responsible to supply or

manufacture the goods, material, equipment or services as specified in the
Purchase Order
CONTRACT: The agreement between CONTRACTOR and SUPPLIER constituted by the

contractual documents
GOODS: Items to be provided by the SUPPLIER according to the terms of the

PURCHASE ORDER
WORK: All the activities, accessories and equipment, necessary to cover the scope
of work
SUB-SUPPLIER: Any Manufacturer used by the SUPPLIER
SHALL: Use of the word “shall” implies a mandatory requirement, which can be
relaxed only with the written confirmation by the CONTRACTOR and/or
COMPANY
SHOULD: The use of the word “should” implies a recommendation
MAY: Is used where alternatives are equally acceptable
1.2 ABBREVIATIONS
A Welding Current (Amp)

API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
CE Carbon Equivalent
CVN Charpy V-Notch
D Pipe Outer Diameter (In. Or Mm)
DC Direct Current
DWE Double-Wall Exposure
DWV Double-Wall Viewing
HAZ Heat-Affected Zone
ID Inside Diameter
IDS Inspections Data Sheet
IOM Installation, Operation and Maintenance manual
IQI Image Quality Indicator
IRN Inspection Release Note
ISI Isolated Slag Inclusion
ITP Inspection test plan
J Heat Input (Joules Per in.)
KOM Kick Off Meeting
MPS Manufacturing Procedure Specification
NDT Non-destructive Testing
OD Outside Diameter
PIM Pre-Inspection Meeting
PO Purchase Order
QCP Quality control Plan
LY0001-000-QA-11023
LY0001-000-ZH-11023
RDDS Required documentation data sheet

SAT Site Acceptance Test
SAWH Submerged-Arc Helical Weld
SAWL Submerged-Arc Longitudinal Weld
SDR Supplier Document Register
SMYS Specified Minimum Yield Strength
SMTS Specified Minimum Tensile Strength
SOW Scope of work
SWE Single-Wall Exposure
SWV Single-Wall Viewing
t Specified Pipe Wall Thickness (in. or mm)
T Transverse
V Welding Arc Voltage (Volt)
WT Wall Thickness
Y/T Yield-To-Tensile Ratio
LY0001-000-QA-11023
LY0001-000-ZH-11023
2 REFERENCE STANDARD AND SPECIFICATIONS

1.3 GENERAL
All works described in this specification shall be carried out in accordance with the laws of Libya.
Unless otherwise stipulated, the latest edition of the international standards (at the Contract signature date)
and specifications referenced hereinafter shall apply.
1.4 PROJECT’S SPECIFICATIONS
DATA SHEET FOR LINE PIPE LY0001-000-LB-08350
TECHNICAL SPECIFICATION FOR LINEPIPE LY0001-000-LB-08300
BASIS OF DESIGN LY0001-000-ZB-04000
1.5 INTERNATIONAL CODES AND STANDARDS
API 5L Specification for Line Pipe
API 1104 22nd Edition Welding Pipelines and Related Facilities
ASME B16.9 Factory-Made Wrought Butt-welding Fittings
Pipeline Transportation Systems for Liquid Hydrocarbons and

ASME B31.4
Other Liquids
Standard Test Methods and Definitions for Mechanical Testing
ASTM A370
of Steel Products
ASTM E164 Standard Practice for Contact Ultrasonic Testing of Weldments
Standard Test Methods for Notched Bar Impact Testing of

ASTM E23
Metallic Materials
Standard Test Method for Knoop and Vickers Hardness of
ASTM E384
Materials
ASTM E709 Standard Guide for Magnetic Particle Testing
AWS A3.0 Standard Welding Terms and Definitions
Specification for Carbon Steel Electrodes for Shielded Metal

AWS A5.1
Arc Welding
Specification for Carbon Steel Electrodes and Rods for Gas
AWS A5.18
Shielded Arc Welding
Specification for Carbon Steel Electrodes for Flux Cored Arc
AWS A5.20
Welding
LY0001-000-QA-11023
LY0001-000-ZH-11023
Specification for Low-Alloy Steel Electrodes and Rods for Gas

AWS A5.28
Shielded Arc Welding
Specification for Low-Alloy Steel Electrodes for Shielded Metal
AWS A5.5
Arc Welding
ISO 14731 Welding Coordination Tasks and Responsibilities
Destructive tests on welds in metallic materials - Macroscopic

ISO 17639
and microscopic examination of welds
Non-destructive testing—Image quality of radiographs —Part
ISO 19232-1, 1: Image quality indicators (wire type)—Determination of image
quality value
ISO 6507 Metallic materials — Vickers hardness test

LY0001-000-QA-11023
LY0001-000-ZH-11023
1.6 LANGUAGE
All documents and any other written information shall be submitted by the SUPPLIER in the English
language.
1.7 UNITS OF MEASUREMENT
International System (SI) shall be used, unless otherwise specified in the applicable specifications.
1.8 WELDING TERMS
Arc Strikes Localized areas where an electrical arc has heated an area away from
the weld joint bevel and weld heated affected zone.
Cap Pass The final weld layer or pass in a multi-pass weld.
Company Owner company or the engineering agency in charge of construction. A

company may act through an inspector or another authorized
representative.
Controlled A section of welds consisting of a defined number of welds which
Welding demonstrate SUPPLIER's ability to establish and maintain a consistent
Section workmanship standard as defined by Company
Defect Imperfection of sufficient magnitude to warrant rejection based on the
acceptance criteria in applicable standard.
Double Repair Second repair in a previously repaired area of a completed weld;
typically referred to as a “repair of a repair” or a “re-repair.”
Essential A welding change that may affect the mechanical properties or quality
Change of the weld
Fill Pass Any weld bead applied between the hot pass and the cap pass in a
groove weld or between the root pass and the cap pass in a fillet weld.
Full Thickness Repair weld originating from the weld face that penetrates completely
Repair through the weld thickness
Golden Welds Tie-in welds that are not pressure tested.
Grinding Mechanical means to remove weld metal using abrasive methods
Hot Pass The second pass in a multi-pass weld.
Imperfection Discontinuity or irregularity that is detectable by methods outlined in

this standard.
Inclement Weather conditions which prevent SUPPLIER from operating safely or
Weather within the scope of this specification
Indication Evidence obtained by non-destructive testing.
Internal Bead that is properly fused to and completely penetrates the pipe wall
Concavity thickness along both sides of the bevel but whose centre is somewhat
below the inside surface of the pipe wall.
Latent Defects Welding defects, which take time to initiate and propagate e.g.
hydrogen cold cracks
LY0001-000-QA-11023
LY0001-000-ZH-11023
Maximum The maximum temperature of the weldment between weld passes

Interpass measured immediately before the start of any weld pass, at a location
Temperature 12.7 millimetres from the edge of the weld.
Maximum The maximum temperature that the pipe and weld area can be heated
Preheat to at any location any time before or during welding.
Temperature
Mechanized Process where parameters and torch guidance are controlled
Welding mechanically or electronically but may be manually varied during
welding to maintain the specified welding conditions.
Minimum The minimum temperature of the weldment at any time between weld
Interpass passes measured at a location fifty (50) millimetres from a production
Temperature weld joint.
Minimum The minimum temperature that the pipe and weld area must be
Preheat immediately before welding is performed measured at a location fifty
Temperature (50) millimetres from a production weld joint, or one hundred and fifty
(150) millimetres from the edge of a repair weld
Multiple More than one individual repair area location in a completed weld
Repairs
Partial Repair weld originating from the weld face or root bead surface
Thickness extending into the weld but does not completely penetrate through the
Repair weld thickness.
Position Welding in which the pipe or assembly is not rotating while the weld is
Welding being deposited.
Procedure Compliance to all welding essential changes as defined by this
Compliance specification and API 1104 22nd Edition
Procedure Procedure Qualification Records are the actual documented variables
Qualification recorded during the qualification welding of test coupons to
Record demonstrate the compatibility of consumables and techniques in the
joining of materials typical for a given application. It also contains the
mechanical test results of the tested specimens
Qualified Tested and proven detailed method by which sound welds with suitable
Welding mechanical properties can be produced.
Procedure
Specification
Repair Any grinding or welding on a completed weld to correct an individual
defect or accumulation of defects in the weld that has been rejected by
visual or non-destructive testing in accordance with acceptance criteria
in this standard.
Repair Area One individual repair location in a completed weld that may include a
single defect or accumulation of defects.
Repair Tested and proven detailed method by which sound repairs with
Procedure suitable mechanical properties can be produced.
Repair Weld Weld made to repair a defect (or defects) found in a completed weld.
Qualified Welder who has demonstrated the ability to produce welds that meet
Welder the requirements of Section 6 of this standard.
Root Bead First or stringer bead that initially joins two sections of pipe, a section of
pipe to a fitting, or two fittings.
LY0001-000-QA-11023
LY0001-000-ZH-11023
Semiautomatic Arc welding with equipment that controls only the filler metal feed. The
Welding advance of the welding is manually controlled.
Stacked Individual imperfections aligned in the radial (through thickness)
Defects direction, at the same circumferential location, and exceed the
acceptance standards.
Tack Welds A temporary weld segment designed to hold a weldment in alignment
prior to and during welding
Tie-In Welds Welds for the purpose of connecting piping sections or connections to
prefabricated assemblies, normally carried out in a ditch.
Travel Speed The rate of a weld passes along the axis of the weld; i.e. distance
travelled over a period of time.
Weld Repair The percentage of welds, which do not meet specified weld acceptance
Rate criteria. The Weld Repair Rate is calculated by dividing the total
number of welds produced during a given period by the number of
welds that require repair over the same period
Welding (WPS) The WPS identifies the essential changes recorded during the
Procedure development of the PQR and extends these into a range of essential
Specification changes to be followed for a specific task. Welding requirements such
as preheat temperatures, consumables and heat inputs are identified in
the WPS.
3 SCOPE
This document describes the technical requirements that SUPPLIER shall follow for the execution of pipeline
girth welds and mainly related to:
• Bevel Preparation.
• Equipment and Materials.
• Welding Procedures Qualification.
• Welder Qualification Testing.
• Production Welding.
• Visual and Non-Destructive Examination.
• Repair Welding Procedure.
This specification shall govern the welding processes permitted for use in the construction of all equipment
covered by these specifications.
This specification shall apply to all suppliers, sub-suppliers, and fabricators of welded equipment who shall
not sub-contract the welding fabrication of any equipment without COMPANY and/or CONTRACTOR prior
written approval. Such written approval shall not be forthcoming until approval for the type of welding to be
carried out by the proposed welding fabricator has been granted.
This standard also covers the procedures for radiographic, magnetic particle, liquid penetrant, and ultrasonic
testing, as well as the acceptance standards to be applied to production welds tested to destruction or
inspected by radiographic, magnetic particle, liquid penetrant, ultrasonic, and visual testing methods.
The SUPPLIER shall furnish all labour, materials, and equipment necessary for the cleaning, surface
preparation, and inspection of the weld in accordance with this specification.
LY0001-000-QA-11023
LY0001-000-ZH-11023
Material Test Certificates shall be provided for all materials.
In addition to the SUPPLIER’s inspections, CONTRACTOR may perform any inspection to verify compliance
with this specification. Inspection may include all work equipment, inspection equipment, materials or
procedures and may be conducted at any time CONTRACTOR chooses.
The SUPPLIER shall correct any work which CONTRACTOR has determined not to comply with the
requirements of this specification. Corrections shall be made without additional cost to CONTRACTOR.
Failure to discover or reject defective work or materials does not constitute acceptance of such work or
materials.
It is the responsibility of the SUPPLIER to meet the requirements of this specification, to use equipment
capable of meeting the requirements, and to perform all inspections necessary to ensure compliance.
SUPPLIER shall provide, and maintain in good working order, all facilities required to meet this specification
including the following:
 The SUPPLIER must liaise with qualified testing laboratory and experienced personnel and the
necessary equipment to perform all quality assurance tests required by this specification.
 All equipment must be in good working order and properly calibrated. Testing must be completed in
a timely manner to avoid disrupting the production schedule.
 The SUPPLIER shall notify CONTRACTOR at least three (3) weeks prior to beginning the PQR
It is the responsibility of the SUPPLIER to perform all work in a manner consistent with all applicable health
and safety regulations.
4 GENERAL REQUIREMENTS
Welding shall be performed in accordance with API 1104 22nd Edition and the additional
requirement of this document.
4.1 WELDING PROCESS

SUPPLIER shall qualify at least the following welding procedures for the specific project according
with all the essential variables highlighted.
 Main Line Welding

 Tie-In and Golden welds
 Repair Welding Procedures
4.2 JOINT DESIGN

 Butt Welds
Butt welds between pipes of unequal nominal wall thickness shall be according to the permissible
weld configuration given in ASME B31.4 Figure 434.8.6-2. or as otherwise specified for NDE
purpose
 Tack Welds
When necessary tack welds shall be performed with the same weld procedure specification as the
root run and by a welder qualified for that run. They have to be evenly distributed around the pipe
circumferences. Tack welds shall be at least 30 mm long and for > DN 400 at least 50 mm. Where
LY0001-000-QA-11023
LY0001-000-ZH-11023
preheating is required for the root run, this shall be applied prior to tack welding and maintained until
the joint is completed.
4.3 EQUIPMENT
SUPPLIER shall supply all necessary welding equipment for the satisfactory completion of the work.
The equipment shall be maintained in such condition as to provide continuity of operation and safety
of personnel.
Welding equipment, both gas and arc, shall be of a size and type suitable for the work and shall be
maintained in a condition that ensures acceptable welds, continuity of operation, and safety of
personnel. Arc welding equipment shall be operated within the amperage and voltage ranges given
in the qualified welding procedure specification (WPS). Gas welding equipment shall be operated
with the flame characteristics and tip sizes given in the qualified welding procedure specification.
Equipment that does not meet these requirements shall be repaired or replaced.
SUPPLIES shall submit to CONTRACTOR all relevant calibration certificates for welding generators,
gas mixers or any other equipment to be used during production.
SUPPLIER shall use internal line-up clamps designed to avoid mechanical damage to the pipe and
maintain the alignment within the specified tolerances in WPS.
4.4 MATERIALS
 Pipe and Components
Materials shall be welded according to the ranges of qualified welding procedure specification.
Material grouping system according to API 1104
 Filler Metals and Fluxes
All filler metals and fluxes shall conform to one of the following, except as provided below:
a) AWS A5.1,
b) AWS A5.2,
c) AWS A5.5,
d) AWS A5.17,
e) AWS A5.18,
f) AWS A5.20,
g) AWS A5.23,
h) AWS A5.28,
i) AWS A5.29.
All welding consumables shall be selected to produce welds with yield strength at least equal to the
minimum specified for the parent material.
All welding consumables shall be supplied in sealed, dirt and moisture proof containers. Filler metals
and fluxes shall be stored and handled in accordance with manufacturer’s datasheet
recommendations and to avoid any damage to the containers in which they are shipped. Filler metals
and fluxes in opened containers shall be protected from deterioration, and filler metals that are
coated shall be protected from excessive changes in moisture. Filler metals and fluxes that show
signs of damage or deterioration shall not be used.
Filler materials shall be supplied with certificate in accordance EN ISO 10204 at least 3.1 chemical
analysis, 2.2 for Tensile and Impact.
 Shielding Gases
LY0001-000-QA-11023
LY0001-000-ZH-11023
Components of shielding gases are recommended to have a purity of at least 99.5% and a dew point
of -34°C. Gas mixtures can be supplied in pre-mixed cylinders or by field mixing.
Shielding gases shall be kept in the containers in which they are supplied, and the containers shall
be stored away from extremes of temperature. Gases in containers that show signs of damage shall
not be used.
5 WELDING PROCEDURE SPECIFICATION
5.1 GENERAL
Before production welding is started, a detailed welding procedure specification shall be established
and qualified to demonstrate that welds produced are suitable in mechanical properties (such as
strength, ductility, and hardness) and soundness.
Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR) for main line
welding, tie-in welding and repair welding procedures shall be submitted to CONTRACTOR prior the
commencement of production welding. SUPPLIER shall prepare and test all qualification test
coupons required to meet all design and materials within the scope of work.
The WPS shall represent a summary table showing type of process, filler materials/ consumables,
direction of welding, type of weld, WPS no., wall thickness range qualified, outer diameter, and
scope of specification.
The WPS shall be in accordance with Error! Reference source not found. and include the
additional details noted hereafter, in accordance with COMPANY and/or CONTRACTOR
requirements:
 Minimum preheating temperature;

 Maximum inter-pass temperature;
 Number of welders;
 Type of Joint;
 Type of line-up clamp and backing supports;
 Fit-Up tolerances and bevel dimensional tolerances;
 Electrode stick-out length (if applicable);
 Cleaning and/or grinding;
 Manufacturer and trade name of consumables;
 Shielding gases and flow rate;
 Scope of qualification in terms of material sourcing, steel grade, outer diameter and wall
thickness group;
 The specific welding process or combination of processes;
 Details of weld joint configuration giving the shape of the groove, angle(s) of bevel, root face
dimensions and allowable tolerances;
 Dimensions of test weld pieces and range of pipe sizes covered by it;
 Welding positions covered, e.g. horizontal, vertical;
 Details of filler metal giving trade name, classification and size of electrode or filler wire and
chemical composition;
 Details of shielding gas including type, composition, flow rate;
 Method of cleaning procedure prior to welding;
 Electrical characteristics of welding, i.e. current and voltage range and polarity for each size
of electrode or filler wire;
 Heat input range;
 Welding travel speed ranges;
LY0001-000-QA-11023
LY0001-000-ZH-11023
5.2 QUALIFICATION OF WELDING PROCEDURE
Welding procedure shall be qualified in accordance with essential variables in compliance with
Error! Reference source not found. and the additional requirements of this document. SUPPLIER
shall simulate field production welding as closely as practical during the qualification of Welding
Procedure.
Two pipe pup pieces shall be joined by following all the details of the preliminary welding procedure
specification.
The quality of the weld shall be determined by both destructive and non-destructive testing and shall
meet the requirements of Error! Reference source not found..
All welding procedure qualification tests shall be conducted in the presence of the Inspector and a
third party.
SUPPLIER shall be responsible for all aspects of welding procedure qualification, and shall:
 Notify CONTRACTOR and/or COMPANY at least three (3) weeks in advance of welding
procedure qualification test;
 Develop and document welding procedures for the entire range of materials and welding
variables within the scope of work;
 Prepare and test all qualification test coupons required to meet all operation and materials
within the scope of work;
 Instruct and supervise welding personnel during the preparation of test welds;
 Measure and record welding parameters used during the preparation of test welds;
 Check preheat/interpass temperatures to verify compliance with calibrated instrumentations;
 Test the welds using both non-destructive (e.g. visual and radiographic) and destructive
tests;
SUPPLIER may submit previously qualified welding procedure qualifications for approval by
CONTRACTOR and/or COMPANY.
5.3 ADDITIONAL ESSENTIAL CHANGES

Any change from the welding process or method of application established in the welding procedure
specification constitutes an essential variable. Over those essential variables given by Error!
Reference source not found., par. 5.4.2. WPSs shall be limited by the following additional essential
changes:
 Base Materials: A change in grade from one grouping to a higher grouping.

NOTE: Qualification in one grade grouping qualifies for welding materials in a lower grade
grouping.
 Preheat temperature: A change in preheat temperature to a lower temperature than that
recorded during procedure qualification.
 A change of the manufacturer of consumables used for qualification welds shall not be permitted
without written consent from CONTRACTOR and/or COMPANY
 A change in the minimum specified yield strength of the filler metal.

 All repair welding shall use a minimum preheat and interpass temperature of one hundred and
twenty (120°) Celsius.
LY0001-000-QA-11023
LY0001-000-ZH-11023
 Change to a minimum design temperature lower (colder) than that used for impact toughness
testing or fracture toughness testing during procedure qualification shall necessitate retesting for
impact toughness.
5.4 TEST WELD ACCEPTABILITY FOR DESTRUCTIVE TESTING
Test welds shall meet standards of acceptability for non-destructive visual inspection given in API
1104 22nd Edition, Table 4, par. 9.
Test welds failing to meet the standards of acceptability for non-destructive inspection shall not be
submitted to destructive testing.
5.5 DESTRUCTIVE TESTING

To test the butt-welded joint, test specimens shall be cut from the joint at the locations shown as per
Error! Reference source not found., Figure 3. The minimum number of test specimens and the
tests to which they shall be subjected are given in Error! Reference source not found., Table 2
and the other mechanical tests reported in this specification.
The specimens shall be air cooled to ambient temperature prior to being tested.
SUPPLIER shall destructively test weld procedure test coupons following successful completion of
non-destructive examination according with Error! Reference source not found., Table 2 and the
inspection methods of this specification.
SUPPLIER, unless otherwise agreed, shall prepare a cutting sheet detailing all the destructive test to
be performed each welding procedure qualification test coupon.
The facility chosen by SUPPLIER for Mechanical Testing shall be approved by COMPANY and/or
CONTRACTOR.
5.6 TRANSVERSE TENSILE TEST

The full-thickness tensile strength test specimens shall be either of the types shown in Error!
Reference source not found., Figure 4.
 The standard specimens shall be prepared as shown in Error! Reference source not found.,
Figure 4 a). They may be machine cut or oxygen cut, and no other preparation is needed unless
the sides are notched or are not parallel. If necessary, the specimens shall be machined so that
the sides are smooth and parallel.
 The reduced section specimens shall be prepared as shown in Error! Reference source not
found., Figure 4 b). The weld reinforcement may be removed
The tensile strength test specimens shall be broken under tensile load using equipment capable of
measuring the load at which failure occurs. The tensile strength shall be computed by dividing the
maximum load at failure by the smallest cross-sectional area of the specimen, as measured before
the load is applied.
The tensile strength of the weld, including the fusion zone of each specimen, shall be greater than or
equal to the specified minimum tensile strength (SMTS) of the pipe material but need not be greater
than or equal to the actual tensile strength of the material. If the specimen breaks outside the weld
and fusion zone (i.e., in the parent metal) at a tensile strength not less than 95 % of that of the SMTS
of the pipe material, the weld shall be accepted as meeting the requirements.
If the specimen breaks in the weld metal, it shall be considered acceptable provided that the
specified minimum tensile strength of the base metal has been achieved.
5.7 IMPACT TOUGHNESS TESTING

Each procedure qualification record shall include testing of three weld metal and three heat affected
zone Charpy Impact specimen.
LY0001-000-QA-11023
LY0001-000-ZH-11023
Charpy impact tests shall be prepared and tested in accordance with ASTM E23, each test
corresponds to one set of three specimens.
The specimens shall be machined with their longitudinal axis transverse to the weld. The specimens
and notch locations with respect to weld cross-section shall be as described in ASTM E23.
The average value of the Charpy V-notch energy for the three (3) specimens shall be a minimum of
30 J, minimum impact for each specimen 27 J.
If the stated impact requirements are not satisfied for one set, three further specimens to be tested.
The mean value of all six tests shall be at least equal to the specified minimum average value.
Impact Test shall be conducted at or below -7°C.
5.8 HARDNESS TESTING

A Vickers HV10 hardness survey according to ASTM E384. Hardness value at any measurement
point shall not exceed 275 HV.
The measured hardness values of the base metals, heat-affected zones and weld metal shall be
recorded on the laboratory test report. Hardness testing shall be performed on each macro
examination specimens according to Figure 2
Figure 2
5.9 BEND TESTING

Specimens and testing for bend testing for butt joints shall be in accordance with Error! Reference
source not found.. Four side bend specimens shall be used for thickness above 12 mm.
During testing, the test specimens shall not reveal any imperfection >3 mm in any direction.
Imperfections appearing at the corners of a test specimen during testing shall be ignored in the
evaluation.
5.10 MACROSCOPIC EXAMINATION
The test specimen shall be prepared and etched in accordance with ISO 17639 on one side to
clearly reveal the fusion line, the HAZ and the build-up of the runs.
The test specimen shall include unaffected parent metal and shall be recorded by at least one
photograph of macro cross-section per procedure test.
5.11 REPAIR WELDING
Weld repair procedure qualification shall be performed by producing a segments of through-

thickness weld repair on full-circumference girth welds. The minimum repair length for weld repair
procedure qualification shall be 300 mm. Coupons shall be removed from such repaired location,
300 mm wide, centred on the weld, with a minimum of 50 mm excess length on either side of the
clearly marked repair area. Qualification of full thickness repair qualifies mid-thickness repair and cap
Repair.
LY0001-000-QA-11023
LY0001-000-ZH-11023
All repair welding shall use a minimum preheat and interpass temperature of 120 °C. Each repair
weld shall be non-destructively tested by radiographic methods and magnetic particle methods after
the weld has cooled to ambient temperature and destructively tested.
Two transversal tensile tests, two root bends, two face bends (or 4 side bend as per par.5.9), weld
metal impact tests, HAZ impact tests, and a hardness survey shall be carried out on samples
removed.
As an option, separate qualification is required for internal root pass repair. The internal repair length
shall be minimum 100 mm, performed in one pass using low hydrogen electrodes of 2.5- or 3.2-mm
diameter. Repair area to be subjected to macro section, hardness test and bend test in accordance
with API 1104 22nd Edition.
6 QUALIFICATION OF WELDERS
6.1 GENERAL
The aim of WQT (welder qualification test) is to establish the ability of a welder to follow verbal or
written instruction and verification of a person’s skills are important factors in ensuring the quality of
the welded product.
Prior to starting the qualification tests, the welder shall be allowed reasonable time to adjust the
welding equipment to be used. The welder shall follow the requirements of the applicable qualified
welding procedure specification. The qualification of welders shall be conducted in the presence of a
representative acceptable to the company.
Each welder shall be qualified and shall submit a corresponding certificate according to API 1104 for
each welding work he will perform.
Each welder shall make a complete test weld (root, hot pass, filler and cap pass) regardless of the
type of weld he is assigned for.
For pipe diameter greater than 323,9 mm OD, for the purpose of welder qualification testing,
terminology “weld” shall mean one half of the total pipe circumference.
SUPPLIER shall provide training for welders before starting qualification test to allow them to obtain
adequate skills to produce acceptable welds on consistent basis.
6.2 QUALIFICATION TEST PERFORMANCE

Welders or operator’s qualification shall be performed according to a qualified WPS. The qualification
test coupon shall be visually and radiographically / ultrasonically inspected (depending on the
qualified NDT inspection). The acceptance criteria shall be in accordance with Error! Reference
source not found.
6.3 REPAIR WELDER QUALIFICATION

Welders shall be qualified for repair welding by producing two (2) segments of through-thickness
weld repair on full-circumference girth welds: in the flat/vertical (12 to 2 o’clock) and
overhead/vertical (4 to 6 o’clock) positions. Each repair segment shall be a minimum of 100 mm
long.
SUPPLIER shall qualify welders performing repairs in accordance with the approved full through
thickness repair welding procedure, as this test shall qualify welders performing repairs to complete
for partial through thickness repairs and back weld repairs.
6.4 TEST WELD ACCEPTABILITY FOR WELDER QUALIFICATION

Welders or operators shall be qualified when they produce a test weld that:
 is within the essential variables of the welding procedure specification;
 meets the visual inspection and non-destructive inspection requirements of 8;
LY0001-000-QA-11023
LY0001-000-ZH-11023
 Test welds failing to meet the visual inspection requirements shall not be submitted to non-
destructive inspection;
6.5 RECORDS OF QUALIFIED WELDERS
Records shall be made of the tests given to welders and of the detailed results of each test.
A list of qualified welders and the procedure specifications in accordance with which they are
qualified to weld shall be maintained and shall be submitted to the Company upon request.
Welders shall be assigned a unique number for the purpose of identification on all welds. Once the
number is assigned to a welder it may not be re-assigned to another welder during the project.
SUPPLIER shall prepare and maintain a list of qualified welders and their qualification
7 PRODUCTION WELDING
SUPPLIER shall perform welding of pipe using qualified welders in accordance with Company
approved qualified welding procedure specifications. SUPPLIER shall continuously monitor welding
to ensure compliance with the welding requirements.
Piping shall be welded by qualified welders using qualified procedures. The surfaces to be welded
shall be smooth, uniform, and free from laminations, tears, scale, slag, grease, paint, and other
deleterious material that might adversely affect the welding. The joint design and spacing between
abutting ends shall be in accordance with the welding procedure specification used.
7.1 RECORD OF WELDING PROCEDURE QUALIFICATIONS AND WELDING SPECIFICATIONS

Details of the welding procedure qualification tests shall be documented on the PQR.
During construction, copies of the welding specifications shall be available for reference at the local
work site where the welding is being completed.
7.2 CLEANING OF PIPE ENDS

Areas to be cleaned free of oxides shall include the weld bevel and both internal and external pipe
surfaces in the vicinity of the weld for a distance of at least 5-20 mm from the end of the pipe.
SUPPLIER shall clean the pipe removing bevel shavings, dirt, snow, ice, water prior to alignment for
welding
SUPPLIER shall clean to sound metal all piping ends which are to form a part of the welded joint
prior to welding to ensure complete removal of all paint, grease, oxide, rust and any other
extraneous matter. Cleaning shall extend for at least twenty-five (25) millimetres from the piping
edges on both internal and external surfaces. SUPPLIER shall grind out and blend small score
marks, indentations or other small defects within the joint preparation area shall. SUPPLIER shall
remove clusters of surface porosity, bead starts, heavy glass deposits and high points prior to
depositing weld metal over them.
7.3 PIPE IDENTIFICATION

Pipe identification shall be transferred to both sides of any cut. Die stamping of the pipe or weld shall
not be permitted for that purpose. SUPPLIER shall transfer manufacturer's pipe joint numbers, pup
length and heat numbers to each length of pipe cut from any joint of pipe. Identification shall be
made by suitable marking using indelible permanent marking crayons.
7.4 LAMINATIONS
a) Should any lamination or split end be discovered at the bevelled end of a pipe joint, either
before or during welding, the joint shall be cut back until the lamination has been completely
removed and the end re-bevelled.
LY0001-000-QA-11023
LY0001-000-ZH-11023
b) Consideration shall be given to using ultrasonic, liquid penetrant or magnetic particle inspection
methods to confirm the new cut end is free of laminations or splits prior to welding.
7.5 GRINDING OF LONGITUDINAL SEAM WELDS

Submerged arc welded pipe seam welds shall be ground flush (-0, +0.5 mm) with a gradual
transition to the weld reinforcement for a minimum distance of 10 mm from the top edge of the bevel,
or 125 mm where mechanized welding and/or mechanized ultrasonic inspection is specified
7.6 BEVELLING
If bevelling is mandatory as per Welding Procedure Specification, SUPPLIER shall supply suitable
labour to train in the use of the facing/bevel machine prior to starting production welding. SUPPLIER
shall use bevel dimensions as specified on CONTRACTOR approved welding procedure and shall
be checked and documented by SUPPLIER on a regular basis.
If the difference in nominal wall thickness of adjoining pipes exceeds 1.6 millimetres, transitioning of
the thicker pipe down to the thinner pipe shall be required, in accordance with ASME B31.4 Figure
434.8.6-2.
Original mill bevels shall be cleaned to a bright metal finish, internally and externally to at least 5-20
mm wide. Any dent not suitable for the welding process or any crack close to ends shall be cut and
bevelled again.
Field bevelling shall be made by machine tool or machine oxygen cutting. Bevelling by hand cutting
torch shall not be allowed. The bevelled ends shall be reasonably smooth and uniform, and
dimensions shall be in accordance with the qualified welding procedure.
When oxy-cut bevels is used, bevel surface shall be grind back to bright metal.
Bevel geometry shall be in accordance with the relevant approved WPS.
7.7 ALIGNMENT AND FIT-UP

SUPPLIER shall use line-up clamps in accordance with the approved welding specification.
All joints with diameter over 323.9 mm shall be aligned with an internal line-up clamp, except for tie-
ins or when the use of an internal clamp is not practical. Offset, caused by dimensional variations,
shall be equally distributed around the circumference of the pipe.
Except in the case of bends, longitudinal seam welds shall be located at approximately the 10
o’clock and 2 o’clock positions for mainline activities.
For pipe diameter 400 mm OD and larger pipe, longitudinal, spiral and skelp end welds in adjacent
lengths of welded pipe should be offset by a minimum distance of 50 mm. Exceptions may be
considered for field bends, tie-ins, and counter-bore and taper transitions on spiral seams.
Hammering of the pipe shall not be permitted (use of a small hard plastic or steel hammer to signal
release of internal clamps is acceptable as long as there is no damage to the pipe surface or
adjacent coating). Where external line-up clamps are used, minor out of roundness and
misalignment shall be corrected using wedges.
SUPPLIER shall use external line-up clamps for tie-in welds.
7.8 WEATHER CONDITIONS

Welds shall be protected during welding from weather conditions considered detrimental to weld
quality. Portable enclosures may be used to make conditions satisfactory for welding.
LY0001-000-QA-11023
LY0001-000-ZH-11023
7.9 GROUNDING AND CABLES

Grounding devices shall be designed to prevent ark strikes. Device’s grounding in the bevel area
shall be made of steel, copper or bronze tips shall not be used for such purpose.
Welding cables and connections shall be insulated to prevent arc strikes to the pipe surface.
Grounding devices shall be securely attached in a manner to prevent arc burns, but shall not be
welded to the pipe, nor placed on the pipe body. This contact shall preferably be made within the
weld groove and shall be large enough to prevent local overheating or arcing, i.e., minimum 12 mm
wide x 3.2 mm thick.
7.10 PROTECTION OF COATINGS
Consideration shall be given to protect existing coatings on piping to minimize damage that may
result from the welding operations.
7.11 PREHEATING AND INTERPASS TEMPERATURE
SUPPLIER shall preheat using approved methods as specified on the approved welding procedure
specifications. The minimum preheat temperature shall extend around the entire circumference of
the pipe and at least fifty (50) millimetres on each side of the weld joint. During completion of the
weld, the joint shall be maintained at a temperature between the minimum and maximum interpass
temperatures and shall be checked using temperature indicating crayons or other suitable method
immediately prior to, and during the full welding operation.
SUPPLIER shall prevent overheating and no part of the area shall be heated more than two hundred
degrees (200°) Celsius
Preheating temperature shall be established during procedure qualification and specified in the
welding procedure. Interpass temperature shall not be allowed to exceed 200°C.
The minimum preheat temperature shall be checked for a band of 50 mm from the bevel edge. The
welds must be at the minimum preheat temperature (or higher) prior to welding each pass. When
preheating with a flame, a minimum of 15 seconds shall elapse after the flame is removed from the
surface before preheating and interpass temperatures are measured.
No passes of a weld shall be cooled at a rate greater than that provided by natural air-cooling.
7.12 START OF WELDING
Welding shall not commence until all parts to be joined are secured against movement.
7.13 RELEASE OF LINE-UP CLAMP
When using internal line-up clamps the root pass shall be completed for 100% of the circumference
prior to release.
For external line-up clamps the root pass shall be at least 50% complete before removal of the
clamp.
Cautionary Note: To minimize the risk of cracking of manual welds it may be necessary to weld the
hot pass for an approximate length of 300 mm in highest anticipated stresses, prior to moving the
pipe. This area would typically be on the bottom of the pipe but could be on the top of the pipe in an
over-bend situation, or on the sides of the pipe in a side bend situation.
7.14 CLEANING BETWEEN PASSES
Interpass cleaning for slag removal by grinding or power brush.
7.15 INTERRUPTIONS IN WELDING
Welding of a production weld shall normally continue without interruption and the weld temperature
shall be maintained above the minimum interpass temperature until at least two (2) passes are
completed, or half weld thickness is filled. If welding is interrupted at this point, the weld shall be
preheated to the minimum preheat temperature before welding commences.
LY0001-000-QA-11023
LY0001-000-ZH-11023
The maximum time delay between weld passes is:
 Root and hot pass – (to be qualified during WPQT).

 Hot and first fill - 60 minutes.
Mainline welds shall be completed within 72 hours. Tie-in welds shall be completed within 48 hours.
7.16 FILLER AND FINISH BEADS
Unless specified otherwise in the welding procedure, no beads shall commence until the preceding
bead has been completed.
The circumferential start locations of consecutive beads shall overlap by at least 25 mm.
The face of the completed weld should be 3 mm greater than the width of the original groove, but no
more than 5 mm greater.
7.17 IDENTIFICATION OF WELDS AND WELDERS
Weld identification shall be visible from 2 meters away.

Welders shall be responsible for marking their individual welder number on the top quadrant of the
pipe adjacent to each weld they have worked on.
On coated pipe, markings shall not be made closer than 200 mm from the edge of the coating, so as
not to be removed by sandblasting and coating activities.
Wax and/or oil -based markers and steel die stamping shall not be used for such a purpose.
Cut-out shall maintain the original weld identification.
7.18 CLEAN-UP OF THE WELD
Weld spatter, coating or loose debris shall be completely removed from the surface of the joint for a
minimum distance of 150 mm on each side of the weld.
LY0001-000-QA-11023
LY0001-000-ZH-11023
8 INSPECTION AND TESTING OF PRODUCTION WELDS
8.1 GENERAL
Non-destructive inspection procedures used shall be documented and all such procedures shall be approved
by personnel qualified as specified in ISO 9712 Level III for the inspection method being employed and shall
be accepted by the company.
All butt welds shall be non-destructively inspected for 100% of their length by visual inspection and by
radiographic testing methods or automatic ultrasonic testing AUT, according with ASME and API
standards.
8.2 PERSONNEL
Inspectors shall be qualified in accordance with ISO 9712 and their qualifications shall be approved by the
CONTRACTOR and/or COMPANY.
CONTRACTOR and/or COMPANY can require personnel responsible for non-destructive inspection to
demonstrate the capability of the procedure to detect imperfections and to demonstrate their ability to
correctly interpret indications.
8.3 VISUAL INSPECTION

100% visual inspection is required for each production joint.
Visual Inspection procedure shall include personnel qualification and visual acuity, maximum
viewing distance and angle, lighting conditions, evaluation tools, and reporting.
It shall be permissible to repair imperfections in the cap or root pass detected by visual inspection before
non-destructive testing, provided that all welding is done in accordance with the requirements of an approved
welding procedure, and visual inspection of the weld is performed after the repair work.
8.4 RADIOGRAPHIC TEST

SUPPLIER shall guarantee all labour and materials necessary to perform 100% radiography on all circular
welds. Each radiograph shall cover the entire weld. For weld repair, the film shall cover 100 mm on either
side of weld area of repair.
All radiographic techniques and procedures as well as quality of films shall comply with ISO 19232-1, ISO
17636, ISO 5579, EN 1435, ISO 11699-1 and this document. Standards of acceptance shall comply with the
requirements of API STD 1104 and this document. Any weld which in Inspector’s opinion is not satisfactory
as indicated by the radiography shall be repaired or cut-out and re-welded. Radiographic performance shall
comply with relevant Country and Project safety codes and radiation acts.
Radiography shall be by means of X-rays only. Tie-in welds should be carried out by means of gamma-rays
(using film system C2 according to ISO 11699-1) plus ultrasonic inspection subject to approval of Company.
Radiographic procedures shall be qualified using penetrometers located at both source side and film side.
This applies for all Single Wall/Single Image (SW/SI) techniques.
The radiographic procedure qualification test shall be repeated at the discretion of the Inspector whenever
any change is made to the operating techniques, or whenever production films differ appreciably from the
sensitivity, contrast or density of the qualification radiographs.
Coating and wrapping of the joint shall not begin until the weld is judged satisfactory.
Film system shall be C5 according to ISO 11699-1, film overlap shall be 50 mm minimum.
Intensifying screens of the lead type shall be used for welder and welding procedure qualifications, and tie-
ins. Fluorometallic screens shall not be permitted with gamma-rays sources. Salt screens shall not be used.
LY0001-000-QA-11023
LY0001-000-ZH-11023
Only wire type Image Quality Indicators (IQI), according to ISO 19232-1 shall be used. The radiographic
technique shall comply with EN 1435 class B.
IQI's shall be placed so that each film has at least two: one within 25 mm from interpretable film extremity
and one at center of film. Four IQIs shall be placed 90° apart when a complete girth weld is radiographed in
a single exposure (panoramic exposure).
For qualification purpose (WPQ, welder qualification), radiographic technique shall comply with EN 1435
class B using film system class C2 according to ISO 11699-1.
Exposure shall be such that density through the weld is between 2.1 and 3.6.
Viewing conditions and facilities shall be such that film densities up to 4.0 can be viewed and interpreted. A
densitometer (with valid calibration) shall be available on Site at all times.
Inspection set-up SHALL be determined so that geometric unsharpness is maximum 0.25.
Final film interpretation shall be carried out on dry film.
Processing: All radiographic films shall be dried thoroughly prior to viewing and shall be processed and fixed
to allow storage of the films without image deterioration for at least 10 years. All films shall be re-fixed to
achieve the specified minimum archival life.
As a minimum, the film identification shall include:
 Project Identification (as previously agreed with CONTRACTOR and/or COMPANY)
 Line Size and Identification
 Joint Number
 Date (Day, Month, Year)
 Radiographic Location.
The zero datum shall be located at the 12 o'clock position. The direction of numbering on tape shall be
clockwise when looking in the direction of flow. Defect location shall be in the metric system. Each
radiograph shall have reference markers at 100 mm (minimum) intervals.
All films shall be protected in individual plastic bags and stored in aluminium boxes closed with tight fit lids
before delivery to the Company. All film boxes shall be individually numbered and indexed (arrangement of
films to be stated) on their top.
Radiographers shall be certified level 2 in accordance with the requirements of ISO 9712, CSWIP scheme or
equivalent Company approved standard. At least one certified level 2 (minimum) radiographer shall be
present on each shift for film interpretation
The qualifications of each member of the NDT team shall be subject to approval of the Inspector.
Radiographic performance shall comply with the relevant Country and Project safety codes and radiation
acts. Attention is drawn to the necessity for audible and visual warning arrangements and for regular
monitoring or radiation levels.
If Computed radiography or radioscopy is considered it shall be qualified and used in production as per real
time radioscopy inspection optimum requirements.
Where quality and/or interpretation of radiograph is affected by the presence of a cable inside the pipe
(buckle detector …), an alternative NDE technique such as manual UT shall be qualified and used to inspect
the area.
8.5 MAGNETIC PARTICLE (MPI)
100% Magnetic Particle Inspection (MPI) is required for all fillet welds. Magnetic particle inspection according
to ASME V Art.7.
Magnetic particle inspection shall be used for:
 Fillet Welds;
LY0001-000-QA-11023
LY0001-000-ZH-11023
 Examination of repair area of excavation;

 Final examination of weld repair.
 All arc strike outside weld groove area
The finished weld bevel shall be Magnetic Particle Inspected following field cut back of pipe, at least when
this cut back is located within a range of 25 mm from original bevel.
Electromagnetic (a.c.) yoke and/or adjacent cable techniques shall be used.
SUPPLIER shall provide a MPI procedure based on ASTM E709 or equivalent for review and approval by
CONTRACTOR and/or COMPANY. Calibration blocks and approved magnetic flux indicators shall be
available on Site at all times.
Inspector reserves the right to test the proposed MPI procedure prior to acceptance.
MPI operators will be qualified level 2 in accordance with ISO 9712 or Company approved equivalent
standard.
8.6 ULTRASONIC INSPECTION

The inspection requirements shall be as per ASME V Art.4.
The equipment and supplies shall be as specified in ASME V Art.4 and shall satisfy the requirements of API
1104 22nd Edition.
The SUPPLIER shall be pre-approved prior to bidding the work. During the pre-approval process the
SUPPLIER must successfully demonstrate system performance by examining a minimum of five welds
supplied by the Company.
Ultrasonic operators shall be certified level 2 in accordance with ISO 9712, CSWIP scheme or Company
approved equivalent standard. The Inspector reserves the right to test proposed UT operators on a test weld
prior to accept them on the job.
 MANUAL ULTRASONIC INSPECTION (MUT)
Manual ultrasonic (pulse echo technique) shall not be the primary inspection method for girth welds. MUT
might be applied only in the following cases:
o Lamination check and thickness measurement (0° probe angle);
o Examination of weld repair;
o Butt welds with a V or compound bevel preparation;
 SEMIAUTOMATIC ULTRASONIC INSPECTION (PAUT)
The inspection technique shall be contact method with register using TOFD - Time of Flight Diffraction in
combination with Phased Array technique that covers the entire volume of the weld plus HAZ.
Semiautomatic PAUT technique is applied for the inspection of:
o Examination of weld repair;
o Butt welds with a V or Compound bevel preparation;
 AUTOMATIC ULTRASONIC INSPECTION (AUT)
The inspection technique, in lieu of RT, shall consist of a fully automatic Phased Array and TOFD inspection.
AUT system shall include an automatic multichannel ultrasonic flaw detector, which provides an adequate
number of channels for inspection to ensure 100 % volumetric examination of the weld including heat
affected zone through the thickness at one circumferential scan.
In addition, scanning for transverse defects shall be performed.
AUT technique could be applied for:
 Butt-welds performed by mechanized welding on a narrow gap “J” bevel;
LY0001-000-QA-11023
LY0001-000-ZH-11023
 Butt-welds with V or Compound bevel preparation (Tie-In by Manual or Hybrid Welding Procedures);
Being AUT result highly sensitive on bevel changes, AUT inspection on repairs should not be allowed.
8.7 ACCEPTANCE CRITERIA FOR GIRTH WELDS

Weld imperfections shall be evaluated according to the defect acceptance criteria defined by API 1104
22nd Edition workmanship criteria.
9 REPAIR OF WELDS CONTAINING DEFECTS
Defects other than cracks in the root, filler, and finish beads may be repaired with prior company
authorization. Repair welding procedures shall be prepared for both full thickness repairs and mid
thickness repairs.
A qualified repair procedure shall be required whenever a repair is made by welding when:
a) using a welding process, combination of welding processes, or method of application or filler

metals different from that used to make the original weld; or
b) repairs are made in a previously welded repaired area; or
c) required by the company
9.1 CRACKS
Metallurgical crack of any size shall not be repaired, and the joint cut out. Crater cracks of any
dimension shall be subject to repair.
9.2 REPAIR PROCEDURE

Repair of defects in production welds shall be performed by qualified welders using qualified welding
procedure; and be documented on the inspection reports.
9.3 REMOVAL OF DEFECTS

a) Except as permitted below, defects in welds shall be removed by grinding.
b) It shall be permissible to remove defects in welds by air carbon arc gouging provided:
i) a 300 mm wide area centred around the defective weld metal is preheated to a minimum
of 50°C and a maximum 150°C before the gouging process begins.
ii) after gouging and prior to commencement of welding, gouged surfaces are made smooth
and free of irregularities by grinding a minimum of 2 mm of material from the bottom and
edges of the groove.
iii) the cavity shall comply with bevel requirements indicated in the repair procedure.
iv) the groove preparation is visually examined to ensure that all traces of carburized metal,
copper deposits, or other extraneous matter have been removed from the groove; and
c) The maximum through-wall repair length shall be no greater than 200 mm at a time. Once this
area has been repaired, then the process can be repeated. If there is any deviation from this,
Welding Engineering shall be contacted before proceeding.
9.4 START AND STOP OF REPAIR WELDS
The start and stop of repair welds shall be ground to conform to the contour of the original weld. The
start and stop areas for multi pass welds are to be staggered by at least 12 mm.
LY0001-000-QA-11023
LY0001-000-ZH-11023
9.5 MINIMUM LENGTH OF REPAIR

The minimum length of a repair shall be 50 mm.
9.6 INSPECTION OF REPAIRS

Repairs shall be inspected using the non-destructive inspection method(s) and procedures specified
for production welds in par. 8 of this document.
SUPPLIER may perform remedial work on the cap pass prior to non-destructive testing but only with
prior approval from COMPANY and/or CONTRACTOR and only in accordance with the requirements
of the approved repair welding specification.
9.7 FURTHER REPAIR ATTEMPTS

Further attempts at repairing a given defective area of a given weld beyond the first repair shall be
supported by a qualified welding procedure that included multiple repairs.
A double repair requires prior COMPANY and/or CONTRACTOR authorization. For repair procedure
qualification purposes, this is a partial thickness or full thickness repair that tests a HAZ that has
received three full thermal cycles from welding. A grinding repair is not considered to be one of the
thermal cycles.
Subsequent repair of a double repair weld is not permitted unless specifically authorized by the by
the company and repaired with a qualified repair procedure appropriate for the number of thermal
cycles used.

Ly001-Let-Bon-Fial-0007

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ly001-Let-Bon-Fial-0007

Uploaded by

Copyright:

Available Formats

Head Office BONATTI - Società per Azioni

Via Nobel, 2/A Capital Stock € 50,696,792.28 wholly paid-up

Att.n. Mr. Gregory Zajaczkowski

Subject: SUBCONTRACT AGREEMENT N° OC/22000005

CONTRACTOR refers to the SUBCONTRACTOR’s letters ref. FPO22001-FIA-BON-L-CS-

Please find attached CONTRACTOR’s comments to the following procedures:

Doc. 22001-QAPR-705 “General Procedure for Welding Activities”

Doc. 22001-QAPR-706 “Welder & Welding Procedure Qualification Procedure”

To this extent, CONTRACTOR is hereby attaching its document LY0001-000-ZH-11023

For example, the following documents were missing:

- Pipeline Site survey procedure.

SUBCONTRACTOR is kindly requested to speed up the preparation of these basic

Paolo Destro Cappellano

Doc. 22001-QAPR-705 “General Procedure for Welding Activities” commented BNT

Doc. 22001-QAPR-706 “Welder & Welding Procedure Qualification Procedure” commented

LY0001-000-ZH-11023 “Technical Specification for Welding & NDT”.

GENERAL PROCEDURE FOR WELDING ACTIVITIES

Rev. Date Issued Reviewed Approved Revision Description

This document is processed digitally and does not require signatures.

7. RECORDS AND DOCUMENTATION ........................................................... 15

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 2 of 15

3. DEFINITIONS AND ABBREVIATIONS

3.1 Definitions Commented [DG1]: Put the definition in

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 3 of 15

ASME B31.3 Process Piping

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 4 of 15

Formatted: French (France)

API 1104 Welding of Pipelines and Related Facilities

6.1 General Requirements

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 5 of 15

6.3 Welding Procedures

6.3.2 Application Method

6.3.3 Joint Design

6.4 Welding Procedure Qualifications

6.5 Welder Qualification

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 7 of 15

6.5.2 API 1104

6.5.1 Records of Qualified Welders and Welding Operators

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 8 of 15

6.6 Weld Execution

6.6.2 Compliance with Specifications

6.6.1 Weld Preparations

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 9 of 15

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 10 of 15

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 11 of 15

 Inter‐pass Temperature. Formatted: Font: Tahoma, 10 pt, (Intl) Verdana,

6.6.1.11 Number of Welders Formatted: Font: Tahoma, 10 pt, (Intl) Verdana,

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 13 of 15

6.6.1.14 Cleaning between Passes

stress stamps is acceptable for pressure piping).

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 15 of 15

6.7 Inspection and Nondestructive Examination of Welds

6.7.1 Disposition of Defective Welds

6.7.2 NDE Records

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 17 of 15

6.7.3 Standards of Acceptability

6.7.4 Repair of Welds Containing Defects

7. RECORDS AND DOCUMENTATION

8. APPLICABLE DOCUMENTS AND TOOLS

Doc. No.: 22001-QAPR-705 Rev. 0 IDM No.: FIA2101215 Ver. 0 Page 19 of 15

WELDER AND WELDING PROCEDURE QUALIFICATION

Rev. Date Issued Reviewed Approved Revision Description

This document is processed digitally and does not require signatures.