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Specification

CONTENTS

1 Purpose .................................................................................................................................................................... 3
2 Scope........................................................................................................................................................................ 3
3 Hazard Recognition and Other HES Considerations ............................................................................................... 3
4 Definitions and Terms............................................................................................................................................... 3
5 Specifications ........................................................................................................................................................... 3
5.1 CODES, REGULATIONS & STANDARDS ....................................................................................................... 3
5.1.1 American Welding Society (AWS)............................................................................................................. 3
5.1.2 American Society of Non-destructive Testing (ASNT) .............................................................................. 4
5.1.3 American Society for Testing and Materials (ASTM) ................................................................................ 4
5.1.4 American Society of Mechanical Engineers (ASME) ................................................................................ 4
6 Specification ............................................................................................................................................................. 4
6.1 QUALITY CONTROL ........................................................................................................................................ 4
6.1.1 Responsibilities ......................................................................................................................................... 4
6.1.2 Fabrication and Erection ........................................................................................................................... 4
6.2 EXECUTION ..................................................................................................................................................... 5
6.2.1 Compliance ............................................................................................................................................... 5
6.2.2 Test Specimens......................................................................................................................................... 5
6.2.3 Structural Welds ........................................................................................................................................ 5
6.3 PROCEDURE QUALIFICATION....................................................................................................................... 5
6.3.1 Submittals .................................................................................................................................................. 5
6.3.2 AWS/AISC Non-Pre-qualified Joints ......................................................................................................... 5
6.3.3 Electrodes, Wire and Fluxes ..................................................................................................................... 6
6.3.4 Record Availability ..................................................................................................................................... 6
6.3.5 Welding Process Evaluation ..................................................................................................................... 6
6.3.6 Filler Materials Requirements ................................................................................................................... 6
6.4 WELD JOINT PREPARATION.......................................................................................................................... 7
6.4.1 Requirements ............................................................................................................................................ 7
6.5 THERMAL TREATMENT .................................................................................................................................. 8
6.5.1 Preheat and Interpass Temperature Control ............................................................................................ 8
6.5.2 Postweld Heat Treatment .......................................................................................................................... 8
6.6 NON-DESTRUCTIVE EXAMINATION (NDE) ................................................................................................... 8
6.6.1 General ...................................................................................................................................................... 8
6.6.2 Drawings for Contractor ............................................................................................................................ 9
6.6.3 Non-Destructive Examination Requirements ............................................................................................ 9
6.6.4 Non-Destructive Examination Methods ..................................................................................................... 9
6.6.5 Visual Examination .................................................................................................................................... 9
6.6.6 Magnetic Particle Examination .................................................................................................................. 9
6.6.7 Liquid Penetrant Examination ................................................................................................................... 9
6.6.8 Ultrasonic Examination.............................................................................................................................. 9
6.6.9 Radiographic Examination ........................................................................................................................ 9
6.7 MECHANICAL TESTING OF WELDS ............................................................................................................ 10
6.7.1 Requirements .......................................................................................................................................... 10
6.7.2 Impact Testing (Charpy V-Notch)............................................................................................................ 10

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Specification

1 Purpose

The purpose of this specification is to define the welding, thermal treatment, examination and testing requirements for shop and
field fabrication of structural welded and tubular components, shapes and plate materials for the OXY Oman Facilities
Development projects.

This specification supplements the codes listed in Section 5 of this specification.

2 Scope

This specification applies to all structural welding and welding inspection conducted within the Oxy Oman Facilities Development
projects.

3 Hazard Recognition and Other HES Considerations

All Welding and inspection activities must be performed in accordance with the relevant safety regulations.

4 Definitions and Terms

Definitions of welding processes, methods, techniques and applications shall be in accordance with AWS A3.0, Definitions and
Terms.

5 Specifications

5.1 CODES, REGULATIONS & STANDARDS

All materials, equipment and workmanship shall be governed by, but not limited to, the latest version of the following standards. In
cases where more than one code, regulation, specification and standard apply to the same condition, the most stringent shall be
followed. In the event of a conflict between this specification and other specifications or correspondence, the COMPANY shall be
consulted and a ruling, in writing, shall be obtained before any work is started.

5.1.1 American Welding Society (AWS)

AWS A2.4 Standard Symbols for Welding, Brazing and Non-destructive Examination

AWS A3.0 Standard Welding Terms and Definitions

AWS A5 Filler Metal Specification (Series)

AWS B1.10 Guide for the Non-destructive Examination of Welds

AWS B1.11 Guide for the Visual Examination of Welds

AWS B4.0 Standard Methods for Mechanical Testing of Welds

AWS D1.1 Structural Welding Code

AWS A5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding

AWS PHSS Suggested Preheat Temperatures for Welding Structural Steel Materials

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AWS PRG Practical Reference Guide for Radiographic Inspection Acceptance Criteria

5.1.2 American Society of Non-destructive Testing (ASNT)

SNT-TC-1A Recommended Practice

5.1.3 American Society for Testing and Materials (ASTM)

ASTM-A36 Specification for Structural Steel

ASTM-E709 Standard Guide for Magnetic Particle Examination

ASTM-E165 Standard Test Method for Liquid Penetrant Examination

ASTM-A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM-A578 Standard Specification for Straight-Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special
Applications

ASTM-E23 Standard Test Methods for Notched Bar Impact Testing of Metallic Materials

ASTM-E92 Standard Test Method for Vickers Hardness of Metallic Materials

5.1.4 American Society of Mechanical Engineers (ASME)

BPVC-CC-N Boiler and Pressure Vessel Code (2004), Section II

6 Specification

6.1 QUALITY CONTROL

6.1.1 Responsibilities

When requested, the Contractor shall submit to the COMPANY representative an outline of the quality control measures that will
be enforced by the Contractor to insure that the authorized welding procedures are employed for all welding.

Welds made by procedures which are not pre-qualified or have not been properly qualified and authorized shall be rejected and
completely removed at Contractor's expense.

Cleanliness shall be maintained throughout welding with all stubs, rods, flux, slag and other foreign materials removed from the
structure.

The fabrication and erection Contractor shall be certified by the local (welding) technical authorization for the class of work.

6.1.2 Fabrication and Erection

The welders and welding operators shall be qualified in accordance with appropriate AWS D1.1 and/or related regulations, and
have the certificates on file. Those qualification records shall be made available to the COMPANY upon request. The COMPANY
reserves the right to require and witness the testing or re-testing of welders for qualification. All costs material required for the
qualification of welders shall be at the Contractor's expense.

When required by AWS D1.1 and/or related regulations, the Contractor shall develop appropriate specifications for welding
procedure and appropriate procedure qualification records.

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6.2 EXECUTION

6.2.1 Compliance

Fabrication specification shall conform to the requirements of AWS D1.1 and/or appropriate codes.

Compliance with the requirements of AWS D1.1 shall in no way relieve the Contractor of the responsibility of providing welds which
are sound and suited to the services for which they are intended.

6.2.2 Test Specimens

The COMPANY reserves the right to remove test specimens from any portion of the work to verify the quality of the welding.

The Contractor, at his/her expense shall repair or replace any base metal or filler metal found to be defective.

6.2.3 Structural Welds

Structural welds shall be defined as the welds which are necessary for the development of strength between adjoining pieces of
steel.

Structural welds shall be made as shown or noted on design drawings.

For structural pipe welds, longitudinal weld seams shall be parallel to the longitudinal axis, and complete penetration butt welds.

Longitudinal seams of adjoining rolled plate shall not be in-line, but shall be offset from other longitudinal seams at least five (5)
times the wall thickness of the pipe.

Back-up rings or strips shall be of the same chemical analysis as the base plate. Except for low alloy plate, the back-up strip may
be ASTM A36 or equivalent.

6.3 PROCEDURE QUALIFICATION

6.3.1 Submittals

The Contractor shall submit a Welding Register indicating the various Welding Procedure specifications, supporting Procedure
qualification records and Welder procedure qualification records. The COMPANY representative has every right in seeking the
Contractor to revalidate the records by having a procedure at site on case to case basis. Moreover, performance tests of welders,
welding operators shall be sought, based on varying site conditions.

Welding procedure specifications and procedure qualification records for the subcontracted items by the Contractor shall be
reviewed by the Contractor prior to submittal to the COMPANY.

The non destructive inspection certifications and procedures shall be submitted to the COMPANY upon request in which case
examination shall not proceed until authorized by the COMPANY. In addition, other records pertaining to inspection shall be made
available to the COMPANY.

6.3.2 Qualification Procedures for weld Joints

The Contractor shall develop and submit the following, for the Company’s approval:

a) Welding procedure specifications; and

b) Procedure qualification records designed to produce welds in accordance with the intent of these Specifications.

The Contractor shall show that consideration has been given to the selection of type and size of electrode, heat input, interpass
temperature, preheat, head deposition, technique and welder qualification.
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Welding shall not start until documents specified are returned to the Contractor with authorization by COMPANY.

The Contractor, shall submit welding procedures specifications when requested by the COMPANY, prior to start of fabrication.

Use of pre-qualified procedure is not permitted. All Procedures shall be qualified by testing in line with AWS D1.1, Welding shall
not start until documents specified are returned to the Contractor with authorization by COMPANY.

6.3.3 Electrodes, Wire and Fluxes

The fabricator shall mobilize only those electrodes meeting to ASME Sec II Part C as a minimum / AWS A5. The consignment
mobilized to site shall have batch test certificates duly vetted by a TPIA/Classification society like Lloyds, BV, ABS, DNV etc. The
necessary storage, handling arrangements during receipt, issue to the individual welders/operators shall comply with the
manufacturers’ recommendations.

Covered electrodes shall be identified on the coating with a positive identification (near the grip end) such as trade name, tensile
strength or type with a heat resistant paint.

If color coding is utilized, the color material shall be stable with the temperature applied during welding.

Bare wire (including cut lengths) shall be flag tagged at least at one end with the proper identification.

Rolls of wire, bare or flux-core shall be identified on the spool they are wound to.

Opened bags of fluxes shall be stored in closed, containers for positive identification and moisture control.

6.3.4 Record Availability

The following records shall be kept available for the examination of COMPANY:

a) Welding procedure specifications and procedure qualification records.

b) Welder Qualification Records.
c) Records of Stress Relieving if applicable.

6.3.5 Welding Process Evaluation

Submit all pertinent data and intended application of all specific welding processes for evaluation. Fabrication welding shall be
achieved by any one or combination of the following welding processes:

a) AWS Letter Designation

b) Shielded Metal-Arc Welding – SMAW
c) Gas Tungsten-Arc Welding - GTAW
d) Flux Cored-Arc Welding - FCAW
e) Automatic Submerged Arc Welding – SAW
f) Electroslag Welding - EW
g) Electrogas Welding – EGW
h) Stud Welding SW

6.3.6 Filler Materials Requirements

Filler material shall be used in accordance with AWS A5 and have minimum tensile strength of 70 ksi (485 MPa).

Low hydrogen electrodes shall be used when Charpy impact testing is required.

Tack welds shall be made with the same type of electrode that is used for depositing the root pass.

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After opening shipping containers of electrodes, fluxes and other welding materials, storage and handling shall be as specified in
the Manufacturer's recommendations.

The Contractor shall submit the procedure for the storage and handling of electrodes, filler metal and fluxes to the COMPANY for
review prior to the start of fabrication.

The procedure shall include moisture, cleanliness and identification controls.

Fluxes that the manufacturer recommends for single pass shall not be used for multiple pass welds.

Active fluxes are not permitted.

Carbon and low alloy steel wire that have a non-specific chemistry shall not he used.

6.4 WELD JOINT PREPARATION

6.4.1 Requirements

Weld bevels shall be prepared by:

a) machining
b) grinding
c) thermal cutting

The bevel surface shall be smooth and true to the mating surface. Oxy-fuel cutting of stainless steel or nickel alloys shall not be
used.

a) The parts to be joined by fillet welds shall be brought together as closely as practicable.
b) The gap between faying surfaces of lap joints shall not exceed 1.5 mm.
c) If the separation is greater than 1.5 mm after straightening and assembly, the leg of the fillet weld shall be increased by the
amount of separation, but the gap shall not exceed 5 mm.
d) For the fillet weld (square groove) butt joint, base material thickness, t shall be not more than 3 mm, and a back plate is
required if the gap is greater than t. When t is between 3 mm and 20 mm, a single bevelled butt joint should be used. Double
bevelled butt joint shall be adopted for t greater than 20 mm.

BUTT JOINT ( FILLET WELD )

THICKNESS UP TO 3 MM

BUTT JOINT ( SINGLE BEVELLED )

THICKNESS FROM 3 MM TO 20 MM

BUTT JOINT ( DOUBLE BEVELLED )

THICKNESS GREATER THAN 20 MM

Fig. 1 Butt Joints

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All surfaces to be welded shall be free of paint, oil, dirt, scale, oxides and other foreign materials detrimental to weld soundness.

Flux, weld spatter and slag shall be removed from each weld bead prior to depositing each succeeding pass.

Welding starts and stops in continuous welds shall be held to a minimum.

a) Each such stop shall be properly conditioned before continuing the welding.
b) The use of starting and stopping plates where possible is recommended.

6.5 THERMAL TREATMENT

6.5.1 Preheat and Interpass Temperature Control

All preheat requirements shall be per AWS D1.1, AWS PHSS and the welding procedure specifications which reference the
minimum preheat requirements and interpass temperature for carbon steels, low alloy high strength steels and heat treated steels.

Minimum preheat shall be given as below (to be used as a guide only) to prevent crack formation. Temp above the minimum
stated maybe required for highly restrained weldments.

Thickness in mm Low and Medium Restraint oC High Restraint (like T Cross joint) oC
< 20 24 80
20 to 30 38 108
30 to 60 65 150
> 60 108 150

6.5.2 Postweld Heat Treatment

Postweld heat treatment shall be required when specified on drawings or specifications.

For shop welded members with butt welds greater than 30 mm in thickness, or with double fillet welds exceeding 22 mm leg
dimensions, stress shall relieve at 595~650 °C, one hour per 25 mm of thickness, minimum one hour, and cooling may take place
in furnace or in still air.

6.6 NON-DESTRUCTIVE EXAMINATION (NDE)

All the NDE procedures shall be prepared by Level III person qualified in accordance with SNT-TC-1A.

6.6.1 General

The Contractor shall perform NDE in accordance with AWS B1.10 for chosen test method.

As a minimum, the Contractor shall ensure all welds are visually inspected.

Defective welds shall be repaired in accordance with relevant AWS/SA standards. Additional testing of welds will be at the
discretion of the QA/QC representative and shall apply to the Contractor as well as Subcontractors

The Contractor shall repair or replace any base metal or filler metal found to be defective, at their expense.

The COMPANY reserves the right to request any other NDE method for any corrective work performed by the Contractor or in
course of the work.

The COMPANY shall reserve the right to require third party inspection.

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6.6.2 Drawings for Contractor

Specific non-destructive examination, in addition to AWS B1.10 requirements, shall be noted on purchase drawings, purchase
specifications or purchase orders

When the purchase drawings are not used, these requirements shall be noted on the Contractor's drawings.

6.6.3 Non-Destructive Examination Requirements

Welds that are to be examined shall be furnished as required for the applicable inspection method.

Personnel evaluating the results of examinations for acceptance or rejection shall be certified as appropriate level.

Non-destructive examinations are to be performed in accordance with written procedures. These procedures shall be submitted to
and authorized by the COMPANY, prior to performing any examinations.

Non-destructive examinations shall be recorded on forms authorized by COMPANY; In addition, all other records pertaining to
inspection shall be made available to COMPANY.

6.6.4 Non-Destructive Examination Methods

All non-destructive examination methods, acceptance criteria, and additional general requirements shall be in accordance with the
following subsections.

Unless otherwise specified in AFC drawings, as a minimum 10% of the welds for all Primary and load bearing members shall be
examined with Magnetic Particle method, all splice joints and butt welds with size over 13mm shall be examined with Ultrasonic
method

6.6.5 Visual Examination

Visual examination procedures shall be in accordance with AWS B1.11. The requirements of AWS D1.1 shall be binding for the
acceptance criteria. The weld profile shall be smooth & even otherwise the uneven profiles of the ripple cannot be properly surface
prepared during the painting thus may lead to starting point of corrosion.

6.6.6 Magnetic Particle Examination

Magnetic Particle Examination shall be in accordance with ASTM E709-1. The requirements of AWS D1.1 shall be binding for the
acceptance criteria.

6.6.7 Liquid Penetrant Examination

Liquid Penetrant Examination shall be in accordance with ASTM Specification E165. The requirements of AWS D1.1 shall be
binding for the acceptance criteria.

6.6.8 Ultrasonic Examination

Ultrasonic Examination method, procedure and acceptance criteria for groove welds shall be in accordance with AWS D1.1. Any
parent metal indication interpreted as a lamellar tear with a transverse dimension greater than 3 mm and a length in excess of 50
mm shall be rejected.

6.6.9 Radiographic Examination

Radiographic Examination method, procedure, and acceptance criteria shall be in accordance with AWS D1.1. The requirements
of AWS D1.1 shall be binding for the acceptance criteria.

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6.7 MECHANICAL TESTING OF WELDS

6.7.1 Requirements

Mechanical Test Procedure qualifications shall be mechanically tested in accordance with AWS B4.0.

6.7.2 Impact Testing (Charpy V-Notch)

When required by the applicable material specification, Charpy V-Notch impact tests of the weld and heat affected zone, shall
meet the minimum requirements specified for the base metal.

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