Rumaila Operating Organisation Specification For Welding, PWHT and Nde of Process and Utility Piping

RUMAILA OPERATING ORGANISATION SPECIFICATION FOR WELDING, PWHT AND NDE OF PROCESS AND
UTILITY PIPING.
RUMAILA OPERATING ORGANISATION SPECIFICATION FOR

WELDING, PWHT AND NDE OF PROCESS AND UTILITY PIPING.
0000BF-C-G0-G000-QA-SPC-0001
th
Date 18 February 2018
Rev Description Originator Review Approved Date

th
B01 - Stephen Keegan Laurie Beppler Dominic Paisley 4 Aug 2014
th
4 Oct
B02 - Stephen Keegan Laurie Beppler Dominic Paisley
2014
th
25 Nov
B03 - Stephen Keegan Laurie Beppler Dominic Paisley
2014
th
B04 - Steve Wright Tim Johnston Dominic Paisley 10 Aug 2015
th
Stephen Keegan/ 8 January
B05 Alan Henderson Dominic Paisley
Steve Wright 2016
04
Stephen Keegan/
B06 Carlos Caceres Dominic Paisley September
Steve Wright
2016
Stephen Keegan/ 12th October
B07 Tim Johnston Dominic Paisley
Steve Wright 2016
th
Stephen Keegan/ Tim Johnston Nick Kennigton 18 February
B08
Steve Wright John Farrell James Onslow 2018
Digitally signed by
Stephe TIMOTHY
Digitally signed by
Stephen Keegan TIMOTHY JOHNSTON
Digitally signed by Nick
Nick
DN: cn=Stephen DN: cn=TIMOTHY Kennington
JOHNSTON, o=ROO,
n
Keegan, o=ROO,
JOHNST
DN: cn=Nick Kennington, o=ROO,
ou=Developments, ou=ENGINEERING, ou=Operations,
email=stephen.keegan email=timothy.johnston
Kennington email=Nick.kennington@roobasra
ON
@roobasra.com, c=IQ .com, c=US
Keegan
@roobasra.com, c=IQ
Date: 2018.02.18 Date: 2018.02.20 07:53:18 Date: 2018.02.22 07:15:16 +03'00'
11:52:13 +03'00' +03'00'
Document Number
0000BF-C-G0-G000-QA-SPC-0001 Rev B08 – Date 18th February 2018 Page 1 of 41
This document is the property of Rumaila Field Develops Projects. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
UTILITY PIPING.
REVISION DESCRIPTION SHEET
Rev. Para. Reason for Revision

B02 2.3 Reference to BS EN 9712 added.
4.2,4.3, 4.4 Vision acuity / Colour differentiation requirements added.
12.3 Density range revised to 2.0-3.5.
Technique diameter limitations revised as per ASME Section V article 2.
Safety measures for working with ionizing radiation added.
12.4 Calibration of pie indicator added.
12.5 Examination area band width details for cleaning added.
12.7 Operator training requirements added.
Maximum HT values for production joints added.
B03 12.7 Section deleted – HT not required.
Appendix 5 HT Requirements deleted.
B04 12.6 Phased Array UT included as preferred method of Ultrasonic examination.
Appendix 5 PAUT included as alternative to Radiography for plate 12mm thickness and above and
pipe welds 8” diameter and above, 12mm wall thickness and above.
B05 All Removed reference to Vessels and Equipment.
1.2 Replaced reference to BP with ROO.
5.1 Reworded requirements for digital macro photographs. Maximum hardness value
250HV10. MDMT 2°C or better.
5.2 Additional requirements included for reference to Brownfield Piping Class.
6.1 Added details for welder qualified on a PQR and welder qualifications made by others.
9.1 Deleted reference to ISO 15156 hardness criteria in the as welded condition. Added
all joints above 20mm require PWHT.
Appendix 5 Added reference to U03E2B and Rumaila MOC CP-0021-A2
Added reference to S01N1B
Appendix 3 Replaced NPS 4 with 2.
(3)
B06 Appendix 5 NDE requirements updated for Brownfield piping Specifications. 100% RT requirement
for hydrocarbons in Degassing Stations and HP Water Injection piping at CPS Stations
revised to 10%.
9.1 Deleted PWHT requirements for all joints above 20mm and referenced ASME B31.3.
12.2 Added CPS and DS are not included in the High Consequence areas requiring 100%
RT.
B07 2.3 Added Specification for Brownfield Piping Class U03E2B
5.1 Added impact testing requirements for U03E2B
5.2 Deleted Minimum Interpass temperature
Deleted temperature from Min& Max heat input
5.3 Deleted (using an arc monitoring system approved by COMPANY
Document Number
UTILITY PIPING.
Rev. Para. Reason for Revision

6.3 Deleted PWHT if applicable
7.1 Deleted core and replaced with or filler
7.5 Deleted reference to vessels.
8.3 Deleted reference to interpass temperature. Covered in section 8.5
8.4 Included multiple head gas torches as an alternative to electric resistance heating
mats.
8.9 Deleted Full penetration repairs shall be specifically qualified if the root gap or joint
preparation is outside the limits of the original PQR.
Reworded repair after PWHT paragraph
9.1 Added all joints above 25mm require PWHT.
Added reference to ASME B31.3 for branch weld PWHT requirements.
12.1 Deleted Final examination shall be performed after completion of heat treatment.
Duplicated in paragraph above
Appendix 3 Deleted vertical down

Note 2
Appendix 4, Deleted flanges and fittings.
note 6 Added stainless steel filler for GTAW and SMAW
Appendix 5 Added reference to section 12.2 for progressive sampling requirements.
Note 10 Added tie-in joints (golden welds) requirements
Note 11
B08 Title Changed document title from Brownfield Projects to Rumaila Operating Organisation
1.1 Changed Brownfield Projects to Rumaila Operating Organisation
2.2 Added A5.32 Specification for Weld Shielding Gases
2.3 Added Specification for Brownfield Piping Class A03M8B
Added Specification for Brownfield Piping Class A01M9B
2.4 Revised Heirachy to be consistent with other project documents
3.2 Added
• SUPPLIERS that offer wide ranging services, from project system design to
materials selection and procurement, welding, fabrication, construction,
inspection, and installation, shall demonstrate that control of operations
involving welding conforms to the principles of ISO 3834-1 and the detailed
“comprehensive quality” requirements of ISO 3834-2. The requirements of
ISO 3834-2 shall apply to COMPANY criticality 1 and 2 items.
• SUPPLIERS that offer services of a more limited scope and/or fabricators
working under subcontracts shall be required to demonstrate that control of
operations involving welding conforms to the principles of ISO 3834-1 and the
“standard quality” requirements of ISO 3834-3. The requirements of ISO
3834-3 shall apply to COMPANY criticality 3 and 4 items.
• SUPPLIERS that offer services involving simple welded fabrications or
maintenance items of a noncritical nature (e.g., the fabrication of simple
structural steel or pipe work support structures) for which any design review
will be performed by others shall be required to demonstrate that control of
welding operations conforms to the principles of ISO 3834-1 and the
“elementary quality” requirements of ISO 3834-4.
Document Number
UTILITY PIPING.
4.4 Added CP-106 to ASNT

Added certification schemes to first paragraph
Added All UT and PAUT operators shall be assessed by COMPANY for competency
prior to commencement of any activities to fifth paragraph
5.2 Deleted AWS from filler metal type, brand, classification
5.3 Added Volts, Preheat and Shielding Gas Flow Rate if required to Recorded Welding
Parameter
7.2 Added to fourth paragraph, both internally and externally
Deleted vessel wall from fifth paragraph
Added to fifth paragraph Laminar defects in the parent material. Additional MT or PT
shall be performed to ensure no surface breaking defects are present
7.6 Added, pipe to qualified welders
7.5 Deleted one pipe diameter and replaced with 50mm in second paragraph
8.2 Added completion date to last paragraph
8.3 Added reference to Table 330.1.1 in first paragraph
Deleted 80 and replaced with 95°C in first paragraph
Deleted Standard and replaced with Specification
8.9 Added new paragraph, Repairs shall be recorded and supported by sketches detailing
location, dimensions and where possible, the identification of the discontinuity
Added to first paragraph, when the approved PQR and corresponding WPS permits
this
Deleted wherever practical from second paragraph
9.1 Added to fifth paragraph, when the approved PQR and corresponding WPS permits
this in fifth paragraph
Deleted 5 √Dt over the full circumference of the butt weld and the minimum insulation
width shall be 10√Dt where D = inside diameter in mm and t = wall thickness in mm.
Replaced with in accordance with the requirements of ASME B31.3.
Added, Welds may be locally post weld heat treated by heating a circumferential band
around the entire component with the weld located in the centre of the band. The width
of the band heated to the specified temperature range shall be at least three times the
wall thickness at the weld of the thickest part being joined. For nozzle and attachment
welds, the width of the band heated to the specified temperature range shall extend
beyond the nozzle weld or attachment weld on each side at least two times the run
pipe thickness, and shall extend completely around the run pipe.
Deleted eighth paragraph, The maximum heating rate above 400°C shall not exceed
220°C/h or 5500/t°C/h (where t = wall thickness), whichever is the lower. The cooling
rate from temperatures above 400°C shall not exceed 275°C/h or 6875/t°C/h,
whichever is the lower.
Deleted 93 and 649°C and replaced with 95 and 650°C
Document Number
UTILITY PIPING.
12.2 Added to second paragraph, Progressive Sampling for Examination shall be applied in
accordance with ASME B31.3 section 341.3.4
When required spot or random examination reveals a defect, then
(a) two additional samples of the same kind (by the same welder) from the original
designated lot shall be given the same type of examination
(b if any of the items examined as required by (a) above reveals a defect, two further
samples of the same kind shall be examined for each defective item found by that
sampling
(c) if any of the items examined as required by (b) above reveals a defect, all items
represented by the progressive sampling shall be fully examined and repaired or
replaced as necessary, and re-examined as necessary to meet Project requirements
Deleted details of repair rates per CONTRACTOR
Added This requirement shall not form part of the percentage NDE requirements
specified in appendix 5.
Deleted,
• For the high consequence areas, Deleted River and channels stream
crossings
• Marshes areas subject to frequent inundation
• Railroad or major public roads crossings
12.4 Added technique sheets in first paragraph
Deleted test and replaced with examination in eighth paragraph
12.5 Added to first paragraph, (PT) shall be carried out in accordance with COMPANY
approved procedures and technique sheets, for expected applications according to
the requirements and methods specified in
Added to last paragraph, The CONTRACTOR/SUPPLIER shall report each
examination on a format acceptable to COMPANY.
12.6 Added to first paragraph, (UT) shall be carried out in accordance with COMPANY
approved procedures and technique sheets, for expected applications according to
the requirements and methods specified in
Added to second paragraph, Scanning restrictions to be recorded.
Added to last paragraph, The CONTRACTOR/SUPPLIER shall report each
examination on a format acceptable to COMPANY.
Appendix 3 Deleted CO2 shielded from Table
(3) Deleted up to and including and replaced with below
Appendix 5 NDE Group 1. Type of Inspection Deleted 100% RT on branch welds
NDE Group 2. Type of Inspection Deleted 10% RT on branch welds added 10% MT or
10% PT
10% PT
5% PT
Deleted Note 3. For established CONTRACTOR/SUPPLIER, levels of NDE shall be
assessed and subject to performance reduced on approval by COMPANY.
Deleted Note 9. The NDE% requirements of Appendix s supersede the requirements
of Rumaila MOC CP-003, Rumaila MOC CP-0021 and Rumaila MOC 0000BF-C-WM-
G000-QA-MOC-0049
Note 10. Added reference to COMPANY approved deviation Rumaila DR-085 for
hydrotest waivers
Document Number
UTILITY PIPING.
Hold No. Para. Description of Hold
Document Number
UTILITY PIPING.
Table of Contents
1.0 INTRODUCTION ....................................................................................................................... 10
1.1 Purpose ........................................................................................................................... 10
1.2 Definitions ....................................................................................................................... 11
1.3 Abbreviations ................................................................................................................. 12
2 REFERENCE DOCUMENTS ........................................................................................... 13
2.1 Statutory Regulations, Codes and Standards ............................................................ 13
2.2 International Codes and Standards ............................................................................. 13
2.3 Project Documents ........................................................................................................ 15
2.4 Code Hierarchy............................................................................................................... 16
3 GENERAL REQUIREMENTS ......................................................................................... 17
3.1 Health Safety and Environmental (HSE) ...................................................................... 17
3.2 Quality Conformance ..................................................................................................... 17
3.3 Deviations ....................................................................................................................... 17
3.4 Production Documentation ........................................................................................... 17
4 PERSONNEL ................................................................................................................... 18
4.1 Welding Engineer ........................................................................................................... 18
4.2 Welding Inspectors ........................................................................................................ 18
4.3 Senior Welding Inspectors ............................................................................................ 18
4.4 Non-Destructive Examination (NDE) personnel ......................................................... 18
5 WELD PROCEDURES .................................................................................................... 19
5.1 WPS & PQR Requirements ........................................................................................... 19
5.2 Weld Procedure Specification Records ....................................................................... 21
5.3 Procedure Qualification Records ................................................................................. 21
6 WELDER QUALIFICATION ............................................................................................ 22
6.1 Pre-Qualification ............................................................................................................ 22
6.2 Welder & Welder Operator Identification ..................................................................... 23
6.3 Welder Performance Registration ................................................................................ 23
7 WELDING GENERAL REQUIREMENTS ....................................................................... 23
7.1 General ............................................................................................................................ 23
7.2 Preparation for Welding ................................................................................................ 24
Document Number
UTILITY PIPING.
7.3 Cutting and Bevelling .................................................................................................... 24
7.4 Alignment ........................................................................................................................ 24
7.5 Proximity of welds ......................................................................................................... 25
7.6 Tack Welding and Clamping ......................................................................................... 25
8 WELD EXECUTION......................................................................................................... 26
8.1 General ............................................................................................................................ 26
8.2 Identification ................................................................................................................... 26
8.3 Preheat Temperature Requirements ............................................................................ 26
8.4 Preheat Application ....................................................................................................... 26
8.5 Inter-pass Temperature ................................................................................................. 26
8.6 Interruption of Welding ................................................................................................. 27
8.7 Arc Strikes ...................................................................................................................... 27
8.8 Weld Finish ..................................................................................................................... 27
8.9 Weld Repairs .................................................................................................................. 27
9 POST WELD HEAT TREATMENT (PWHT).................................................................... 28
9.1 General ............................................................................................................................ 28
9.2 Post Weld Heat Treatment Procedure.......................................................................... 29
10 WELDING ELECTRODES, FLUXES AND CONSUMABLES ........................................ 29
10.1 General ............................................................................................................................ 29
10.2 Consumable Certification ............................................................................................. 30
10.3 Filler Metals .................................................................................................................... 30
11 STORAGE AND CONTROL OF WELDING CONSUMABLES ...................................... 30
11.1 General ............................................................................................................................ 30
11.2 Consumable Control ...................................................................................................... 30
11.3 Manual Metal Arc Electrodes ........................................................................................ 31
11.4 Welding Wires ................................................................................................................ 31
11.5 Submerged Arc Welding Fluxes ................................................................................... 32
11.6 Shielding Gas ................................................................................................................. 32
12 NON-DESTRUCTIVE EXAMINATION (NDE) ................................................................. 32
12.1 General ............................................................................................................................ 32
12.2 Extent of NDE ................................................................................................................. 33
Document Number
UTILITY PIPING.
12.3 Radiographic Examination (RT) ................................................................................... 33
12.4 Magnetic Particle Examination (MT) ............................................................................ 34
12.5 Liquid Penetrant Examination (PT) .............................................................................. 35
12.6 Ultrasonic EXAMINATION (UT) ..................................................................................... 35
APPENDIX 1 - Vickers Hardness Examination as per ASTM E384: ...................................... 37
APPENDIX 2 – Charpy Impact notch location ............................................................................ 38
APPENDIX 3 - Acceptable Welding Processes ........................................................................ 39
APPENDIX 4 - Ac c ep t ab le f i ll e r met a ls ............................................................................... 40
APPENDIX 5 - Extent of NDE ..................................................................................................... 41
Document Number
UTILITY PIPING.
1.0 INTRODUCTION
1.1 Purpose
This Specification defines the minimum requirements for the Welding, PWHT and NDE of Process and Utility
Piping which is intended for Rumaila Operating Organisation. Supplementing the Codes & Standards listed in
Section 2 of this document.
These requirements shall be incorporated by all CONTRACTORS/SUPPLIERS.
Document Number
UTILITY PIPING.
1.2 Definitions
COMPANY ROO Rumaila Operating Organisation
PROJECT Rumaila Project
CONTRACT Shall mean the formal agreement between COMPANY and SUPPLIER
The party which carries out all or part of the described work and services. The
CONTRACTOR
CONTRACTOR may undertake all or part of the duties of the CONTRACT
The SUPPLIER is the party, which manufactures or supplies equipment and services
SUPPLIER
to perform the duties of the CONTRACTOR.
Shall mean the party supplying goods, equipment or material specified by the
SUB-SUPPLIER
SUPPLIER
Shall mean all and any of the works, services and materials required to be provided by
WORK
the CONTRACTOR
DOCUMENT This shall include both text documents and drawings
MUST / SHALL A mandatory requirement
SHOULD A preferred requirement
MAY One possible course of action
Document Number
UTILITY PIPING.
1.3 Abbreviations
The following abbreviations apply in this specification:
Abbreviation Definition
ASME American Society of Mechanical Engineers
ASNT American Society for Non-Destructive Examination
ASTM American Society for Examination and Materials
AWS American Welding Society
BS EN British Standard / Euro Norm
CS Carbon steel
CSWIP Certification Scheme For Welding Inspection Personnel
CWI Certified W elding Inspector
CV Curriculum Vitae
DN Nominal Diameter
FCAW Flux Cored Arc Welding
FL Fusion Line
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
HF High Frequency
HV10 Hardness Vickers (with 10 kg load)
ISO International Organisation for Standardisation
IQI Image Quality Indicator
MDMT Minimum Design Metal Temperature
MPa Mega Pascal
MT Magnetic Particle Examination
NACE National Association of Corrosion Engineers
NDE Non-Destructive Examination
NPS Nominal Pipe Size
PAUT Phased Array Ultrasonic Examination
PQR Procedure Qualification Record
PT Liquid Penetrant Examination
PWHT Post Weld Heat Treatment
QA/QC Quality Assurance/Quality Control
QMS Quality Management System
QP Quality Plan
RT Radiographic Examination
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
UNS Unified Numbering System
UT Ultrasonic EXAMINATION
WPS Welding Procedure Specification
WT Wall Thickness
Document Number
UTILITY PIPING.
2 REFERENCE DOCUMENTS
2.1 Statutory Regulations, Codes and Standards
CONTRACTOR/SUPPLIER shall comply with applicable Iraqi codes, regulations, ordinances, and rules. It shall
be their responsibility to identify and comply with the requirements of any statutory International and National
codes, laws, rules, regulations and standards for the materials, design, fabrication, import, installation and
operation of the equipment within Iraq.
2.2 International Codes and Standards
As a minimum, equipment shall be designed, manufactured, tested and delivered in accordance with the latest
revisions of relevant sections of the international Codes, Standards and Regulations below.
The current edition or revision of the Codes and Standards referenced within this specification shall be used at
the time of activity.
Any conflicts between the requirements of this Specification and other reference documents shall be referred to
COMPANY for resolution.
In case of conflict between documents, order of precedence is shown in section 2.4.
Document Number
UTILITY PIPING.
Document Number Title
ASME (American Society of Mechanical Engineers)
Section II Part A ferrous Materials (Volume 1 & 2)
Section II Part C Welding Consumables
Section V Non-Destructive Examination
Section VIII Pressure Vessel Code
Section IX Welding and Brazing Qualifications
B 31.3 ASME Code for Pressure Piping Process Piping
ASTM (American Society for Examination and Materials)
Standard Test Methods and Definitions for Mechanical

ASTM A370
Examination of Steel Products
Standard Specification for Straight-Beam Ultrasonic

ASTM A578
EXAMINATION of Rolled Steel Plates for Special Applications
Indentation Hardness of Metallic Materials by Comparison

ASTM A833
Hardness Testers
Standard Test Method for Indentation Hardness of Metallic

ASTM E110
Materials by Portable Hardness Testers
Standard Hardness Conversion Tables for Metals Relationship

Among Brinell Hardness, Vickers Hardness, Rockwell Hardness,
ASTM E140
Superficial Hardness, Knoop Hardness, and Scleroscope
Hardness
ASNT (American Society of Non Destructive Testing)

Recommended Practice for Qualification of Non-destructive
SNT–C–1A Examination Personnel
AWS (American Welding Society)
Standard Welding Terms and Definitions Including Terms for

A3.0 Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and
Thermal Spraying
A5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding
A5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
A5.18 Carbon Steel Electrodes and Rods for Gas Shielded Arc
Welding
A5.20 Carbon Steel Electrodes for Flux Cored Arc Welding
Document Number
UTILITY PIPING.
A 5.32 Specification for Weld Shielding Gases
ISO (International Organization for Standardization )
Welding and Allied Processes- determination of Hydrogen

ISO 3690
Content in Ferritic Steel arc weld metal.
ISO 3834 Quality Requirements for fusion welding of metallic parts

Petroleum and natural gas industries, Materials for use in H2S-
(NACE MR 0175) ISO 15156 Parts 1-3 containing environments in oil and gas production
Non-destructive examination – Qualification and certification of
BS EN ISO 9712
NDE personnel
2.3 Project Documents
Mechanical Statics, Piping & Rotating Equipment: Basis of

0000RP-C-G0-G000-ME-BOD-0001
Design
0000RP-C-G0-G000-QA-IDX-0001 Index of Engineering Codes and Standards
0000RP-C-G0-G000-PE-SPC-0001 Specification for Brownfield Piping Class A01E2B
0000RP-C-G0-G000-PE-SPC-0010 Specification for Brownfield Piping Class S01N1B
0000RP-C-G0-G000-PE-SPC-0004 Specification for Brownfield Piping Class U03E2B
0000RP-C-G0-G000-PE-SPC-0016 Specification for Brownfield Piping Class A03M8B
0000RP-C-G0-G000-PE-SPC-0024 Specification for Brownfield Piping Class A01M9B
0000RP-C-G0-G000-QA-PRO-0003 Materials Traceability & Certification
0000RP-C-G0-G000-QA-PRO-0004 Deviation Request
0000RP-C-G0-G000-QA-PRO-0001 Technical Query
Project Documents shall be current revision at the effective date of the agreement.
Document Number
UTILITY PIPING.
2.4 Code Hierarchy
The following hierarchy shall apply to the WORK
1. Statutory Iraqi Laws and Regulations

2. CONTRACT terms and conditions
3. The Material Requisition
4. This PROJECT Specification
5. Other Industry codes and standards
6. Recognised Contractor, Manufactures and Technology specifications
In the event of ambiguity or contradiction between the above, precedence shall be given in the order listed
above. In the event of ambiguity or contradiction within the SPECIFICATION, CONTRACTOR shall apply the
most onerous requirement. In all cases, CONTRACTOR shall seek APPROVAL via an Engineering or
Technical Query before proceeding.
For the avoidance of doubt, hierarchy stipulations in any other document within the SPECIFICATION are
superseded by the above hierarchy.
International codes and standards shall be the latest edition and latest addenda at the time of CONTRACT
award.
Document Number
RUMAILA OPERATING ORGANISATION SPECIFICATION FOR WELDING, PWHT AND NDE OF PROCESS AND UTILITY
PIPING.
3 GENERAL REQUIREMENTS
3.1 Health Safety and Environmental (HSE)
Welding, Cutting, NDE and associated operations shall be performed in a safe manner, with focus on individual
health, safety and the minimisation of environmental impact consistent with COMPANY requirements. All such
activity shall be featured in the operational safety plan and safety audit schedule.
3.2 Quality Conformance
CONTRACTOR/SUPPLIER shall demonstrate to the satisfaction of the COMPANY that their activities within the scope
of this document are in accordance with the relevant clauses from BS EN ISO 3834 and EN ISO 9001.
• SUPPLIERS that offer wide ranging services, from project system design to materials selection and
procurement, welding, fabrication, construction, inspection, and installation, shall demonstrate that control of
operations involving welding conforms to the principles of ISO 3834-1 and the detailed “comprehensive
quality” requirements of ISO 3834-2. The requirements of ISO 3834-2 shall apply to COMPANY criticality 1
and 2 items.
• SUPPLIERS that offer services of a more limited scope and/or fabricators working under subcontracts shall
be required to demonstrate that control of operations involving welding conforms to the principles of ISO
3834-1 and the “standard quality” requirements of ISO 3834-3. The requirements of ISO 3834-3 shall apply
to COMPANY criticality 3 and 4 items.
• SUPPLIERS that offer services involving simple welded fabrications or maintenance items of a noncritical
nature (e.g., the fabrication of simple structural steel or pipe work support structures) for which any design
review will be performed by others shall be required to demonstrate that control of welding operations
conforms to the principles of ISO 3834-1 and the “elementary quality” requirements of ISO 3834-4.
CONTRACTOR/SUPPLIER shall submit to COMPANY for review and approval, a Quality Plan and procedures prior to
commencement of work.
The Procedures shall include but not be limited to:-

• Weld Procedure Specification and Qualification Records
• Welder Performance Qualification
• Non Destructive Examination (NDE)
• Post Weld Heat Treatment (PWHT)
• Storage and Control of Materials and Welding Consumables
3.3 Deviations
There shall be no deviation from or addition to this Specification and pertaining documents without specific written
approval from COMPANY.
3.4 Production Documentation
CO NT RACT O R/SUPPLIER shall maintain production records related to welding, using a recording system that
has been approved by COMPANY. These records shall include as a minimum:-
• Material and welding consumable certificates

• Post W eld Heat Treatment records
• Visual and dimensional inspection reports
• NDE reports
• W eld Summary lists
• Isometric drawings marked up with weld numbers (Weld Maps)
• Welder and welding operator qualification records
• Authenticated copies of NDE operator certificates
• Records of agreed deviations & technical queries
Document Number
PIPING.
Documentation shall be in the English language and presented in an agreed format.
4 PERSONNEL
Manufacturing, fabrication, and construction shall be performed using suitably competent and experienced workforce.
Welders, Welding operators, NDE and inspection personnel shall be trained and qualified to recognised industry
standards by examination and/or by individual test.
4.1 Welding Engineer
CONTRACTOR/SUPPLIER shall use a competent and suitably qualified Welding Engineer as responsible Welding
Coordinator. CV and job description shall be subject to COMPANY approval.
The Welding Engineer shall be responsible for all technical aspects of welding operations.
4.2 Welding Inspectors
Competent and certified welding inspection personnel shall be used by CONTRACTOR/SUPPLIER. Sufficient
numbers of personnel shall be assigned to ensure that welding related activities are adequately inspected in
accordance with the approved Quality Plan (QP).
Welding inspectors shall hold, as a minimum, current certification to any of the following standards:
• AWS – Certified Welding Inspector.

• CSWIP –Welding inspector
• PCN - Weld inspection level 2.
Alternative Welding Inspector certification shall not be acceptable, unless approved by COMPANY.
All Welding Inspection personnel shall be examined annually for near vision acuity capable of reading Jaeger Number
2 at a distance of 12inches (30.5cm) as well as Colour contrast differentiation at five year intervals.
4.3 Senior Welding Inspectors
For major scope of works involving multiple work fronts a Senior Welding Inspector should be used to coordinate and
supervise the work of the Welding Inspectors.
Senior welding inspectors shall hold, as a minimum, current certification to any of the following standards:
• AWS – Senior Certified Welding Inspector

• CSWIP – Senior Welding Inspector
• PCN - Weld inspection level 3.
CV and current certification of Weld Inspection personnel shall be available for review by COMPANY.
All Senior Welding Inspection personnel shall be examined annually for near vision acuity capable of reading Jaeger
Number 2 at a distance of 12inches (30.5cm) as well as Colour contrast differentiation at five year intervals.
4.4 Non-Destructive Examination (NDE) personnel
NDE personnel shall be competent and qualified. Supervisors and interpreters shall hold, as a minimum, current level
2 certification (or equivalent) specific to weld examination for the appropriate NDE methods, according to the
requirements of BS EN ISO 9712 and any of the following certification schemes:
• ASNT CP-106 (It is mandatory that training and examination shall be carried out by an independent body)
Document Number
PIPING.
• CSWIP
• PCN
All NDE personnel shall be examined annually for near vision acuity capable of reading Jaeger Number 2 at a distance
of 12inches (30.5cm) as well as Colour contrast differentiation at five year intervals.
All NDE personnel shall have at least six months post qualifying experience
Level 1 personnel may perform NDE operations under the supervision of level 2 personnel.
All UT and PAUT operators shall be assessed by COMPLANY for competency prior to commencement of any
activities.
Personnel responsible for the preparation of inspection procedures shall be Level 3 qualified. NDE personnel certified
to the requirements of a company written practice under the rules of SNT-TC-1A shall not be used, unless the
company written practice and the personnel certification have been reviewed and accepted by COMPANY for the
specific work. Approval will be subject to satisfactory demonstration of independence and control of the qualification
specifications.
5 WELD PROCEDURES
5.1 WPS & PQR Requirements
Weld Procedure Specifications (WPS) and supporting Procedure Qualification Records (PQR) shall be submitted to
COMPANY for approval prior to the start of welding activities. WPS shall include range of variables qualified according
to the requirements of ASME Boiler and Pressure Vessel Code, Section IX.
WPS previously qualified by CONTRACTOR/SUPPLIER may be submitted for COMPANY approval, provided they
meet the requirements of this Specification and are supported by PQR endorsed by a recognised Third Party.
The use of procedures qualified by others is not permitted unless specific approval is given by COMPANY.
The basis for rejection of welding procedure Specifications shall be non-compliance with the requirements of ASME IX
or this Specification.
The approval of WPS by COMPANY is subject to acceptable performance in subsequent production. Approval may be
withdrawn where excessive repair rates are encountered that cannot be attributed to bad workmanship.
Each WPS shall be written in English and be qualified by PQR in accordance with ASME Boiler and Pressure Vessel
Code, Section IX, ASME B31.3, ANSI/NACE MR0175/ISO15156 and this Specification. All procedure qualifications
shall be witnessed and endorsed by a recognised Independent Third Party approved by COMPANY.
All welding procedures shall be identified by a unique number. The information contained in each welding procedure
specification and in the procedure qualification test records shall include, but not be limited to, the information
contained on forms QF 482 and QF 483 shown in the ASME Boiler and Pressure Vessel Code, Section IX.
All welding procedure qualification tests shall include Macro hardness survey (Appendix 1).
Digital macro photographs (approx. x3 to x10) showing the location of each hardness impression shall be included.
The location of the hardness indents in the HAZ shall be clearly visible. Two macro sections shall be taken from the
completed joint, approximately 90° apart as close as practically possible to the 3 o’clock and 6 o’clock position. The
specimens shall be polished, etched and examined under a magnification of x5 to ensure freedom from defects in
accordance with ASME B31.3 and this specification
Original photo-macrographs of macro-sections at approximately 3 to 10 times magnification shall be included in the
PQR documentation.
Following satisfactory macro examination, a Vickers hardness survey using a 10 kg load (HV10) shall be made on the
macro specimens in accordance with ASTM E384. The hardness traverse shall be in accordance with Appendix 1 of
this specification. The first indentation on the heat-affected shall be within 0.5 mm from the fusion line but not on the
fusion line. Three traverses shall be made, one mm below each surface and one across the centre. The distance
Document Number
PIPING.
between measurements across the weld shall not exceed 2 mm. No value shall exceed 250 HV10 in the Base metal,
HAZ and weld root.
The requirement for impact examination per piping class shall be determined by ASME B31.3, Fig. 323.2.2A, and
Minimum Temperatures without Impact testing for Carbon Steel Materials. Recognition shall be given to the procedure
qualification range thickness limits 2t (t is thickness of test coupon) according to the requirements of ASME IX. For
non-impact tested procedure qualification test t max shall be further limited to the intersection point in Fig. 323.2.2A at
the MDMT of -2°C or better. Qualification of ‘t’ greater than the intersection point in Fig 323.2.2A requires impact
testing.
Impact testing requirements per piping class:-

• A01E2B – No impact examination is required
• A06E2B – Impact examination is required on material above 24mm thick (Note ASME IX requirements 2t)
• A09E2B – Impact examination is required on material above 24mm thick (Note ASME IX requirements 2t)
• A15E2B – Impact examination is required
• S01N1B – No impact examination is required
• U03E2B - No impact examination is required
The above guidance is based on a MDMT of -2C, if for process requirements an MDMT below this is specified, further
testing shall be required as approved by the COMPANY.
Impact testing shall be performed in accordance with the requirements of ASTM A370 and ASME B31.3, at the
Minimum Design Metal Temperature -2°C. The Charpy V-notch impact values for parent material, weld metal, and
heat affected zones shall be not be less than the minimum average and minimum single readings specified in ASME
B31.3 Table 323.3.5.
Charpy V-Notch impact testing of piping materials, fittings and weldments shall be in accordance with ASME B31.3
Table 323.2.2 and 323.3.1
Impact testing of repair weld procedures shall sample weld metal and both adjacent HAZs.
Charpy Impact test locations shall be weld centreline, fusion line and fusion line plus 2 mm. The Charpy specimen top
surfaces shall be within 1.5 mm of the inner surface, shown in appendix 2 of this document.
When materials are over 25 mm thick, additional sets at weld centreline, fusion line and FL+2 mm shall be taken within
1.5 mm of the outer surface, shown in appendix 2 of this document.
Where a different welding process or consumable is used for root and fill welding, both the root and fill weld metals
shall be sampled.
Where welding position is other than 1G (rotated), Charpy specimens shall be removed from the 3 o’clock or 9 o’clock
positions.
When using impact tested materials with thicknesses less than 10 mm, the test temperature for impact testing sub-size
specimens shall be calculated in accordance with ASME B31.3 Paragraph 323.3.4
Document Number
PIPING.
5.2 Weld Procedure Specification Records
The relevant COMPANY approved WPSs shall be displayed at each work location and shall be readily available to
each welder in a minimum of two languages (English and Local).
Each WPS shall include as a minimum the following information:
• Unique procedure number
• Reference to relevant Brownfield Piping Specification (Piping Class)
• Specification of parent material including specific grades covered by the relevant Piping Class
• Material Grouping
• Filler metal type, brand name, classification
• Filler Metal Grouping
• Sequence of welding, including the number and individual weld bead deposition sequence
• Shielding gas composition and flow rate if required.
• AWS classification, if any, and manufacturer’s trade name or designation for welding flux if required.
• Non consumable electrode
• Welding process
• Welding current type, polarity, amperage and voltage(s) including appropriate ranges
• Joint type (Edge preparation sketch / Fit up sketch)
• Welding position and progression, up or down
• Diameter Range
• Thickness Range
• Method of tacking or clamping
• Type & Removal of Line-up Clamp
• Cleaning and/or Grinding
• Minimum Preheat temperature
• Maximum Interpass temperature
• Travel speed
• Minimum & Maximum heat input
• PWHT if required including heating rate, soak time and temperature, and cooling rate
• Temporary backing if required
• Single or multiple arcs
• Specific precautions that will be taken for welding if applicable, to prevent wind or drafts from interfering with
the shielding gas protection.
5.3 Procedure Qualification Records
Each PQR shall include all of the following original documents and information, where applicable, when submitted with
WPS for approval:
As-run data sheet:

• Weld Procedure number
• Date and time of test
• Welders name and identification number
• Material Specification, type, heat no, diameter wall thickness
• Welding position
• Welding progression
• Welding consumable: Specification, Classification, Trade Name, diameter, batch numbers
• Shielding gas
• Preheating method
• Weld preparation sketches
• Weld run deposition sketches
• Method and temperature of preheat
• Reference to PWHT procedure and records chart if applicable
• Welding Machine type and manufacturer
Recorded welding parameters:

• Welding process
Document Number
PIPING.
• Amps & volts

• Preheat
• Wire stick out length
• Wire and electrode diameters per weld pass
• Gas cup size
• Tungsten electrode diameter and type
• Shielding Gas Flow Rates if required
• Current type
• Travel speed (run out length and time)
• Wire feed speed
• Heat input
• Inter pass temperature
Reports and Certification:

• Radiographic
• Ultrasonic
• Magnetic Particle
• Dye Penetrant
• PWHT Reports and charts
• Mechanical Examination Reports and Macro Photographs
• Material Test Reports
• Hardness test reports
• Welding Consumable Batch Certificates
• Any other relevant information
Calibration certificates for equipment and measuring devices and test house approval certification shall be available for
review if requested by COMPANY
6 WELDER QUALIFICATION
Welders and welding operators shall be qualified in accordance with the requirements of ASME Boiler and Pressure
Vessel Code, Section IX. All qualification examination shall be witnessed and endorsed by a recognised Third party
acceptable to COMPANY.
Qualification shall be completed prior to commencement of welding activities and records shall be made available to
COMPANY upon request.
All performance qualifications shall be endorsed for every 6 month prolongation by CONTRACTOR/SUPPLIER.
Requalification shall be required if the Welder has not welded with the qualified process during a period of 6 months or
more.
A Welder or Welding Operator may be qualified by volumetric NDE of their initial production joint on acceptance by
COMPANY.
6.1 Pre-Qualification
Welder and welding operator performance qualifications from other employers shall not be used unless approved by
COMPANY. The acceptance of Performance qualifications made by others is limited to qualifications that were made
on pipe or tube test coupons and have been witnessed and endorsed by a recognised Third Party acceptable to
COMPANY.
The CONTRACTOR shall provide proof that the welder has been employed in the previous six months with reasonable
continuity and has been welding with the processes qualified during that time, to the same, or similar, procedures with
satisfactory results.
A welder who has satisfactorily completed a procedure qualification test is automatically qualified for that procedure.
Document Number
PIPING.
Previous welder qualifications tests may be accepted by COMPANY provided they are fully documented and are less
than 6 months old, supported by production records demonstrating satisfactory welder performance. These tests shall
have been conducted utilising a WPS that includes the same essential variables as that for the scope of work to be
executed. The CONTRACTOR shall provide proof that the welder has been employed in the previous six months with
reasonable continuity and has been welding with the processes qualified during that time, to the same, or similar,
procedures with satisfactory results.
Any welder who, in the opinion of COMPANY, is either consistently ignoring good welding practice or specification
requirements or is responsible for a high level of repairs during production shall be removed from the work, and shall
undergo a re-training programme approved by COMPANY before a retest may be considered.
6.2 Welder & Welder Operator Identification
Each qualified welder and welding operator shall be assigned a unique identification number, letter, or symbol by
CONTRACTOR/SUPPLIER which shall be used to identify their work.
Whilst on site all welders and welding operators shall be easily identifiable. This may be by the following means:
• A badge bearing name, photograph and unique identification number

• By the Contractor maintaining a report of welder IDs including name, photograph, and welder ID number
In the event that a welder or welding operator leaves for alternative employment, their welder ID number shall not be
assigned to another welder.
6.3 Welder Performance Registration
Prior to commencement of work, CONTRACTOR/SUPPLIER shall submit a register of proposed welders and all
welder performance qualification certificates, including relevant back-up documentation, such as NDE and mechanical
test certificates
In order to maintain the validation of performance qualification, a welder performance register should be kept up to
date. This register should at least contain the following data:
• Welder’s unique identification number

• Position Qualified
• Date of weld inspection and inspection results.
• Materials (base and consumable)
• Configuration data (diameter, wall thickness, etc.)
• Reference to WPS used
• All other essential variables
• Prolongation validation date
7 WELDING GENERAL REQUIREMENTS
7.1 General
All welding shall comply with the requirements of this specification and ASME Code for Pressure Piping Process
Piping B31.3.
The welding environment should be such that all welding is adequately screened from draughts and inclement
weather. Particular care shall be taken where gas shielded methods are employed.
When fabrication is to be carried out in the vicinity of plant or equipment which may be damaged or otherwise
compromised by such planned construction work, i.e. weld spatter, fumes, grinding dust, etc., then adequate
protection shall be provided for this ancillary plant and equipment.
Care shall be taken to avoid overstressing or other mechanical damage to any process equipment or piping fabrication
at all stages of the work.
Document Number
PIPING.
The welding processes listed in Appendix 3 of this specification are acceptable for fabrication subject to the limitations
stated therein. Request to use any other welding process shall be submitted to COMPANY for approval.
The following restrictions apply to all welding processes:
• The use of permanent backing strips is prohibited.

• Stringer bead welding technique is preferred; however weave beads shall be allowed for positional welding
providing the maximum width of weave does not exceed 3 times the electrode or filler wire diameter.
7.2 Preparation for Welding
All material shall be visually inspected prior to welding, to confirm freedom from mechanical damage/ corrosion and
confirm correct marking. Any deviations shall be reported in writing to COMPANY.
Deep gouges and dents on the preparation surface shall be cause for rejection. Weld repair of such defects shall only
be permitted by approval of COMPANY. Laminations identified on the bevel surface by visual examination shall be
investigated by MT or PT prior to removal.
Weld preparations shall be in general accordance with ASME B16.25. Square butt ends are permissible below 2mm
wall thickness.
Surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides, and other foreign material detrimental
to the integrity of the weld both internally and externally for a distance of 25 to 50 mm beyond the substrate surface
actually touched by the arc.
Prior to preparation/fabrication/cutting of or process piping for branch connection i.e. flange or weldolet attachment,
UT examination shall be performed to confirm freedom from laminar defects in the parent material. Additional MT or
PT shall be performed to ensure no surface breaking defects are present.
Where applicable, wooden or plastic covers shall be provided to protect weld bevels from mechanical damage and
prevent ingress of foreign material into the vessel, piping or other process equipment.
7.3 Cutting and Bevelling
Items may be cut mechanically or by oxy-fuel gas cutting. Weld bevels are to be prepared by machining or flame
cutting. Internal and external flame cut bevel surfaces shall be ground to bright metal and shall be free from, paint, oil,
rust, scale, and other material that would be detrimental to either the weld or the base metal when heat is applied.
7.4 Alignment
Equipment used to hold and support process equipment, vessels, piping, etc., must be capable of bearing the load in a
safe manner whilst maintaining the stability required for working in both the vertical and horizontal planes.
Alignment shall conform to ASME 31.3 section 328.4 and the relevant ASTM for the tolerances on thickness
(effectively +/- 12.5% tolerance on thickness).The permitted maximum misalignment for piping butt welds shall be:
Internal
Pipe Diameter Misalignment
≤100mm 1.0mm
> 100mm 1.6mm
External
Pipe Diameter Misalignment
≤ 12mm Pipe thickness / 4
> 12mm 3.0mm
Misalignments greater than these limits may be corrected by grinding or machining to a taper of 1:4, provided the wall
thickness is not reduced below the minimum tolerance.
Document Number
PIPING.
The use of deposited weld metal to correct contour, shape or misalignment tolerances or to provide sufficient material
for machining shall not be carried out without specific agreement by COMPANY.
Application of heat for correction of minor distortions on piping spools shall only be undertaken with COMPANY
approval. Any such heating shall be performed in accordance with an approved procedure and the maximum
temperature employed shall be limited to 450°C. Spot heating techniques shall not be used and neither shall materials
be quenched to correct alignment
7.5 Proximity of welds
Pipe longitudinal seams shall be separated by at least 45 degrees of rotation or 150mm, whichever is the less.
The minimum distance between the toes of adjacent welds shall be the lesser of one pipe diameter or 150mm.
However, between fittings, short lengths may be required. In this situation butt welds shall not be within 100mm of
adjacent welds. For sizes less than NPS 3, butt welds may be within the greater of four (4) times the wall thickness
or 50mm to the adjacent butt weld toe, but only with written COMPANY approval.
Branches and attachment welds shall be separated from similar welds and circumferential welds by weld toe-toe
minimum distance of 4 times the nominal wall thickness.
Non-pressure attachments (e.g. pipe supports) shall be located at a minimum distance of 50mm minimum or 2t,
whichever is greater from any butt weld in pipe, where ‘t’ is the pipe wall thickness. Where the attachment distance is
unavoidably less than 2t, the following procedure shall be adopted:
• The weld cap of the butt weld shall be ground flush in the region of the clash plus 50mm either side (or 2t,
whichever is the greater).
• NDE on the butt weld shall be completed prior to making the attachment weld.
• Both the butt weld and the attachment weld shall be ground in the toes using a rotary burr to a minimum
radius of 10mm. The rotation of the burr shall be with the rotation of axis aligned with the length of the weld
and the grinding shall be a minimum depth of 0.5mm, ensuring that the required minimum wall thickness is
maintained. Properly radiused GTAW welds are acceptable without grinding.
• The welding preheat shall be a minimum of 100ºC during welding of the attachments.
• On completion of welding and grinding, 100% MT / PT of all affected welds shall be performed.
Note: This procedure is not acceptable on pipes which require PWHT after attachment welding if NDE cannot be
performed satisfactorily on the butt weld.
7.6 Tack Welding and Clamping
All tack welds shall be made in accordance with an approved WPS, and shall be performed by qualified pipe welders.
Tack welds shall be of sufficient cross-section and length in order to avoid cracks, especially on high strength steel
materials.
They shall be at least 25mm in length and shall be equally spaced around the circumference in sufficient number to
support the process piping, equipment or fitting.
Tack welds intended to be an integral part of the root weld shall be ground to a taper edge to facilitate weld pick-up.
Prior to commencement of any welding all tack welds shall be inspected for cracks and any cracked tacks removed.
If line-up clamps are used without tack welding they shall not be removed until after the root pass has been fully
completed
The required preheat temperature shall be attained prior to tack welding.
Document Number
PIPING.
8 WELD EXECUTION
8.1 General
Using qualified and competent personnel, CONTRACTOR shall carry out daily welding surveillance, including
parameter checks. Sampling each welder at a frequency agreed with COMPANY in accordance with an approved
Inspection and Test Plan.
8.2 Identification
CONTRACTOR shall carry out daily welding parameter checks sampling each welder at a frequency agreed with the
COMPANY and in accordance with an approved Inspection and Test Plan by qualified inspection personnel.
GTAW shall be carried out using HF equipment.
Welds shall be uniquely identified.
The CONTRACTOR/SUPPLIER shall demonstrate to the satisfaction of COMPANY that individual welds can be
positively identified at all stages of construction.
Particular attention shall be given to maintaining identification during grit-blasting and painting.
Weld identification numbers shall be marked adjacent to the weld by crayon, paint stick or similar marker prior to
welding.
Similarly, welders shall mark their numbers and completion date adjacent to each completed weld.
8.3 Preheat Temperature Requirements
The minimum requirements for preheating shall be in accordance with the requirements of ASME B31.3 Table 330.1.1.
In addition, for welds under a high degree of restraint (e.g. branch connections or major attachments) all ferritic
materials shall be preheated to 95°C minimum irrespective of the thickness and tensile strength.
When preheat is not explicitly required by this Specification and ambient temperature is below zero, or
condensation/moisture is apparent on work surfaces, then sufficient preheat should be applied to ensure work
surfaces are dry and remain warm to touch.
8.4 Preheat Application
For up to and including 25 mm wall thickness, preheating shall be by gas torch or electrical resistance heaters. Oxy-
fuel gas cutting torches shall not be used.
Above 25 mm, electric resistance heating mats or multiple head gas torches shall be used unless it is agreed with
COMPANY that access or location makes it impractical.
Preheat shall be uniform and shall include a zone which is not less than 2t (t = wall thickness), with a minimum of
75mm, either side of the weld preparation. When electric heating elements are used they shall be covered with a
minimum of 25 mm of insulation, extending 75mm either side of the heated zone.
8.5 Inter-pass Temperature
Interpass temperatures shall be checked immediately prior to commencement of the next welding pass adjacent to the
start position and maximum distance of 25mm from the weld bevel.
The maximum interpass temperature and method of measurement shall be as stated on the WPS. For carbon steel,
maximum interpass temperature shall be 316°C.
In general the maximum inter-pass temperature shall not exceed that measured during PQR by more than 55°C.
Document Number
PIPING.
Attainment of preheat and interpass temperatures shall be confirmed by temperature-indicating crayons, contact
pyrometers, thermocouples or other suitable means. It is CONTRACTOR/SUPPLIER responsibility to determine
suitable brands and melting temperatures that may be used. This information shall be made available to COMPANY
on request
8.6 Interruption of Welding
Welds shall be completed as far as practicable without interruption
As a minimum, the root and second (hot) pass shall be completed before it is permissible to interrupt welding progress
and allow the joint to cool.
When interruption of welding is unavoidable, slow cooling is mandatory and shall be achieved by wrapping the joint in
a suitable insulation material.
If cooling has occurred and the completed weld ligament depth is less than 25% of the total joint thickness. The pipe
joints shall be fully supported at all times and before recommencement, the weld shall be subject to both visual and
surface inspection (MT or DPI), to ensure freedom from deleterious defects.
8.7 Arc Strikes
The welding arc shall only be struck on the prepared welding surface or previously deposited weld metal.
Any erroneous arc strikes shall be removed by grinding or other suitable method and the area shall be subject to
surface inspection MT, to ensure continued freedom from defects. The thickness of material remaining after the
removal of such defects shall be measured by UT and be within code tolerance. If this measurement reveals loss of
wall thickness below the minimum required thickness then the item shall be replaced. Weld repair of such areas shall
not be permitted.
8.8 Weld Finish
Weld beads shall be contoured to promote complete fusion at the sides of the bevel and must be finished with a
smooth profile, without overlap, abrupt ridges or valleys. Flux and slag shall be removed completely from weld beads
and from the surface of completed welds and adjoining base material. Peening is not permitted
Toe profile grinding or cosmetic grinding shall only to be carried out when directed by the design drawings or with the
approval of COMPANY.
If fillet welds are concave, or not equal, the minimum throat size shall not be less than 0.7 x the specified leg length.
8.9 Weld Repairs
Repairs shall be recorded and supported by sketches detailing location, dimensions and where possible, the
identification of the discontinuity.
Two repair attempts shall be allowed on any one defective area when the approved PQR and corresponding WPS
permits this, No further attempts to repair shall be carried out without the authorisation of the COMPANY.
Weld repairs shall be carried out prior to PWHT.
In the event of a repair after PWHT, the joint shall be deemed as a full cut out. Unless the SUPPLIER/CONTRACTOR
has an approved WPS and supporting PQR, that duplicates actual construction conditions. I.e. weld, PWHT,
excavate, weld and PWHT.
Before starting fabrication, SUPPLIER/CONTRACTOR shall agree with COMPANY which types of welding defects are
to be notified prior to rectification.
SUPPLIER/CONTRACTOR shall subsequently advise COMPANY of the need to perform such repairs which shall be
subject to further approval prior to further work on defective welds.
Document Number
PIPING.
As a minimum, any instance of cracking (except small crater cracks less than or equal to 4 mm [5/32 in] in length) shall
be reported to COMPANY. Cracked welds shall be completely cut out of the pipe work and the cause of cracking
established to the satisfaction of the COMPANY.
Unacceptable discontinuities shall be completely removed by chipping, gouging, or grinding, to clean, sound metal,
and the excavated area shall be examined by MT or PT to assure complete removal of defects
Repairs to correct weld defects shall be made using the same WPS used for the original weld or other previously
authorised WPS.
Where a different welding procedure is to be used for repair welding (e.g. SMAW for the repair of SAW welds) a
procedure shall be qualified in accordance with this specification. Subject to the approval of the COMPANY internal
repairs shall be specifically qualified.
As minimum, repair welds shall be inspected to their full extent using techniques used for inspection of initial weld.
Detailed records of repairs shall be retained by SUPPLIER/CONTRACTOR.
9 POST WELD HEAT TREATMENT (PWHT)
9.1 General
Post weld heat treatment (PWHT) shall be applied to all joints above 25mm wall thickness and performed in
accordance with the requirements of ASME B31.3 and this specification.
PWHT requirements for branch welds shall be according to the requirements of ASME B31.3 paragraphs 331.1.3.
All PWHT procedures shall be submitted to COMPANY and approved prior to any PWHT operations.
Post weld heat treatment cycles shall be clearly specified in the WPS and PQR. PQR test coupons shall be subjected
to the maximum anticipated heat treatment to be used in production.
A maximum of two complete PWHT cycles is permitted for each weld when the approved PQR and corresponding
WPS permits this further PWHT cycles shall not be carried out without the authorization from COMPANY.
No welding or heating is permitted after PWHT without COMPANY approval.
Exothermic chemical reaction packs and direct flame heating shall not be used as a heat source.
The temperature shall be measured by a suitable number of thermocouples equally spaced around the weld joint.
Each thermocouple shall have been calibrated within 30 days of the performance of heat treatment.
Thermocouples shall be located on the weld centre line and shall either be held in intimate contact with the surface of
the weld mechanically or be attached by capacitance discharge welding. The attachment points of capacitance
discharge welded thermocouples shall be dressed by grinding after removal.
Procedures for attachment of thermocouples by capacitor discharge welding shall be subject to approval of
COMPANY. Use of this technique shall be carefully monitored by COMPANY.
All thermocouple attachments shall be adequately insulated to avoid temperature misreading caused by the effect of
radiation.
Document Number
PIPING.
The minimum number and position of thermocouples shall be as follows:
Pipe Diameter Number of Thermocouples Required
Up to DN 80 (NPS 3) 1
Over DN 80 (NPS 3 and up to DN 350 (NPS 14) 2 (to be placed 180 degrees apart)
Over DN 350 (NPS 14) 4 (to be placed 90 degrees apart around the weld)
Temperature shall be continuously recorded. A chart of the heat up, soak and cool down while at temperature above
260°C is required. Time intervals shall be recorded with temperature, and clearly indicated. Temperature
measurements shall be recorded at intervals no greater than 15 minutes throughout the heating, holding cycles. Heat
treatment charts shall be provided to COMPANY for each heat treatment.
For circumferential butt welds the minimum heating band shall be in accordance with the requirements of ASME
B31.3. Welds may be locally post weld heat treated by heating a circumferential band around the entire component
with the weld located in the centre of the band. The width of the band heated to the specified temperature range shall
be at least three times the wall thickness at the weld of the thickest part being joined. For nozzle and attachment
welds, the width of the band heated to the specified temperature range shall extend beyond the nozzle weld or
attachment weld on each side at least two times the run pipe thickness, and shall extend completely around the run
pipe. The temperature of the heated band shall be within the specified PWHT soak Temperature range e.g. 95 to
650°C or as specified on the WPS
In the case of a branch connection, the temperature gradient shall be such that length of material from each crotch
heated to temperature equalling half heat treatment temperature shall be 1.8 √Dt (where ‘D’ and ‘t’ are the nominal
diameter and thickness of the main pipe and branch as appropriate.
Thread and gasket surfaces shall be suitably protected from excessive oxidation during heat treatment.
9.2 Post Weld Heat Treatment Procedure
• Name of CONTRACTOR/SUPPLIER
• Ruling Specification
• Material & Item description
• Method of heating
• Size & type of electrical element
• Type, location & number of thermocouples
• Method of thermocouple attachment
• Details of loading & supporting arrangements to avoid distortion
• Holding time & temperature
• Heating & cooling rates
• Type of recording equipment including number of channels
• Chart speed
10 WELDING ELECTRODES, FLUXES AND CONSUMABLES
10.1 General
All filler materials and fluxes shall be in accordance with ASME II Part C. Equivalence to ASME/AWS specifications
may be considered subject to COMPANY approval. The basis for equivalence may be determined by review of
consumables (electrodes and fluxes) from the manufacturer’s catalogues and/or by chemical analysis and mechanical
examination of the weld deposits.
In general the nominal analysis of the principal elements in the deposited weld metal shall meet the nominal analysis
of the base metal.
Document Number
PIPING.
All completed weld joints shall be within the mechanical property limits specified for the base materials to be
joined.
Storage and control of all welding consumables shall be in accordance with the manufacturer’s recommendations and
Section 11 of this specification.
10.2 Consumable Certification
As a minimum, welding consumables shall be delivered in accordance with their product data sheet and shall have
with certification including chemical analysis according to EN 10204, Type 3.1.
Each consumable, or consumable batch, shall have individual marking relative to its certification.
Batch testing of the welding consumables may also be acceptable. In such case welding and testing shall be carried
out in accordance with a typical welding procedure specification and certification presented in the format of a WPQR.
Production material or an equivalent parent metal specification shall be used for such product certification.
Fluxes for submerged arc welding processes shall be delivered with certification according to EN 10204, Type 2.2.
10.3 Filler Metals
The welding consumables listed in Appendix 4 of this specification are acceptable for fabrication subject to the
limitations stated therein. Request to use any other welding consumables shall be submitted to COMPANY for
approval.
11 STORAGE AND CONTROL OF WELDING CONSUMABLES
11.1 General
In order to prevent the use of incorrect, contaminated or damaged consumables, an auditable procedure for the
storage and control of welding consumables shall be exercised.
Detailed written procedures for the systematic receipt, storage, issue and control of welding consumables shall be
submitted to COMPANY for approval prior to the commencement of fabrication.
Records of consumables shall be maintained to ensure an auditable trail from receipt, through pre-treatment, their
issue to operators and return to stores so that their identity can be verified at any stage.
Consumable handling shall be controlled by a procedure approved by COMPANY. Storage shall be in accordance with
the manufacturers’ recommendations for the consumable type.
11.2 Consumable Control
All welding consumables shall be received into a quarantine area within the welding consumable storage facility. Full
details, including supplier, manufacturer, brand name, batch number, quantity received and delivery date shall be
recorded and the certificates suitably filed. Any further checks required on the consumables shall be undertaken
before they are released from the quarantine area.
On completion of all records and checks, the consumables shall be clearly labelled and segregated according to
consumable type and specification.
All consumable storage areas (including the quarantine area) shall be dry, i.e. relative humidity equal to or less than
60%, and maintained at a minimum temperature of 20°C.
All non-identified, wet, partially used, contaminated or damaged consumables found in any storage or fabrication area
shall be discarded.
Consumables that cannot be identified to the satisfaction of the COMPANY shall be removed from the work site and
any welds made with such consumables must be cut out and re-welded.
Document Number
PIPING.
11.3 Manual Metal Arc Electrodes
Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other types, such as rutile
type electrodes.
Basic low hydrogen electrodes shall be dried to ensure the weld metal hydrogen level does not exceed 8 ml of
diffusible hydrogen per 100g of weld metal.
The CONTRACTOR/SUPPLIER shall issue drying instructions based on the manufacturer's recommendations for all
manual metal arc electrodes as required.
Drying and subsequent elevated temperature storage shall be performed in purpose built, thermostatically controlled
ovens located within the storage facility. These ovens shall be equipped with a calibrated temperature indicator.
Ovens should not be overloaded. For the purpose of drying, oven shelves shall not be stacked with more than three
layers of electrodes.
Each type and specification of consumable shall be clearly marked and segregated within the drying and storage
ovens.
After drying, basic low hydrogen electrodes shall be stored in holding ovens at a temperature of 150°C for a maximum
period as recommended by the consumable supplier.
After the maximum time period has elapsed, the electrodes shall be re-dried in accordance with the original drying
procedure
Manual welding consumables shall be issued to a welder only on production of an authorized requisition. No welder
shall be issued with more electrodes than can be used in a four hour period. Basic low hydrogen electrodes shall be
issued into quivers heated to a minimum temperature of 70°C.
All manual consumables remaining at the end of a work period shall be returned to the storage facility. All returns shall
be recorded. All basic low hydrogen electrodes shall be re-dried in accordance with the original drying procedure.
All electrodes requiring re-drying shall be marked in a clear manner to indicate the number of drying cycles to which
they have been subjected. No electrode shall be subject to more than 3 drying cycles and shall be destroyed.
However, for electrodes subject to drying temperatures in excess of 350°C, only one drying cycle is permitted.
Use of vacuum packed electrodes may be acceptable providing CONTRACTOR can demonstrate to the COMPANY
that controls and checks are in place to ensure claimed hydrogen levels are met at the point of application.
Vacuum packed electrodes unused at the end of the period recommended by the manufacturer shall be discarded
unless the CONTRACTOR obtains the COMPANY approval for re-baking and recycling.
Cellulose coated electrodes should be kept apart from low hydrogen electrodes. If possible, the packs of electrodes
should be taken out of storage in the sequence in which they were received.
For cellulose coated electrodes, exposure to air moisture and excessive differences in temperature should be avoided.
Cellulose coated electrodes shall neither be baked nor dried and shall be used straight from the original packaging.
11.4 Welding Wires
Wire for GTAW, SAW and FCAW, shall be dry and free from rust, oil or any other foreign matter.
All welding wires shall be clearly labelled as required by the procedures referenced in Section 11.1. GTAW wire shall
have the grade stamped on the wire.
GTAW filler wires shall be cleaned with a solvent immediately prior to their use. Any wire that cannot be cleaned
without damage to the surface, change in size or other damage that would adversely affect its use should be
discarded.
Document Number
PIPING.
Wire spools for automatic and semi-automatic processes shall be stored in original packaging preferably in dedicated
cabinets.
Filler wire for automatic or semi-automatic welding, remaining from a partly used coil or spool, may be reused as new
wire if it is promptly repackaged after use in new sealed containers and stored as a new consumable.
Any wire in coils or spools that has not been kept in sealed containers after use or has been contaminated with rust,
grease or other debris, shall not be re-used without cleaning in accordance with the wire manufacturer’s advice.
11.5 Submerged Arc Welding Fluxes
Flux shall be supplied and stored in accordance with manufacturer’s instructions.
Flux shall be supplied in moisture resistant sealed containers and stored in controlled environment as recommended
by the manufacturer.
Each batch of flux shall be labelled with the information from the supply container.
The CONTRACTOR/SUPPLIER shall issue drying instructions based on the manufacturer's recommendations for all
submerged arc fluxes as required.
Flux remaining unused at the end of each shift shall be returned to the storage facility. Surplus submerged arc flux
shall not be reclaimed and re-used.
Flux shall not be left in machine hoppers for extended periods, when welding is not being carried out, e.g. overnight or
during non-productive shifts.
Recycling of flux shall only be allowed if the procedure is endorsed by the consumable manufacturer and by the
COMPANY.
11.6 Shielding Gas
The composition of shielding gas used for welding shall be compatible with the material being welded and the weld
properties required, with a dew point of less than or equal to minus 40ºC, with the essential variables of composition,
purity and flow rate stated on the WPS.
Changing gases from the PQR shall only be considered with specific COMPANY approval.
All bottles containing shielding gases shall have clear identification labels
12 NON-DESTRUCTIVE EXAMINATION (NDE)
12.1 General
CONTRACTOR/SUPPLIER shall submit non-destructive examination (NDE) procedures to COMPANY for approval of
all non-destructive methods to be used. Each NDE procedure shall be specific to the work scope and shall detail the
examination technique, the extent of inspection and acceptance criteria.
Inspections of welds shall conform to procedures and acceptance standards required by ASME V and ASME B31.3.
The percentage NDE stated applies to all piping weld joints and applicable fillet welds for each NDE technique.
Minimum acceptance criteria for all NDE methods shall be as per ASME B31.3 - Table 341.3.2.
Percentage inspection shall mean the percentage of complete welds, not percentage lengths of individual welds.
Where less than 100% inspection is specified, the welds selected for examination shall include welds by each welder
and all appropriate WPS’s. “5%” examination is the minimum requirement for each welder for each line and shall be
defined as 100% examination of one weld in twenty.
Document Number
PIPING.
Random selection shall be such as to include a sample of each welder’s work. Progressive sampling for examination
shall apply for each welder performing a defective weld as specified in and in accordance with ASME B31.3 Section
341.3.4.
NDE shall be carried out at least 24 hours after completion of welding. PWHT shall be completed before NDE and
final acceptance inspection.
Where COMPANY determines, as a result of NDE cross-checking or otherwise, that a particular NDE operation or
examination procedure has failed to detect unacceptable defects, COMPANY may request additional examinations
and methods to be applied.
All NDE reports shall be subject to review and endorsement by the COMPANY/SUPPLIER inspector.
All NDE operators shall be certified for the examination they perform according to section 4.4 of this document. The
certification shall be reviewed and approved by COMPANY/CONTRACTOR.
12.2 Extent of NDE

The minimum extent of NDE shall be as per Appendix 5.
Acceptance criteria for welds shall be according to ASME B31.3 Table 341.3.2 Normal Fluid Service.
CONTRACTOR/SUPPLIER weld repair rates shall be continuously monitored and repair statistics provided to
COMPANY for review on an agreed basis. Progressive Sampling for Examination shall be applied in accordance
with ASME B31.3 section 341.3.4.
When required spot or random examination reveals a defect, then

(a) two additional samples of the same kind (by the same welder) from the original designated lot shall be given the
same type of examination
(b if any of the items examined as required by (a) above reveals a defect, two further samples of the same kind shall
be examined for each defective item found by that sampling
(c) if any of the items examined as required by (b) above reveals a defect, all items represented by the progressive
sampling shall be fully examined and repaired or replaced as necessary, and re-examined as necessary to meet
Project requirements
For the high consequence areas listed below 100% radiography shall be applied. This requirement shall not form part
of the percentage NDE requirements specified in appendix 5.
• Populated areas and Industrial areas (DS, CPS are not included in this requirement)
Defined populated area are those locations that contain a concentrated population, such as an city, town, village,
buildings, houses, hospitals, army and police forces quarters, check points or any other location designated as
residential, commercial or industrial areas, including workshops, contractor camps, fabrication shops and
warehouses, when they aren’t located within a ROO operation site.
For populated areas and industrial areas we have defined a buffer zone of 100 m either side of the pipe. If any
construction in a location intended to be inhabited by people defined above, this shall be considered as a high
consequence area for a radius of 100m.
12.3 Radiographic Examination (RT)
As a minimum, radiographic operations shall comply with local regulations. Adequate safety measures shall be
ensured for working with ionizing radiation.
Document Number
PIPING.
Radiographic examination procedures shall be in accordance with the requirements and methods specified in ASME
Section V, Article 2. Radiographic procedures shall include technique sheets incorporating a shooting sketch.
X-Ray or Gamma Ray techniques is acceptable, however X-Ray is preferred for shop radiography of pipework up to
25mm WT. For both methods, prior to production radiography the technique shall be qualified using source side
image quality indicators. Wire type image quality indicators (IQI) shall be used according to the requirements of
ASME V Article 22.
IQIs shall be positioned source side across the weld seam. If a complete joint circumference is radiographed in a
single exposure four IQI’s placed at 90 degree intervals shall be used.
If the surface of the weld facing the source is not accessible then the sensitivity must be determined separately on a
procedure qualification radiograph using a work piece similar to the item under examination but with both surfaces
accessible. An IQI should be placed source side and film side, and by comparison of the readings of the IQI sensitivity,
the relationship between source side and film side sensitivity can be obtained.
Care must be taken to ensure that the same radiographic technique and conditions are used on production
radiographs.
Interpretation and acceptance criteria of radiographs shall be in accordance with ASME B31.3.
Lead intensifying screens and fine or very fine grain high contrast film shall be used to achieve required ISO wire
penetrometer sensitivities. The film shall be high contrast, fine grained (e.g. Agfa D5 or equivalent) or better.
Radiographic films shall be free from defects or processing marks which could obscure weld imperfections
The film density shall be 2.0 to 3.5 through the thickest portion of the weld. In those instances where the variable
thickness makes a single film impractical, double-film viewing may be used with COMPANY/CONTRACTOR
concurrence. For the double-film technique, the film density shall be in the range of 2.6 to 4.0 for the double-film
combination, with a minimum density of 1.3 for each film.
Radiographic films shall be thoroughly dried and viewed with an illuminator that conforms to ISO 5580.
Radiographic films shall be processed to allow storage without deterioration for a period of 5 year or the life specified
in the fabrication contract. Provisions for digitalised radiographs shall be approved by COMPANY.
Double Wall Exposure and Double Wall Viewing shall be used for all diameters up to 89 mm OD. For elliptical
technique a minimum of 2 exposures and for superimposed technique a minimum of 3 exposures is required. Double
Wall Exposure and Single Wall Viewing shall be used for all diameters greater than 89 mm OD with minimum 3
exposures. Additional exposures may be performed if required for qualification of technique.
Each production radiograph shall include, through the use of lead characters or flashing indent, the following
information:
• Project Number
• Drawing number
• Joint number (including repair number, i.e. R1, R2)
• Date
• Welder Identification
• IQI position (film side or source side)
CONTRACTOR/SUPPLIER shall interpret the radiographs and the results of the interpretation shall be reported on a
format acceptable to COMPANY.
12.4 Magnetic Particle Examination (MT)
Magnetic Particle Examination (MT) shall be carried out in accordance with COMPANY approved procedures and
technique sheets according to the requirements and methods specified in ASME V Article 7.
Document Number
PIPING.
The evaluation of indications and the acceptance criteria shall be in accordance with ASME B31.3
Magnetic particle examination of welds shall include a band of base metal at least 25 mm wide on each side of the
weld.
A background of white contrast paint shall be used in conjunction with a black magnetic ink (wet particle). Calibration
of pie indicator for direction of current and flux strength shall be done over white contrast paint.
The technique shall be carried out in the continuous mode and cover for longitudinal and transverse defects.
AC electromagnetic yokes shall be used.
AC yokes shall be capable of lifting a carbon steel weight of 4.5 kg. Alternatively, field strengths quoted in A/m may
be used provided comprehensive details of actual material permeability are produced.
The CONTRACTOR/SUPPLIER shall report each examination on a format acceptable to COMPANY.
12.5 Liquid Penetrant Examination (PT)
Liquid Penetrant Examination (PT) shall be carried out in accordance with COMPANY approved procedures and
technique sheets, for expected applications according to the requirements and methods specified in ASME Section
V, Article 6.
Examination areas shall be cleaned prior to inspection and shall be free from surface irregularities, such as weld
spatter.
Liquid Penetrant Examination of welds shall include a band of base metal at least 25 mm wide on each side of the
weld.
Colour contrast, solvent removable penetrant shall be used.
Penetrant materials shall meet the requirements of ASME Section V, Article 6 for sulphur and halogen content
regardless of the type of material to be examined.
The evaluation of indications and the acceptance criteria shall be in accordance with ASME B31.3.
12.6 Ultrasonic EXAMINATION (UT)
Ultrasonic Examination (UT) shall be carried out in accordance with COMPANY approved procedures and
associated technique sheets for all applicable methods according to the requirements and methods specified in
ASME Section V, Article 4 and 5.
Ultrasonic examination technique sheets for each joint configuration and thickness shall have prior approval from the
COMPANY/CONTRACTOR before commencement of any UT examinations. On branches, O-lets and similar
geometry’s, scanning from the internal surface shall be carried out if practicable. Scanning restrictions to be
recorded.
Document Number
PIPING.
Ultrasonic examination of welds shall be in accordance with ASME V Article 4. The acceptance criteria shall be in
accordance with ASME B31.3. For PAUT examination ASME V Article 4 Mandatory Appendix V shall apply.
Ultrasonic methods utilised for weld inspections may be manually operated, semi-automated or automated. Phased
Array UT (PAUT) is the preferred method for ultrasonic examination of welds and may be used in lieu of Radiography
for 12mm wall thickness in pipe and plate and 8” diameter and above pipe welds. Manual UT may only be used if
approved by COMPANY for specific applications.
Each technique shall be demonstrated on representative samples to ensure 100% coverage of the weld volume and
HAZ is achieved. (Refer ASME B31.3 Code Case 181)
The use of semi-automated or automated TOFD is not allowed as a standalone technique. Pulse echo shall be
utilised for the root and cap areas.
Document Number
PIPING.
APPENDIX 1 - Vickers Hardness Examination as per ASTM E384:
a. Sections for hardness examination shall be prepared to a 1 µm (39.4 µin) diamond paste finish and etched
to reveal the microstructure.
b. Indents:
- Each hardness survey shall consist of three rows of indents.
- One traverse shall be located below the cap, one above the root (or internal surface), and one at mid
thickness. The positions are shown in Figure 2.1.
- Mid thickness traverse may be waived for single sided welds below 12.7 mm (0.5 in).
- COMPANY may require additional hardness indent positions (e.g., if a consumable type has not
been sampled by the specified three traverses).
Figure 2.1 - Location of hardness indents
Notes:-
(1) Parent material indentations shall be at least 20 mm (0.8 in) from the fusion line.
(2) The mid thickness hardness traverse may be omitted on materials of thickness ≤12.7 mm (0.5 in).
(3) The first HAZ indentation shall be placed as close as possible to the fusion line. Further indentations into the
HAZ shall be separated by approximately 0.5 mm (0.02 in). However, the minimum centre to centre separation
requirement of 2.5 times or 3 times the mean diagonal of the nearest indentation shall be maintained (see ISO
6507-1 and ASTM E92).
(4) The same survey pattern shall be applied to double-sided welds. For double sided welds, the mid thickness
traverse shall be located to sample the root region of the weld.
Document Number
PIPING.
APPENDIX 2 – Charpy Impact notch location
(1) Notch at root weld centre line,

1.5mm of the inner surface
1.5mm
(2) Notch at root weld fusion line,

1.5mm of the inner surface
1.5mm
(3) Notch at 2mm from root weld

fusion line, 1.5mm of the inner
surface
2mm
1.5mm
1.5mm
(4) Notch at weld reinforcement

centre line, 1.5mm of the outer
surface
1.5mm
(5) Notch at weld reinforcement

fusion line, 1.5mm of the outer
surface
1.5mm
(6) Notch at 2mm from weld

reinforcement fusion line,
1.5mm of the outer surface
2mm
NOTE:
(1) , (2) and (3) – All welds

(4) , (5) and (6) – Additional requirement for material of 25mm wall thickness
Document Number
PIPING.
APPENDIX 3 - Acceptable Welding Processes
Welding Process Restriction (see below)
SMAW Shielded Metal Arc (1), (2)
GTAW Gas Tungsten Arc (3),(4),(5),(6)
FCAW Fluxed-Cored Arc

(6)
SAW Submerged Arc (6),(7),(8),(9)
RESTRICTIONS:
Unless otherwise authorized in writing by COMPANY, use of these welding processes is subject to indicated
restrictions:
(1) Rutile electrodes shall not be used for shielded metal arc welding on pressure retaining parts.
(2) In applications in which cellulose coated electrodes are being evaluated for use, the possibility of employing
low hydrogen electrodes shall be considered.
(3) GTAW shall be used for all passes when welding pipes below NPS 2.
(4) Autogenous GTAW welding is not permitted.
(5) GTAW equipment shall include a high frequency arc initiation capability.
(6) Suitable precautions shall be taken to shield the welding area from wind or drafts which could interfere with
the shielding gas protection.
(7) The use of neutral flux (non-voltage sensitive) is required for submerged arc welding when base metal
thickness is greater than 25mm. If voltage sensitive flux is used, each production shall be tested for
hardness. Maximum allowable hardness of weld deposit shall be in accordance with the requirements of
ANSI/NACE MR0175/ISO15156 check consumable requirements
(8) The use of alloy wire and neutral flux, rather than alloying through the flux, is required. Weld deposits shall
not derive principal elements from the flux.
(9) Use of manual submerged arc welding is not permitted.
Document Number
RUMAILA BROWNFIELD PROJECTS
SPECIFICATION FOR WELDING, PWHT AND NDE OF PROCESS AND UTILITY PIPING
APPENDIX 4 - Accept able filler metals
Manual shielded metal arc Submerged Arc

Flux Cored Gas Tungsten Arc
Flux Arc
Wire
(3)
E7018 (1) (5) Carbon ER70S-2

E70T-1 (5)
E7016 (1) (5) Steel Neutral ER70S-3
E70T-5 (5)
E7015 (1) (5) (4) (5) ER70S-6
E6011 (2) (5) (6)
E6010 (2) (5) (6)
E316L ER316L
NOTES:
(1) Low hydrogen electrodes shall be stored and used only in accordance with electrode manufacturer's
instructions and section 7 of this specification.
(2) Shall only be used for root pass welding provided sufficient overall weld strength and toughness is
obtained.
(3) Welding electrodes shall have the alloying agents in the wire and not in the flux.
(4) Manganese-Molybdenum steel electrode wires may be used provided that the weld deposit hardness
does not exceed the requirements of ANSI/NACE MR0175/ISO15156.
(5) All SAW, SMAW & FCAW low hydrogen welding consumables shall contain (≤ 8 ml hydrogen per
100g of weld metal).
(6) Shall not be used for the welding of valves.
Document Number
RUMAILA BROWNFIELD PROJECTS
SPECIFICATION FOR WELDING, PWHT AND NDE OF PROCESS AND UTILITY PIPING
APPENDIX 5 - Extent of NDE

NDE Group Type of Inspection Type of Weld
1. Lethal Service and above #2500 Flange Rating 100% Visual, 100% RT or 100% UT Girth Groove
High consequence areas defined in Section 12.2 of this document 100% Visual, 100% RT or 100% UT Longitudinal Groove
100% Visual, 100% UT 100% MT or PT Branch Connection
100% MT or PT Fillet Weld
2. Hydrocarbon, Including Sour Service >#300 Flange Rating Water 100% Visual, 10% RT Girth Groove
Injection #1500 Flange Rating 100% Visual, 10% RT Longitudinal Groove
Buried / Underground Hydrocarbon and Water Injection Flow lines and 100% Visual, 10% UT, 10% MT or PT Branch Connection
Pipelines, excluding high consequence areas mentioned in 1. above.
3. Hydrocarbon, Including Sour Service ≤ #300 Flange Rating 100% Visual, 10% RT Girth Groove
100% Visual, 100% RT Longitudinal Groove
100% Visual, 10% UT, 10% MT or PT Branch Connection
4. Utilities; Nitrogen, Instrument Air, Plant Air, Produced Water, Water 100% Visual, 5% RT Girth Groove
Injection (excluding Water Injection #1500 Flange Rating) 100% Visual, 100% RT Longitudinal Groove
100% Visual, 5% UT, 5% MT or PT Branch Connection
Notes:
1. Visual examination shall be in accordance with the requirements of ASME B31.3 and ASME V Article 9.
2. On branches, O-lets and similar geometry’s, scanning from the internal surface shall be carried out if practicable
3. Magnetic Particle examination is preferred method where MT or PT is required
4. PAUT may be used in lieu of radiography for plate and pipe nominal thickness of 12mm and pipe diameter 8” and above.
5. Refer to section 12.2 for instances where 100% Radiography is required.
6. All attachment welds in thicknesses greater than 15mm, shall be subject to 10% UT if practicable.
7. The contents of this table shall be applied with reference to section 12.2 of this specification
8. Refer to section 12.2 for progressive sampling requirements per welder.
9. Tie-in joints (golden welds) shall be 100% RT or UT and 100% MT or PT in accordance with COMPANY approved deviation Rumaila DR-0085
for hydrotest waivers
Document Number

Rumaila Operating Organisation Specification For Welding, PWHT and Nde of Process and Utility Piping

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RUMAILA OPERATING ORGANISATION SPECIFICATION FOR WELDING, PWHT AND NDE OF PROCESS AND

RUMAILA OPERATING ORGANISATION SPECIFICATION FOR

Rev Description Originator Review Approved Date

REVISION DESCRIPTION SHEET

Rev. Para. Reason for Revision

Rev. Para. Reason for Revision

Appendix 3 Deleted vertical down

4.4 Added CP-106 to ASNT

Hold No. Para. Description of Hold

1.1 Purpose ........................................................................................................................... 10

1.2 Definitions ....................................................................................................................... 11

1.3 Abbreviations ................................................................................................................. 12

2 REFERENCE DOCUMENTS ........................................................................................... 13

2.1 Statutory Regulations, Codes and Standards ............................................................ 13

2.2 International Codes and Standards ............................................................................. 13

2.3 Project Documents ........................................................................................................ 15

2.4 Code Hierarchy............................................................................................................... 16

3 GENERAL REQUIREMENTS ......................................................................................... 17

3.1 Health Safety and Environmental (HSE) ...................................................................... 17

3.2 Quality Conformance ..................................................................................................... 17

3.3 Deviations ....................................................................................................................... 17

3.4 Production Documentation ........................................................................................... 17

4.1 Welding Engineer ........................................................................................................... 18

4.2 Welding Inspectors ........................................................................................................ 18

4.3 Senior Welding Inspectors ............................................................................................ 18

4.4 Non-Destructive Examination (NDE) personnel ......................................................... 18

5 WELD PROCEDURES .................................................................................................... 19

5.1 WPS & PQR Requirements ........................................................................................... 19

5.2 Weld Procedure Specification Records ....................................................................... 21

5.3 Procedure Qualification Records ................................................................................. 21

6 WELDER QUALIFICATION ............................................................................................ 22

6.1 Pre-Qualification ............................................................................................................ 22

6.2 Welder & Welder Operator Identification ..................................................................... 23

6.3 Welder Performance Registration ................................................................................ 23

7 WELDING GENERAL REQUIREMENTS ....................................................................... 23

7.1 General ............................................................................................................................ 23

7.2 Preparation for Welding ................................................................................................ 24

7.3 Cutting and Bevelling .................................................................................................... 24

7.4 Alignment ........................................................................................................................ 24

7.5 Proximity of welds ......................................................................................................... 25

7.6 Tack Welding and Clamping ......................................................................................... 25

8.1 General ............................................................................................................................ 26

8.2 Identification ................................................................................................................... 26

8.3 Preheat Temperature Requirements ............................................................................ 26

8.4 Preheat Application ....................................................................................................... 26

8.5 Inter-pass Temperature ................................................................................................. 26

8.6 Interruption of Welding ................................................................................................. 27

8.7 Arc Strikes ...................................................................................................................... 27

8.8 Weld Finish ..................................................................................................................... 27

8.9 Weld Repairs .................................................................................................................. 27

9 POST WELD HEAT TREATMENT (PWHT).................................................................... 28

9.1 General ............................................................................................................................ 28

9.2 Post Weld Heat Treatment Procedure.......................................................................... 29

10 WELDING ELECTRODES, FLUXES AND CONSUMABLES ........................................ 29

10.1 General ............................................................................................................................ 29

10.2 Consumable Certification ............................................................................................. 30

10.3 Filler Metals .................................................................................................................... 30

11 STORAGE AND CONTROL OF WELDING CONSUMABLES ...................................... 30

11.1 General ............................................................................................................................ 30

11.2 Consumable Control ...................................................................................................... 30

11.3 Manual Metal Arc Electrodes ........................................................................................ 31

11.4 Welding Wires ................................................................................................................ 31

11.5 Submerged Arc Welding Fluxes ................................................................................... 32