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PETROIRAN DEVELOPMENT COMPANY

SALMAN OFFSHORE FACILITIES(EPC-3)

AMIDCO I.O.E.C.

PROJECT DOCUMENT NO.

Page 1 of 45Project Facility Document Discipline Sequence Revision

SL-430 0000 SP PL 1512 D2

SALMAN OFFSHORE FACILITIES EPC-3

AMID CONTRACT NO. SALMAN 127 – CONT – 001

TECHNIP PROJECT NO. 9068G

JOB SPECIFICATION

SPECIFICATION FOR LAY BARGEWELDING OF LINE PIPES

This document has completely changed from revision D1 to D2.

D2 11.07.04 RE-ISSUED AS FINAL H.NOUROZI S. VENUGOPAL S. VENUGOPAL J. BARRON

D1 20.12.03 ISSUED FOR APPROVAL M.A.MOSTAFA S. VENUGOPAL S. VENUGOPAL J. BARRON

D0 08.11.03 ISSUED FOR COMMENTS M.A.MOSTAFA S. VENUGOPAL S. VENUGOPAL J. BARRON

REV NO. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY AUTHORIZED

BY

TECHNIP Project No. TECHNIP Document No.

9068G 9068G-000-JSS-3520-512/tt/file_convert/5695cfef1a28ab9b02902d9b/document.doc

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CONTENTS

1. INTRODUCTION

1.1 Scope

1.2 Definition of Terms

1.3 Quality Assurance System

1.4 Inspection

1.5 Codes and Standards

2. MATERIAL

2.1 Linepipe

2.2 Equipment

2.3 Welding Consumables

3. QUALIFICATION OF WELDING PROCEDURE

4. QUALIFICATION OF WELDING PROCEDURE FOR WELDS CONTAINING FILLER-METAL ADDITIVE

4.1 Welding Procedure Specification

4.2 Essential Variables

4.3 Welding of Test Joints - Butt Welds

4.4 Testing of Welded Joints - Butt Welds

4.5 All Weld Metal Tensile Test

4.6 Macro Examination / Hardness Surveys

4.7 Charpy Impact Testing

4.8 Chemical Analysis

4.9 Crack Tip Opening Displacement Test (CTOD)



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4.10 Testing of Welded Joints - Fillet Welds

4.11 Performance

5. QUALIFICATION OF WELDERS AND WELDING OPERATORS

5.1 General

5.2 Welding Inspection and Testing

5.3 Requalification

5.4 Validity of Welder and Welding Operator Qualification Certificates

6. PRODUCTION WELDING

6.1 General

6.2 Line Pipe End Preparation

6.3 Alignment

6.4 Proximity of Welds

6.5 Tack Welding

6.6 Temporary and Non-Structural Attachments

6.7 Movement of Pipe

6.8 Storage and Handling of Consumables

6.9 Preheating and Interpass Temperatures

6.10 Post-Weld Heat Treatment

6.11 Repair Welding

7. WELD PROFILE AND SURFACE FINISH

8. IDENTIFICATION OF WELDS

9. WEATHER CONDITIONS

10. INSPECTION AND TESTING



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10.1 Visual Inspection

10.2 Non-Destructive Testing (NDT)

10.3 Stages of Inspection

10.4 Radiography

10.5 Magnetic Particle Inspection (MPI)

10.6 Ultrasonic Examination

10.7 Acceptance Criteria For Inspection and NDT

10.8 MPI Testing

10.9 Dye Penetrant Testing

10.10 Ultrasonic Testing

10.11 Random Hardness Testing

10.12 Metallic Inclusions

11. DOCUMENTATION

11.1 Prior to Production Welding

11.2 ON COMPLETION OF THE WORK

APPENDIX A



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1. INTRODUCTION

1.1 SCOPE

1.1.1 This specification covers field and laybarge welding of pipes for the Salman Oil and Gas Integrated Development project including the associated risers.

The new pipelines are listed below:

Ten 4 inch lift gas pipelines from new Salman GLP platform to designated tripods.

Eleven 8 and 10 inch oil gathering pipelines from existing designated tripods to a new Riser Platform PP3 located at the Salman Complex.

Two 20 inch gas gathering pipelines from new 2SKB and 2SKC Platforms to new KPP platform located at the Dalan Complex.

One 6 inch gas condensate pipeline from Dalan KPP to the new PP3 riser platform located at the Salman Complex.

One 14 inch associated gas pipeline from the new GLP platform located at the Salman Complex to Dalan KPP.

One 36 inch Flare gas pipeline with 2 inch piggy back pilot gas between KPP and the new FPP Flare platform located near Dalan complex.

One 30 inch, 220 km long export gas pipeline from Dalan KPP to AP Mobarak Platform via Sirri island.

1.1.2 This Specification defines the minimum Company requirements for the Offshore lay-barge welding, laying and testing of the pipelines for the Salman Oil and Gas Field Integrated Development Project. This specification also applies to ancillary pipeline and riser welding in the field including Contractor fabrication yards.

1.1.3 The scope of this specification covers the welding of carbon steel line pipe including bends made from material with specified minimum yield strength of 414 MPa (60,000 p.s.i.) and fittings supplied to ASTM or other standards of equivalent strength grades.

1.1.4 The following welding processes are pre-approved for use:



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Gas tungsten Arc Welding (GTAW)-Manual

Shielded Metal Arc Welding (SMAW)- Manual

Submerged arc welding (SAW)

Gas metal arc welding (GMAW)

Root runs in pipe of diameters less than 60mm shall be made using GTAW process.

1.1.5 This specification also applies to pipeline risers and includes shore approach sections towards landfall points of the export pipeline to AP Mobarak complex.

1.1.6 Welding and inspection activities within the scope of this Specification shall be carried out in accordance with API 1104, and as amended by this Specification.

1.1.7 This specification shall be used in conjunction with the additional requirements given in the Purchase requisition for the lay-barge welding of the line pipes.

1.1.8 This specification does not cover the reeling method of pipeline installation.

1.1.9 This specification does not apply to Hyper-baric method of welding.

1.2 DEFINITION OF TERMS

1.2.1 Terminology used within this Specification is defined as follows:

Company Petro-Iran Development Company (PEDEC) or its authorised representative.

Contractor AMID / I.O.E.C or its authorised representative(s)

Supplier Party(s) designated on the purchase order or contract for supply of welding material.

Approval indicates prior Approval in writing, by the Company and where required, by the Certifying Authority.

ASNT American Society for Non-Destructive Testing

AWS American Welding Society



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Basic Describes flux type for welding consumables which has a high soda and lime content; basic fluxes may be baked to reduce moisture content such that the electrode depositing weld metal has a controlled amount of diffusible Hydrogen. Low Hydrogen Electrodes refer to hydrogen content below 10ml/100g of weld metal deposited.

However, basic fluxes absorb moisture from atmosphere and will then have high diffusible Hydrogen content.

TP Third Party Inspection Authority appointed by the Company

CTOD Crack Tip Opening Displacement

DAC Distance Amplitude Correction

FCAW Flux Cored Arc Welding (Includes FCAW (G) Gas shielded Flux Cored Arc Welding and FCAW(S) Self Shielded Flux Cored Arc Welding)

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding

HAZ Heat Affected Zone

IIW International Institute for Welding

ISO International Standards Organisation

IQI Image Quality Indicators (Penetrameters)

May indicates a possible course of action

MPI Magnetic Particle Inspection

NDE (NDT) Non Destructive Examination

PCN Personnel Certification in Non-Destructive Testing

PWHT Post Weld Heat Treatment

pWPS Provisional Welding Procedure Specification

RE (RT) Radiographic Examination



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SAW Submerged Arc Welding

Shall indicates a mandatory requirement

Shapes any structural section except plate and tubulars

Should indicates a recommended course of action

SMAW Shielded Metal Arc Welding

UE (UT) Ultrasonic Examination

Welder Welder, including welding operator using automatic equipment

WPQ Welding Procedure Qualification validating a WPS

WPQR Welding Procedure Qualification Record of a WPQ

WPS Welding Procedure Specification qualified by a WPQ

1.3 QUALITY ASSURANCE SYSTEM

1.3.1 The Contractor shall operate a Quality Assurance System (QAS) within his organisation, which will ensure that the requirements of this Specification will be fully achieved.

1.3.2 The Contractor’s quality system shall be based on ISO 9001 (or an approved equivalent) and shall be described in a quality manual. The manual shall provide details for the preparation of a quality plan, which shall include provisions for the QA/QC of all welding consumables, weld procedures, line pipe welding equipment, testing and final inspection. The quality plan shall ensure that all quality related requirements are determined prior to commencement of the works and subsequently satisfied throughout all phases of construction and inspection. Where changes are made to the Contractor’s quality system/manual after Approval and commencement of the works, these shall be submitted to Company for approval prior to their implementation.

1.3.3 The effectiveness of implementation of the Contractor quality system may be subject to monitoring by Company or its nominated representative and, may be audited following an agreed period of notice.



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1.4 INSPECTION

1.4.1 Company reserves the right to inspect and reject the work at any and all stages of construction.

1.4.2 The Contractor shall take still photographs of the pipeline on request by Company at any stage of fabrication.

1.4.3 All nominated representatives of Company shall be allowed free access to all parts of the laybarge where field welding of the pipeline, and associated operations as described in this specification, will be performed.

1.4.4 The Contractor shall telex Company giving appropriate notice (Period to be agreed at Bid Stage) prior to the start of pipe lay operations to enable TP inspection arrangements to be made.

1.5 CODES AND STANDARDS

1.5.1 Fabrication of the pipeline under this specification shall comply with the latest edition including all current addenda of the following specifications, and all referenced publications within this specification:

Reference Codes & Standards

The following codes and specifications are referenced in this specification:

API Spec 5L Specification for Linepipe

API 5LD Specification for CRA clad or lined line pipe

API Spec 1104 Welding of Pipelines and Related Facilities

ASNT SNT-TC-1A Guidelines for Personnel Qualification and Certification in Non-Destructive Testing

ASTM A320 Alloy Steel Bolting Materials for Low Temperature Service

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



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ASTM A563 Carbon and Alloy Steel Nuts

ASTM A578 Specification for Straight Beam Ultrasonic Examination of Plain and Clad Steel Plates

ASTM B568 Test Method for Measurement of Coating Thickness By X-Ray Spectrometry

ASTM B695 Coatings of Zinc Mechanically Deposited on Iron and Steel

ASTM E747 Design, Manufacture and material Grouping Classification of Wire Image quality Indicators (IQI) Used for Radiology

ASTM F436 Hardened Steel Washers

ASTM F568 Carbon and Alloy Steel Externally Threaded Metric Fasteners

ASTM F844 Washers, Steel, Plain (Flat), Unhardened for General Use

AWS A5 Filler Metal Specifications

AWS B1.11 Guide for the Visual Inspection of Welds

ASME B 31.4 Liquid Transportation Systems for Hydrocarbons

ASME B 31.8 Gas Transmission and Distribution Piping Systems

AWS C5.3-91 Recommended Practices for Carbon Arc air Gouging and cutting.

AWS QC1 Standard and Guide for Qualification and Certification of Welding Inspectors

BS 4515 Welding of Steel Pipelines on Land and Offshore

BS 7448 Fracture Mechanics Toughness Tests - Method for Determination of K1C, Critical CTOD and Critical J Values of Metallic Materials

BS 7910 Guide On Methods for Assessing the Acceptability of Flaws in Metallic Structures

DNV OS-F-101 Submarine Pipeline Systems 2000



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EN 287 Approval Testing Of Welders - Fusion Welding

EN 288 Specification and Approval of Welding Procedures for Metallic Materials

EN 462 Non-Destructive Testing - Image Quality Of Radiographs - Image Quality Indicators

ISO 262 General Purpose ISO Metric Screw Threads

ISO 2553 Welded, Brazed and Soldered Joints - Symbolic Representation on Drawings.

ISO 6520-1 Welding and Allied Processes- Classification of Geometric Imperfections in Metallic Materials; Part 1 Fusion Welding, 1998.

ISO 9001 Quality Management Systems - Requirements

ISO 9001:2000 supersedes both ISO 9001:1994 AND ISO 9002:1994. The requirements of both former standards are covered by the new ISO 9001.

ISO 9712 Non-Destructive Testing - Qualification and Certification of NDT Personnel

ISO 3834 Quality Requirements for Welding: Fusion Welding of Metallic Materials

ISO 10474 Steel and Steel Products - Inspection Documents

1.5.2 Company Specification

SL430-0000-SP-PL-1502 Specification for Seamless Line pipe

SL430-0000-SP-PL-1503 Specification for Longitudinally Welded Line pipe

SL430-0000-SP-PL-1504 Specification for Heat Induction Bends

SL430-0000-SP-PL-1508 Specification for Asphalt Enamel and Fusion Bonded Epoxy Coating of Line pipe

SL430-0000-SP-PL-1509 Specification for Concrete Weight Coating



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1.5.3 Contract Document

All codes and Standards shall be in the editions stated above and with all published amendments to latest editions. Where the Contractor is proposing to work to another edition this shall be clearly stated by the Contractor in his bid.

The Contractor shall be in possession of all the above referenced Codes, Standards and Specifications before commencement of welding fabrication. All such documents shall be made readily available to personnel involved in executing the work, including Company personnel.

The Contractor shall obtain written approval from the Company for any deviations from the requirements of this Specification, referenced codes and Standards, contract drawings or accompanying purchase order.

The requirements of this Specification shall take precedence over the referenced Codes and Standards. Where this Specification does not stipulate any overriding requirements, the referenced Codes and Standards shall apply in full.

1.5.4 Conflicting Requirements

The applicable specifications, standards, codes, and requirements for design, construction and fabrication shall apply according to the following priority:

a) Purchase order and Approved variations.

b) Requisition and Data Sheets.

c) This Specification.

2. MATERIAL

2.1 LINEPIPE

The line pipe in seamless and SAW forms will be API 5L grade X 60 for the 30” export pipeline, the 36” flare pipeline and the in-field pipelines.

The line pipe materials will be supplied conforming to the requirements of NACE MR 01-75 and this requirement shall also apply to the qualified welding procedures to be used for this project.



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2.2 EQUIPMENT

All welding shall be performed using reliable equipment suitable for the work being done.

The contractor shall establish a procedure to check and demonstrate to the Company or its authorized representative that all welding machines are properly grounded to avoid the occurrence of stray arcing.

Contractor shall provide the procedures for calibration of all welding equipment and gauges and confirmation of calibration date.

Ammeters and voltmeters shall be fitted to all GMAW, SAW and FCAW equipment. Portable Voltmeters and Ammeters shall also be available at the welding stations.

The contractor shall provide internal clamps of an approved design and employ only insulated electrode holders and/or leads.

All electrical equipment shall be calibrated immediately prior to commencement of production welding in accordance with agreed calibration procedures.

All production welding equipment shall be of the same type and model that will be used for the qualification of automatic welding procedures.

2.3 WELDING CONSUMABLES

Filler metals used in fabrication welding shall be certified as conforming to AWS Standard A-5.2.

All filler metals proposed to be used in welding fabrication shall be subject to individual approval by the Company.

The yield strength of the deposited weld metal shall meet the upper quartile value for the line pipe steel used. The maximum weld metal tensile strength shall not exceed the line pipe specified minimum UTS plus 30%.

2.3.1 Batch Testing of Filler Metals

Batch testing is not required if Electrode / Filler Wires are supplied with EN 10204 3.1.C certificate.



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The following tests shall be made by the Supplier on the weld metal deposit in accordance with Section 4.4:

Charpy V-notch impact test (weld centreline only)

All weld metal tensile

Hardness survey (Weld only)

Where a consumable is used for the welding of root pass only, weld metal chemical analysis as well as hardness survey shall be carried out.

The certificate for the flux shall be 3.1C or 3.1B as verified by TP.

3. QUALIFICATION OF WELDING PROCEDURE

3.1 The Contractor shall submit preliminary welding procedure specification (pWPS) including preheating proposals for each welding procedure to be qualified using the project material for review and approval by Company.

3.2 Welding procedure specifications shall also be proposed and qualified for all weld repair configurations including half depth excavation followed by re-welding. (See Figure 3)

3.3 Where a semi-automatic and or an automatic welding procedure will be used during pipe laying, a manual back up weld procedure shall also be qualified. This weld procedure shall be subjected to all the NDT and mechanical tests including SSC tests (if required) as for the automatic welding procedures.

3.4 Separate weld procedure qualification tests are required for the welding of flanges, valves and fittings. The contractor shall establish, by examination the relevant material test certificates the need for qualification of additional welding procedures.

3.5 The SMAW welding of fittings shall be carried out using the uphill weld progression technique and basic, low hydrogen electrodes. The butt welds on all fittings and fillet welds in contact with the production fluids shall be subject to PWHT in accordance with ASME B31.8.

3.6 The tie-in welds and butt welds for the riser pipes shall be made with basic low hydrogen electrodes using the uphill technique.



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3.7 Longitudinal Seam Orientation

Two consecutive longitudinal seams (if any) shall be radially offset by 30° approx. and positioned on the upper quarter of the line (i.e. +/- 45° from the vertical axis).

3.8 Internal Run Order

Internal root sealing runs shall not be permitted except on pipe to fitting welds where PWHT will be carried out. Where internal welding is used as an integral part of a mechanised GMAW process, the contractor shall furnish documented evidence that the completed weld is resistant to Sulphide Stress Cracking.

Internal weld repairs shall not be permitted except on pipe to fitting welds where PWHT is to be applied. However for GMAW process, it is allowed if misfire defect length was less than 10mm and frequency of one misfire for every one hour operation.

Double-sided SAW girth welding shall not be allowed.

3.9 Application of Post Weld Heat Treatment

Welds in all materials not in accordance with the line pipe Specifications and having CE value higher than allowed by that specification shall be subject to post weld heat treatment. The holding temperature shall be 640°C + 10°C unless otherwise agreed but should in no case be lower than 580°C.

3.10 Sour Service Requirements

3.10.1 Hydrogen Induced Cracking Tests (Line Pipe)

The pipelines will be exposed to wet sour service conditions throughout the design life, therefore, the welding procedures shall comply with NACE MR 01-75 requirements. The welding procedures shall be qualified by hydrogen induced cracking (HIC) testing as follows:

HIC tests shall be conducted on samples from each of the weld procedures proposed to be qualified for the welding of line pipe on the lay barge. Testing shall be performed in accordance with NACE TM02-84 using Solution A, as per NACE TM 01-77

The acceptance criteria for all tests (NACE solution A) shall be:

CSR = 1.5%



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CLR = 10%

CTR = 1.5%

3.10.2 Hardness test survey carried out 1.5mm from the outer and inner surfaces of a macro-section through the welded joint shall sample the parent material, HAZ, and the weld deposit. The maximum hardness anywhere on the macro-section shall not exceed 248 Hv10.

3.10.3 Sulphide Stress Corrosion (SSC) Tests

SSC tests as per Appendix A shall be performed on girth welded joints representing each type of welding procedure qualified for pipeline welding on the lay barge.

4. QUALIFICATION OF WELDING PROCEDURE FOR WELDS CONTAINING FILLER-METAL ADDITIVE

4.1 WELDING PROCEDURE SPECIFICATION

The welding procedure specification proposed for qualification by the Fabrication Contractor shall include all the information listed in Table 1 of this specification.

TABLE 1 - Welding Procedure Details and Changes Affecting Approval

Item Welding procedure specification details

Changes affecting approval (essential variables)

Welding Process The specific arc welding process (or combination)

A change from one arc welding process to another

Base Material Specification

Specified standard and grade Any change

Manufacturer (and plate steel mill for SAW pipe)

Any change

Heat Treatment Condition Any change

Composition (Note 1) For line pipe - any change outside range contractually agreed with the line pipe manufacturer. For fittings - Any change greater than that permitted by Table 2

Diameter Nominal outside diameter, D, of pipe For mechanised GMAW - any change

For other processes -Change in excess of 0.5



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to 1.5D

Thickness Nominal wall thickness t of pipe A change outside the range 0.75t to 1.5 t

Joint configuration Type of bevel Any change

Angle of bevel Any change outside approved tolerances (Note 2)

Size of root face Any change outside approved tolerances (Note 2)

Width of root gap Any change outside approved tolerances (Note 2)

Any use of (temporary) backing rings Any addition or deletion, or change in material

Dimensions of fillet weld Not essential variable

Electrode or wire The following information is needed for each run:

Nominal diameter of electrode or wire Any change for the capping layer or the first two layers

Any increase for other runs

Trade name Not Essential Variable

Classification Any change

Any drying or pre-treatment for hydrogen- controlled electrodes

Any relaxation

Number of wires for each run Any change

Number of runs and number of sides welded

Number of runs from each side Any change from single to multi-run or vice versa

Sides welded first and last (double sided welds only)

Any change

Shielding gas or Shielding gas Change in gas selected

Flux Composition of any gas mixture A change exceeding 10% of the nominal addition in a mixture.

Gas flow rate Any change exceeding 10%

Trade name and type of flux Not Essential Variable

Electrical characteristics

Current (ac or dc) and polarity Any change.

Welding Parameters

Electrical stick-out (SAW, GMAW, FCAW) Any change 5mm

Arc Voltage Any change 10%



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Welding current Any change 10%

Wire feed speed Any change 10%

Travel speed Any change 10%

Calculated value of heat input No separate restriction

Welding Position Angle of pipe axis to horizontal Any change exceeding 25

Direction of Welding

Vertical up or vertical down Any change

Welding technique Maximum amplitude of any mechanised weave

Any Change

Frequency of any mechanised weave Any Change

Dwell time at the side of any mechanised weave

Any change outside approved tolerances (Note 2)

Number of welders Number of root run and of second run welders

Any reduction

Time lapse between runs

For cellulosic electrodes only: Time lapse between start of the root run and the start of the second run;

Any increase

Partially completed joint

Number of runs before cooling to ambient Any reduction

Line up clamp Internal, external or alternative method A change from internal to external, or from internal clamp to alternative.

Number or runs before removal of clamp Any reduction

Lowering off (on land) or Barge move-up (offshore)

Number of runs before this activity commences

Any reduction

Preheating Preheat temperature Any reduction, or an increase exceeding 50C

Method of applying heat Not Essential Variable

Method of controlling temperature Not Essential Variable

Method of measuring temperature Not Essential Variable

Maximum and minimum interpass temperature for each layer

Any change

Post-weld heat Method of applying heat Any change

treatment Soaking temperature Any change



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Soaking time (specified as time/ thickness)

Any change

Repair welds Welding procedure details for repair welding

Any of the changes affecting approval listed above

Welding procedure details for the weld to be repaired

Any change affecting the approval of the procedure for the weld on which the repair welding procedure was qualified

Note 1 - CE calculated as per IIW—Value tested –0.06% to + 0.03%.

Note 2 - To be agreed with Company after qualification of the welding procedure.

4.2 ESSENTIAL VARIABLES

The essential variables shall be as listed in Table 1 of this specification with the following additional restriction for the welding of line pipe.

For mechanised GMAW, any change in diameter of wire.

4.3 WELDING OF TEST JOINTS - BUTT WELDS

The welding of test joints shall be made using either using the same welding, heating clamping and support equipment, that is to be used in production or equipment identical to it.

Welding shall be carried out using pipe nipples of sufficient length to properly demonstrate the clamping, support and preheating method and in no case shall be less than 3 meters in length.

The test joint material shall be selected from material of the highest carbon equivalent (CE(IIW)) available at the time of welding. Table 1 Note (1) provides guidance for re-qualification of weld procedures with change in CE of line pipe material.

4.4 TESTING OF WELDED JOINTS - BUTT WELDS

After welding, the test joint shall be allowed to cool for 12 hours. It shall then be subject to 100% radiographic examination prior to sectioning for mechanical tests.



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In addition to radiography, welds made by GMAW (manual or mechanised) shall be subject to 100% volumetric ultrasonic examination.

Non-destructive examination methods shall be in accordance with Sec.10, with the exception that radiography shall be carried out using lead screens.

Acceptance criteria shall be as for production welds.

Table 2

Test TypeOutside Diameter. 4” - 12” (Note 1) Outside Diameter > 12”

Number of Tests/Specimens

Clock Position of Specimens

Number of Tests/Specimens

Clock Position of Specimens

Transweld Tensile 2 2, 8 4 2, 4, 8, 10

All weld tensile 1 (where possible) Not specified 1 Not Specified

Macro/hardness 3 12, 3, 6 3 12, 3, 6

Charpy Impact Tests

1(Note 2)

9 to 12 (Note 3)

2(Note 2)

9 to 10, 4 to 6 (Note 3)

Weldmetal Chem. Analysis

1 Not Specified 1 Not Specified

CTOD test - - As specified in Purchase Order

N/A

Full Ring stress Corrosion Test

If Required N/A If Required N/A

Note 1: Tests for pipe under 4” OD to consist of 2 macro/ hardness test specimens taken at the 3 and 6 o’clock positions and one transweld tensile test

Note 2: A Charpy impact test consists of 4 sets of three specimens (Weld, FL, FL+2mm and FL+5mm ) for pipe wall up to and including 20 mm thick and 5 sets of three specimens (Weld [Root and Cap], FL, FL+2mm and FL + 5mm) for pipe wall greater than 20mm thickness. See Fig 2.

Note 3: The positions given for the Charpy impact test are approximate. They may be adjusted to allow removal of tensile and macro specimens from their indicated positions

General Note:

Nick break and bend specimens are required by this specification for procedure qualification since they also demonstrate the welders’ capability of making sound welds using the parameters specified in the Contractor’s pWPS.



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4.5 ALL WELD METAL TENSILE TEST

4.5.1 Method

The test specimen shall be taken within the weld deposit over the full gauge length. Specimen dimensions and testing shall be in accordance with ASTM A370

4.5.2 Requirements

The yield strength and ultimate tensile strength values obtained shall be higher than the minimum specified values (SMYS) for the parent material.

4.6 MACRO EXAMINATION / HARDNESS SURVEYS

4.6.1 Method

Sections shall be ground to, as a minimum 600 grit finish and etched for macro examination. Examination at a magnification of x5 shall be made using a hand lens or stereoscopic microscope.

Hardness survey shall be carried out by Vickers hardness test method using a 10Kg load for welds made using SMAW process. For butt welds made using GMAW process a 5Kg load shall be used. The position of the hardness impressions is given in Figure 1a.

4.6.2 Requirements

Each section shall show full penetration, be free from lack of fusion and cracks. Any cavities or inclusions shall not exceed 5% of the surface area on each section.

The maximum permitted value is 248 Hv10 for hardness impressions adjacent to the internal surface and at mid thickness and 275 Hv10 for hardness impressions adjacent to within 1.5mm of the cap reinforcement area.



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4.7 CHARPY IMPACT TESTING

4.7.1 Method

For welds in pipe up to and including 20mm wall thickness, each test (as indicated in Table 3, above) shall consist of three sets of four, transverse specimens notched at weld centreline, fusion line (i.e. with the mid point of the notch intersecting the fusion line) f.l. + 2mm and f.l. + 5mm (i.e. with the midpoint of the notch intersecting a line 5mm from, and parallel to, the fusion line). These specimens shall be taken from the mid-thickness area of the section through the weld.

However, for welds in pipe over 20mm in thickness, additional impact test specimens shall be taken from the root area and the specimen locations shall be as shown in Figure 2.

Specimen preparation and testing shall be in accordance with ASTM A370.

Impact Test temperature shall be in accordance with Table 3

Design Temperature Wall Thickness t (mm) Test Temperature (C)

0C or above t 20 -10

20 < t 30 -20

t > 30 -30

T C (Less than 0C) T 20 T –10

20 < t 30 T –20

t > 30 T –30

4.7.2 Requirements

The minimum required energy for all impact tests shall be as follows:

Table 4

Specimen Size (mm) (Note 1)

Average per Set of Three (Joules) min.

Individual value min.(Joules)

10 x 10 42 35



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SL-430 0000 SP PL 1512 D2

10 x 7.5 38 32

10 x 5 26 22

Note 1: Only specimens of the sizes stated in Table 4 above shall be tested.

Note 2: Line pipe materials with SMYS < 414 MPa see Table 6-3 Sec.6 of DNV-2000.

4.8 CHEMICAL ANALYSIS

4.8.1 Method

Chemical analysis shall be performed on a section of weld metal. Analysis shall be in accordance with ASTM A370. The elements listed in the relevant line pipe specification shall be analysed.

4.8.2 Requirements

The analysis shall confirm the manufacture’s stated limits for the chemical composition of the weld metal. The results of analysis for other elements are for information.

4.9 CRACK TIP OPENING DISPLACEMENT TEST (CTOD)

4.9.1 Method

CTOD tests shall be conducted at the minimum design temperature for all pipeline welding procedures and representative weld repair procedures. Each test shall consist of three (3) specimens. CTOD testing will not be required for pipe to fitting welding procedures.

Testing will be on preferred geometry (Bx2B) type specimens in accordance with BS 7448 Part 2.

4.9.2 Requirements

The results are for Company information.



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SL-430 0000 SP PL 1512 D2

4.10 TESTING OF WELDED JOINTS - FILLET WELDS

4.10.1 Preparation

Fillet weld test joints shall be allowed to cool to ambient temperature and then be subject to 100% magnetic particle examination (Refer Section 10.5), prior to sectioning.

Four weld sections shall be taken from the 12, 3, 6 and 9 o’clock positions of the test weld. For test welds other than full circumference welds the four sections shall be equally spaced.

4.10.2 Method

Sections shall be ground to, as a minimum, 600 grit finish and etched for macro examination. Examination shall be made using a hand lens or stereoscopic microscope at a magnification of x5.

On two of the sections a hardness survey is to be carried out by Vickers hardness test using a 10Kg load. The position of the impressions is given in Figure 1b.

4.10.3 Requirements

Cracks or other planar defects detected by magnetic particle examination shall be unacceptable.

Each section shall show full penetration, be free from lack of fusion and cracks. Any cavities or inclusions shall not exceed 5% of the surface area on each section.

The maximum permitted hardness for external fillet welds is 275 HV10 and 248 HV10 for internal fillet welds (i.e. those in contact with the sour production fluids.

4.11 PERFORMANCE

Should a test weld fail any of the required tests or the permitted retests, the cause of the failure shall be established and rectified and the complete procedure test shall be repeated.



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No lay barge field welding shall commence until the appropriate welding and repair procedures have been qualified and approved by the Company.

Should a qualified procedure show poor production performance the causes for the poor performance shall be assessed and a modified welding procedure shall be qualified and submitted to the Company for approval.

5. QUALIFICATION OF WELDERS AND WELDING OPERATORS

5.1 GENERAL

All welders and welding operators shall be qualified in accordance with API 1104 and this Specification.

Welders or operators shall be qualified for this project prior to the start of production welding by making a complete test butt weld using the qualified welding procedure. The test weld shall be made with the pipe in the same positions as for production welding. Tests shall be conducted on the same material as that to be used in production, and welding of test joints shall be carried out on the lay barge.

All welders qualified to work on this project will be provided with identity badges.

5.2 WELDING INSPECTION AND TESTING

Each test weld shall be subject to both visual and non-destructive inspection. Non-destructive inspection shall be in accordance with Section 10.0 of this Specification.

If the test weld is visually acceptable it shall be subject to mechanical testing as detailed earlier.

5.3 REQUALIFICATION

Re-qualification of welders or welding operators for lay barge operation is required if any change is made to the welding procedure which necessitates re-qualification of the welding procedure.



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5.4 VALIDITY OF WELDER AND WELDING OPERATOR QUALIFICATION CERTIFICATES

5.4.1 Re-qualification of welders and welding operators is required if any change is made to the welding procedure that necessitates its re-qualification.

5.4.2 Renewal of a qualification certificate is required whenever a welder or welding operator has not used the appropriate welding process for a period of more than three months or whenever there is a reason to question the performance of production welding. Validity of the certificate is maintained as long as acceptable performance of welding fabrication is documented with regular non-destructive testing during lay barge operations and the Contractor keeps records of periods of time and type of work for each certified welder and welding operator.

6. PRODUCTION WELDING

6.1 GENERAL

All production welding equipment shall be suitable for the job and capable of producing welds of the specified quality.

All equipment shall be maintained in a good working order and any unsuitable equipment shall be replaced immediately.

All welding shall be performed by qualified welders. They shall use qualified welding procedures and welding consumables. Welding fluxes and gases shall be properly identifiable and acceptance within the contractor's QA/QC control.

6.2 LINE PIPE END PREPARATION

Pipe lengths will be supplied with machined bevels specified in Company specifications as appropriate. Should the Contractor elect to use a different groove, prior approval shall be obtained from the Company and incorporated in the procedure and welder qualifications. For pipe-to-pipe fittings, pipe-to-flange, or pipe-to-pipe welds where wall thickness changes are involved, the proposed joint design shall be submitted for Company approval prior to use. In the event the bevel configuration is changed from that supplied by the line pipe manufacturer the re-machined bevel faces shall be 100% examined by wet MPI. However this test may be reduced to 20% upon the Company approval based on satisfactory test result.



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Details of end preparation machines shall be forwarded to Company for approval.

Any pipe bevel showing evidence of end area lamination shall be cut back until the laminated section is removed and rebevelled. After rebevelling the pipe end shall be ultrasonically inspected in accordance with ASTM A578. Any discontinuity (e.g. lamination) causing a reflection echo > 50% DAC and accompanied by a 50% loss of back wall reflection shall be cause for rejection when the discontinuity area is greater than 30 mm2.

Pipe Bevels shall be cleaned by power tools to a bright finish prior to lining up the pipe for welding.

6.3 ALIGNMENT

6.3.1 Details of line up clamps shall be forwarded to the Company for approval prior to commencement of welding. For pipe welding internal line-up clamps shall be mandatory unless otherwise agreed by the Company. End preparation machines and line up clamps shall not damage the pipe or coatings. Line up clamps shall ensure that pipe bores are aligned to the tolerances of BS 4515. Line up clamps shall not be removed until both root and hot passes have been completed.

6.3.2 For the welding of fittings and flanges the line-up procedure shall be approved by the Company. It shall conform to the requirements of BS 4515 and this specification.

6.3.3 Hammering or heating shall not be used for correction of misalignment. Spacer tools are to be used to check final fit-up.

6.4 PROXIMITY OF WELDS

Girth welds shall be separated by a minimum distance of one pipe diameter. The minimum distance between nozzle welds and between nozzle and girth welds shall be 4 times the nominal wall thickness of the run pipe. Distances shall be measured weld toe to weld toe.

6.5 TACK WELDING

Bar tacks are preferred, i.e. welds to bridging pieces within the weld bevel, not affecting the root area and totally removed prior to completion of the final weld.



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Where root tacks are to be used they must be at least 50mm long and must be at least four in number for pipe over 4” in diameter. Root tacks incorporated into the final weld must be welded to the same procedure, by a welder qualified for that procedure and shall be ground to a feather edge at each end to ensure adequate fusion into the root pass.

6.6 TEMPORARY AND NON-STRUCTURAL ATTACHMENTS

Temporary or non-structural attachments to the linepipe or pipelines are not permitted without the written approval of the Company. The written request shall include details of proposed welding procedures and controls on their location and methods of removal.

The Contractor shall prepare a procedure for welding the doubler plates onto those pipe lengths intended to carry anodes and for CAD welding the anode bonding strap onto the doubler plate.

6.7 MOVEMENT OF PIPE

The pipes on both sides of the weld joint shall not be moved until both the root and hot passes have been completed.

In the case of offshore pipe laying the barge shall not be moved until the root and second pass have been completed.

6.8 STORAGE AND HANDLING OF CONSUMABLES

6.8.1 As a minimum the storage and handling of welding consumables shall conform to the recommendations of the consumable manufacturer. A detailed storage and handling procedure shall be submitted by the Contractor for approval by the Company.

6.8.2 Special care shall be taken to ensure that basic coated low hydrogen electrodes are stored in a warm dry environment. Prior to use low hydrogen electrodes shall be baked in accordance with the manufacturer's recommendations to achieve a hydrogen content of less than 10ml/100g of weld metal. In the absence of written recommendations the electrodes shall be baked for two hours at 300°C. After baking the electrodes shall be transferred to a holding oven operating at 150°C then issued from the oven to heated quivers at 70°C for use. Any low hydrogen electrode remaining unused after 2 hours in a quiver shall be returned to the baking oven and re-



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dried for 2 hours at 300°C before being returned to the holding ovens and re-issued. No electrode shall be redried more than 2 times.

6.9 PREHEATING AND INTERPASS TEMPERATURES

6.9.1 Preheat shall be applied under the following conditions:

a) When specified in the approved welding procedure, related to the carbon equivalent (CE or Pcm) of the pipe.

b) When required to ensure dryness in the joint.

c) When the ambient temperature measured on the pipe is below that established during the procedure qualification.

6.9.2 The requirements for preheat and the temperatures shall be formalised during welding procedure qualification, taking into account pipe wall thickness, carbon equivalent and welding process including weldability data available from line pipe manufacturer.

6.9.3 Preheat shall be applied in a uniform manner preferably by using gas ring or electrical heating. However hand held gas torch heating is permitted if minimum of two torch used for preheating of pipe sizes up to 14" and four for upper pipe sizes.

6.9.4 The preheat temperature shall be established over minimum distance of 75mm on each side of the weld and shall be measured using a calibrated thermocouple or melting indicator crayon. The actual preheat temperature shall not exceed the specified temperature by more than 50°C.

6.9.5 The minimum preheat temperature for repairs shall be 50°C higher than that specified for the original welding, up to a maximum of 150°C.

6.9.6 The minimum preheat temperature for welding of fittings to line pipe and at tie-ins shall be 150°C.

6.9.7 If, notwithstanding the above requirements, HAZ hydrogen cracking is found, then the whole weld procedure together with the level of preheat and the consumable handling procedure shall be reviewed and reassessed.



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SL-430 0000 SP PL 1512 D2

6.10 POST-WELD HEAT TREATMENT

Post-weld heat treatment shall be used when so specified in the qualified welding procedure. Only electrical methods shall be used for heating. Measurement of post weld heat treatment temperatures shall be in accordance with ASME VIII part 1. Post-weld heat treatment, when specified, shall be performed in accordance with a written procedure approved by the Company.

6.11 REPAIR WELDING

6.11.1 General

No weld shall be repaired without informing and consent of the Company.

Only one attempt at a repair shall be made. Any further repair attempt shall require prior approval by the Company.

Should the weld be removed (cut-out), re-bevelling performed shall ensure removal of the prior heat affected zone material.

6.11.2 Repair Procedure

Weld repair procedures shall be qualified in the same manner, and at the same time, as production welding procedures are qualified. In addition to the details of the procedure qualification the repair welding procedure presented shall also include full details of the following:

Method of defect removal;

Preparation of weld area;

Non-destructive inspection method for confirmation of defect removal;

Maximum and minimum repair cavity sizes;

Repair procedures which include the above requirements shall be subject to approval by the Company.

The qualification test specified covers the typical weld repair situation. Company reserves the right to require additional testing for very shallow or very deep repair situations.



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SL-430 0000 SP PL 1512 D2

6.11.3 Defect Removal

Weld defects shall be removed by grinding, machining or air-arc gouging. If air arc gouging is used then the defect area shall be subsequently cleaned by grinding. The cut-out portion shall be sufficiently deep and long to remove the defect. At the ends and side of the cut there shall be a gradual taper from the base of the cut to the surface of the weld metal. The width and profile of the cut shall be such that adequate access for re-welding is provided.

External defects such as undercuts and pin holes shall be repaired by re-capping the weld for a minimum distance of 40mm past both ends of the defect. This distance shall be measured parallel to the length of the weld. Re-capping shall only be accepted if the maximum hardness is shown by procedure qualification to be within the acceptance limits of this Specification.

7. WELD PROFILE AND SURFACE FINISH

7.1 Welds shall meet the appearance criteria of BS 4515 Table 5. Welds shall be left as-welded for initial inspection and shall not be doctored with a torch or by mechanical means to alter their appearance.

Grinding or mechanical dressing shall be permitted only when specified on the Contract Drawings or after approval by the Company.

7.2 For coated pipes the Contractor shall arrange for the coating to be applied in the weld area in accordance with Company Specifications after the weld has been inspected and accepted. The Contractor shall also arrange for the repair of any damaged coating.

7.3 Surface Imperfections

Prior to completion and field joint coating the Contractor shall remove all burrs, scars and marks made by welding during fabrication.

Surface imperfections such as gouges, grooves, shallow surface cracks, laps, slivers and arc strikes may be removed by grinding to a smooth profile provided that the resulting wall thickness is within the tolerances allowed by Company Specifications as appropriate. Repair welding on the body of the pipe shall not be attempted.



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SL-430 0000 SP PL 1512 D2

Where defects that penetrate to the extent that after grinding the remaining wall thickness will be below the minimum wall thickness the damaged portion shall be cut out as a cylinder, and replaced to the requirements of this Specification.

Arc strikes are not permitted on pipe body during welding. Arc strikes, inadvertently caused may be removed by grinding provided the remaining wall thickness is above the minimum wall thickness required by line pipe specification. The ground surfaces shall be examined by magnetic particle inspection to demonstrate removal of defect to the satisfaction of the Company.

7.4 Dents

Unacceptable dents (as defined in the appropriate Company Specification) shall be removed by cutting the pipe as a cylinder and replacing it to the requirements of this Specification.

8. IDENTIFICATION OF WELDS

Each welder shall mark in waterproof crayon that section of weld on which he has worked with his code No. If different welders work on different sides a separate set of numbers shall be put on each side. The root welder shall put his number at the top, with each subsequent welder marking below it, in sequence. These numbers shall not be removed until the weld is cleared by NDT.

Contractor shall submit detailed procedures for identification and marking of welds including NDE for Company review and approval prior to mobilisation of welding personnel on the lay barge.

9. WEATHER CONDITIONS

All welding shall be performed in areas where prevailing weather conditions can have no influence on weld quality.



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SL-430 0000 SP PL 1512 D2

10. INSPECTION AND TESTING

10.1 VISUAL INSPECTION

The Company shall have the right of inspection and/or rejection at all times during the welding and after the weld has been completed.

10.2 NON-DESTRUCTIVE TESTING (NDT)

10.2.1 Butt welds shall be 100% visually inspected 100% inspected using X-ray Radiography for permanent film methods. Any approved fillet welds shall be 100% inspected by magnetic particle inspection.

The Company reserves the right to require all suspect areas to be re-examined by ultrasonic examinations for the purpose of clarifying acceptability or otherwise. The Contractor shall have available suitably qualified technicians to ASNT level II.

Where welding is conducted using a gas shielded welding (GMAW) process the first three production welds per day shall be examined by ultrasonic. The Company reserve the right to increase this if lack of fusion or cracks are found which escape detection by radiography. In case of using (GMAW) for only root pass and (SMAW) for the other runs, ultrasonic test is not required.

10.2.2 The qualifications and competence of NDT Personnel used by the Contractor shall be subject to approval by the Company.

NDT Supervisors shall have full knowledge or all Specification requirements and the applicable codes and standards. Current copies of all pertinent documentation such as this Specification and approved welding procedures shall be at the disposal of all relevant personnel during all welding and associated operations.

10.3 STAGES OF INSPECTION

10.3.1 As a minimum, the inspection stages employed by the Contractor for welded joints shall be as follows:

a) Fit-up prior to first pass.

b) Following root pass.



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c) Following completion of weld (after PWHT where appropriate).

Inspection of stage (a) will be visual and dimensional.

Inspection of stage (b) will normally be visual only.

Inspection at stage (c) will be visual and, as required by this Specification, using the methods listed in Section 10.4 or 10.6 of this Specification.

10.3.2 Marking

The Contractor's quality control personnel shall clearly identify with a distinguishing mark all parts or joints that have been inspected and accepted. The system of marking shall be submitted to the Company for approval.

10.4 RADIOGRAPHY

10.4.1 General

Prior to the start of production radiography the Contractor shall submit a detailed radiographic procedure for approval by the Company. As a minimum the procedures shall include the details specified in BS EN 1435.

The radiation source shall consist of X-ray unless otherwise approved by the Company. Tie-in weld radiography can be done by means of using - ray provided on using D4 or equivalent films.

Wire type image quality indicators shall be used.

Only fine grain film shall be used. The use of fluoro-metallic intensifying screens shall be permitted subject to satisfactory procedure qualification. Damaged screens shall not be used.

10.4.2 Procedure Radiographs

Three radiographs shall be made of each welding procedure qualification weld. It is the intent of this Specification to establish these radiographs as the quality level for all production welding. Welding Procedures shall not be deemed Qualified unless these radiographs have been accepted and approved by the Company. Should any variables



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SL-430 0000 SP PL 1512 D2

in the welding procedure specification change, the radiographic procedure shall be requalified.

For procedure qualification image quality indicators are to be placed on both the source side and the film side of the weld. IQI sensitivity shall be:

Source side - better than 1.8%

Film side - better than 1.6%

Film density shall be a minimum of 2.5.

10.4.3 Production Radiography

Production radiography shall be in accordance with the approved radiographic procedure, with image quality indicators on the film side only. When a circumferential weld is carried out in a single shot four IQI's shall be used - one per quadrant. Otherwise two shall be used per film length.

Interpretation of radiographs will be conducted by the Company.

10.4.4 Radiation Protection

The Contractor shall be responsible for the protection and monitoring of radiographic personnel and shall ensure that work is carried out in accordance with the relevant Health and Safety Regulations.

10.4.5 Qualification of Radiographers

Radiographers shall be qualified in accordance with the requirements of ASNT level II or an approved equivalent.

10.4.6 Film Identification

As a minimum, the film identification shall include:

Company Name

Line number/spool No./Line size



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SL-430 0000 SP PL 1512 D2

Weld Number

Date

Location of the film on the weld (Clock Positions)

10 cm divisions around the pipe

An indication of weld status. i.e. original, repair, re-repair etc.

The zero datum shall be at the top of the pipe. Divisions for location of weld defects shall run clockwise in ascending order viewed in the direction of pipelay.

10.4.7 Film Processing

Film shall be processed on site in such a way as to allow storage for up to 5 years without deterioration. The Contractor shall submit a procedure for ensuring that film processing chemicals have been removed prior to storage of the radiographs. The film handling and storage procedure shall be subject to approval by the Company.

10.4.8 Film Storage

All unexposed film shall be stored in a clean dry place where surrounding conditions will not be detrimental to the emulsion. If deemed necessary by the Company unexposed film will be developed and the extent of fogging shall produce a density of less than 0.3. The processed films shall be kept in an Air Conditioned room.

10.5 MAGNETIC PARTICLE INSPECTION (MPI)

The Contractor shall submit his MPI procedure to the Company for approval.

The Contractor's procedure shall be in accordance with BS 6072 or approved equivalent using a wet particle method. The yoke method shall be used in preference for all magnetic particle inspection, the use of the prod method shall be subject to Company approval. Magnetic particle operators shall be qualified to ASNT-Level II or approved equivalent.



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SL-430 0000 SP PL 1512 D2

10.6 ULTRASONIC EXAMINATION

10.6.1 General

The Contractor shall have facilities available for ultrasonic examination of welds in accordance with Section 12.5 of BS 4515.

The Contractor shall submit his detailed procedure and technique sheets for ultrasonic examination to the Company for approval prior to the start of production. The Procedure shall include for the ultrasonic examination of welds between pipes of equal and unequal wall thickness and between pipes and fittings where the wall thickness differs.

10.6.2 Qualification of Ultrasonic Technicians

Ultrasonic Technicians shall be qualified to the appropriate level of ASNT-Level II or approved equivalent scheme.

10.7 ACCEPTANCE CRITERIA FOR INSPECTION AND NDT

The acceptance criteria shall be as stated in Clause 13.1 and Table 5 of BS 4515 and the following additional requirements:

10.7.1 Radiographic Testing

The diameter of any, individual gas pore shall not exceed 2mm or 20% of the nominal wall thickness, whichever is the smaller.

All cracks are unacceptable.

Root Penetration

The weld root excess penetration at any point shall not exceed 3mm.

Centre-line Shrinkage in GMAW Welds

Centreline shrinkage (hot cracking) in mechanised GMAW welds is unacceptable.



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SL-430 0000 SP PL 1512 D2

10.8 MPI TESTING

No additional requirements.

10.9 DYE PENETRANT TESTING

No additional requirements.

10.10 ULTRASONIC TESTING

Where ultrasonic testing is used to compliment radiographic inspection the acceptance criteria shall be as for Section 10.7.1

Where automated ultrasonic inspection is used as the primary means of weld inspection then acceptance criteria are to be agreed with the Company.

10.11 RANDOM HARDNESS TESTING

Random hardness tests shall be carried out on the first 50 completed girth welds in order to ensure compliance with NACE MR 01-75 hardness (248 Hv10) requirement. This shall consist of hardness testing the weld cap of the finished girth welds at three equidistant positions around the circumference. Subject to compliance with the acceptance criteria the testing frequency may be reduced to 1 in 10 welded joints.

10.12 METALLIC INCLUSIONS

The largest dimension of any tungsten inclusion shall not exceed 2mm or 20% of the nominal wall thickness, whichever is the smaller. Adjacent inclusions shall be separated by at least 50mm and there shall not be more than four inclusions in any 300mm length.

Copper inclusions are unacceptable and shall be excavated followed by re-welding using the qualified repair weld procedure.



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SL-430 0000 SP PL 1512 D2

11. DOCUMENTATION

11.1 PRIOR TO PRODUCTION WELDING

Copies of the following documents shall be supplied to the Company prior to commencement of production welding:

Welding Procedure Specifications

Welding Procedure Qualification and Test Reports

Repair Welding Procedure and Test Reports

Welder Qualification Records

Non-destructive Inspection Procedures and Qualification Reports.

Quality Plan

11.2 ON COMPLETION OF THE WORK

On completion of the work, the Contractor shall submit the following documentation to the Company.

Non-destructive Examination Reports for all welds, including repair welds, carried out.

List of Certified Welders.

Weld radiographs.

Pipe number / Joint number / Pipe location.

Welding Procedure Proposals.

Welding Procedure Specifications.

Welding Procedure Qualifications.

Welder Approval Qualifications.

NDE Operator Qualifications.

NDE Procedures.



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SL-430 0000 SP PL 1512 D2

Records relating pipe number to welder, NDE, PWHT (if applicable)

Chemical analysis and other tests required by the specification.

Heat treatment records (if applicable).



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SL-430 0000 SP PL 1512 D2

FIG. 1 POSITION OF HARDNESS SURVEYS

1.5mm

FIG 1a: Butt Welds and Full Depth Repair Welds

FIG1b: Hardnesss Traverse on Fillet Welds



Hardness Traverse 1.5mm from outer surfaceSpecimen

centre line

Hardness traverse root side

1.5mm

Traverse through fillet cap

Traverse through fillet root

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SL-430 0000 SP PL 1512 D2

Fig 2. Charpy Specimen Locations for Welding Procedure Qualification Tests

NOTES:

1. Charpy specimens to be etched to ensure correct notch location

2. Fusion line charpy should be taken from the steeper face if weld is not symmetrical Centre Line of specimen intersects Centre Line of notch on fusion line for fl Specimens



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SL-430 0000 SP PL 1512 D2

Figure 3. Charpy Test Locations for Partial Repair Weld Procedure

NOTES

1. Charpy Specimens to be etched to ensure correct notch location

2. Centre Line of specimen intersects Centre Line of notch on fusion line for fl specimens



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SL-430 0000 SP PL 1512 D2

APPENDIX-A

Method Statement for HIC and SSC Tests

A.1 General

This procedure describes the testing of both the base material, the circumferential and longitudinal (SAW) welds of line pipe to be exposed to wet sour gas or multiphase fluids. The testing procedure forms part of the lay barge welding procedure qualification requirement.

A.3 Welding Requirements

Welding shall be carried out by the Fabrication Contractor using the Company approved welding procedure specification to be used on the pipe laying barge, utilising the same make of electrodes (manual welding) or welding wire (automatic welding).

The girth weld shall be made on pipe sections from a selected heat representing the highest carbon equivalent (CE) of the heats produced by the line pipe manufacturer and as used for the conventional weldability tests.

Welding shall be performed in the 5G position.

The pipe sections shall be stamped by the Inspector and marked with:

a. Heat number

b. Unique pipe number

The top of the pipe shall be marked with a line and stamped TOP at each end at the time of welding.

A.4 Specimen Preparation

Number, Location, Orientation and size of the specimens shall be based on NACE TM 0284-96.

A.5 Test Details

Test method shall be based on NACE TM 0284-96 for HIC and NACE TM 0177 for SSC tests.



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A.6 Specimen Examination

Prior to testing, the complete test section shall be fully examined by ultrasonic testing. UT examination will be repeated after 7 days exposure and at regular intervals thereafter to determine initiation and or extension of any cracks. The test shall be terminated following final UT examination after 30 day test period or earlier if ultrasonic testing indicates excessive crack extension such that failure could occur.

The decision for early termination of the test based on the results of ultrasonic indications will be subject to agreement between the Company and the Test house.

At the completion of testing period the internal weld surfaces will be examined by wet magnetic particle examination (MPI). Any crack like or other surface indications found by MPI or by UT examination during testing will be characterised by metallographic examination of the relevant areas and reported with photomicrographs of representative features found.

A.7 Acceptance Criteria.

a. No stress corrosion cracks greater than 1mm.

c. No HIC cracking greater than 1mm.

Crack area value < 3% based on results of ultrasonic indications and selected metallography.

No delamination cracks greater than 5mm.

A.8 Reporting

Any test ring failure occurring within the 30 day test period shall be reported to Company.

Following the completion of testing the Testing Contractor shall prepare and submit a draft report within seven (7) working days for discussion of results. Following the meeting the report shall be finalised and three (3) copies submitted to Company.



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