GENERAL SPECIFICATION FOR WELDING AND NDE

EMPLOYER: LOTOS PETROBALTIC S.A. JOB 113A20

Revision

COUNTRY: POLAND 00 01 02 03 04

AREA: SOUTH-EAST BALTIC SEA Doc. N.

PLANT: B8 OIL FIELD 113A20-PP-SP-10124

GENERAL SPECIFICATION FOR WELDING AND NDE

Contractor Doc. N. : 113A20-PP-SP-10124

Sheet / of 1 / 43

Date 23/09/16

This document undergoes an issuance cycle within EDMS "I-DOC". Its distribution is electronically controlled. Printing not reporting the name of the destine, shall be considered as “NOT CONTROLLED” copy

“PETROBALTIC” RIG CONVERSION PROJECT


CONTR. DOC N. : 113A20-PP-SP-10124

04 IFC Issued for Construction

M. Colombo P.S.L.

A. Mariani P.E.M.

A. Mariani P.E.M.

23/09/16

03 IFC Issued for Construction

M. Colombo P.S.L.

A. Mariani P.E.M.

A. Mariani P.E.M.

08/07/16

02 IFC Issued for Construction M. Colombo

P.S.L. R. Marchegiani

D.P.E.M. A. Mariani

P.E.M. 29/04/14

01 IFA Issued for Approval M. Colombo


D.P.E.M. A. Mariani

P.E.M. 14/03/14

00 IFA Issued for Approval M. Colombo


D.P.E.M. A. Mariani

P.E.M. 20/12/13

Rev. Status Description Prepared Checked Approved Date


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REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

03 10 Revised pickling and passivation paragraph

04 10 Revised pickling and passivation paragraph

Hold No.

Para. Description of Hold


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INDEX

1. INTRODUCTION ....................................................................................................... 6

1.1 Definitions .............................................................................................................. 6

1.2 Abbreviations ......................................................................................................... 6

1.3 International Codes and Standards ...................................................................... 7

1.4 Project Specification and Philosophies ............................................................... 7

2. PURPOSE ................................................................................................................. 8

3. MATERIAL OF CONSTRUCTION............................................................................. 8

4. MATERIALS IDENTIFICATION ................................................................................ 9

5. WELDING ................................................................................................................. 9

5.1 General ................................................................................................................... 9

5.2 Welding Processes ................................................................................................ 9

5.3 Welding Procedures .............................................................................................. 9

5.4 Qualification of Welding Procedures ................................................................. 11

5.5 Qualification of Welders and Welding Operators .............................................. 11

5.6 Filler Materials and Fluxes .................................................................................. 12

5.7 Storage and Control of Welding Consumables ................................................. 12

5.7.1 General ........................................................................................................................ 12

5.7.2 Consumable Control .................................................................................................... 13

5.7.3 Submerged Arc Welding Fluxes .................................................................................. 13 5.8 Production Test Plates ........................................................................................ 13

6. FIELD WELDING .................................................................................................... 14

7. WELD CONTOUR AND FINISH ............................................................................. 14

8. THERMAL TREATMENT ........................................................................................ 14

8.1 Preheat and Interpass Temperature ................................................................... 14

8.2 Post-Weld Heat Treatment (PWHT) .................................................................... 15

9. WELD IDENTIFICATION ........................................................................................ 15


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10. CHEMICAL CLEANING FOR PICKLING AND PASSIVATION OF PIPING ............ 15

11. NON DESTRUCTIVE EXAMINATION .................................................................... 16

11.1 General ................................................................................................................. 16

11.2 Visual Inspection ................................................................................................. 17

11.3 Magnetic Particle Inspection (MPI) ..................................................................... 17

11.4 Dye Penetrant Inspection (DPI) ........................................................................... 17

11.5 Radiography ......................................................................................................... 18

11.6 Ultrasonic ............................................................................................................. 19

11.7 Extent of NDE ....................................................................................................... 19

11.8 Acceptance Criteria ............................................................................................. 20

11.8.1 General .................................................................................................................... 20

11.8.2 UT Acceptance Criteria ............................................................................................ 20

11.8.2 API 10,000# Piping Class ........................................................................................ 21 11.9 NDE Personnel Qualification .............................................................................. 21

11.10 Documentation ..................................................................................................... 21

12. REPAIRS ................................................................................................................ 21

12.1 Repairs to Welds .................................................................................................. 21

12.2 Other Repairs ....................................................................................................... 22

13. MATERIAL TRACEABILITY .................................................................................... 23

14. APPENDIX A ADDITIONAL REQUIREMENTS FOR WELDING OF LOW

TEMPERATURE CARBON STEEL ................................................................................... 23

15. APPENDIX B ADDITIONAL REQUIREMENTS FOR WELDING OF LOW ALLOY

STEEL API 5L/ISO 3183 X65QO PSL2 ASME B31.8 CHPT VIII ...................................... 27

16. APPENDIX C ADDITIONAL REQUIREMENTS FOR 300-SERIES STAINLESS

STEELS ............................................................................................................................. 30

17. APPENDIX D ADDITIONAL REQUIREMENTS FOR WELDING 22% Cr DUPLEX

STAINLESS STEEL ........................................................................................................... 33

18. APPENDIX E WELDING PROCEDURES FOR API 10,000# API 5L/ISO X65QO PSL2

ASME B31.3 CHPT IX ....................................................................................................... 38


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19. APPENDIX F ADDITIONAL REQUIREMENTS FOR WELDING OF CUPRONICKEL

PIPING ............................................................................................................................... 41

20. FIGURE 1 LOCATIONS AND NOTCH POSITIONS FOR CHARPY IMPACT TESTING

OF SINGLE BEVEL WELDMENTS ................................................................................... 43


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1. INTRODUCTION The B8 oilfield is located in Southern Baltic Sea, at a distance of about 33.9 nautical miles north-north east of the Rozewie lighthouse and about 39.1 nautical miles north of the Jastarnia lighthouse. The nearest ports are located about 65 Nm south south-east of the B8 oilfield.

1.1 Definitions

EMPLOYER: LOTOS PETROBALTIC S.A. CONTRACTOR: ROSETTI MARINO S.p.A. Shipyard Contractor Is the shipyard selected for the implementation of assembly phase, Supplier/Manufacturer Is the party that is in charge the supply of material, equipment, skid,

package or services to perform the duties specified by the Employer or EPMS Contractor or SHIPYARD Contractor

Shall Indicates a mandatory action, Should Indicates a preferred course of action, May Indicates one acceptable course of action.

1.2 Abbreviations

CTOD Crack Tip Opening Displacement SSFCAW Self-shielded flux cored arc welding TMCP Thermo-mechanical controlled process NPS Nominal Pipe Size, inches WPS Welding Procedure Specification PQR Procedure Qualification Record HAZ Heat Affected Zone MDT Minimum Design Temperature PWHT Post-Weld Heat Treatment SAW Submerged arc welding GTAW Gas tungsten arc welding SMAW Shielded metal arc welding FCAW Flux cored arc welding GMAW Gas metal arc welding HV Hardness Vickers CS Carbon Steel CVN Charpy Vee-Notch CHPT Chapter


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1.3 International Codes and Standards

ASME B31.3 Process Piping including CHPT IX.

ASME B31.8 CHPT VIII Gas Transmission and Distribution Piping Systems

ASME IX Qualification Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators.

ASME II Part C ASME Boiler and Pressure Vessel Code, Section II – Materials Specification, Part C – Welding Rods, Electrodes and Filler Metals.

ASME V ASME Boiler and Pressure Vessel Code -Non-destructive Examination

API 1104 Welding of Pipelines and Related Facilities

PED 97/23/EC Pressure Equipment Directive

ISO 9606 Qualification testing of welders

ISO 9712 Non-destructive testing - Qualification and certification of NDT personnel

EN 473 Non-destructive testing. Qualification and certification of NDT personnel. General principles

1.4 Project Specification and Philosophies

113A20-PP-SP-10016 General Specification for Piping Fabrication and Installation

113A20-PP-SP-10053 Insulation Specification

113A20-PP-SP-10054 General Specification for Chemical cleaning, Pressure Testing and Flushing

113A20-PP-SP-10055 Painting and Coating Specification

113A20-PP-SP-10001 Piping Design Specification


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2. PURPOSE This specification defines the technical requirements for the welding, PWHT and NDE of piping in ASME B31.3 including CHPT IX and ASME B31.8 CHPT VIII for the Petrobaltic rig conversion project. The definition of design codes are as follows –

Location Design Code

Topside process, utility and welded instrument piping/tubing.

ASME B31.3 including CHPT IX

DN 4” pipeline originating from gas pig launcher B8-17-VL-001 to topside/riser-sealine spec break.

ASME B31.8 CHPT VIII

Sections 1 to 13 of this specification provide the general requirements applicable for all materials whilst the Appendices identify requirements for specific materials. Piping systems excluded from the scope include -

Risers, All heating, ventilation, air and water services within the living quarters unless otherwise

indicated on design drawings. General fabrication requirements for piping are included in 113A20-PP-SP-10016. External coating of piping and insulation shall be in accordance with project specifications 113A20-PP-SP-10055 and 113A20-PP-SP-10053 respectively.

3. MATERIAL OF CONSTRUCTION This specification applies to the following materials -

a) Impact tested Low Temperature Carbon Steels within the P-No. 1, Groups 1 and 2 of ASME IX, and ASME B31.3,

b) 316/316 L Stainless Steels Stainless steels within the P-No. 8, Group 1 of ASME IX, c) 22% Cr Duplex Stainless Steels, d) Copper Nickel Alloys, e) Low Alloy Steel API 5L/ISO 3183 X65QO PSL2 ASME B31.8 CHPT VIII, f) Low Alloy Steel API 5L/ISO 3183 X65QO PSL2 ASME B31.3 CHPT IX.


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Any materials not covered in the above list shall be referred to the EMPLOYER for clarification.

4. MATERIALS IDENTIFICATION The Shipyard Contractor shall maintain a system of material identification such that all materials used in the fabrication of piping systems and related pressure retaining equipment may be traced to the appropriate certification. Alloy materials shall be identified by positive materials identification (PMI) in accordance with 113A20-PP-SP-10016. Identification marking for materials shall be made by purpose made low stress stamps (conventional stamps not acceptable) or vibro-etching. The identification mark shall be ringed by white paint. Additionally, when vibro-etching is used, the identification mark shall also be protected by a clear paint lacquer. Where the material identification mark is unavoidably removed, transfer of the identification mark to the pressure retaining part shall be witnessed by a third party inspectorate. Material which cannot be identified will be rejected.

5. WELDING

5.1 General

All welding shall comply with the requirements of this specification, ASME B31.3, ASME B31.8 CHPT VIII and the Pressure Equipment Directive (PED 97/23/EC). Welding of high pressure piping class API 10,000# shall also comply with the additional requirements of ASME B31.3 CHPT IX. Appendices A to E of this specification indicate where, requirements, in addition to those in ASME B31.3, ASME B31.8 CHPT VIII, ASME IX and the Pressure Equipment Directive (PED 97/23/EC) are necessary. All tack welding shall be by welders qualified in accordance with this specification. Tack welds to be incorporated into the main weld seams shall have the ends ground and feathered. The Shipyard Contractor shall maximize the number of shop welds, field welds shall only be undertaken for final tie-ins.

5.2 Welding Processes

Permitted welding processes for each material are indicated in Appendices A-E.

5.3 Welding Procedures

Welding procedure specifications (WPS’s) and procedure qualification records (PQR’s) shall be in writing and comply with ASME B31.3, ASME IX and this specification. All procedure qualifications shall be witnessed and endorsed by an appropriate independent inspectorate.


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Complete welding procedures for all materials shall be submitted for review and approval. These procedures shall be submitted as “Welding Book” and include: WPS’s and supporting PQR’s, a weld procedure register and a weld map. The weld procedure register shall list all weld procedures to be utilized and their respective qualification records. All WPS's shall be identified by number on a weld map clearly defining the application of each procedure for each type of joint (buttweld, fillet, socket, o-let). The complete Welding Book shall be submitted sufficiently in advance of production welding to allow for adequate review and approval of retesting if required. No welding shall start until the Welding Book has been fully approved. The information in each WPS and PQR shall include but not be limited to the information on forms QW 482 and QW-483 in ASME IX. Additional information, including heat input and fit-up tolerances shall also be incorporated. Appendices A to E indicates essential and supplementary essential variables that shall apply in addition to those required in ASME B31.3, ASME B31.8 CHPT VIII & ASME IX. Welding position shall be an essential variable for groove welds in all welding processes. Qualification in the 2G or 5G position shall qualify also for the 1G position. Qualification in the 5G positions shall also qualify for the 2G position. Qualification in the 6G position, shall qualify for all positions. When specified in the appendices, limitations in position qualification shall be applied. Each Shipyard Contractor or Sub-Supplier shall qualify their own weld procedures. All fillet weld procedures shall be qualified by a butt welded PQR. When specified in the appendices, fillet welds shall be specifically qualified as with single or multi-pass tests in addition to a butt weld. Previously qualified welding procedures are acceptable provided that they comply with the requirements of this specification with the exception of the procedures for the API 10,000# rated piping class which shall be newly qualified on specific project material. All dissimilar metal welds shall be qualified separately. All manual GTAW shall be with the addition of a filler wire. The equipment should also include a high frequency starting unit. The following restrictions apply to all welding processes:

a) Vertical welding shall be performed vertically up. b) Stitch or block welding is not permitted. c) The use of permanent backing strips is prohibited.

Stringer bead welding technique is preferred; however weave beads will be allowed for positional welding providing the maximum width of weave does not exceed 3 times the electrode core wire diameter. If FCAW is approved, then a maximum weave of 15mm shall be permitted. For GTAW passes, max weaving shall be limited to the lesser of 4 times the wire diameter or 10mm.


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All welds will have a minimum of 2 passes.

5.4 Qualification of Welding Procedures

Appendices A-E indicate where, additional requirements to those in ASME B31.3, ASME B31.8 CHPT VIII, ASME IX & the Pressure Equipment Directive (PED 97/23/EC) are necessary. For permanent joining of PED categorized item (cat II, III, IV), the welding procedures must be approved by a competent third party such as a Notified Body or a Third Party organization recognized by Poland for PED purpose. Where WPS's specify a combination of two or more welding processes, each combination shall be qualified as a combination. For all materials, the location and orientation of impact test specimens shall be determined by wall thickness in accordance with figure 1 (a) - (c) as appropriate. For high pressure piping class API 10,000#, all the additional qualification requirements of ASME 31.3 CHPT IX shall also apply. For all materials, additional impact test samples shall be taken as per figure 1 depending thickness.

5.5 Qualification of Welders and Welding Operators

Welders and welding operators shall be qualified in accordance with ASME B31.3, ASME IX & the Pressure Equipment Directive (PED 97/23/EC). Qualification shall be completed before the start of fabrication and performance qualification records shall be made available to the EMPLOYER upon request. All performance qualifications shall be witnessed and endorsed by an appropriate independent inspectorate (Third Party). For permanent joining of PED categorized item (cat II, III, IV), the welding procedures must be approved by a competent third party such as a Notified Body or a Third Party organization recognized by Poland for PED purpose. Welder and Welding Operator performance qualifications from other employers are not acceptable. ISO 9606 is deemed an acceptable equivalent standard to ASME IX for qualification of welding operators and welders. It should be noted that all testing and examinations requested by PED 97/23/EC shall be fulfilled. The qualification of all welders and welding operators shall be checked at the worksite before the start of production by the EMPLOYER inspector and periodically thereafter during construction. For high pressure piping class API 10,000# additional requirements of ASME B31.3, CHTR IX K328 shall also apply.


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5.6 Filler Materials and Fluxes

All filler materials and fluxes shall be in accordance with ASME II, Part C. Since various national specifications for welding consumables are not freely interchangeable, equivalence to ASME / AWS specifications shall be indicated. The basis for equivalence shall be subject to approval. Equivalence may be determined by review of consumables (electrodes and fluxes) and manufacturer’s catalogues and/or by chemical analysis and mechanical testing of weld deposits. Filler metal for welding similar materials shall be of the same nominal analysis as the base material, except as follows -

Nickel bearing carbon manganese consumables shall be employed for low temperature, impact tested carbon steel. Filler metals for welding low temperature carbon steel, impact tested at (minus) - 46°C or lower, shall be nominally 1% nickel bearing with the maximum nickel level certified at 1%.

Dissimilar welds between ferritic and austenitic steels shall be made using consumables as follows:

AISI Type 309 Mo, provided that the process operating temperature is below 310°C. For dissimilar welds subjected to PWHT, filler materials shall be reviewed and approved on a case by case basis. All pressure containing butt welds or welds onto pressure retaining parts shall be made using low hydrogen welding consumables or using techniques that are inherently free of hydrogen. All welding consumables shall be used within the limits recommended by their manufacturers. All welding consumables (filler material and fluxes) shall be provided with the manufacturer’s certificate of specific product control.

5.7 Storage and Control of Welding Consumables

5.7.1 General

Storage and control of all welding consumables shall be in accordance with the manufacturer’s recommendations and this specification. In order to prevent the use of incorrect, contaminated or damaged consumables a strict procedure for the storage and control of welding consumables shall be used. Regular audits shall be carried out to ensure that the procedure is being followed. Detailed written procedures for the systematic receipt, storage, issue and control of welding consumables shall be submitted for approval prior to the commencement of fabrication.


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5.7.2 Consumable Control

All welding consumables shall be received into a quarantine area within the welding consumable storage facility. Full details, including consumable supplier, manufacturer, brand name, batch number, quantity received and delivery date, shall be recorded and 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 labeled and segregated according to consumable type and specification. All consumable storage areas (including the quarantine area) shall be dry, with a relative humidity equal to or less than 60% and maintained at a minimum temperature of 20°C. If vacuum pack electrode is used, specific instructions will be issued for management during working shift and treatment of remaining electrodes. The Shipyard Contractor’s Welding/Quality Engineer shall issue drying instructions based on the manufacturer’s recommendations for all submerged arc fluxes and manual metal arc electrodes as required. All non-identified, contaminated or damaged consumables found in any storage or fabrication area shall be discarded. Wire for gas tungsten arc, submerged arc or other approved welding processes shall be dry and free from rust, oil or any other foreign matter.

5.7.3 Submerged Arc Welding Fluxes

Submerged arc fluxes shall be stored in sealed containers within the storage facility. Flux remaining unused at the end of each shift shall be returned to the storage facility. The baking of submerged arc fluxes shall be in strict accordance with the manufacturer’s recommendations. Surplus submerged arc flux may be reclaimed and re-used in combination with new flux. Reclaimed flux shall not account for more than 50% of any flux mixture. All re-claimed flux should be sieved to eliminate fines and other contaminants.

5.8 Production Test Plates

Production test plates for impact tested materials shall be required in the event that the material thickness range qualified in the PQR falls outside the more stringent thickness range T/2 to T+6mm, stated in ASME B31.3 Table 323.3.1. Further in case of non-conformity in applying correct welding parameters within the qualified ranges, the Shipyard Contractor may be requested to carry out a test plate based on his own experiences.


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6. FIELD WELDING The Shipyard Contractor shall minimize the number of field welds and wherever possible field welding shall be restricted to final tie-in welds. Adequate weather protection shelters shall be provided to shield all site welding operations. No welding shall be performed on damp materials. Gas shielded processes shall not be used for field welding unless a weather protection shelter is provided and the weather protection can maintain the wind velocity below 4mph at the work piece. The maximum wind velocity shall not exceed 8mph for SMAW.

7. WELD CONTOUR AND FINISH Weld beads shall be contoured to permit complete fusion at the sides of the bevel and to minimize slag inclusions. Flux and slag shall be removed completely from weld beads and from the surface of completed welds and adjoining base material. The flux removal shall be performed in a manner that will not cause the weld or adjoining base material to become contaminated or overheated. Visual examination of welds shall satisfy the requirements of ASME B31.3 table 341.3.2 or K341.3.2. Peening is not permitted.

8. THERMAL TREATMENT

8.1 Preheat and Interpass Temperature

The minimum preheat temperatures for thermal cutting, arc-air gouging and welding (including butt, fillet, socket, seal and tack welds) in Table 330 1.1 of ASME B31.3 including ASME B31.3 CHPT IX and ASME B31.8 VIII sect. 824 are mandatory, except that all ferritic materials shall be preheated to 80°C (175°F) minimum, regardless of thickness and tensile strength, if the weld is under a high degree of restraint e.g. branch connections or major attachments. For shop welds, preheating shall be performed using fuel gas/air burners electrical or infrared elements. Oxy acetylene preheating shall not be used. For field welds the following methods of preheating shall be applied:

• Pipe diameters ≤ NPS 10” fuel gas/air burners, electrical or infrared elements, • Pipe diameters > NPS 10” ring fuel gas/air burners (hand-held gas torches not permitted),

electrical or infrared elements. 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 25mm of insulation, extending 75mm either side of the heated zone. Welds shall be completed as far as practicable without interruption. Where production conditions are such that welds have to be left partially completed the following conditions shall apply:


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Welding shall not be discontinued until at least ⅓ of the joint thickness is completed, Upon discontinuation of welding the joint shall be wrapped in a dry insulating material and

shall be cooled in a slow and uniform manner, Prior to recommencement of welding the joint shall be examined using the magnetic particle

inspection technique and reheated to within the specified preheat range. Maximum interpass temperatures indicated in Appendices A-E shall apply. Preheat and interpass temperature shall be determined by temperature-indicating crayons, contact pyrometers, thermocouples or other equally suitable means. Temperature indicating crayons used on austenitic stainless steels and nickel-base alloys shall not cause corrosive or other harmful effects; nor shall they contain more than one percent by weight of total halogens or sulphur and not more than 200 ppm by weight of inorganic halogens. It is the Shipyard Contractor’s responsibility to determine suitable brands and melting temperatures that may be used. This information shall be made available to the EMPLOYER on request.

8.2 Post-Weld Heat Treatment (PWHT)

PWHT is only applicable to carbon steel piping when required by ASME B31.3. The requirements for PWHT of carbon steel materials are given in Appendix A and D.

9. WELD IDENTIFICATION In field and shop welding each qualified welder or welding operator shall have a welder stamp. Unless specified otherwise the welder shall permanently mark each pressure weld with this identification symbol. If more than one welder welds a joint each shall apply his symbol in such a manner as to indicate the part of the joint welded by each welder. In addition an accurate record keeping system shall be established to identify welds and the welders that fabricated them.

10. CHEMICAL CLEANING FOR PICKLING AND PASSIVATION OF PIPING All 316SS and 22% Cr duplex, intended for use in seawater, firewater, chemicals, process or utilities service shall be internally and externally pickled and passivated including welds. The Shipyard Contractor shall submit a full pickling and passivation procedure to the EMPLOYER for review and approval before commencement of the work. (See also project specifications 113A20-PP-SP-10055 chpt. 4 and 113A20-PP-SP-10054 chpt. 9.2) Field chemical cleaning materials shall generally be limited to biodegradable detergent cleaners and/or citric acid based cleaners. Passivation materials will generally be sodium nitrate or inhibited phosphoric acid. However, other degreasing, pickling, cleaning or passivation compounds may be submitted for EMPLOYER approval. After chemical cleaning, the piping system shall be thoroughly flushed and rinsed with hot water. Chloride content of stainless steel cleaning solutions and rinse water shall not exceed 30ppm.

04


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Piping and equipment manufactured of a corrosion resistance alloys shall not be permitted to come into contact with solutions containing chlorides such as hydrochloride acid and chemicals containing chlorides as impurities. A 100% visual inspection of the effectiveness of the cleaning operation shall be completed.

11. NON DESTRUCTIVE EXAMINATION

11.1 General

The Shipyard Contractor shall submit for the EMPLOYER's approval non-destructive examination (NDE) procedures for all non-destructive testing to be carried out, prior to work commencing. Each NDE procedure shall be specific to the work scope and shall detail the techniques, extent of examination and acceptance criteria. Where standard NDE procedures are used they shall be submitted with a project specific front sheet which shall detail the techniques, the extent of inspection, and the acceptance criteria. All NDE procedures shall have prior approval (signed and stamped) from an NDE specialist certified to ISO 9712 (EN 473) Level III in the applicable technique. In general, NDE procedures shall be in accordance with ASME V, ASME B31.3, and this specification. In particular, for the DN 4” pipeline originating from gas pig launcher B8-17-VL-001 to topside/riser-sealine spec break, the NDE procedures shall detail the techniques and the acceptance criteria in accordance with ASME B31.8 CHPT VIII and this specification. NDE Sub-Supplier's, if used, shall be nominated at the bid stage and will be subject to the EMPLOYER's approval. It is the responsibility of the Shipyard Contractor to ensure that all the EMPLOYER requirements relating to NDE are passed on to the NDE Sub-Supplier. Inspection representatives of the EMPLOYER shall have free access at all reasonable times to inspect work and, where appropriate, to perform NDE cross checking. Where the EMPLOYER determines, as a result of NDE cross-checking or otherwise, that a particular NDE operation or examination procedure has failed to detect rejectable defects, the EMPLOYER may request additional examinations or examination methods to be applied. The minimum extent of NDE shall be as per Section 11.7, except for severe cyclic service when 100% NDE (RT, UT, MT/PT) shall apply regardless of pressure. Those lines which are subject to severe cyclic service shall be advised. NDE shall be carried out at least 24 hours after completion of welding. Where PWHT is required, NDE and final acceptance inspection shall be carried out after PWHT. Where less than 100% inspection is specified, the welds selected for testing shall include welds from all welders, and all appropriate WPS’s.


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The first two radiographable production welds from each welder shall be subjected to 100% radiography. If any repairs are required, the next two production welds from that welder shall be radiographed, and if further repairs are necessary the welder shall be removed from the job for training and requalification. Percentage inspection shall mean percentage of complete welds, not percentage lengths of individual welds. The hidden inner circumferential welds of jacketed pipework shall be 100% radiographed. All NDE reports shall be reviewed and endorsed by the Inspector.

11.2 Visual Inspection

Visual inspection shall be carried out in accordance with ASME B31.3.

11.3 Magnetic Particle Inspection (MPI)

Magnetic Particle Inspection (MPI) shall be carried out on ferritic materials in accordance with EMPLOYER approved procedures based upon the requirements of ASME V Articles 7 with the acceptance criteria in accordance with ASME B31.3. AC electromagnetic yokes shall be used. A background of white contrast paint shall be used in conjunction with a black magnetic ink (wet particle). The technique shall be carried out in the continuous mode and cover for longitudinal and transverse defects. All consumables used shall be from the same manufacturer. 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. All indications found by this inspection method shall be removed and the area repaired by grinding and, where necessary, welding. Any repair welding shall be performed with an approved weld repair procedure in accordance with Section 12. If grinding only is required, the excavation shall be blended and the final thickness checked using an ultrasonic thickness meter.

11.4 Dye Penetrant Inspection (DPI)

Dye Penetrant Inspection (DPI) shall be carried out in accordance with EMPLOYER approved procedures in accordance with the requirements of ASME V Articles 6 with the acceptance criteria in accordance with ASME B31.3. Unless requested otherwise, DPI shall be carried out using the solvent removable method. All consumables used shall be from the same manufacturer. If necessary, welds may be lightly dressed to facilitate DPI testing or to assist in the interpretation of any indications.


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All indications found by this inspection method shall be removed and the area repaired by grinding, and where necessary, welding. Any repair welding shall be performed with an approved weld repair procedure, in accordance with Section 11. If grinding only is required, the excavation shall be blended and the final thickness checked using an ultrasonic thickness meter.

11.5 Radiography

Radiography shall be in accordance with ASME V Articles 2 and the techniques employed shall be documented in the NDE procedure. The acceptance criteria shall be in accordance with ASME B31.3. Radiographic procedures shall include technique sheets incorporated a shooting sketch. X-ray or gamma-ray radiography shall be used. Where possible the single wall single image technique shall be used. Where the double wall double image technique is used a minimum of two exposures are required for sizes up to 2" NB and minimum three exposures between 2" and 4" NB. Over 4" NB single image techniques shall be employed, and sufficient exposures taken to ensure adequate coverage takes place. The double wall techniques shall not be used on pipe sizes greater than 10" NB unless access to the bore is impossible. Wire type Image Quality Indicators (IQI) in accordance with ASME V, Article 2 Table T-276 (ASTM type) shall be used. IQIs shall be positioned source side across the weld seam. If the surface of the weld facing the source is not accessible, the sensitivity must be determined separately on a procedure qualification radiograph, using a workpiece 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. The film shall be high contrast, fine grained (e.g. Agfa D5 or equivalent) or better. Each production radiograph shall include, through the use of lead characters or flashing indent, the following -

• Weld identification. • Radiograph location with respect to weld datum point. • Radiograph number or NDE report number to which the radiograph relates. • Project identification. • Whether radiograph is of an original or repaired weld. • Whether IQIs are placed on film side or source side. • Welder identification.

Radiographic films shall be free from defects or processing marks which could obscure weld imperfections.


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Shipyard Contractor shall interpret the radiographs and the results of the interpretation shall be reported on a format acceptable to the EMPLOYER. Following the Shipyard Contractor's interpretation, all radiographs shall be submitted, along with the relevant report, for assessment and endorsement by EMPLOYER's Inspector on request.

11.6 Ultrasonic

Ultrasonic inspection of welds, where required shall be in accordance with ASME V Article 4. The acceptance criteria shall be in accordance with ASME B31.3. The Shipyard Contractor shall submit a detailed ultrasonic testing procedure for EMPLOYER's review. Each ultrasonic examination performed shall be reported on a format approved by the EMPLOYER.

11.7 Extent of NDE

The full extent of NDE required for all lines shall be shown on the completed line list. For items of equipment not covered by the line list, the following tables shall be followed. Table 1 Definition of NDE Groups

NDE Group

Piping category

according to PED

Type of Connection(1)

Visual Inspection(2)

Radiography

Dye Penetrant/Magnetic Particle Inspection

1 SEP Buttweld 100% 0 0

2 I and II Buttweld 100% 10% (3) & (4) 10% (3) & (4)

3 III Buttweld 100% 100% 100% Table 2 Percentage Extent of NDE Notes

NDT

GroupSystem Service PED Fluid Group Pressure Rating Design Temp. (°C)

1 1), 2) Non-Flammable and non-toxic

fluids only2 Class 150 (minus) - 10°C to 200

2All systems except those in

NDT Group 11 and 2 Class 150 and 300 All

3 All systems 1 and 2 Class 600 and above 3) All

Notes

1) Applicable to carbon steels and stainless steel Type 316 only,

2) Applicable for all materials in open drain systems

3) Includes ASME B31.3 CHPT API 10,000 and ASME B31.8 CHPT VIII


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(1) Angular branch welds shall be examined to the same extent as butt welds but ultrasonic shall be used instead of radiography. Angular branch welds that cannot be inspected by ultrasonic shall be visually inspected (all passes) and the root shall be checked visually internally for complete penetration. All socket, branch connections, “O”-lets and attachment welds shall be Dye Penetrant/Magnetic Particle Inspected to the same extent as stated for butt welds. (2) Visual inspection shall, in addition to all welds in the piping system, include all supports and attachments welded to the piping. (3) When Radiography is specified as a percentage (E.I. 10%), RT shall be carried out on the complete circumference (E.I. 10 inches) of each size or piping BW. For radiographic examination, as a minimum, shall be taken on work performed in early stages of fabrication by each welder or welding operator. (4) Progressive examination shall be applied according to ASME B31.3 para 341.3.4

11.8 Acceptance Criteria

11.8.1 General

For the following NDT Methods the acceptance criteria is as defined in ASME B31.3 table 341.3.2 and table K341.3.2 (for high pressure piping).

• Visual, • Magnetic, • Penetrant, • Radiographic.

11.8.2 UT Acceptance Criteria When ultrasonic examination is used the UT Acceptance Criteria shall be as follows All indications producing a response equal to or greater than 20% DAC shall be investigated in order that the operator can evaluate the shape, identify and location of all such reflectors. In general, defect/indication acceptance criteria shall be in accordance with ASME B31.3 Section 344.6.2. and section K344.6.3 (for high pressure piping) as given below. A linear-type discontinuity is unacceptable if the amplitude of the indication exceeds the reference level and its length exceeds:

(a) 6 mm (1⁄4 in.) for WT ≤ 19 mm (b) WT/3 for 19 mm < WT ≤ 57 mm (c) 19 mm for WT > 57 mm

Sizing of defects shall be performed using the 6 dB drop technique. In particular, defect/indication acceptance criteria for high pressure piping shall be in accordance with ASME B31.3 Section K344.6.3 as given below -


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Any indication greater than that produced by the calibration notch represents a defect. Defective piping shall be rejected.

No cracks, lack of fusion, or lack of penetration shall be permitted regardless of length.

11.8.2 API 10,000# Piping Class

For the API 10,000# piping class, the NDE acceptance criteria shall be in accordance with ASME B31.3 CHPT IX.

11.9 NDE Personnel Qualification

All NDE operators shall be qualified in accordance with ISO 9712 (EN473). Interpretation shall be performed by Level 2 personnel. Current certification shall be available for review. All NDE personnel shall have at least six months post qualifying experience and satisfy the requirements of Pressure Equipment Directive (PED 97/23/EC). In particular for welding examination of PED categorized item (cat II, III, IV) the qualification of NDE operators must be approved by a competent third party such as a Notified Body or a Third Party organization recognized by Poland for PED purpose.

11.10 Documentation

During production, the Shipyard Contractor shall maintain an up-to-date log of all welding and inspection work, which shall eventually form the basis for the final welding and inspection documentation in the Shipyard Contractor's dossier. This shall include the following for each individual spool and field weld:

Isometric/GA/reference drawing Unique weld number Welder(s) reference number(s) WPS / PQR Visual inspection sign off and date Heat treatment report number NDE report numbers including repair report number where applicable Hardness test reports Final sign-off with date

12. REPAIRS

12.1 Repairs to Welds

The Shipyard Contractor shall submit qualified weld repair procedures for EMPLOYER approval. All welds that fail to meet the acceptance criteria shall be replaced or repaired at the Shipyard Contractor's cost in accordance with an approved qualified weld repair procedure.


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Only one repair is permitted in any single location. Additionally, for a repair of length `L', the original weld shall be subject to a repeat NDE for a distance of 0.5L from each extremity of the repair. If further unacceptable defects are discovered during this additional NDE then the whole weld shall be re-examined. Additionally, following a repair in carbon steel piping the weld metal and heat affected zone hardness shall be hardness tested with a portable hardness tester and the maximum hardness shall be in accordance with Appendix A. The same welding process, consumables and size shall be used for the repairs of the original weld as qualified and accepted by EMPLOYER. In case of repair using a different weld process of the actual weld, a full repair qualification deposit and mechanical tests are required. Impact tests shall be made either in previous weld metal and base metal fusion line of the repair weld. For repairs to corrosion resistant alloys excavation of defects shall be by grinding or machining only. For repair welding, back purging shall be applied in accordance with the qualified welding procedure when the depth of repair leaves a ligament of less than 8mm. The minimum physical length of repair welds for gouge and grind type repairs, shall be suitable to allow electrode manipulation and run in/out of the cavity. The minimum length of cavity shall be 100 mm centered about the deepest point in the cavity, providing the slope is 1:1 or greater. If slope is less than 1:1 the minimum length shall be increased. Repair welds shall be subject to the same PWHT applied to the original weld, unless the weld repair is performed before vessel PWHT is applied. Two repair attempts only shall be permitted for each repair that requires significant weld metal removal (1/3rd wall thickness or more). If this fails to remove the defect the EMPLOYER shall be advised and a new repair procedure jointly agreed. EMPLOYER specific permission is required for any further repair attempts. For major weld repairs in API 10,000# piping class, a specific repair welding procedure qualified, which will require a welding of a test plate, excavation to the required thickness, repair and full testing (including impact and corrosion testing) as per the original welding procedure qualification.

12.2 Other Repairs

Repairs to the base metal of any component are not permitted with the exception of grinding of small surface defects. Grinding of such defects shall not reduce the wall thickness below the minimum required. All arc strikes, starts and stops shall be confined to the welding groove. Accidental arc strikes outside the welding groove shall be dressed and examined to ensure the absence of cracking by Wet Magnetic Particle Inspection or Dye Penetrant Inspection. The remaining wall thickness shall be measured and be within code tolerance.


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13. MATERIAL TRACEABILITY During fabrication the Shipyard Contractor shall record material traceability for all process pipework and also for the fuel gas, flare gas and closed drains systems. Material traceability shall be a permanent record identifying for each fabricated spool, the heat/cast number, test number and certificate reference number of all individual pipe lengths, fittings, outlets etc. which make up the spool. A permanent record means an identified, traceability log/record to be issued, updated and made available for verification during the entire life of the project. It shall be made available for verification of Employer/Third Party and it shall be part of the Final Dossier documentation. The Shipyard Contractor shall submit detailed procedures for material traceability to the EMPLOYER for approval.

14. APPENDIX A ADDITIONAL REQUIREMENTS FOR WELDING OF LOW TEMPERATURE CARBON STEEL

GENERAL Welding of Low Temperature Carbon Steel material shall follow ASME B31.3. The maximum inter-pass temperature for carbon (P-1) steels shall be 250°C. WELDING PROCESSES Welding shall be performed using the Gas Tungsten Arc Welding (GTAW), Shielded Metal Arc Welding or Flux-Cored Arc Welding (FCAW) as described below. A - Welding from one side (OD) only for pipes up to and including 2” nominal diameter Root passes, fill and cap GTAW with filler rod, all passes. B - Welding from one side (OD) only for pipes larger than 2” nominal diameter Root passes GTAW with filler rod. Fill out SMAW using basic (low hydrogen) coated electrodes or FCAW using gas shielding or GTAW with filler rod all passes Cap passes As used for fill out C – Rotatable and double joints, welded from outside only. (Pipe is rotated such that all welding is performed in the downhand position), Applies for in shop and on site welds Root passes Any manual or automatic gas shielded welding process Fill out and cap SMAW using basic (low hydrogen) coated electrodes or FCAW using gas shielding


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or SAW using wire and basic agglomerated flux Note : SAW shall be single arc, single wire using conventional equipment. All SAW, SMAW & FCAW pressure containing welds or welds onto pressure retaining parts shall be made using low hydrogen (≤ 8ml hydrogen per 100g of weld metal) welding consumables (including flux). However, where the combined thickness of the weld joint exceeds 80 mm, the process shall achieve less than 5 ml hydrogen per 100g of weld metal. FCAW with CO2 shielding gas only, shall not be used under any circumstances. On no account shall FCAW without shielding gas be permitted. SAW shall be performed using a single wire and a basic agglomerated flux. PWHT shall be undertaken when required by ANSI B31.3. For welding procedure qualifications for repair, due consideration needs to be given to extend the time for an additional PWHT cycle. WELDING PROCEDURES For submerged arc welding (SAW) brand name and grade of flux shall be recorded on both the WPS and the PQR. Additionally, the weld travel speed, wire feed rate input specified on the WPS shall not differ from the values used for the PQR. Heat input shall be limited to the maximum recorded in PQR. The following variables shall be classed as supplementary essential variables and recorded on both the WPS and PQR shall include the following information: For GTAW - composition and flow rate of the shielding and when used backing gases For SAW - the electrode brand name and grade of flux For SMAW - the electrode brand name QUALIFICATION OF WELDING PROCEDURES Charpy V-notch tests shall be performed at (minus) -10°C or lower for all impact tested low temperature carbon steel in accordance with by ASME B31.3, paragraph 323.3. Acceptance criteria for the weld, parent steel and heat affected zones after all fabrication processing and thermal treatments are as follows: Specified Minimum Tensile Strength, N/mm2 Minimum Average of Three Specimens, J Minimum (1) Individual, J Carbon Steels, P No.1 Less than 450 27 21

Specified Minimum Tensile Strength, N/mm2

Minimum Average of Three Specimens, J

Minimum (1) Individual, J

Carbon Steels, P-No.1 Less than 450

27 21


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(1) Not more than one value per test set of three specimens shall be below the minimum average value. The location and orientation of impact test specimens shall be determined by wall thickness in accordance with Figure 1 (a) - (c) as appropriate. All weld procedure qualifications shall include a hardness survey. Vickers Hv10 measurements shall be carried out on an etched macro sample. Three traverses shall be made 2mm from surface of weld cap, 2mm from surface of root and in mid-thickness region, indents shall sample parent metal, fusion zone and weld metal. Hardness values shall be measured in Vickers (HV) numbers and shall not exceed 250HV10 in root and 275HV10 in cap. For welding positions 5G and 6G, two samples shall be taken at 3 and 6 o’clock positions to carry put hardness. For gas tungsten arc welding (GTAW) the procedure specification and the qualification record shall include the composition and flowrate of the inert shielding gas. Base material used in qualification tests shall have the nominal chemistry and mechanical properties of the material to be welded and the carbon content and carbon equivalent shall be at the higher end of the specification range. For parent material thicknesses greater than 25 mm, the qualification range shall be restricted to 50% to 150% of the test weld thickness in addition to thickness requirement restrictions of ASME IX. Dissimilar welds between austenitic and ferritic steels shall be separately qualified except that dissimilar welds between low temperature, impact tested carbon steel and austenitic steel may also qualify dissimilar welds between regular carbon steel and austenitic steel. FILLER MATERIALS AND FLUXES SMAW ELECTRODES All basic low hydrogen electrodes shall be dried as recommended by the consumable manufacturer to reduce the weld metal hydrogen level to that permitted by the fabrication specification. 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 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.


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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. Electrodes shall be issued into special containers, or in the case of basic low hydrogen electrodes, 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 for electrodes subject to drying temperatures in excess of 350°C, only one drying cycle is permitted. As mentioned in sect. 5.7.2, if a vacuum pack envelope is used, specific instructions shall be provided to conclude usage. PWHT Post-weld heat treatment (PWHT) shall be performed when required by and in accordance with ASME B31.3 and this specification. The maximum heating rate above 400°C shall not exceed 220°C/h or 5500/t°C/h (where t = wall thickness), whichever is lower. The maximum cooling rate above 400°C shall not exceed 275°C/h or 6875/t C/h, whichever is lower. A PWHT procedure in accordance with ASME B31.3 and this specification shall be submitted and approved by the Purchaser prior to commencing the PWHT operation. If PWHT is performed in a furnace, the temperature shall be measured by a minimum of two thermocouples. The thermocouples shall be attached by means of capacitance discharge connection to the thickest section of the piping being heat treated and shall be adequately insulated to shield from radiation effects. These thermocouples shall be located in the coldest and hottest parts of the furnace. Neither temperature shall be out of the specified PWHT range. The actual number and location of thermocouples should be clearly indicated in the PWHT procedure and is subject to prior approval. Instrumentation used to verify the PWHT temperatures shall have been calibrated within 6 months of the performance of the heat treatment. All machined surfaces shall be protected by a suitable paint or compound to prevent damage from scaling during heat treatment. During PWHT the furnace atmosphere shall be controlled so as to avoid excessive oxidation of the surface of the piping components. There shall be no direct flame impingement onto the fabrication. All piping shall be supported in the furnace during heat treatment to minimize warpage and other distortion. On loads of 12 in. and larger diameter, a loading sketch shall be submitted with the heat treatment documentation.


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Sheet / of 27 / 43

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When local PWHT is applied, the minimum heated zone width shall be 3.5√Dt and the minimum insulation width shall be 7√Dt (where D = Nominal Pipe Size, t = wall thickness). Temperature shall be measured by a suitable number of thermocouples (2 minimum) equi-spaced around the weld joint. Each thermocouple shall have been calibrated within six months of the performance of heat treatment. The actual number and position of the thermocouples for each size range of pipe shall be clearly indicated in the PWHT procedure, which shall be submitted for review and acceptance. Valves shall not be subjected to furnace PWHT without the approval from COMAPNY. Local PWHT of end welds on valves shall be carefully performed so that valve packing, bonnet gasket and internal trim are not damaged. Exothermic methods of heat treatment are prohibited. No welding or heating is permitted after PWHT.

15. APPENDIX B ADDITIONAL REQUIREMENTS FOR WELDING OF LOW ALLOY STEEL API 5L/ISO 3183 X65QO PSL2 ASME B31.8 CHPT VIII

GENERAL Welding of Low Alloy Steel API 5L/ISO 3183 X65QO PSL2 material shall follow ASME B31.8 CHPT VIII. The maximum inter-pass temperature for carbon (P-1) steels shall be 250°C. WELDING PROCESSES Welding shall be performed using the Gas Tungsten Arc Welding (GTAW), Shielded Metal Arc Welding or Flux-Cored Arc Welding (FCAW) as described below. A - Welding from one side (OD) only for pipes up to and including 2” nominal diameter Root passes, fill and cap GTAW with filler rod, all passes. B - Welding from one side (OD) only for pipes larger than 2” nominal diameter Root passes GTAW with filler rod. Fill out SMAW using basic (low hydrogen) coated electrodes or FCAW using gas shielding or GTAW with filler rod all passes Cap passes As used for fill out C – Rotatable and double joints, welded from outside only. (Pipe is rotated such that all welding is performed in the downhand position), Applies for in shop and on site welds Root passes Any manual or automatic gas shielded welding process


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Sheet / of 28 / 43

Date 23/09/16


Fill out and cap SMAW using basic (low hydrogen) coated electrodes or FCAW using gas shielding All SMAW & FCAW pressure containing welds or welds onto pressure retaining parts shall be made using low hydrogen (≤ 8ml hydrogen per 100g of weld metal) welding consumables (including flux). However, where the combined thickness of the weld joint exceeds 80 mm, the process shall achieve less than 5 ml hydrogen per 100g of weld metal. FCAW with CO2 shielding gas only, shall not be used under any circumstances. On no account shall FCAW without shielding gas be permitted. WELDING PROCEDURES The following variables shall be classed in addition to those of API 1104, as supplementary essential variables and recorded on both the WPS and PQR shall include the following information: For GTAW - composition and flow rate of the shielding and when used backing gases For SMAW - the electrode brand name For FCAW - the wire brand name QUALIFICATION OF WELDING PROCEDURES Charpy V-notch tests shall be performed, in lieu of nick break tests, at (minus) -10°C or lower for all impact tested low temperature carbon steel in accordance with by ASME B31.3, paragraph 323.3. Acceptance criteria for the weld and heat affected zones (fusion line FL+2mm and FL+5mm after all fabrication processing and thermal treatments are as follows: Specified Minimum Tensile Strength, N/mm2 Minimum Average of Three Specimens, J Minimum (1) Individual, J Carbon Steels, P No.1 Less than 450 27 21

Specified Minimum Tensile Strength, N/mm2

Minimum Average of Three Specimens, J

Minimum (1) Individual, J

Carbon Steels, P-No.1 Less than 450

27 21

(1) Not more than one value per test set of three specimens shall be below the minimum average value. The location and orientation of impact test specimens shall be determined by wall thickness in accordance with Figure 1 (a) - (c) as appropriate. All weld procedure qualifications shall include a hardness survey. Vickers Hv10 measurements shall be carried out on an etched macro sample. Three traverses shall be made 2mm from surface of weld cap, 2mm from surface of root and in mid-thickness region, indents shall sample parent metal, fusion zone and weld metal. Hardness values shall be measured in Vickers (HV) numbers and shall not exceed 250HV10 in root and 275HV10 in cap.


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Sheet / of 29 / 43

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For welding position 5G, two samples shall be taken at 3 and 6 o’clock positions to carry put hardness. For gas tungsten arc welding (GTAW) the procedure specification and the qualification record shall include the composition and flowrate of the inert shielding gas. Base material used in qualification tests shall have the nominal chemistry and mechanical properties of the material to be welded and the carbon content and carbon equivalent shall be at the higher end of the specification range. Dissimilar welds between austenitic and ferritic steels shall be separately qualified except that dissimilar welds between low temperature, impact tested carbon steel and austenitic steel may also qualify dissimilar welds between regular carbon steel and austenitic steel. FILLER MATERIALS AND FLUXES SMAW ELECTRODES All basic low hydrogen electrodes shall be dried as recommended by the consumable manufacturer to reduce the weld metal hydrogen level to that permitted by the fabrication specification. 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 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. 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. Electrodes shall be issued into special containers, or in the case of basic low hydrogen electrodes, 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 for electrodes subject to drying temperatures in excess of 350°C, only one drying cycle is permitted. As mentioned in sect. 5.7.2, if a vacuum pack envelope is used, specific instructions shall be provided to conclude usage.


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16. APPENDIX C ADDITIONAL REQUIREMENTS FOR 300-SERIES STAINLESS STEELS

GENERAL Shop fabrication of stainless steels shall be carried out in a segregated area, or preferably in a separate shop, away from the area used for carbon-manganese and low alloy steels. Removable backing strips or inserts are not permitted. Stainless steel wire brushes and solvent degreasing shall be used to remove oxides, dirt, grease, paint or other contaminants, which may be harmful to the weld. Precautions shall be established to ensure that grinding wheels, files, wire brushes and similar tools that have been used on carbon-manganese and low alloy steels are not used on CRAs. Immediately prior to welding, or tacking, the weld preparation and adjacent surfaces shall be stainless steel wire brushed then degreased using a non-toxic, non-flammable solvent. Where surface contamination by iron is suspected a ferroxyl, test shall be performed. Surfaces to be welded which have iron contamination present, or are oxidised or not supplied pickled shall be cleaned with either iron-free abrasives or pickled with a solution of hydrofluoric acid/nitric acid solution followed by rinsing in potable water and then acetone and left to dry. Steel wire brushes shall not be used. Any suspected oil contamination shall be removed by acetone prior to abrasive cleaning/pickling. Hydrocarbon solvents such as trichloroethylene, industrial methylated spirits or methanol shall not be used for degreasing. Once cleaned handling shall be kept to a minimum and welding commenced as soon as possible. When welding is not performed immediately the proposed method to protect the fusion faces shall be subject to EMPLOYER approval. All solvents, temporary markers, tapes etc. shall be chloride-free and sulphide-free. Stainless steels shall be cut mechanically or by plasma arc cutting followed by grinding only. The maximum inter-pass temperature for austenitic stainless (P-8) steels shall be 150°C. PMI shall also be carried out on at least 10% of the materials used in each spool. The EMPLOYER may increase this inspection level if materials are discovered to be out of specification. WELDING PROCESSES The root and 2nd pass of all stainless steel welds shall be made by the GTAW process. Subsequent passes can be made by SMAW coated electrodes or FCAW using gas shielding.


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Sheet / of 31 / 43

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1. Shielding of the backside of the root run shall be carried out by purging with argon to prevent oxidation or coking of root run or internal surface. This purge shall be maintained for a minimum of the root and second fill weld pass.

2. The oxygen content of the back-purge shall not exceed 0.05% immediately prior to welding.

This shall be demonstrated during welding by means of a suitable oxygen meter.

3. Evaluation and acceptance of coloring inside will, be made as per attached photos as per Norsok M-601 (see pg 31 of 42).


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Sheet / of 33 / 43

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4. For initiating back purging, all the enclosed air shall be evacuated by introducing a quantity of

purge gas of at least six times the volume of air to be displaced. When welding the root run and first two fill weld passes, a positive pressure of purging gas shall be maintained at all times.

GTAW of stainless steels shall be performed using argon or helium shielding and backing. Backing gas shall be maintained for a minimum of the first three passes. Nitrogen shall not be used. FILLER MATERIALS AND FLUXES Welding consumables for austenitic stainless steels shall provide weld deposits with ferrite content in the range 3 to 7%. Ferrite content shall be measured by chemical composition and reference to the Schaeffler or Delong diagram (Figure 2) per consumable batch. Additionally, each weld procedure qualification record shall include a direct ferrite measurement using a calibrated ferrite meter. QUALIFICATION OF WELDING PROCEDURES During weld procedure qualification the flow rate of purge gas shall be recorded and used for the application of back purging during production welding. Hardness survey shall be carried out for all stainless steel procedure qualifications. Vickers Hv10 measurements shall be carried out on an etched macro sample. Three traverses shall be made 2mm from surface of weld cap, 2mm from surface of root and in mid-thickness region, indents shall sample parent metal, fusion zone and weld metal. Hardness values shall be measured in Vickers (HV) numbers and shall not exceed 248 HV10.

17. APPENDIX D ADDITIONAL REQUIREMENTS FOR WELDING 22% Cr DUPLEX STAINLESS STEEL

GENERAL Shop fabrication of stainless steels shall be carried out in a segregated area (preferably a separate shop) away from the area used for carbon-manganese and low alloy steels. Removable backing strips or inserts are not permitted. Stainless steel wire brushes and solvent degreasing shall be used to remove oxides, dirt, grease, paint or other contaminants, which may be harmful to the weld. Precautions shall be established to ensure that grinding wheels, files, wire brushes and similar tools that have been used on carbon-manganese and low alloy steels are not used on CRAs. Immediately prior to welding, or tacking, the weld preparation and adjacent surfaces shall be stainless steel wire brushed then degreased using a non-toxic non-flammable solvent.


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Sheet / of 34 / 43

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Where surface contamination by iron is suspected a ferroxyl, test shall be performed. When iron contamination is present, or the surface oxidised or not supplied pickled, surfaces to be welded shall be cleaned with either iron-free abrasives or pickled with a solution of hydrofluoric acid/nitric acid solution followed by rinsing in potable water and then acetone and left to dry. Steel wire brushes shall not be used. Any suspected oil contamination shall be removed by acetone prior to abrasive cleaning/pickling. Hydrocarbon solvents such as trichloroethylene, industrial methylated spirits or methanol shall not be used for degreasing. Once cleaned handling shall be kept to a minimum and welding commenced as soon as possible. When welding is not performed immediately the proposed method to protect the fusion faces shall be subject to EMPLOYER approval. All solvents, temporary markers, tapes etc. shall be chloride-free and sulphide-free. The maximum inter-pass temperature for duplex stainless steels shall be 120°C. All consumables used shall be supported by manufacturer or other certified performance data. The test results shall be attached to the relevant welding consumable test certificate. Welding consumables shall be selected to achieve a minimum Pitting Resistance Equivalent Number (PREN) as per the Material Data Sheets. Duplex stainless steels shall be cut mechanically or by plasma arc cutting followed by grinding only. In addition to the NDE required in Section 11 all duplex and super duplex welds all shall be subjected to Ferrite Testing. The ferrite /austenite balance shall be checked with a calibrated Ferritescope at a minimum of 2 areas around the weld and the test result recorded. The Shipyard Contractor shall submit a testing and calibration procedure which shall be subject to review and approval by the EMPLOYER. The ferrite level of the weld metal shall between 30% to 65% volume fraction. If any weld is found to be out of the above criteria, the weld shall be quarantined, EMPLOYER immediately notified and surface metallography shall be undertaken to confirm the ferrite balance. Welds outside the specification shall be completely removed. PMI shall also be carried out on at least 10% of the materials used in each spool. The EMPLOYER may increase this inspection level if materials are discovered to be out ofwith specification. WELDING PROCESSES Permitted welding processes are SMAW and GTAW. The root and 2nd pass of all duplex stainless steel welds shall be made by the GTAW process. Subsequent passes can be made by SMAW basic coated electrodes. Autogenous welding shall NOT be used.


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Sheet / of 35 / 43

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1. Shielding of the backside of the root run shall be carried out by purging with argon to prevent

oxidation or coking of root run or internal surface. This purge shall be maintained for a minimum of the root and second fill weld pass.

2. The oxygen content of the back-purge shall not exceed 0.05% immediately prior to welding.

This shall be demonstrated during welding by means of a suitable oxygen meter.

3. Evaluation and acceptance of coloring inside will, be made as per attached photos as per Norsok M-601 (see pg 35 of 42).


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4. For initiating back purging, all the enclosed air shall be evacuated by introducing a quantity of

purge gas of at least six times the volume of air to be displaced. When welding the root run and first two fill weld passes, a positive pressure of purging gas shall be maintained at all times.

All GTAW equipment shall be fitted with high frequency starting unit and a crater eliminating slope out control. FILLER MATERIALS Consumables shall be over alloyed in nickel, generally 2-4% greater than the nominal parent metal, for example ER2209type consumables shall be used for duplex stainless steels. SMAW shall be low hydrogen (≤ 8ml hydrogen per 100g of weld metal). Data sheets of proposed consumables shall be submitted for approval prior to the start of production. MACRO EXAMINATION A full macro section shall be prepared and the austenite/ferrite phase balance determined by point counting. The ferrite content shall be measured 1mm from both root and cap surfaces for base metal, HAZ and weld metal. The ferrite level shall be determined in accordance with ASTM E562 and shall be in the range 40-60% for the base metal and 35-65% for the HAZ and weld metal. The microstructure of the weldment shall be assessed at a magnification of at least 400x and reported in the PQR. The microstructure shall exhibit a phase distribution consistent with the material manufacturer’s recommendations and shall be free from intermetallic-phases that could reduce the mechanical or corrosion resistant properties. Original copies of photo micrographs taken at a magnification of x400, of the HAZ at the fusion line and the weld metal shall be included in the PQR package. CORROSION TESTING To ASTM G48 including specimen size, test method A. The specimen shall have the internal and external surfaces in the as delivered condition. Cut edges shall be prepared according to ASTM G48. The test shall expose the external and internal surfaces. The test specimen shall include the weld across the full wall thickness including the full root and cap. Test temperature shall be: 35°C for 24 hours for 25%Cr duplex and 22°C for 22%Cr duplex. No pitting is acceptable at 20X magnification. HAZ HARDNESS DETERMINATION All weld procedure qualifications shall include a hardness survey. Hardness measurements shall be carried out on an etched macro sample. Three traverses shall be made 2mm from surface of weld cap, 2mm from surface of root and in mid-thickness region, indents shall sample parent metal, fusion zone and weld metal. The maximum acceptable hardness shall be ≤ 25 HRC.


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CHARPY TESTING Charpy V-notch testing according to ASME IX, ASME B31.3 and ASTM A370 at (minus) –10°C. The minimum absorbed energy shall be 27J average and 21J single. A set of 3 specimens shall be taken at each of the following locations, with notch located in weld metal center line, fusion line, fusion line +2mm and fusion line +5mm. Reduction factors for sub-size specimens shall be multiplied by the ratio of the actual specimen width to that of a full-size specimen

18. APPENDIX E WELDING PROCEDURES FOR API 10,000# API 5L/ISO X65QO PSL2 ASME B31.3 CHPT IX

WELDING PROCEDURES Welding procedures shall be qualified for all welded joints in accordance with ASME B31.3 CHPT IX, ASME IX and the additional requirements of this Appendix. The essential variables and supplementary essential variables in ASME IX shall apply in addition to the essential variables listed below.

• Welding parameters: Any change in the parameters affecting the heat input (current, voltage, welding speed) outside a range of ±10% from those qualified for root, fill and cap locations.

• The polarity, or electrical characteristics (alternating or direct current), shall not be changed

for any weld pass from that qualified • Heat input: No change over that qualified • Interpass Temperature: Any increase in maximum interpass temperature • Weave width: Any increase in the weave width above that qualified. • Weld Preparation: Change in weld preparation including bevel angle if 10° less than the

qualified one, shall require separate qualification. • Joint Design: Any change in joint fit-up outside the tolerances in the approved welding

procedure specification. Root gap tolerances are critical to ensure adequate penetration of filler metal into root

• Welding Consumable: Any change in consumable (electrode or flux) from one brand name to

another (even in the same classification), manufacturer, classification or country of origin. • The electrode or filler wire shall not be changed at any stage of welding from the size

qualified.


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QUALIFICATION OF WELDING PROCEDURES Material used for qualification testing shall be positively identified and traceable to chemical analysis and mechanical properties that confirm that it is technically consistent with the materials to be welded in production and the requirements of this specification. To qualify a WPS for positional welding the PQR shall be carried out in the 5G or 6G position. Full mechanical testing in accordance with ASME IX, ASME B31.3 CHPT IX (for API 10,000#) and this specification shall be carried out, together with the additional requirements stated below. All weld metal tensile testing at the design temperature is required for all Procedure Qualification Tests for piping designed to ASME 31.3 CHPT IX i.e. piping class 10,000#. The yield and tensile strength shall be recorded and shall be not less than the specified minimum UTS and yield of the pipe material at the design temperature. All PQR’s shall be undertaken using calibrated portable arc monitoring equipment. NON-DESTRUCTIVE TESTING NDT of welding procedure qualification shall be as follows:

Butt Welds Fillet Welds

100%-Visual Inspection 100%-Visual Inspection

100%-Magnetic Particle Inspection 100%- Magnetic Particle Inspection

100%-Radiographic Inspection - CHARPY TESTING Charpy V-notch testing according to, ASME IX, ASME B31.3 Chapter IX (for API 10,000# classes) and ASTM A 370 at (minus) –10°C is required for pipe wall thickness < 2”. The minimum absorbed energy shall be 34J average and 27J single. A set of 3 specimens shall be taken at each of the following locations, with notch located in weld metal centre line, fusion line, fusion line +2mm and fusion line +5mm. Reduction factors for sub-size specimens shall be multiplied by the ratio of the actual specimen width to that of a full-size specimen. HAZ HARDNESS DETERMINATION All weld procedure qualifications shall include a hardness survey. Vickers Hv10 measurements shall be carried out on an etched macro sample. Three traverses shall be made 2mm from surface of weld cap, 2mm from surface of root and in mid-thickness region, indents shall sample parent metal, fusion zone and weld metal. The maximum acceptable hardness shall be 250 HV10 for root and 275HV10 for cap. Samples shall be taken at position 3 and 6 o’clock.


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PWHT Post-weld heat treatment (PWHT) shall be performed when required by and in accordance with ASME B31.3 and this specification. An additional time for eventual repetition of PWHT after repair in final condition shall be foreseen. The holding time to consider is that of the thicker production size. A sample shall be representative for the extended time for transverse tensile, all weld metal tensile and impact tests. Hardness tests shall be determined on a sample after the normal holding time. The extended time may be applied as a single cycle. The maximum heating rate above 400°C shall not exceed 220°C/h or 5500/t°C/h (where t = wall thickness), whichever is lower. The maximum cooling rate above 400°C shall not exceed 275°C/h or 6875/t C/h, whichever is lower. A PWHT procedure in accordance with ASME B31.3 and this specification shall be submitted and approved by the Purchaser prior to commencing the PWHT operation. If PWHT is performed in a furnace, the temperature shall be measured by a minimum of two thermocouples. The thermocouples shall be attached by means of capacitance discharge connection to the thickest section of the piping being heat treated and shall be adequately insulated to shield from radiation effects. These thermocouples shall be located in the coldest and hottest parts of the furnace. Neither temperature shall be out of the specified PWHT range. The actual number and location of thermocouples should be clearly indicated in the PWHT procedure and is subject to prior approval. Instrumentation used to verify the PWHT temperatures shall have been calibrated within 3 months of the performance of the heat treatment. All machined surfaces shall be protected by a suitable paint or compound to prevent damage from scaling during heat treatment. During PWHT the furnace atmosphere shall be controlled so as to avoid excessive oxidation of the surface of the piping components. There shall be no direct flame impingement onto the fabrication. All piping shall be supported in the furnace during heat treatment to minimize warpage and other distortion. On loads of 12 in. and larger diameter, a loading sketch shall be submitted with the heat treatment documentation. When local PWHT is applied, the minimum heated zone width shall be 3.5√Dt and the minimum insulation width shall be 7√Dt (where D = Nominal Pipe Size, t = wall thickness). Temperature shall be measured by a suitable number of thermocouples (2 minimum) equi-spaced around the weld joint. Each thermocouple shall have been calibrated within 30 days of the performance of heat treatment. The actual number and position of the thermocouples for each size range of pipe shall be clearly indicated in the PWHT procedure, which shall be submitted for review and acceptance. Valves shall not be subjected to furnace PWHT without the approval from COMAPNY. Local PWHT of end welds on valves shall be carefully performed so that valve packing, bonnet gasket and internal trim are not damaged.


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Exothermic methods of heat treatment are prohibited. No welding or heating is permitted after PWHT.

19. APPENDIX F ADDITIONAL REQUIREMENTS FOR WELDING OF CUPRONICKEL PIPING

GENERAL Shop fabrication of CRAs shall be carried out in a segregated area or preferably a separate shop, away from the area used for carbon-manganese and low alloy steels. Removable backing strips or inserts are not permitted. Stainless steel wire brushes and solvent degreasing shall be used to remove oxides, dirt, grease, paint or other contaminants, which may be harmful to the weld. Precautions shall be established to ensure that grinding wheels, files, wire brushes and similar tools that have been used on carbon-manganese and low alloy steels are not used on CRAs. Immediately prior to welding, or tacking, the weld preparation and adjacent surfaces shall be stainless steel wire brushed then degreased using a non-toxic non-flammable solvent. Once cleaned handling shall be kept to a minimum and welding commenced as soon as possible. When welding is not performed immediately the proposed method to protect the fusion faces shall be subject to EMPLOYER approval. During weld procedure qualification the flow rate of purge gas shall be recorded and used for the application of back purging during production welding. All solvents, temporary markers, tapes etc. shall be chloride-free and sulphide-free. The maximum inter-pass temperature for Cu/Ni material shall be 100°C. Cu/Ni shall be cut mechanically or by plasma arc cutting followed by grinding only. Correction of misalignment shall not be carried by cold working unless subsequent heat treatment is applied by annealing at 600°C. WELDING PROCESSES Permitted welding processes are SMAW and GTAW. The root runs of all single sided welds shall be made using GTAW. A stringer bead technique shall be used.


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Plasma arc welding (PAW) may be used subject to prior approval by the EMPLOYER. Autogenous welding shall not be permitted. The pipe bore shall be purged with inert gas prior to and during welding. For initiating back purging, all the enclosed air shall be evacuated by introducing a quantity of purge gas of at least six times the volume of air to be displaced. Purging shall be maintained until completion of welding. Shielding and purging gases shall be high purity oxygen free argon (99.995%) or argon/helium mixture. The maximum oxygen content of the back purge shall be 1%. This shall be demonstrated during weld procedure qualification and production welding by means of a suitable oxygen meter. FILLER METALS Welding consumables shall be 70/30 Copper/Nickel containing titanium deoxidant and conforming to AWS A5.6 E Copper/Nickel (electrodes) or AWS A5.7 ER Copper/Nickel (filler wire). WELDING PROCEDURE QUALIFICATION Essential variables Changes to the following additional essential variables shall require re-qualification:

• A decrease in root gap • A change in current, voltage, travel speed or heat input of more than 10% • Any change from regular to pulsed GTAW, or in the pulse parameters or dwell time of pulsed

GTAW • A change of composition or more than a 10% change of flow rate of shielding or purging gas

from that qualified. • Copper/Nickel welds shall be assessed by the following tests in addition to those required by

ASME IX and the main text: • 100% radiography and 100% dye penetrant examination. • Macro-Examination. The macro specimen shall have a smooth profile with no lack of fusion

defects, cracks and porosity, slag etc.


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20. FIGURE 1 LOCATIONS AND NOTCH POSITIONS FOR CHARPY IMPACT TESTING OF SINGLE BEVEL WELDMENTS

GENERAL SPECIFICATION FOR WELDING AND NDE

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