GENERAL SPECIFICATION PIPELINES - RISERS...This document is the property of TOTAL S.A., it contains...
Transcript of GENERAL SPECIFICATION PIPELINES - RISERS...This document is the property of TOTAL S.A., it contains...
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
GENERAL SPECIFICATION
PIPELINES - RISERS
GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore)
according to DNV-OS-F101
01 10/2015 General review
00 10/2013 First issue
Rev. Date Purpose of the revision
Owning entity: DSO/TEC Managing entity: DSO/TEC/PLR
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 2 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Contents
1. Scope ....................................................................................................................... 4
2. Reference documents ............................................................................................. 4
3. Project Particular Specification (PPS) ................................................................... 8
4. Company approval/Quality Control/Quality Assurance ....................................... 8
4.1 Company approval .......................................................................................................... 8
4.2 Inspection by the company ............................................................................................. 9
4.3 Quality Control ................................................................................................................ 9
4.4 Quality Assurance ......................................................................................................... 10
5. Documentation ...................................................................................................... 10
5.1 Pipe and weld log .......................................................................................................... 10
5.2 Final dossier ................................................................................................................. 10
5.3 Dossier for bid submission ............................................................................................ 11
6. Technical Queries/Non-Conformance Reports ................................................... 12
7. Fatigue sensitive welds definition ....................................................................... 12
8. Abbreviations ........................................................................................................ 18
9. Amendments to DNV-OS-F101 ............................................................................. 21
Sec. 8 Construction - Components and Pipeline Assemblies ................................. 22
F. Pipeline Assemblies ............................................................................................................. 22
Sec. 10 Construction Offshore ................................................................................... 22
E. Welding and Non-destructive Testing ................................................................................... 22
Appendix A Fracture limit state of girth welds ..................................................................... 24
A. General ................................................................................................................................ 24
Appendix B Mechanical Testing and Corrosion Testing ...................................................... 26
B. Mechanical Testing and Chemical Analysis ......................................................................... 26
Appendix C Welding ........................................................................................................... 27
A. General ................................................................................................................................ 27
B. Welding Equipment, Tools and Personnel ............................................................................ 29
C. Welding Consumables ......................................................................................................... 30
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 3 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
D. Welding Procedures............................................................................................................. 32
E. Qualification of Welding Procedures .................................................................................... 35
F. Examination and Testing for Welding Procedure Qualification ............................................. 45
G. Welding and PWHT Requirements ...................................................................................... 59
H. Material and Process Specific Requirements ....................................................................... 67
Appendix D Non-Destructive Testing (NDT) ....................................................................... 74
A. General ................................................................................................................................ 74
B. Manual Non-Destructive Testing and Visual Examination of Welds ...................................... 76
C. Manual Non-destructive testing and Visual Examination of Plate, Pipe and Weld Overlay ... 86
Appendix E Automated Ultrasonic Girth Weld Testing ........................................................ 87
E. Field Inspection .................................................................................................................... 87
1. Flux dryness .......................................................................................................... 88
2. Additional welding procedure qualification program in the case of girth welds subject to total nominal longitudinal strain ≥ 0.4% (i.e.: reeling) ........... 90
3. Specification for sulfide stress cracking tests on welds (SSC tests) ............... 91
3.1 General ......................................................................................................................... 91
3.2 Specimen preparation ................................................................................................... 91
3.3 Test required ................................................................................................................. 91
3.4 Test set up .................................................................................................................... 93
3.5 Test conditions .............................................................................................................. 93
3.6 Specimen examination .................................................................................................. 95
3.7 Test acceptance criteria ................................................................................................ 95
3.8 Reporting ...................................................................................................................... 95
4. Model applicable for the PPS ............................................................................... 97
4.2 CTOD tests (if required by Company) ........................................................................... 98
4.3 FCGR tests (if required by Company) ........................................................................... 98
4.4 Full scale fatigue tests (if required by Company) ........................................................... 98
4.5 Strip tests fatigue tests (if required by Company) .......................................................... 99
5. Model for quality control plan (qualification and production) ......................... 100
6. Overview of ECA ................................................................................................. 110
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 4 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
1. Scope This specification defines the Company general requirements for welding and inspection of flowlines within the following scope:
Sweet service Sour service
Operating conditions X X
Sweet service carbon steel
Sour service carbon steel
Clad and lined pipes CRA pipes 1)
Materials X
(up to X70 grade) X
(up to X65 grade) X X
Onshore Offshore (S-lay, J-lay …)
Types of welding activities
X Including welding activities in yard and
mill (stalks welding, double or triple joints…)
X
Butt welds Fillet welds
Types of welds X X
Note 1: This specification does not cover the grades 13Cr-2Mo and 13Cr-2.5Mo which are not allowed on TOTAL projects.
It applies to all welding combinations between pipes, bends, flanges and forgings supplied according to GS EP PLR 205, GS EP PLR 226, GS EP PLR 227 and GS EP PLR 228.
The definitions of sweet and sour service conditions are stated in the specification GS EP COR 170.
In mild, intermediate and severe service, due to the presence of sour effluent, all welds shall have a good resistance to any kinds of H2S embrittlement.
This specification shall be used in conjunction with a Project Particular Specification (PPS) to be made for purpose detailing the additional tests and requirements or the possible modifications to the present specification, based on the special design conditions of the pipeline project.
2. Reference documents The reference documents listed below form an integral part of this General Specification.
Welding shall be carried-out to DNV-OS-F101 and the amendments contained in this specification.
All codes, specifications, standards and other documents which are referenced in this specification are listed hereafter.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 5 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
The order of precedence of the applicable documents shall be:
• The Contract
• The Project Particular Specification (PPS)
• The present General Specification
• The codes and standards in reference.
External Documents Unless otherwise stipulated, the applicable version of these documents, including relevant appendices and supplements, is the latest revision published at the effective date of this document.
Reference Title
ASME B31.4 Pipeline Transportation Systems for Liquid and Slurries
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME BPVC Section II Part C
Specifications for Welding Rods, Electrodes, and Filler Metals
ASME BPVC Section IX Welding, Brazing, and Fusing Qualifications
ASME BPVC Section V Nondestructive Examination
ASTM A262 Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels
ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products
ASTM A578 Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications
ASTM E384 Standard Test Method for Knoop and Vickers Hardness of Materials
ASTM E562 Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count
ASTM E647 Standard Test Method for Measurement of Fatigue Crack Growth Rates
ASTM E709 Standard Guide for Magnetic Particle Testing
ASTM G28 Standard Test Methods of Detecting Susceptibility to Intergranular Corrosion in Wrought, Nickel-Rich, Chromium-Bearing Alloys
ASTM G48 Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric Chloride Solution
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 6 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Reference Title
AWS A5.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding
BS 7448 (All parts) Fracture mechanics toughness tests - All parts
BS 7910 Guide to methods for assessing the acceptability of flaws in metallic structures
CSWIP Certification Scheme for Personnel
DNV-OS-F101 Submarine Pipeline Systems
DNV-OS-F201 Dynamic Risers
DNV-RP-C203 Fatigue Design of Offshore Steel Structures
DNV-RP-F108 Fracture control for pipeline installation methods introducing cyclic plastic strain
DNV-RP-F112 Design of duplex stainless steel subsea equipment exposed to cathodic protection
DNV-RP-F118 Pipe girth weld AUT system qualification and project specific procedure validation
EFC Publication No. 16 European Federation of Corrosion Publication No. 16; Guidelines on Material Requirements for Carbon and Low Alloy Steels for H2S - Containing Oil and Gas Field Service
EN 10204 Metallic products - Types of inspection documents
EN 1435 Non-destructive examination of welds. Radiographic examination of welded joints
EN 50504 Validation of arc welding equipment
ISO 11699-1 Non-destructive testing - Industrial radiographic film - Part 1 Classification of film systems for industrial radiography
ISO 14175 Welding consumables - Gases and gas mixtures for fusion welding and allied processes
ISO 14344 Welding consumables - Procurement of filler materials and fluxes
ISO 15156-2 Petroleum and natural gas industries - Materials for use in H2S-containing environments in oil and gas production - Part 2 Cracking-resistant carbon and low-alloy steels, and the use of cast irons
ISO 17636 (Parts 1; 2) Non-destructive testing of welds - Radiographic testing of fusion-welded joints - Parts 1; 2
ISO 17640 Non-destructive testing of welds - Ultrasonic testing - Techniques, testing levels, and assessment
ISO 19232 (Parts 1; 5) Non-destructive testing - Image quality of radiographs - Parts 1; 5
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 7 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Reference Title
ISO 5579 Non-destructive testing - Radiographic testing of metallic materials using film and X- or gamma rays - Basic rules
ISO 7539-2 Corrosion of metals and alloys. Stress corrosion testing - Part 2: Preparation and use of bent-beam specimens
ISO 9001 Quality managements systems - Requirements
ISO 9712 Non-destructive testing - Qualification and certification of NDT personnel
ISO/TS 29001 Petroleum, petrochemical and natural gas industries - Sector-specific quality management systems - Requirements for product and service supply organizations
MSS SP-97 Integrally reinforced forged branch outlet fittings - Socket welding, threaded and buttwelding ends
NACE TM 0177 Laboratory testing of metals for resistance to sulfide stress cracking and stress corrosion cracking in H2S environments
NACE TM 0284 Evaluation of pipeline and pressure vessel steels for resistance to hydrogen-induced cracking
Total General Specifications Unless otherwise stipulated, the applicable version of these documents, including relevant appendices and supplements, is the latest revision published in the applicable yearly collection.
Reference Title
GS EP COR 170 Materials for upstream sour service application - Specification for selection and design
GS EP COR 401 Installation of anodes on submerged pipelines
GS EP PLR 100 Submarine pipeline systems
GS EP PLR 205 Carbon steel, clad and lined pipe manufacturing for linepipe applications according to API SPEC 5L and DNV-OS-F101 (sweet and sour service, onshore and offshore)
GS EP PLR 226 Fabrication of hot bends for pipelines
GS EP PLR 227 Carbon steel flanges and branch outlet fittings and forged components for pipelines
GS EP PLR 228 Carbon steel tees for pipelines
GS EP PLR 430 Automated Ultrasonic Testing of pipeline girth welds according to DNV standards
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 8 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Reference Title GS EP PLR 431 Real time radioscopy inspection
GS EP PVV 175 Cleaning of piping and vessels
3. Project Particular Specification (PPS) The PPS shall contain welding data sheets as per the requirements listed in the additional section 4 of this specification with at least the following information:
1. Details about pipe geometry and pipe material.
2. Clarification on the details of end bevels.
3. Materials ordered with a simulated PWHT.
4. The sour service severity and pipeline effluent to clarify the H2S test conditions, in the case of mild, intermediate and severe service.
5. Impact test temperature(s) and impact test absorbed energy requirement for WT above 25 mm.
6. CTOD tests requirements (if any): number of specimens, sampling location, specimen geometry, test environment, test temperature and minimum CTOD values.
7. FCGR tests requirements (if any): number of specimens, sampling location, specimen geometry, test environment, test temperature and targeted FCGR.
8. Full scale fatigue tests requirements (if any): number of specimens, sampling location, specimen geometry, test environment, test temperature and targeted fatigue class according to DNV-RP-C203.
9. Strip tests fatigue tests requirements (if any): number of specimens, sampling location, specimen geometry, test environment and test temperature.
10. Knockdown factors to account for effects of sour environment on fatigue strength (if applicable).
4. Company approval/Quality Control/Quality Assurance
4.1 Company approval All suppliers shall be previously approved on the financial, HSE, quality and technical sides by Company.
As part of this approval process, a technical audit shall be performed by HQ Pipeline & Riser department and the supplier shall be approved. Non approved suppliers shall not be considered on Company projects.
Company can suspend the approval of a manufacturer due to a negative feedback concerning pipe quality, delivery time, missing documentation or HSE issues.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 9 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
4.2 Inspection by the company All procedures shall have prior approval of HQ Pipeline & Riser department.
For each project, Company appoints inspector(s) to supervise welding procedures qualifications and production.
All qualification tests shall take place under the supervision of the inspector.
Welding contractor shall ensure, prior to the commencement of welding qualification, a one day training to company inspector (s) with the following objectives:
• Show the equipments: power source, welding bug, clamp, preheating device...
• Explain to company inspector the main steps of the inspection and test plan and show in particular how hi-lo, preheat temperature, interpass temperature and cap profile are checked
• Explain to company inspector how welding parameters are monitored/recorded and how the welding heat input is calculated
• Explain to company inspector which type of equipments he can used and where he can do the measurements to cross-check welding parameters.
4.3 Quality Control Responsibility for quality control shall rest with the Contractor aided by such staff as may be required.
Four weeks prior to commencement of any work the Contractor shall prepare and submit a Quality Control Plan which describes the systematic control of the construction, inspection and testing, as dictated by the overall Contract quality program. The Quality Control Plan shall set forth “witness”, “hold”, “review” and “monitor” points. It shall be written following the format given in the additional section 5
Regarding inspection, the Quality Control Plan shall include:
• A flowchart illustrating each inspection point and its relative location in the procedure cycle, where conformance of characteristics is verified.
• The characteristics to be inspected at each inspection point, the procedures and acceptance criteria to be used. The procedures shall be provided to the Company, as requested.
• Copies of specific forms used by Contractor to record the results of each inspection.
The Contractor shall maintain quality records as documentary evidence of compliance with quality requirements. Quality records shall be available to the Inspector for analysis and review.
All Contractor inspection systems shall be subject to evaluation and checks by the Inspector to ensure that the system is effectively applied and meets the requirements of this specification.
The Contractor shall employ competent supervisors to ensure that both the standard of workmanship and the quality of materials used comply with the requirements of this specification.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 10 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
4.4 Quality Assurance The Contractor shall operate a Quality Assurance system in accordance with ISO 9001 or ISO/TS 29001, approved by a Company recognized authority. The Quality assurance Manual shall be submitted prior the start of work.
5. Documentation
5.1 Pipe and weld log Contractor shall maintain a welding log (within a pipe tracking system) and shall update it as the work progresses.
This document shall include, but is not restricted to, the following information:
• Number, origin, steel grade, nominal diameter and nominal thickness of each pipe, flange or fitting in its order of installation
• Actual length of each pipe laid/welded and cumulative length
• Date and time each weld or repair was made
• Number of each weld and welder/operator(s) used
• Location of each weld with respect to the pipeline kilometric point or with respect to one end of the pipeline, as appropriate or agreed with Company
• Location of obstacles, accessories, anodes, potential test points, etc., and their location with respect to neighbouring welds
• Information pertaining to weld inspections carried out (results, defects found, repairs, etc.)
• Cut off lengths.
This document shall be available to the Inspector at all times for information and review.
5.2 Final dossier Upon completion of the fabrication and/or installation work, Contractor shall provide Company with a final dossier including at least the following documents:
• The laying/welding log
• The Welding Procedure Specifications (WPS) for main welds and repair welds
• The Welding Procedure Qualification Test Records (WPQR) for main welds and repair welds
• The H2S embrittlement test procedure and test reports
• The welder and welding operator qualification certificates
• The NDT procedures and qualification test reports
• The NDT operator qualification certificates
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 11 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
• The technical data sheets of welding consumables (coated electrodes, wire, fluxes), the Mill certificates and Contractor tests per batch, the consumables procedure for handling, drying and traceability
• The non-destructive inspection reports
• The pickling and passivation reports (if applicable)
• The Quality Control Plan
• The present specification and related PPS.
The PPS shall state the number of originals and copies of the final dossier which is to be supplied to the Company.
The final dossier shall be completed and submitted to Company within one month after completion of site welding.
5.3 Dossier for bid submission Upon submission of his proposal, Contractor shall provide Company with the following minimum information and documentation:
1. The specification data of the equipment to be used in the production welding line (offshore, onshore):
• Layout and make up of the production welding line: welding stations, repair welding station, NDT station, etc., together with location of tensioners
• Maximum and minimum pipe lengths which are acceptable for welding with the welding installation
• Technical data of welding equipment for main line, double joints, etc.
• Technical characteristics of preheating and post-weld heat treatment equipment (where applicable)
• Alignment clamp type and technical data
• Bevelling machine for main line, double joints, etc.
2. Same data as above (where applicable) for pre-installation work (e.g. double jointing, expansion loop prefabrication, etc.).
3. The proposed WPSs for welds and repair welds with execution sequence of the various passes in relation to the welding stations used or types of weld.
4. The welder qualification scheme.
5. The location where WPS and welders will be qualified.
6. The nominated Company for performance of NDT.
7. The preliminary NDT procedures, together with data sheets on the equipment used.
8. The nominated laboratory for conducting the H2S embrittlement tests, with preliminary SSC procedure or typical procedure, when SSC tests are required.
9. Quality Assurance Certification.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 12 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
10. Contractor’s past experience in welding/installing pipeline similar to that of the Project (e.g. past experiences from similar jobs performed successfully, WPS and WPQR previously used in production, etc.).
11. Deviations to present specification, if any.
6. Technical Queries/Non-Conformance Reports 1. Any Contractor’s requests for clarifications or deviations to Company specifications shall be
submitted to Company only through Technical Queries (TQ), the format of which shall have prior approval of the Company.
A deviation to specification shall not be considered as accepted if it has not been submitted to and accepted by Company through a Technical Query.
2. Approval given by the Company to any Contractor’s work procedures, specifications, equipment, etc. shall not release in any way the Contractor from his obligation to meet the Company specifications.
Any work performance or test result which is found, at a later date, not in conformance with Company specifications or agreed procedure shall be subject to a Non-Conformance Report (NCR) to be issued by the Contractor for submission to Company. NCR report shall indicate corrective action intended by the Contractor.
7. Fatigue sensitive welds definition All contributions to fatigue shall be considered in fatigue calculations: ViV, slugging, shutdowns.
Miner’s rule shall be used to combine all cyclic load cases:
�𝑁𝑖𝑁𝑓𝑖
< 1𝑖
1
Where:
𝑁𝑖 is the number of cycles corresponding to a lifetime of 10 times the field lifetime (as required in GS EP PLR 100 § 19.7) and corresponding to fatigue safety factor “HIGH” in DNV-OS-F101 and DNV-OS-F201.
𝑁𝑓𝑖 is the number of fatigue cycles to failure for ∆𝜎𝑖.
In the present specification, fatigue sensitive lines (“FS1” designation) are those which the accumulated fatigue damage is ≥ 0.05 (including the safety factor of 10 as required in GS EP PLR 100).
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 13 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
The fatigue class shall be as per DNV-RP-C203 for the relevant class detail and environment:
For D-class, the Stress Concentration Factor (SCF) is given by:
𝑆𝐶𝐹 = 1 +3. 𝛿𝑚𝑡
𝑒−�𝑡/𝐷
Where:
t is the pipe nominal thickness
D is the pipe outside nominal diameter
δm is the misalignment which shall be determined as follow:
For seamless pipes, the value of δm shall be replaced by δtot:
𝛿𝑡𝑜𝑡 = �𝛿𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠2 + 𝛿𝑜𝑣𝑎𝑙𝑖𝑡𝑦2
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 14 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
𝛿𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =(𝑡𝑚𝑎𝑥 − 𝑡𝑚𝑖𝑛)
2
𝛿𝑜𝑣𝑎𝑙𝑖𝑡𝑦 = (𝐷𝑚𝑎𝑥 − 𝐷𝑚𝑖𝑛)
Fatigue Crack Growth Rate (FCGR) shall be as per BS 7910: mean + 2SD in the relevant environment.
The following table specifies the FCGR values that shall be considered in Engineering Critical Assessments (ECA):
FCGR values to be considered
Environment FCGR
Air BS 7910 in air, Mean + 2SD.
Sea water + CP BS 7910 in air, Mean + 2SD with a multiplying factor of 9.
Sour BS 7910 in air, Mean + 2SD with a multiplying factor equal to the knockdown factor.
Every time the contractor wants to consider a better fatigue class, full scale fatigue tests and FCGR tests shall be performed to demonstrate the actual fatigue performance.
Alternatively, results of full scale or FCGR tests from past experience can be considered provided the tested welding procedures are within the acceptable range of the following essential variables:
Full scale or strip and FCGR tests essential variables
Variables Changes requiring new full scale or FCGR tests
1. Welding process
FCG
R
Full
scal
e or
str
ip
The process(es) used X X Any change.
The order of processes used X X Any change when multiple processes are used.
Manual, partly-mechanized, mechanized or automatic welding
X X Any change between manual, partly-mechanized, mechanized and automatic welding.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 15 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Full scale or strip and FCGR tests essential variables
Variables Changes requiring new full scale or FCGR tests
2. Welding equipment FC
GR
Full
scal
e or
str
ip
Welding X X Any change in make, type and model for partly-mechanized, mechanized and automatic welding.
Welding equipment X X Any change in type for manual welding.
Number of wires X X
Change from single wire to multiple wire system and vice versa (e.g. going from tandem/twin to single wire). This does not apply to multiple torch systems where the wires feed into separate weld pools.
3. Base materials
FCG
R
Full
scal
e or
str
ip
Material grade X X A change of material grade.
Supply condition X X A change in material supply condition (TMCP or Q/T).
Manufacturing process X X A change in manufacturing process (rolled, seamless, forged).
4. Material thickness and diameter FC
GR
Full
scal
e or
str
ip
Material thickness (t = nominal thickness of test joint.)
X X - t ≤ 25 mm: A change outside 0.75 t to 1.5 t. - t > 25 mm: A change outside 0.75 t to 1.25 t.
D/t ratio X Any change of ± 10%.
5. Groove configuration
FCG
R
Full
scal
e or
str
ip
Groove design/configuration. X X
Any change from J to V bevel. Any change in groove dimension ± 10%.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 16 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Full scale or strip and FCGR tests essential variables
Variables Changes requiring new full scale or FCGR tests
6. Alignment FC
GR
Full
scal
e or
str
ip
Line-up clamp X X Omission of a line-up clamp and a change between external and internal line-up clamp.
Backing X Any change from copper or ceramic shoes to no copper or ceramic shoes and vice versa.
Internal misalignment X Any increase.
7. Welding consumables
FCG
R
Full
scal
e or
str
ip
Welding consumables X X Any use of a welding consumable type (standard designation) or a change in tensile or impact properties of more than ±10%.
8. Electrical characteristics and pulsing data FC
GR
Full
scal
e or
str
ip
AC, DC or pulsed current X X Any change in type of current and a change from normal to pulsed current and vice versa.
Pulse frequency range in pulsed manual welding X X
Any change in: Pulse frequency for background and peak current exceeding ± 10% and pulse duration range exceeding ± 10%.
9. Welding techniques
FCG
R
Full
scal
e or
str
ip
Welding direction X X A change from upwards to downwards welding and vice versa.
Stringer/weave X X A change from stringer to weave of more than 3X electrode/wire diameter or vice versa.
Sequence of deposition of different consumables X X Any change in the sequence.
Sequence of sides welded first and last (double sided welds)
X X Any change in the sequence.
Passes welded from each side X X Change from single to multi pass welding and vice versa.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
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Full scale or strip and FCGR tests essential variables
Variables Changes requiring new full scale or FCGR tests
10. Preheating FC
GR
Full
scal
e or
str
ip
Preheat temperature X X Any reduction.
Initial temperature when preheat is not used X X Any reduction.
11. Interpass temperature
FCG
R
Full
scal
e or
str
ip
Maximum and minimum interpass temperature X X Any increase above 25°C for C-Mn and low alloy steel.
12. Heat input
FCG
R
Full
scal
e or
str
ip
Heat input range X X Any change exceeding ± 5%.
13. Post weld heat treatment FC
GR
Full
scal
e or
str
ip
Post weld heat treatment X X Addition or deletion of post weld heat treatment. Any change in holding temperature exceeding ± 20°C. Any change in heating and cooling rates outside ± 5%.
Holding time X X Any change in holding time outside ± 5%
14. Weld profile
FCG
R
Full
scal
e or
str
ip
Cap extension beyond the fusion line X Any change above ± 2 mm.
Cap external profile X Any change in height of more than ± 1.5 mm.
In sour environment, a knockdown factor might be applicable. This shall be specified in the PPS.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 18 of 110
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Knockdown factors shall be incorporated in fatigue design calculations as follow:
• The reference curve shall be that used for design calculations i.e. D, F, F1 or F3 (the reference curves shall also be specified in the PPS).
• No limit at 107 cycles shall be considered.
• The slope of the S-N curve: m = 3 shall be used.
• For the same stress amplitude level, the fatigue life shall be reduced by the knockdown factor (see here below).
A pre-classification of welds (between non fatigue sensitive and fatigue sensitive “FS1”) shall be mutually agreed at the bid stage.
As a guideline and in the absence of any data from the basic engineering, the following welds shall be considered “FS1” at the bid stage:
• Riser welds (at least hanging and touchdown areas)
• Riser base spool welds
• Flow-lines welds in buckling initiation areas.
8. Abbreviations AUT Automatic Ultrasonic Testing
AYS Actual Yield Strength
CE Carbon Equivalent
CR Cap Repair
CRA Corrosion Resistant Alloys
CRR Cap Re-Repair
CTOD Crack Tip Opening Displacement Test
D Diameter
∆σ
N
m=3
m=5
m=3
N1/kdf N1
Air
Sour environment
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 19 of 110
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DPI Dye Penetrant Inspection
ECA Engineering Critical Assessments
EDX Energy-Dispersive X-ray Spectroscopy
EPMA Electron Probe Micro Analyzer
ET Eddy Current Testing
FCAW Flux Cored Arc Welding
FCGR Fatigue Crack Growth Rate
FL Fusion Line
GMAW Gas Metal Arc Welding
GMAW STT Gas Metal Arc Welding - Surface Tension Transfer
GS-FCAW Gas Shielded Flux Cored Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
HHI High Heat Input
HI Heat Input
HV Hardness Vickers
ID Internal Diameter
IQI Image Quality Indicators
LHI Low Heat Input
m-GMAW mechanized Gas Metal Arc Welding
m-PGMAW mechanized Pulsed Gas Metal Arc Welding
m-SAW mechanized Submerged Arc Welding
MPI Magnetic Particles Inspection
MPQT Manufacturing Procedure Qualification Test
MUT Manual Ultrasonic testing
NA Not Applicable
NDT Non Destructive Testing
OD Outside Diameter
Pcm Parameter of Crack Measurement
PGMAW Pulsed Gas Metal Arc Welding
PoD Probability of Detection
PPS Project Particular Specification
PTR Partial Thickness Repair
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 20 of 110
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PTRR Partial Thickness Re-Repair
PWHT Post-Weld Heat Treatment
pWPS preliminary Welding Procedure Specification
QC Quality Control
RPR Root Pass Repair
RT Radiography Testing
SAW Submerged Arc Welding
SCF Stress Concentration Factor
SEM Scanning Electron Microscope
SENB Single Edge Notched Specimen In Bending
SENT Single Edge Notched Tension
SMAW Shielded Metal Arc Welding
SMTS Specified Minimum Tensile Strength
SMYS Specified Minimum Yield Strength
SSC Sulfide Stress Corrosion Crack
TTR Through Thickness Repair
TTRR Through Thickness Re-Repair
WT Wall Thickness
WM Weld Metal
WPQ Welding Procedure Qualification
WPQR Welding Procedure Qualification Record
WPQT Welding Procedure Qualification Test
WPS Welding Procedure Specification
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 21 of 110
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The information contained in this document does not substitute to the applicable laws and regulations.
9. Amendments to DNV-OS-F101 The following revision is considered:
DNV-OS-F101
Submarine Pipeline Systems
October 2013
The statements of this specification are modifications to DNV-OS-F101 and are identified as Add or Modify to Read.
The section numbers in this specification correspond to DNV-OS-F101.
Paragraphs of DNV-OS-F101 that are not revised remain applicable.
Additional sections listing Company documents/lists are highlighted in red.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 22 of 110
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Sec. 8 Construction - Components and Pipeline Assemblies
F. Pipeline Assemblies
F 700 Welding and NDT Modify to read
704 Requirements to automated ultrasonic testing (AUT) are given in GS EP PLR 430, DNV-RP-F118 and the DNV-OS-F101 - appendix E.
714 For welds where allowable defect sizes are based on an ECA, automated ultrasonic testing (AUT) shall be performed.
Sec. 10 Construction Offshore
E. Welding and Non-destructive Testing
E 100 General Add
For clad and lined pipe applications, 100% dimensional check of bevel preparation with go no-go gage shall be performed
E 200 Welding Modify to read
203 In case multiple welding stations are used on the installation vessel, the root and the first filler pass shall, as a minimum, be completed at the first welding station before moving the pipe. Moving the pipe at an earlier stage may be permitted provided:
• The root pass is not performed by SMAW using cellulosic coated electrode
• The root pass is 100% completed
• It is demonstrated that the stress level in the weld does not exceed 20% of the parent material SMYS
• An analysis is performed showing that this can be performed without any risk of introducing defects in the deposited weld material. This analysis shall consider the maximum misalignment allowed, the height of the deposited weld metal, the possible presence of flaws, support conditions for the pipe and any dynamic effects
• The pipe is fully supported by rollers to ensure a smooth transfer.
In any case, the pipes on both sides of the joint shall not be raised or lowered until one third (1/3) of the weld filling is completed all around the pipe circumference.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 23 of 110
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E 300 Non-destructive testing Modify to read
306 For “Golden Welds” (critical welds e.g. tie-in welds that will not be subject to pressure testing, etc.) 100% ultrasonic testing (AUT shall be performed whenever it is possible), 100% radiographic testing, and 100% magnetic particle testing or 100% liquid penetrant testing of non- ferromagnetic materials shall be performed.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 24 of 110
Appendix A
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Appendix A Fracture limit state of girth welds
A. General
A 400 Fracture toughness Modify to read
410 The fracture toughness properties shall be determined from a fracture toughness test program as described in Appendix C - F319.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 25 of 110
Appendix A
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
B. Assessment categories
B.100 General Add
The following cases shall be considered for ECA:
Cases Method for ECA Input data Requirements
Installation by S-lay, J-lay, towing and Operation
BS 7910 - Level 2A for HAZ BS 7910 - Level 2B for BM and WM
δmat = lowest between δc, δu
and δm. Material stress-strain curve derived from minimum specified values (for level 2B). Cut-off value determined from minimum specified values.
If δmat = δc then the welding procedure shall not be qualified (case a) If δmat = δu then δmat shall be taken equal to δ0.2BL (case b) for ECA in installation and in operation. If δmat = δm (case c) δmat = δ0.2BL shall be considered for installation and: - δmat = δm shall be considered for ECA in operation when fatigue crack growth occurs - δmat = δ0.2 shall be considered for ECA in operation when no fatigue crack growth occurs
Installation by reeling
BS 7910 - Level 3B for BM and WM
Full CTOD-R or J-R curve Material stress-strain curve derived from minimum specified values (for level 3B). Cut-off value determined from minimum specified values.
It shall be demonstrated that all conditions (input data …) to perform a level 3B assessment are fulfilled. Materials shall be in the upper shelf of the Charpy transition curve at the minimum design temperature (minimum single shear area values ≥ 80%).
In bi-axial operating conditions, the ECA procedure shall be mutually agreed.
C. Generic ECA for girth welds subjected to strains less than 2.25% assessed according to ECA static Not applicable. Generic ECA shall not be accepted.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 26 of 110
Appendix B
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Appendix B Mechanical Testing and Corrosion Testing
B. Mechanical Testing and Chemical Analysis
B 200 Chemical analysis Modify to read
Chemical analysis of weld overlay
202 The chemical composition of the weld overlay shall be obtained 1.5 mm minimum below the surface.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 27 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Appendix C Welding
A. General
A 200 Application Modify to read
202 The base materials covered by this appendix are:
• C-Mn and low alloy steels
• Corrosion resistant alloys (CRA) including ferritic austenitic (duplex) steel, austenitic stainless steels, other stainless steels and nickel based alloys
• Clad and lined steels.
The base material requirements of pipes and fittings supplied by Company are defined in Company General Specifications listed in section Reference documents of this specification.
203 The following welding processes are approved for use:
Welding processes approved for use - Mainline procedures (and double joints)
Root Fill Cap
NO
N F
ATI
GU
E SE
NSI
TIVE
LIN
E
m-SAW m-SAW m-SAW
m-GMAW with or without copper or ceramic shoes (for OD > 4.5” only).
m-GMAW m-GMAW
m-PGMAW without copper or ceramic shoes (for OD > 4.5” only).
m-PGMAW m-PGMAW
SMAW - basic coated rods (cellulosic coated rods are only permitted for grades X56 and below and provided impact tests temperature is > -20°C).
SMAW - basic coated rods. SMAW - basic coated rods.
GTAW is mandatory for pipe diameter less than 2’’ 3/8 (60 mm).
GTAW is mandatory for pipe diameter less than 2’’ 3/8 (60 mm).
GTAW is mandatory for pipe diameter less than 2’’ 3/8 (60 mm).
GS-FCAW (subject to Company approval)
GS-FCAW (subject to Company approval)
Particular requirement for sour service: Welding on copper or ceramic shoes is not allowed.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 28 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Welding processes approved for use - Mainline procedures (and double joints)
Root Fill Cap
FATI
GU
E SE
NSI
TIVE
LIN
E (F
S1)
m-SAW (double side welding shall be required when targeting a D-class or more).
m-SAW m-SAW
m-GMAW without copper or ceramic shoes (copper or ceramic shoes might be acceptable provided fatigue performance is checked by full scale testing)
m-GMAW m-GMAW
m-PGMAW without copper or ceramic shoes.
m-PGMAW m-PGMAW
GTAW is mandatory for pipe diameter less than 2’’ 3/8 (60 mm)
GTAW is mandatory for pipe diameter less than 2’’ 3/8 (60 mm).
GTAW is mandatory for pipe diameter less than 2’’ 3/8 (60 mm).
Particular requirement for sour service: Welding on copper or ceramic shoes is not allowed.
Welding processes approved for use - Tie-in procedures (and stalks welding)
Root Fill Cap
NO
N F
ATI
GU
E SE
NSI
TIVE
LIN
E
m-GMAW m-GMAW m-GMAW
m-PGMAW m-PGMAW m-PGMAW
GTAW GS-FCAW (subject to Company approval)
GS-FCAW (subject to Company approval)
SMAW - basic coated rods (cellulosic coated rods are not permitted for tie-in and repairs). Vertical-up welding.
SMAW - basic coated rods (cellulosic coated rods are not permitted for tie-in and repairs). Vertical-up welding.
SMAW - basic coated rods (cellulosic coated rods are not permitted for tie-in and repairs). Vertical-up welding.
FATI
GU
E SE
NSI
TIVE
LI
NE
(FS1
)
m-PGMAW m-PGMAW m-GMAW
m-PGMAW m-PGMAW m-PGMAW
GTAW GTAW GTAW
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 29 of 110
Appendix C
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The information contained in this document does not substitute to the applicable laws and regulations.
A 300 Definitions Add
The following definitions shall be considered in this specification:
Inspector Company’s authorized representatives or members from Company elected inspection agencies for the time being or from time to time duly appointed in writing by the Company to act as its representative for the purpose of the Contract shall be referred to herein as the "Inspector".
PPS This designates the Project Particular Specification as defined before in this present specification.
Site This term designates the sites, workshops, worksites, barges, ships or other locations where the prefabrication, welding and installation of the pipeline is performed complete or in part.
Approval Authorization in writing given by Company to Contractor to proceed with the performance of a specific part of the work without releasing in any way Contractor from its obligations and liabilities under the Contract or at law. Approve, Approved and Approval shall be construed accordingly.
B. Welding Equipment, Tools and Personnel
B 200 Personnel Modify to read
Welding operators and welders
208 For butt welds, all welders shall be qualified by NDT. Finished coupons shall be visually examined, fully radiographed and, then in the case of automatic (except SAW) or semi-automatic welds, ultrasonically tested. Ultrasonic testing may be waived, at Company's option, for automatic welding, based on bevel configuration. For fillet welds, besides the NDT examination, two additional macrographs located one at the greatest root gap and one at the least root gap shall be made.
Add
Welding operators and welders
Only single qualification is accepted (multiple qualification shall not be permitted).
Pre-qualified manual or semi-automatic welders shall not be permitted.
With previous approval of Inspector, the qualification of a welding machine operator may be accepted without further testing provided Contractor submits satisfactory proof concerning the operator's professional skills (apprenticeship or advanced training, previous work in using similar welding procedures and equipment, previous qualification certificate dated of less than three months, etc.).
All tests for the welder qualification shall be witnessed and approved by Inspector.
Small size pipe nipples (minimum 1500 mm in length) shall be used.
Manual and semi-automatic welders shall be separately qualified for each welding position encountered on the job, in a same way as for the welding procedure qualification test. The
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 30 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
welding positions 2G + 5G qualifies for 6G, but the 6G position shall not qualify for the 2G and/or 5G position.
When testing manual or semi-automatic welders for execution of a weld without back pass, the pipe nipple ends shall be closed so that internal check of the weld root cannot be made by welders during performance of welding.
Test welds shall be free from cracks, lack of penetration and lack of root fusion. Any other defects shall be within the limits of the DNV-OS-F101 and the statements listed in this standard.
Welder qualification for welded branch connections or for welds of special configurations shall include special requirements and testing as directed by the Inspection Agency. Only welders qualified for groove welds in the 6G (inclined, fixed) position may be submitted to particular qualification for welded branch connections.
Retesting
Requalification of welders or operators shall be required if any change is made to the welding procedure which necessitates requalification of the welding procedure. Requalification of welders or operators will be required where established tolerances on weld procedures are exceeded.
For manual metal arc welding, a change in electrode trade name shall require welder re-approval for butt welds.
Identification of welders
A list of qualified personnel (with photographs) shall be kept up to date by Contractor and made available to Inspector for review.
For the specific case of “On-line” activities, welders/operators stamp painting can be avoided provided traceability of welders/operators is ensured. However, relevant procedure shall be issued for Company’s approval.
C. Welding Consumables
C 100 General Modify to read
107 All welding consumables shall be individually marked and supplied with an inspection certificate type 3.1 according to EN 10204. Certificate type 3.1 is also required for SAW flux. These certificates shall be submitted to the Inspector.
Cellulose coated electrodes
108 On C-Mn linepipe grade X60 and above (SMYS ≥ 413 MPa), cellulose coated electrodes are not permitted. On steel grade up to X56, cellulose coated electrodes are allowed provided impact test is not less than -20°C (minus 20°C). If used, the delay between completion of the root pass and the deposition of the hot pass shall be simulated during welding procedure qualification according to the paragraph E 108.
109 Use of cellulose coated electrodes is not permitted for:
• Repair welding of pipeline girth welds
• Welding of pipeline girth welds in C-Mn linepipe grade X60 and above.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 31 of 110
Appendix C
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The information contained in this document does not substitute to the applicable laws and regulations.
Add
All welding consumables shall conform to ASME BPVC Section II Part C or approved equivalent standard.
SAW flux procurement, packing, storage and use shall comply with the requirements of the relevant additional section 1 attached to the present specification.
All welding consumables shall be supplied in sealed, dirt and moisture proof containers.
For SAW, re-cycling of flux is not permitted.
The lot and the level of testing of the welding consumables are specified as per ISO 14344 as follows:
• Covered electrodes: class C5 or alternatively C3 provided it is limited to one heat number and when the chemical composition of wet mixes is controlled by raw material analysis and computerized weighing.
• Bare solid electrodes and rods: class S3
• Flux cored electrodes and metal cored electrodes and rods: class T3
• Flux for submerged arc welding: class F2.
The level of testing shall be as per ISO 14344 - Schedule 4 as a minimum. In addition, for SAW flux, testing of granulometry and testing of diffusible hydrogen and/or moisture, shall be required.
C 200 Chemical composition Modify to read
204 When H2S service (sour service) is specified, the nickel content in consumables shall not exceed 1.0%. The use of C 0.5 Mo consumables is not permitted.
Modify to read
307 Batch testing shall always be performed.
C 400 Batch testing of welding consumables for pipeline girth welds Add
The test procedure (namely, weld preparation, chemical analysis, mechanical tests, etc.) shall be proposed by Contractor and approved by Inspector.
No retests shall be permitted unless an explanation for the failure is accepted by the Company.
Mechanical Testing
For automatic welding processes, impact tests for each batch of consumables shall be performed under the same conditions and with the same equipment as used for the relevant approved welding procedure.
For sour service, batch testing shall also include SSC tests (root and mid-thickness).
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 32 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
C 500 Shielding, backing and plasma gases Add
Gas bottles shall be clearly identified and hoses shall be checked to ensure that all connections are tight and there are no leaks.
C 600 Handling and storage of welding consumables Add
Contractor's procedure relative to storing handling, drying, recycling and traceability of consumables shall be approved by the Inspector before commencement of production welding.
Unopened containers shall be stored in a dry location where a temperature of 20°C and humidity of less than 40% are maintained.
Each tin or packet of electrodes, or reel of filler wire and bag of flux shall be clearly marked with the respective batch no. In the event of consumables being unmarked or showing signs of deterioration or other damage, they shall be discarded.
D. Welding Procedures D 100 General Add
FCAW process shall be thoroughly controlled at all times by Contractor to avoid any excessive scatters in the mechanical properties (and specially impact properties) of weld deposits. In that view, mechanical test results of qualification test welds shall show sufficient safety margins against requirements of this specification. The Company reserves the right to reject such a process when its reliability is not satisfactory.
Only Gas Tungsten Arc Welding process (GTAW) shall be used for pipe diameters less than 2" 3/8 (60 mm).
Only basic coated low hydrogen electrodes shall be used for all fillet welds.
Welding processes for anode connecting welds or any other welds to electrically connect attachments shall have prior approval of Company.
A procedure for welding parameters recording and heat input calculation shall be established and shall apply during both qualification and production.
The heat-input shall be calculated as the average of each pass for root, hot pass and cap and the average of all passes for fill provided heat input variations do not exceed ± 5%. If this is not the case, the weld circumference shall be divided so that heat input variations do not exceed ± 5% in each angular sector. Heat input calculation methodology shall be submitted to Company approval but shall at least be in accordance with the following:
• For non waveform controlled welding:
𝐸 (𝐽/𝑚𝑚) =60 ∗ 𝑈 (𝑉). 𝐼(𝐴)𝑣 (𝑚𝑚/𝑚𝑖𝑛)
For wave form controlled welding, Appendix H of ASME BPVC Section IX (true energy) shall be used. The program shall be printed-out and be part of qualification process. Any change on this program shall require re-qualification welding procedure.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 33 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Electrode stick-out shall be within 10% of the qualified one or maximum 2 mm.
During the qualification and production, the welding equipment shall be equipped with measuring device with high frequency sampling capable of displaying instantaneous welding energy or power. The sampling rate shall be sufficiently high to measure the welding energy or power following the waveform.
Welding equipment used for both qualification and production shall be calibrated as per EN 50504 and certificate of calibration shall be valid within a year and will not be expired during the welding production period.
A procedure for welding equipments calibration shall be established and shall apply during both qualification and production.
D 200 Previously qualified welding procedures Modify to read
Welding procedures qualified for previous jobs shall not be acceptable.
D 500 Welding procedure specification Add
The WPS for both the main welding procedures and weld repair procedures shall be submitted to Company one month minimum before the start of qualification tests. The WPS shall be accompanied by a summary table showing: process, consumables, direction of welding, type of weld, WPS n°, test weld wall thickness and scope of qualification. The welding procedure qualification tests shall not be undertaken until the Inspector has given his approval of the principle on the said WPS.
D 700 Contents of pWPS The pWPS, beyond the information given in Table C-1 and D702, shall also include:
• Time lapse between end of root pass and start of hot pass, and end of hot pass and start of 3rd pass
• Electrode stick-out length (if applicable).
D 800 Essential variables for welding procedures Modify to read
Table C-2 Essential variables for welding of pipeline girth welds and component longitudinal welds
Variable Changes requiring re-qualification
4 Base materials
Chemical composition d Any increase in Pcm, CE or C content of more than 0.02% for C-Mn and low alloy steel.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 34 of 110
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The information contained in this document does not substitute to the applicable laws and regulations.
5 Material thickness and diameter
Nominal thickness (t = nominal thickness of test joint.)
a Any change in pipe wall thickness beyond ± 25% against that used at qualification test.
Nominal OD of pipe b Any change in pipe diameter from one to another of the following ranges:
• OD < 100 mm • 100 ≤ OD ≤ 300 mm • 300 < OD ≤ 610 mm • OD ≤ 610 mm.
12 Welding techniques
Angle of pipe axis to the horizontal
a A change of more than ± 15% from the position welded. The 6G position shall not qualify for the 2G and/or 5G position.
14 Interpass temperature
Maximum and minimum interpass temperature
a Any increase above 30°C of the interpass and preheat temperatures qualified. Any increase for CRAs. Any reduction below the preheat temperature. Any increase of inter-pass temperature over 250°C for carbon steels shall have been previously qualified.
15 Heat input
Heat input range for each pass a For C-Mn and low alloy steels in non-sour service: Any change exceeding ± 5%.
b Any HI value lower or higher than the LHI or HHI qualified, respectively.
c For CRAs: Any change exceeding ± 5%.
Add
Dissimilar material joint
Identical welding procedures qualified on pipes from different sources will also qualify joints between pipes from the two sources (i.e. A/A + B/B do qualify A/B).
Table C-2 Essential variables for welding of pipeline girth welds and component longitudinal welds
Variable Changes requiring re-qualification
3 Welding equipment
Distance between wires d Any change in distance between wires or welding bugs if weld temperature does not drop below 250°C before the subsequent pass.
7 Alignment and tack welding
High-low f Any internal high-low exceeding 2.0 mm.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 35 of 110
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The information contained in this document does not substitute to the applicable laws and regulations.
9 Shielding, backing and plasma gases
Pre-gas and Post-gas e For CRAs: Any change in pre-gas and post-gas duration.
Backing gas flow f For CRAs: Any decrease of passes before backing gas flow is stopped and any increase of oxygen content in the effluent backing gas.
12 Welding techniques
Pass distribution k Any change in pass distribution in the weld.
Number of passes l For manual and semi-automatic welding, any change of more than ± 25% (rounding to highest integer number is not permitted) in the number of passes obtained at procedure qualification test, for manual and semi-automatic welding.
m For automatic welding, any change in the number of passes for a same WT. The number of welding passes may vary in production (-/+ one bead) in accordance with the pipe WT tolerances.
22 Impact test
Impact test requirements a Any change in impact test requirements (notch location in weld or test temperature). However, for a stated energy absorption requirement at impact test, a lower test temperature qualifies for a higher test temperature.
23 Pipe move-up
Barge move-up / Pipe move-up a Any pipe/barge move-up at an earlier stage.
E. Qualification of Welding Procedures E 100 General Modify to read
Test joints
103 The test joints shall be made between full pipe lengths. The use of less than full pipe lengths requires the prior agreement of Company. Anyway, the minimum length of each pipe to be used shall be as following:
• On-line barge welding: 3 meters
• Stalks, yard ant tie-in welding: 1.5 meters
• Manual or semi-automatic welding: 300 mm, but a sufficient number of internal strong backs shall be fully fillet welded on pipe to give realistic restraint during welding.
Add
An ECA according to appendix A of DNV-OS-F101 shall be performed for all welds with total nominal longitudinal strain ≥ 0.4%, all welds in sour service, and all welds classified as fatigue sensitive “FS1”.
Company shall give final acceptance and approval of all welding processes, systems and procedures.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 36 of 110
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A procedure for welding parameters recording and heat input calculation shall be established and shall apply during both qualification and production.
Qualification welding
Basic coated low hydrogen electrodes with a minimum of two weld passes shall be used for all fillet welds.
Roll welding and position welding shall be qualified separately.
For the qualification of a position welding, the following shall apply:
• Horizontal pipes/fittings shall be used to qualify for welds between pipes/fittings within 20° of the horizontal (5G position)
• Vertical pipes/fittings shall be used to qualify for welds between pipes/fittings within 20° of the vertical (2G position)
• Pipes/fittings at 45° to the horizontal shall be used to qualify for welds between pipes/fittings at 20° to 70° to the horizontal (6G position).
Except for duplex stainless steel pipelines (where 6G position shall also require a qualification procedure), 2G + 5G qualifies for 6G. However, the 6G position shall not qualify for the 2G and/or 5G position.
For pipe diameters less than 150 mm and for all welds to valves, flanges or fittings including fillet welds, the complete weld shall be vertical-up.
A minimum preheat of 100°C (-0/+30°C) shall apply to the welding of fittings, repair welds, tie-ins and fillet welds. The measuring control shall be carried at 50 mm distance from bevel ends.
The temperature of the pipe/component shall be measured and recorded before cap welding during MPQT.
Grinding of weld passes between runs shall not be of more extent than that expected on production.
For on-line barge welding, procedure approval test welds shall be made on the pipelay barge. Each pass shall be deposited at the welding station intended to be the normal location for it in production welding. However, this requirement may be waived and qualification tests may be carried out under simulated site conditions if the same equipment are used and if the specified welding procedure is fully reproduced and representative of site work (removal of line-up clamp, time lapse between passes, pipe movement, etc.) to the satisfaction of Company. This shall be clarified by Contractor and agreed with Company at the bid stage.
For stalks, yard and tie-in welding, procedure approval test welds shall be made on site (spoolbase, yard...). Each pass shall be deposited at the welding station intended to be the normal location for it in production welding. This requirement may be waived and qualification tests may be carried out under simulated site conditions if the same equipments are used and if the specified welding procedure is fully reproduced and representative of site work to the satisfaction of Company. However in that case, a production test will have to be performed on site when production starts. Tests required for this production tests are the same than those required for original WPQT. This shall be clarified by Contractor and agreed with Company at the bid stage.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 37 of 110
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The information contained in this document does not substitute to the applicable laws and regulations.
Under H2S (sour) service, SSC tests shall be carried out on qualification tests welds of main welds and repair welds, according to the requirements listed in section F. The SSC test is only required for C-Mn steels and low alloy steels.
Pipeline girth welds
In each case where a semi-automatic and/or automatic welding process or system is approved for use, a manual welding procedure shall be qualified as back up. This requirement may be waived for automatic welding only when Contractor can give evidence of successful past experience and when so specially agreed with Company at the bid stage.
When grouping of wall thickness is agreed for qualifications, then the thicker pipe shall be used for the welding tests.
For any automatic process, the number of passes shall always be established by a welding test made on each different wall thickness.
The number of and position of weld beads shall be chosen to give the completed weld a substantially uniform cross-section. No two welds beads shall start at the same point, unless the area is addressed clean and sound before the second bead is started.
Alignment of seams may be accepted on a case by case basis but shall never exceed two joints.
Single pass welds or internal root sealing welds shall be minimized. This does not apply to an automatic back pass applied internally that is an integral part of the butt weld procedure.
For all tie-ins (closing welds) and all welds where external line-up clamps are used, vertical-up welding shall be used for the root runs.
When manual welding is to be used, a minimum of one complete test joint is to be made for each Welding Procedure. For semi-automatic or automatic welding equipment, a minimum of three consecutive complete test joints shall to be made.
Extreme carbon steel material welding conditions, such as the following ones, which may occur during production welding, shall require qualification tests:
• For any position/location around the weld, when the heat input variation exceeds +/-5% in between minimum and maximum, then the minimum and the maximum max heat input shall be individually qualified
• Interpass temperature beyond 250°C up to 280°C
• Barge move-up/pipe move-up after root pass
• When copper shoes are used, Contractor shall perform a qualification before production welding. That qualification test shall demonstrate there is no detrimental effects in the root face due to copper pick up and/or copper contamination.
For the clad/lined carbon steel and duplex stainless steel pipelines, disregarding the welding process or combination applied, a minimum of three consecutive complete test joints shall to be made.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 38 of 110
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The information contained in this document does not substitute to the applicable laws and regulations.
E 200 Repair welding procedures Modify to read
202 Unless otherwise agreed with Company, the preheat for repair welds shall be 15°C greater than that used at qualification tests with a minimum preheat value of 100°C, and shall be applied uniformly around the circumferential weld.
Add
The Contractor shall submit to Inspector’s approval full details of the proposed repair procedures to be used. This shall include:
• The method of removing defects
• The preparation and inspection of the area to be repaired
• The welding procedure.
E 300 Qualification of girth butt welds and component longitudinal welds welding procedures Modify to read
304 For pipelines girth weld exposed to total longitudinal strain ≥ 0.4%, it should be required to perform testing to determine the properties of weld metal in the strained and aged condition after deformation cycles and also elevated temperature. The qualification of welding procedures in these cases shall be performed as per the requirements stated in the additional section 2 of this specification.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 39 of 110
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Table C-3 Qualification of welding procedures for girth butt welds including component longitudinal welds
Test joint Minimum number of each test specified
Wall thickness
(mm)
D (mm)
Transverse weld
Tensile 1)
Transverse all-weld Tensile
All-weld tensile 2) Root bend Face bend Side bend
Charpy V-notch
sets 3) 4) 5) 6)
Macro and hardness
8)
Other tests
Fracture toughness
≤ 20 ≤ 300 > 300
2 4
2 2
2 2
2 4
2 4
0 0
8 8
4 4
9)
9)
10)
10)
> 20 ≤ 300 > 300
2 4
2 2
2 2
0 0
0 0
4 8
10 7) 10 7)
4 4
9)
9)
10)
10)
Notes: 1) Tensile tests transverse to weld are not required for pipe with D < 114 mm. 2) All weld tensile tests are not required for D ≤ 200 mm and not if transverse all-weld tests are
performed.
Alternative testing procedure for all weld tensile tests (for example based on Digital Image Correlation) can be agreed on a case by case basis. 3) Each Charpy V-notch set consists of 3 specimens. 4) The notch shall be located in the weld metal (2 sets), the fusion line (FL) sampling 50% of HAZ (2
sets), FL+2 mm (2 sets) and FL+5 mm (2 sets), see Appendix B, Figure 3 through Figure 5. 5) For double sided welds on C-Mn and low alloy steels, four additional sets of Charpy V-notch test
specimens shall be sampled from the weld metal, FL (sampling 50% of HAZ), FL+2 mm and FL+5 mm in the root area, see Appendix B Figure 5 of the DNV-OS-F101.
6) For the qualification of welding in the 2G (J-lay) position, the sets of Charpy V-notch from the FL and FL+2 mm shall be sampled from the both HAZs of the weld (i.e. on both sides of the weld metal).
7) When the wall thickness exceeds 20 mm for single sided welds, two additional sets of Charpy V-notch test specimens shall be sampled from the weld metal root and FL in the root area.
8) When using longitudinally welded pipes, one macro and hardness shall include a intersection between a longitudinal and the girth weld.
9) Requirements for corrosion tests, chemical analysis, ferrite content test and microstructure examination are specified in Subsection F.
10) Fracture toughness tests shall be performed only when an ECA is performed or if required in PPS.
For clad and lined pipe girth welds nick break tests (testing method as per API STD 1104) shall also be performed (same locations than bend tests).
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 40 of 110
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Qualification of repair welding procedure
305 Qualification of repair welding procedures shall be performed with the welding process mentioned in the table below:
Welding process for repair procedures
Root Fill Cap
Non fatigue sensitive line
GTAW GMAW GMAW
SMAW - basic coated rods (cellulosic coated rods are not permitted for tie-in and repairs).
PGMAW PGMAW
GS-FCAW (subject to Company approval).
GS-FCAW (subject to Company approval).
Fatigue sensitive line
(“FS1”) GTAW
GMAW GMAW
PGMAW PGMAW
SMAW - basic coated rods (cellulosic coated rods are not permitted for tie-in and repairs).
SMAW - basic coated rods (cellulosic coated rods are not permitted for tie-in and repairs).
GS-FCAW (subject to Company approval).
GS-FCAW (subject to Company approval).
Repeated repairs
309 For the repeated repairs, only partial thickness and single pass cap repeated repairs on C-Mn and low alloy steels in non fatigue sensitive lines shall be permitted (see Table C-7 of this present specification). For these cases, a qualification procedure shall also be performed but the tests required shall be limited to: Charpy V-notch impact test, Transverse tensile test and Macro + hardness.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 41 of 110
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310 The qualification of the permitted repeated repairs (see Table C-7 of this specification) shall be as per the section E 309 above.
Table C-4 Qualification of repair welding procedures for girth butt welds including component longitudinal welds
Test joint Minimum number of each specified test
Type of repair Transverse weld Tensile
Transverse all-weld Tensile
All-weld tensile 1)
Root bend Face bend Side Bend
1)
Charpy V-notch sets 2)
Macro and hardness 4) Other tests Fracture
toughness
Through thickness repair
1 4 3 3) 1 5) 6)
Partial thickness repair
1 4 3 3) 1 5) 6)
In-process root repair 4 1 5)
Single pass cap repair 7) 4 1 5)
Single pass root sealing repair
4 1 5)
Notes: 1) Full pipe thickness specimens. 2) Each Charpy V-notch set consists of 3 specimens. 3) Charpy specimens shall be located at 2 mm from pipe surface at weld cap. The sets shall be: one set
with the notch centered on the weld axis and one set on both sides of weld repair with the notch located at 2 mm from the fusion line.
4) The hardness survey for partial thickness, root and cap repairs shall be performed as indicated on the schema below:
5) Requirements for corrosion tests, chemical analysis, ferrite content test and microstructure
examination are specified in Subsection F. 6) Fracture toughness tests shall be performed only when an ECA is performed or if required in PPS. 7) A cap repair procedure can be qualified by a partial repair procedure.
Add
For semi-automatic and automatic welding, testing shall be made on one test weld only (out of the 3 test welds made).
When using copper shoes, Contractor shall perform a particular qualification test. That qualification shall consist of a welded test piece on project pipe with the project specific batch of
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 42 of 110
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welded consumables. No results from past experience shall be accepted and the tests shall be done for each particular project. Copper or ceramic shoes shall not be used in H2S service.
The qualification for the utilisation of copper shoes shall be performed as follows:
• The performance of welding shall be based on the parameters of the relevant project preliminary Weld Procedure Specification (pWPS).
• The root face of the weld joint bevel shall be machined at the minimum height stated on the pWPS.
• The welding current shall be set 10 amps above the maximum setting to be used during final production.
• After welding, areas exhibiting the highest copper contamination on the surface of the root shall be cut out from the weld.
• Company reserves the right to select three areas of the weld for sampling. The following testing shall be carried out on this samples:
- Macro examination on cross sections
- Root and side bends tests
- Vickers HV5 hardness measurements will be taken at 1 mm from the ID pipe surface with a maximum permitted value of 300 HV5
- Chemical analysis will be performed by EDX on a 1.5 mm x 1.5 mm zone within the weld root but not including the penetration beyond the pipe surface. Copper content within the root pass shall be less than 0.5% (with reference to maximum permitted in AWS A5.18 for the classification of weld consumable used)
- Micro analysis of the test zone shall be carried out by Scanning Electron Microscope (SEM) to determine the weld is free from any cracking due to copper contamination
Qualification of repair welding procedure
Qualification of weld repair procedures shall be carried out at the same time as the qualification tests of main procedures. Repair procedure qualification tests shall include the following, unless a different repair scheme is proposed by Contractor and approved by Company:
• Execution of a through thickness repair centered on the initial weld axis
• Execution of a partial thickness repair with groove centered on the initial weld Fusion Line
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 43 of 110
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• Execution of a simulated repair of an undercut by grinding and depositing a single bead or execution of a cover pass (i.e. the whole of the weld cap is locally replaced), at Contractor's option
or
• Execution of a simulated repair at root by internal welding using a single pass, when internal repairs are proposed by Contractor;
The method used for defect removal shall be considered as an essential variable for weld repair qualification. In particular, defect removal by grinding does not qualify defect removal by arc gouging before weld repair.
E 500 Qualification of procedures for Pin Brazing and Aluminothermic welding of anode leads Modify to read
Qualification of procedures
503 Five consecutive test welds shall be made. They shall be fully visually examined for weld profile and undercuts. Then, one welded connection shall be subject to the tests described in the Table C-6. Where doubler plates are used, the fillet welds shall be test as per the relevant section for fillet welds App. C E 600.
Table C-6 Qualification of Pin Brazing and Aluminothermic welding procedures
Test joint Minimum number of each specified test
Thickness of base material Micro Examination1) - Copper penetration Hardness2)
All 1 1
Notes: 1) The micro-examination shall give evidence of a good bonding and shall also detail the metallurgical constituents
which are present in the HAZ. Any presence of micro-cracks shall not be acceptable. 2) The Vickers micro-hardness shall be carried out under a 5 kg load and shall comprise a line of indentations
made in pipe material and located in HAZ within 0.6 mm maximum from the Fusion Line.
Add
For FS1 lines, it shall be demonstrated through fatigue testing that the pin brazing or the doubler plate welding operation has no detrimental effect on fatigue resistance: the fatigue performance of the pipe shall corresponds at least to a C curve.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 44 of 110
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E 600 Qualification of welding procedures for temporary and permanent attachments and branch welding fittings to linepipe Modify to read
Fillet welds in doubler sleeves and anode pads
605 Fillet welds shall be specifically qualified. A fillet test weld shall be made by the same procedure that will be used in production.
For duplex stainless steel, welds junction for anodes shall be carried out by SMAW or GTAW with a minimum of two weld passes. 606 All fillet welds shall be fully visually and Magnetic Particle Inspected or Dye Penetrant Inspected (when using non-magnetic materials). At this stage, any form of crack or suspected crack shall not be acceptable. Undercut exceeding 0.5 mm in depth shall also be unacceptable and shall be blended out by light grinding.
Each test weld shall also be subject to two macro-examinations and one Vickers micro-hardness test as follows:
• The macro-examinations shall be carried out using a lens of X5 magnification. The weld shall show a profile, pass distribution and weld size as stated in the WPS.
• The Vickers micro-hardness survey shall be carried out according to ASTM E384 and as shown on the following sketch, using a 5 kg load:
The hardness values shall be in accordance with the requirements of the section App. C - F312 of this specification.
Branch welding fittings
607 Fillet welds for branch connections shall be specifically qualified. A fillet test weld shall be made by the same procedure that will be used in production.
608 The qualification tests shall be made as required in the section App. C - E 606 of this specification.
609 Charpy V-notch impact testing is not required for fillet welds qualification.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 45 of 110
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E 700 Qualification of welding procedures for structural components Modify to read
701 This paragraph is not applicable.
F. Examination and Testing for Welding Procedure Qualification F 100 General Modify to read
Visual examination and non-destructive testing
103 After visually inspection and NDT, if a test piece indicates the presence of flaws or other defects exceeding the levels permitted in this specification, the reason of these defects shall be investigated and explained, to the satisfaction of Inspector, before re-welding a test weld to the same (or any other) procedure.
105 Test specimens for girth butt welds on D ≤ 300 mm and D > 300 mm shall be taken from the positions shown in the modified Figure 2 below:
Figure 2 - Welding procedure qualification test - sampling of test specimens for girth butt welds
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 46 of 110
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Note 1: For wall thickness > 20 mm, each couple of Root and Face bend test shall be replaced by two Side bend test. Note 2: Fracture toughness specimens locations are indicated in the dedicated paragraph in the section F. Note 3: When performed, transverse all-weld tensile test specimens shall be sampled on the same locations of all-weld tensile test. Note 4: For qualification of welding in the PA (1G rotated) and PC (2G) the sampling positions are optional.
Add
All welding procedure qualification tests shall be conducted in the presence of the Inspector.
The Inspector shall witness all non-destructive examinations and destructive testings and shall review and approve all related results. All mechanical testings shall be carried out by a certified testing facility subject to prior approval of the Company.
The Contractor shall notify the Company of the date and location of the welding procedure qualification tests at least seven (7) working days before the start of the tests.
The test specimen and the remaining part of tested pipes shall be stored by Manufacturer till the final release of goods. Those pieces may be used for any further investigation or counter tests as addressed in that present specification.
Visual examination and non-destructive testing
Test welds for qualification of a welding procedure, repair welding procedure or repeated repair welding procedure shall satisfactorily pass the visual examination and NDT before sampling the mechanical test specimens. Lacks of penetration at root, incomplete interpenetration between
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 47 of 110
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beads at root area, lacks of root fusion and surface copper contamination shall not be accepted at this stage.
Destructive testing
Test specimens shall be cut mechanically (sawing, milling). Flame cutting shall only be permitted to facilitate machining, and only if cuts are spaced at least 50 mm from any test specimen.
The specimens locations for the qualification of repair welding procedures for girth butt welds shall be as per the Figure 3 hereafter.
Figure 3 - Repair welding procedure qualification test - sampling of test specimens for girth butt welds
Partial thickness repair:
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 48 of 110
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In-process root repair, single pass cap repair and single pass root sealing repair:
Through thickness repair:
Retesting
For the duplex stainless steel, should any specimen/set fail then, retest shall be conducted by using twice the quantity of specimen/set originally required. If the result is acceptable on all test pieces from retesting, the relevant test weld is accepted. Conversely if any additional test result fails, the test weld is considered as not acceptable.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 49 of 110
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F 200 Visual examination and non-destructive testing requirements Add
For duplex stainless steel, the ferrite content shall be measured on all qualification tests welds. Measurements shall be taken on both, weld metal caps and HAZ. Each measurement shall be the average of three measurements and shall be made using the magnetic induction method. Portable device for measurement (e.g. FISHER Feritscope MP30E) shall be approved by Company. The ferrite range shall be within 35 to 65%. The measurement shall be performed as follows:
• 12 locations around the pipe at 30° (one at 12 O’Clock position)
• For each location, 3 measurements shall be taken on HAZ area and 3 measurements shall be taken on weld metal area
• For each area (weld metal or HAZ) on each location, the average of 3 measurements shall be done.
F 300 Testing of butt welds Modify to read
301 All testing shall be performed in accordance with the amendments listed in this specification or in accordance with the appendix B (in absence of amendments to the subject). All-weld tensile testing
303 An all-weld metal tensile test (with specimen of max. practical size) is required from each procedure test in accordance with ASTM A370. Yield and Tensile Strength shall be as specified in PPS. To the pipes with an outside diameter OD < 12.75”, the all-weld tensile test can be replaced by a transverse all-weld test.
Transverse all-weld tensile test
304 The testing laboratory shall have the relevant sensors to precisely measure the elongation in the weld metal area. The overmatch shall be at minimum 80 MPa with respect to the parent material SMYS. This requirement shall be revised in the PPS when strain based design shall be considered (reeling …)
305 The requirements of the above paragraph F 304 shall also apply. Charpy V-notch impact test
307 The test temperature shall be stated in the PPS. However, in no way the test temperature shall be above 0°C. For duplex stainless steel, the test shall be carried out in a temperature 20°C below the minimum design temperature and in no case above -20°C.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 50 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
The absorbed energy requirements for wall thicknesses up to and including 25 mm shall be those stated in the requirements below. For higher wall thicknesses, Charpy requirements shall be stated in the PPS.
For C-Mn steel, the impact test values shall comply with the table 7-5 present in the section 7 of DNV-OS-F101.
In case of low alloy steel, the values shall be as listed hereafter:
Low alloy steel - Impact V-notch Test values
Steel grade Minimum Average
(Joules) Minimum single
(Joules) Minimum area (*Individual)
X 42 30 24 85% (*75%)
X 46 32 26 85% (*75%)
X 52 36 30 85% (*75%)
X 56 39 32 85% (*75%)
X 60 42 35 85% (*75%)
X 65 45 38 85% (*75%)
X70 56 50 85% (*75%)
Note: Lateral expansion of broken specimen shall be recorded.
The values required for CRA pipelines are:
CRAs - Impact V-notch Test values
Alloy Minimum average
(Joules) Minimum single
(Joules)
LC65-22CR DX 40 50
LC65-25CR SDX 40 50
13Cr-2Mo and 13Cr-2.5Mo Not applicable Not applicable
Note: Lateral expansion of broken specimen shall be recorded. For DX and SDX, the impact tests shall be carried out either at the temperature stated below (20°C below the minimum design and in no case less than -20°C).
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 51 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
When sub-size specimens are deemed necessary, the requirements for absorbed energy shall be those for full size specimens multiplied by the corresponding factors shown in the table beneath:
Multiplying factors for sub-size specimens
10 x 10 mm 1
10 x 7.5 mm 5/6
10 x 6.7 mm 7/9
10 x 5 mm 5/7
If the stated impact requirements are not satisfied for one set, the Company may request three further specimens to be tested. The mean value of all six tests shall be at least equal to the specified minimum average value. All three re-test specimens shall meet the specified minimum individual value.
Hardness Testing
312 For each type of service according to the specification GS EP COR 170, the maximum hardness values in the HAZ and weld metal of C-Mn and low alloy steel pipelines shall not exceed:
Low alloy steel and C-Mn - Hardness Test values
Zone Sweet Sour level 1 Sour level 2 Sour level 3
Root + Hot pass 300 HV5 300 HV5 280 HV5 250 HV5
Fill 300 HV5 300 HV5 280 HV5 250 HV5
Cap 300 HV5 300 HV5 280 HV5 (300 HV5*)
250 HV5 (280 HV5*)
* Acceptable values if no sour environment on cap side.
For clad or lined materials, the hardness values shall be:
Clad and Lined materials - Hardness Test values
Material Base metal HAZ Weld metal
C-Mn 250 HV5 300 HV5 300 HV5
Austenitic Stainless Steel 300 HV5 300 HV5 300 HV5
22% duplex steel 290 HV5
300 HV5 for C-Mn HAZ 330 HV5 for duplex HAZ
330 HV5
25% superduplex steel 320 HV5
300 HV5 for C-Mn HAZ 350 HV5 for super duplex HAZ
350 HV5
Ni Alloy (625 OR 825) 345 HV5
300 HV5 for C-Mn HAZ 345 HV5 for CRA HAZ
345 HV5
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 52 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
For duplex stainless steel the maximum acceptable values in the weld metal and heat affected zone are:
CRAs - Hardness Test values
Alloy Hardness (WM and HAZ)
LC65-22Cr DX 330 HV5
LC65-25Cr SDX 350 HV5
In all cases, photomicrographs showing the indent locations shall be included with the Welding Procedure Qualification Record (WPQR).
Corrosion testing
315 Under sour service, sulphide stress cracking testing (SSC) is required for C-Mn steel and low alloy steels. The SSC test shall be performed as per the requirements of the dedicated additional section 3 of this specification, Specification for Sulfide Stress Cracking test on welds (SSC tests).
Acceptance criteria is also described in the dedicated section.
316 The pitting corrosion test shall be performed for the materials listed hereafter, even if they are used as a CRA layer (clad/lined). The test specimen shall be machined perpendicular to the weld axis, with dimensions of full wall thickness by 10 mm along the weld and 50 mm across the weld. The test shall expose the external and internal surface and a cross-section surface including the weld zone in full wall thickness. All surfaces, not subjected to the test, shall be electrolytically polished or be surface finished with 600-grit abrasive paper. All the surfaces shall be degreased in acetone bath, cleaned by ultrasound, pickled (17% HNO3 + 4% HF, 60°C, 5 minutes) and rinsed in ethanol, dried and weighed:
• On nickel based alloys (UNS N08825 and UNS N06625) materials, corrosion testing according to ASTM G28 method A shall be performed. Test duration shall be 120 hours. The maximum allowable corrosion rate shall be 50 mm/y. No localisation of corrosion in HAZ and weld metal shall be evidenced and the corrosion shall be uniform.
• On duplex stainless steel (LC65-22Cr and LC65-25Cr) materials, corrosion testing according to ASTM G48 method A shall be performed. Test temperature and test duration shall be as listed above:
Duplex stainless steel - Pitting corrosion test conditions
Alloy Temperature Exposure time
Duplex- LC65-22Cr 25°C ± 1°C1) 72 Hours
Superduplex - LC65-25Cr 50°C ± 1°C2) 72 Hours 1) Temperature to be reduced to 22°C when testing the weld 2) Temperature to be reduced to 40°C when testing the weld
The maximum allowable weight loss is 4.0 g/m2 and the specimen shall not have evidence of pitting under visual examination with a magnification of x20.
• For austenitic stainless steels (UNS 31603 and UNS N031703), the ASTM G48 method A test shall be replaced by ASTM A262 practice E test. Test temperature shall be 50°C and
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 53 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
test duration shall be 24 hours. No localisation of corrosion in HAZ and weld metal shall be evidenced and corrosion shall be uniform.
Microstructure examination
317 For duplex stainless steel, CRA and clad/lined materials, the microstructure of the weld shall be free from carbides, nitrides and intermetallic phases, especially sigma phase (total maximum content of 0.05%).
For clad and lined pipelines, where duplex or super-duplex filler material is used, metallographic investigations shall be performed as follows:
• Ferrite content shall be determined as per ASTM E562. Ferrite content shall be 40-55% in the base metal and 35-65% in HAZ and weld metal.
• Ferrite content measurements shall be performed on the following locations on specimens machined at the same location than specimens for macro-hardness:
Note: ID and OD measurements shall be as close as practical from ID and OD surfaces.
• Austenite spacing shall be determined as per DNV-RP-F112 Appendix B. Austenite spacing shall be maximum 30 µm. Measurements shall be performed at the same location than ferrite content measurements.
The ferrite content shall be measured in duplex stainless steel, on both tests welds and metallographic specimens. Measurements onto metallographic specimens shall be, in the wall thickness, located as the hardness surveys and shall be in accordance with ASTM E562, using the point count technique. A minimum of two measures shall be carried out on each measurement points. The measurements shall include the weld metal and the heat affected zone and the ferrite range shall be within 35 to 65%.
The ferrite content of austenitic stainless steel weld deposit shall be within the range 5 to 13%.
Fracture toughness testing
319 The fracture toughness tests shall be performed always when required in the PPS. The PPS shall also include the test temperature, the test environment and the number of welding procedures where the test is required. The fracture toughness test shall be conducted in accordance with BS 7448.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 54 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
The number and the location of tests specimens for a welding procedure shall be chosen as per the following table:
Specimens locations - Fracture toughness test
Welding position Sampling positions Number of samples
5G
12 o’clock. 3 Weld Metal (weld centreline).* 3 Fusion line.*
3 o’clock (or 9 o’clock). 3 Weld Metal (weld centreline).* 3 Fusion line.*
6 o’clock. 3 Weld Metal (weld centreline).* 3 Fusion line.*
TOTAL 18 specimens
2G
In the LHI position according to WPQR.
3 Weld Metal (weld centreline).* 3 Fusion line.*
In the HHI position according to WPQR.
3 Weld Metal (weld centreline).* 3 Fusion line.*
TOTAL 12 specimens
* For statistical purposes and due to possible test results variations, three tests shall be performed in the same conditions (same clock position, same specimen direction and same notch location).
Pop-ins shall be taken as critical events, unless they can be attributed to spurious occurrences, such as plate laminations.
An all-weld tensile test (when applicable) to ASTM A370 is required on each weld from which CTOD tests are taken, at a location as close as possible to the CTOD tests.
Tests specimens geometries shall be chosen according to the following picture and table:
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 55 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
CTOD specimens geometries - Sweet environment
Tests Non fatigue sensitive Fatigue sensitive
%4.0≤pε %5.2%4.0 ≤< pε %4.0≤pε %5.2%4.0 ≤< pε
CTOD test specimens
SENB (General case)
NQ B*2B (WM) NQ B*B (FL)
SENB NQ B*2B
(WM) NQ B*B (FL) (BS 7448)
SENB (General case)
NQ B*2B (WM) NQ B*B (FL)
SENT for reel-lay NQ (WM and FL) (DNV-RP-F108)
SENT for reel-lay NQ (WM and FL) (DNV-RP-F108)
Particular tests according to DNV-RP-F108
Segment specimens
for reel-lay (DNV-RP-F108)
Segment specimens
for reel-lay (DNV-RP-F108)
CTOD specimens geometries - SOUR ENVIRONMENT
Tests Non fatigue sensitive Fatigue sensitive
%4.0≤pε %5.2%4.0 ≤< pε %4.0≤pε
CTOD test specimens SENB
NQ B*2B (WM)
NQ B*B (FL) (BS 7448)
SENB (General case) NQ B*2B (WM)
NQ B*B (FL) (BS 7448)
SENB NQ B*2B (WM)
NQ B*B (FL) (BS 7448) SENT for reel-lay
NQ (WM and FL) (DNV-RP-F108)
Particular tests according to DNV-RP-F108
Segment specimens
(DNV-RP-F108)
The a/W ratio shall be between 0.45 and 0.55.
The following values shall be determined and reported:
• δ0.2BL, δc, δu, δm, J0.2BL, Jc, Ju and Jm values
• The CTOD-R and/or J-R curve(s) when BS 7910 level 3B assessment are performed. In that case the number of required test specimens shall be adjusted accordingly.
CTOD values can be determined from J values. J values shall be calculated from load versus clip gauge values.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 56 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
320 The fracture toughness value shall be chosen according to BS 7910 requirements provided all requirements of BS 7910 annex K.2.3 are fulfilled:
Equivalent fracture toughness value to the minimum of three results
Number of fracture toughness test results Equivalent fracture toughness value
3 to 5 Lowest
6 to 10 Second lowest
11 to 15 Third lowest
The following table gives guidelines of the CTOD values in air that shall be considered in ECA and targeted during production (to be confirmed in the PPS):
Guideline of CTOD values
Air environment
CTOD value recommendations in air (mm) (SENB specimen, a/w= 0.45-0.55)
T ≥ -10°C -10°C ≥ T ≥ -30°C
WM FL WM FL
Mainline procedure Mechanized welding
0.60 mm 0.60 mm 0.50 mm 0.50 mm
Double joint SAW welding 0.30 mm 0.60 mm 0.20 mm 0.50 mm
Manual welding and repairs 0.25 mm 0.25 mm 0.15 mm 0.15 mm
Everytime a CTOD value > 0.15 mm (or 0.25 mm for T ≥ -10°C) is required, any repair or manual welding operation shall be avoided or alternatively no defects shall be accepted in the welded or repaired area.
Any CTOD test in sour environment shall be performed for information only. The CTOD value to consider in sour environment for design shall be specified in the PPS depending on the project particular environment.
Add
Transverse weld tensile testing
For clad/lined pipes only, when the CRA thickness is considered for weld strength, full section tensile tests (which includes both C-Mn backing steel and cladding) shall be performed after coating thermal cycle simulation (1 hour at 250°C). Tensile tests shall be performed at the maximum design temperature. Tensile strengths shall be:
𝑆𝑀𝑇𝑆𝑏𝑠+𝑐𝑙 ≥𝑆𝑀𝑇𝑆𝑏𝑠. 𝑡𝑠 + 𝑆𝑀𝑇𝑆𝑐𝑙 . 𝑡𝑐𝑙
𝑡𝑏𝑠 + 𝑡𝑐𝑙
Where:
SMTSbs = SMTS of the C-Mn backing steel
SMTScl = SMTS of the cladding material
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 57 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
tbs = wall thickness of the C-Mn backing steel without including the thickness of the pure Fe/Ni buffer layer
tcl = wall thickness of the cladding material.
For high temperature applications, stress de-rating of CRA materials shall be considered as per requirements of Section 5 - C 304 of the standard DNV-OS-F101 and of the following table:
Stress de-rating of CRA materials in high temperatures
Material type Temperature (°C)
-30 to 40 65 100 125 150 175 200
UNS S31603 170 157 145 137 131 125 121
UNS N08825 240 228 220 214 210 205 201
UNS N06625 275 262 253 247 242 237 233
Macro section
The macro-sections shall be ground and polished (diamond paste finished) and etched to show up the Weld Metal and Heat Affected Zone micro-structures.
For duplex stainless steel, four transverse macrographic examinations (magnification x 10 minimum) and four micrographic examinations (magnification x 100 minimum) shall be carried out.
Chemical analysis
Quantitative chemical analyse of the weld cross-section shall be made in the root zone and filler passes to verify the chemical elements as per the chemistry requirement of the applicable consumable specification.
For C-Mn and low alloy steels in sour service conditions, the following requirements shall also be applied:
• Nickel content shall not exceed 1.0%
• In case of failure of SSC tests (in WM or FL) then, a micro analysis of weld shall be carried out by “Electron Probe Micro Analysis (EPMA)” or equivalent equipment. The EPMA procedure shall be submitted to Company for review and approval. The fusion lines between weld and base metal, and between passes shall be particularly investigated
• The results shall not indicate a variation exceeding 30% for Mn and 20% for Si. Should the variation exceed the required maximum value, then this variation shall be considered as an unacceptable segregation
• Any other significant variation shall be investigated and demonstrated as not being a harmful segregation for the pipe service.
Full scale fatigue tests
The full scale fatigue test shall be performed always when required in the PPS or in accordance with the section Documentation of this specification. The PPS shall also include the test temperature, the test environment (tests in air are recommended) and the number of welding procedures where the test is required. In any case, full scale fatigue test duration shall not exceed 107 cycles.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 58 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
A set of full scale fatigue tests corresponds to:
Set of full scale fatigue test
Number of tests Test conditions
12 tests 3 stress levels, 4 tests per weld.
Strip fatigue tests (sour environment)
The objective of strip tests in sour environment is to confirm knockdown factors defined by Company at the bid stage. Tests results are for information only. The strip fatigue test shall be performed always when required in the PPS. The PPS shall also include the test temperature, the characteristics of the sour test environment (pH and H2S partial pressure) and the number of welding procedures where the test is required.
A set of full strip tests corresponds to:
Set of full strip tests
Number of tests Environment Test conditions
24 tests Air 3 stress levels, 4 tests per weld
Sour as per project specific conditions given in the PPS 3 stress levels, 4 tests per weld
Target curve for fatigue tests
The target curve for fatigue tests shall be determined as follow to qualify n tested welds to a DNV design curve, with a particular confidence level and a probability of survival of 97.5% (Schneider and Maddox, 2003):
∆𝜎3.𝑁𝑓 = 𝑎�1. 102𝑆𝐷. 10𝑋𝑆𝐷√𝑛
Where,
𝑎�1 is the constant of the design S-N curve
n is the number of tested welds (or number of samples)
SD is the standard deviation of log N of the S-N curve. SD is taken equal to 0.2.
X is the factor obtained from probability table assuming a normal distribution. X is taken equal to 2.33 to represent a 99% confidence level.
All tests results (single value) shall be above the target curve (Assessments of the results based on the comparison between the regression of experimental results and the target curve is not allowed).
Fatigue crack growth rate tests
The full scale fatigue test shall be performed always when required in the PPS or in accordance with the section Documentation of this specification. The PPS shall also include the test temperature, the test environment (and the number of welding procedures where the test is required. For FCGR tests, CT specimens as per ASTM E647 shall be used.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 59 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
The number and the location of tests specimens for a welding procedure shall be chosen as per the following table:
Specimens locations - FCGR test
Welding position Sampling positions Number of samples
5G
12 o’clock. 3 Weld Metal (weld centreline).* 3 Fusion line.*
3 o’clock (or 9 o’clock). 3 Weld Metal (weld centreline).* 3 Fusion line.*
6 o’clock. 3 Weld Metal (weld centreline).* 3 Fusion line.*
TOTAL 18 specimens
2G
In the LHI position according to WPQR.
3 Weld Metal (weld centreline).* 3 Fusion line.*
In the HHI position according to WPQR.
3 Weld Metal (weld centreline).* 3 Fusion line.*
TOTAL 12 specimens
* For statistical purposes and due to possible test results variations, three tests shall be performed in the same conditions (same clock position, same specimen direction and same notch location).
Any FCGR test in sour environment shall be performed for information only to check the multiplying factor specified by Company at the bid stage and allow updating the safety factors.
F 500 Testing of pin brazing and aluminothermic welds Modify to read
Copper penetration
503 The fusion line of the weld/brazing test specimen shall not be below the base material surface. Intergranular copper penetration of the base material shall not be present at any point 0.5 mm beyond from the fusion line.
Hardness
504 HV5 hardness shall be made on the test specimen to measure the hardness and the copper penetration.
G. Welding and PWHT Requirements G 200 Production welding, general requirements Modify to read
203 Contractor shall cut and bevel all damaged pipe ends when deemed necessary to the Inspector. When the cut is located at a distance of more than 25 mm from the original bevel, then the cut end shall be ultrasonically inspected for laminations over a zone extending 100 mm from the new field bevel (see Appendix D - C200). Otherwise, the new bevel shall be subject to
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 60 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
MPI or dye penetrant testing, as a minimum. The procedures for ultrasonic and magnetic particle/dye penetrant testing and acceptance criteria shall be in accordance with the appendix D.
207 In any event, prior to commencement of welding, sufficient heat shall be applied to remove all traces of moisture. The preheat temperature required by the qualified WPS shall be maintained throughout the entire welding of the joint. Welding below 20°C shall not be permitted.
208 When preheating is applied prior to welding, including tack welding, the minimum preheat temperature shall be maintained and measured over a distance of at least 50 mm either side of the joint. The preheat temperature to be applied during fabrication shall not be less than the qualified preheat temperature (i.e.: 0 / +30°C).
209 Tack welds shall be performed with the same weld procedure specification as the root run and by a welder qualified for that run. The minimum tack weld length is 50 mm and shall be welded vertical-up. Tack welds to be fused into the final weld shall be made in the weld groove only and the ends of the tack welds shall be ground to a feather edge to ensure an adequate fusion of the root pass. An examination by an adequate NDT method to ensure the absence of cracks shall also be performed.
221 The root gap for fillet welds shall be between 1.0 and 2.5 mm.
Add
Where pipes or fittings of unequal wall thickness are to be welded, the end preparation shown in ASME B31.4 Fig. 434.8.6 or ASME B31.8 Fig. 15 (where applicable) shall be used. Any taper shall not be steeper than 1:4.
Immediately prior to aligning pipe for welding, the bevelled ends of each joint of pipe for a minimum distance of 40 mm shall be thoroughly cleaned of paint, rust, adhesions, dirt and any other foreign matter by use of power-driven wire buffing wheels, disc sanders, or by other methods previously approved by Inspector for each case. Fusion faces shall be visually inspected for laminations after cleaning to a bright finish.
Contractor shall have available on site at all times a de-magnetising system for use when the pipe ends show magnetism unsuitable for welding.
Maximum misalignment or offset of surfaces shall not exceed:
Maximum offset of surfaces
Type of solicitation Permissible hi-lo*
Non fatigue sensitive line 2 mm
Fatigue sensitive F1 or F3 class according to DNV-RP-C203 2 mm
Fatigue sensitive E-class according to DNV-RP-C203 1 mm
Fatigue sensitive D-class and above according to DNV-RP-C203 To be mutually agreed at the bid stage.
* This maximum hi-lo shall include peaking effects for longitudinally welded pipes.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 61 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
For clad and lined pipes, misalignment or offset of surfaces at girth weld location shall not exceed 1 mm. Pipes ends tolerances shall be adjusted accordingly with considering the two following options:
Option 1 Option 2
Pipe ends ID tolerance: ± 0.5 mm Pipe ends ID tolerance: ± 1.0 mm And pipe sorting (at least pipe sorting into three groups identified by colour code in the pipemill).
Contractor shall provide wind breaks and welder's platforms.
Preheat or warm up shall be applied in a uniform manner using gas burner or electrical means except that hand held torch heating shall not be permitted other than where external line-up clamps are used. The method shall be subject to approval by the Inspector.
The temperature shall be measured using contact pyrometer or indicating crayons of the melting type. Colour changing type shall not be permitted.
During production, the temperature shall be checked before cap welding and shall be minimum the temperature measured and recorded during MPQT.
The interpass temperature shall not exceed the maximum interpasses temperature recorded during procedure qualification. Interpasses temperature shall be considered as 250°C maxi, unless higher interpasses temperature has been qualified and tested.
When vertical-down welding is used, the second run (hot pass) shall be deposited immediately after completion of the root run (stringer bead), and the time lapse shall not be greater than that used in the procedure qualification test, with a max. of 15 minutes.
No welds on fittings, tie-ins and repairs shall be allowed to cool below preheat temperature prior to their completion. This requirement also applies to pipe to pipe welds in offshore work.
For GMAW process, specific “tip” electrical connector shall be ceramic coated for the root and hot pass performance in order to avoid any arc strikes inside the narrow bevel.
No welds shall be left partially completed overnight.
All welds shall be marked with paint stick by the welders according to numbers assigned to them by Contractor at the time of their qualifications. Should any welder leaves the job, his number shall be voided and not duplicated on the project. No punch or steel stamping shall be permitted. Alternatively, a record of which welder works in which station or weld may be kept by the welding foreman and QC Inspector(s) of Contractor.
Prior to radiography of the circumferential weld, the Contractor shall paint the weld location number on the covering of the pipe adjacent to the weld at a point where it shall remain visible after field coating. These numbers shall be used by the surveyors to locate and record the welds and for the radiographers for identification of the welds. The numbers shall be applied with a spray can or a brush and water-proof paint of a contrasting colour to the outside pipe coating.
If the Inspector detects a weld being made outside the allowances of the qualified procedure or any weld which in his opinion is not satisfactory, the weld metal shall be removed and the joint re-welded. The Contractor shall guard against this eventuality by qualifying welding procedures at the extreme parameters (e.g. for mini. and max. heat input) that Contractor may consider using.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 62 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
G 300 Repair welding, general requirements Modify to read
301 The allowable repair and re-repairs are given in Table C-7. Repeated repairs, when permitted, are limited to one of a previously repaired area.
Table C-7 Types of weld repairs
Type of repair Type of material
C-Mn and low alloy steel 13 Cr MSS Clad/Lined CRA/Duplex
SS
Non
fatig
ue s
ensi
tive
line
Through thickness repair Permitted Not applicable Not permitted Not permitted
Partial thickness repair Permitted1) Not applicable Permitted1) Permitted1)
In-process root repair Permitted Not applicable Not permitted Not permitted
Single pass cap repair Permitted Not applicable Permitted Permitted
Single pass root sealing repair If agreed Not applicable If agreed If agreed
Through thickness repeated repair Not permitted Not applicable Not permitted Not permitted
Partial thickness repeated repair Permitted Not applicable Not permitted Not permitted
In-process root repeated repair Not permitted Not applicable Not permitted Not permitted
Single pass cap repeated repair Permitted Not applicable Permitted Not permitted
Single pass root sealing repeated repair Not permitted Not applicable Not permitted Not permitted
Fatig
ue s
ensi
tive
line
(FS1
)
Through thickness repair Not permitted Not applicable Not permitted Not permitted
Partial thickness repair Permitted1) Not applicable Permitted1) Permitted1)
In-process root repair Not permitted Not applicable Not permitted Not permitted
Single pass cap repair Permitted2) Not applicable Permitted2) Permitted2)
Single pass root sealing repair Not permitted Not applicable Not permitted Not permitted
Through thickness repeated repair Not permitted Not applicable Not permitted Not permitted
Partial thickness repeated repair Not permitted Not applicable Not permitted Not permitted
In-process root repeated repair Not permitted Not applicable Not permitted Not permitted
Single pass cap repeated repair Not permitted Not applicable Not permitted Not permitted
Single pass root sealing repeated repair Not permitted Not applicable Not permitted Not permitted
Note: 1) A minimum ligament of 6 mm shall be provided. 2) If the cap is exposed to a sour environment, the cap repair is not allowed.
305 Repairs in base materials are not permitted. Weld repairs to bevel are subject to specially approval of Inspector.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 63 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
309 A local weld repair shall be at least 50 mm long or 4 times the material thickness, whichever is longest.
The maximum length of a single repair section or a total repair length shall not exceed 20% of the total weld length for the in-process root repair and through thickness repair. For the other cases, the repair length shall not exceed 30%.
Add
Weld repairs to pipe or fitting body or bevels shall not be permitted.
In case of Copper contamination, then, repair is not permitted.
Only basic coated electrodes shall be used for welding repairs. The coated electrodes shall be of the extra low hydrogen type (i.e. maximum specified hydrogen content of 5 ml per 100 grams of Weld Metal). The electrodes shall be supplied in vacuum packing. Moreover, they shall be guaranteed against moisture absorption for 8 hours after pack opening.
Single-run repairs are permitted where the whole of the weld cap is replaced to the original procedure (such repairs do not require separate qualifications). For any other single-run repair (internal or cap repair), qualification tests shall be required.
All welds repairs shall be re-inspected using the same inspection technique and requirements as for the original weld.
The repeated repairs shall be limited to one per weld. Should the repeated repair fails to meet the NDT requirements, then the whole weld shall be cut out.
Weld found with cracks shall be repaired by complete removal of the weld by cutting out a section of pipe containing the weld.
Defects shall be removed by grinding or by arc-air gouging following by grinding. For duplex stainless steel, arc-air gouging shall not be permitted.
Internal repairs when proposed by Contractor (diameter permitting) and agreed by Company shall require the following from Contractor:
• Safety procedure to cover the "man in pipe" situation, with description of equipment involved (breathing apparatus, rope, welding equipment, etc.)
• Procedure to monitor and control the extent of welding works inside the pipe
• Time and distance limitations.
A full record of all repairs shall be maintained by the Contractor. The record shall include the following:
• Weld number
• Type and size of defect
• Circumferential location (defined to an approved system)
• Estimate of the depth (assessed by ultrasonic test where possible)
• Where possible, the name of the welder who produced the defect
• Repair welding procedure number
• Name of repair welder
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 64 of 110
Appendix C
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The information contained in this document does not substitute to the applicable laws and regulations.
• Copy of the inspection report for the repair
• Date and time of repair.
G 400 Post weld heat treatment Modify to read
402 Post weld heat treatment shall be performed for welds made on C-Mn and low alloy steel pipes or fittings having a nominal wall thickness above 31.8 mm. Then, related base materials shall have been previously tested to ascertain that their physical properties are still acceptable after such a PWHT. In cases where the minimum temperature is less than - 10°C, the thickness limit shall be specially determined.
410 All heat treatment operations shall have a printed chart of the heating cycle at 12 o’clock and 6 o’clock position of the weld, as a minimum. The charts shall be available for verification if requested.
Add
Any requirement for PWHT shall be established during welding qualifications. In such cases, the specific requirements (heating and cooling rates, soaking time and temperature, and temperature tolerances) shall be proposed by the Contractor and be subject to the approval of Company.
G 500 Welding of pipeline girth welds Modify to read
Production welding
508 When lining up longitudinally welded pipe, the pipe shall be positioned so that the seam will be located in the top quadrant of the line and within that area of sixty (60) degrees each side of this position, with a minimum offset of 200 mm between the seams of the pipes. At vertical bends, the seam shall be at the neutral axis of the bend. Adjacent circumferential welds shall be separated by a minimum of one pipe diameter or 750 mm, whichever the least. For duplex stainless steel, the minimum distance between two adjacent girth welds shall be 2 meters.
512 Line-up clamps should not be removed before the first two passes are completed. For spool base and yard (onshore double or triple jointing) welding the internal line-up clamps may be removed after completing root pass when pipe is supported by rollers to ensure a smooth transfer from station to station and it is demonstrated that the stress level in the weld does not exceed 20% of the parent material SMYS. Reference is given to Sec.10 E 203 regarding moving of pipe during installation welding.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 65 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
514 The copper or ceramic shoes shall be cleaned, checked and changed according to the following requirements hereafter:
Cleaning, inspection and replacement of shoes
S-lay (5G position)
J-lay (2G POSITION)
Shoe cleaning by brushing After each weld. After each weld.
Shoe visual inspection 3 times per shift.
Shoes replacement is Inspector decision.
1 time per shift. Shoes replacement is
Inspector decision.
Shoe replacement (Irrespective of its state). Every two shifts. Every six shifts.
Shoes may be repaired to original condition and re-used at Contractor’s discretion.
The Contractor shall ensure an adequate supply of new copper or ceramic shoes.
Repair welding
522 Long defects may require repair in several steps to avoid yielding and cracking. The maximum length of allowable repair steps shall be calculated based on the maximum stresses present in the joint during the repair operation, and shall not exceed 70% of SMYS.
Add
Production welding
The pipes will be supplied with bevelled ends as defined in the material specification. For weld procedures that require a different bevel, re-bevelling shall be done by the Contractor. Hand bevelling shall not be permitted.
All joints with diameter over 150 mm shall be aligned with an internal line-up clamp, except for tie-in line-ups or under exceptional conditions approved by Company, on which occasions an external line-up clamp may be used.
Where external line-up clamps are used, all root runs shall be welded vertically-up. Root runs for riser and expansion loop fabrication shall also be welded vertically up.
Tack welds shall not be permitted when a clamp is used.
The use of the "hinged method" (i.e. moving vertically the pipes at joint to close or adjust the root gap while part the weld filling has been made on a pipe sector) shall be forbidden.
Permanent backing rings or consumables inserts shall not be permitted.
The preheat temperature shall be checked at the 6 o'clock position (as a minimum) on each pipe prior to the start of welding of each run and where an upset in the continuity of welding has occurred.
For onshore pipe to pipe welds, a minimum of four runs or one third of weld thickness, whichever is the greater, shall be completed before cooling below preheat temperature provided that this is confirmed by a qualification test.
For onshore pipelines when in sour service conditions, random Vickers hardness HV5 or HV10 tests of circumferential weld caps shall be carried out by Contractor at the discretion of Inspector. Each weld selected for hardness test shall be checked at the 4, 8, and 12 o'clock
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 66 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
positions. The hardness transverse shall cover the weld cap, HAZ and pipe material, over a range 10 mm each side of the HAZ. Hardness readings shall be made with a portable hardness tester to be approved by the Inspector and shall be recorded.
All on-line butt welds of the pipeline made on lay barge shall be completed in one cycle.
Golden welds (i.e. non-hydrotested welds) shall be minimized. The NDT examination of golden welds shall be as per the dedicated section.
The open end of pipe strings shall be securely closed at the end of each day's or shift's work and lunch breaks by suitable proprietary designed covers. They shall be placed over the pipe ends to prevent the entrance of water, trash, small animals or other objects. These covers shall not be removed until the work is to be resumed. Where the line is left apart at intervals to be later tied-in, ends shall likewise be fully closed. Metal covers shall not be tack welded to the pipe.
Repair welding
In the event that the defect is close to the weld root and the whole thickness of the weld seam is to be removed, the new gap opening at the weld root shall remain within the qualified root gap tolerances defined in the WPS.
The preheating and PWHT (if applicable) shall be applied to the whole girth weld.
For barge welding and repairs performed under stress, the whole girth weld shall be re-inspected.
G 600 Welding and PWHT of pipeline components Add
Hot bends shall be inserted in the pipeline with their tangent lengths (i.e. hot bends shall not be cut into bends of smaller angles and no circular welds shall be present in the bent portion of hot bends).
Only forged fittings (e.g. hot extruded or pressed tee, etc.) shall be used for branches and other pressure containing attachments. To ease welding of the fitting in the line, a pup piece may be welded to the fitting. Its length must be sufficient to accommodate the line-up clamp to be used.
Branches directly welded onto main pipe are not allowed, unless specially agree with Company. All branch outlet fittings (as per MSS SP-97) shall be welded onto a piece of running pipe (shop fabrication) having a minimum length of one pipe diameter of the running pipe, so as a PWHT (if any) can be made on the finished prefabricated item before inserting this item into the pipeline system.
Branches, fittings and attachments shall be sited away from other welds on the pipeline. The minimum separation shall be the greater of:
• A diameter of Branch/Fitting
• Six (6) times the wall thickness of thickest component
• 150 mm.
Where accessible, all welds to valves, flanges and fittings shall be ground back smooth internally prior to proceed with radiography or ultrasonic.
Supports, attachments, lifting devices and the like used for permanent positioning of risers and pipelines shall be welded on doubler ring or plate. Doubler rings for temporary use should be
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 67 of 110
Appendix C
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The information contained in this document does not substitute to the applicable laws and regulations.
clamped. Welding of temporary attachments shall be subject to Company approval and qualification tests.
Perm anent doubler rings and plates shall be made of materials satisfying the requirements for pressure containing parts. Doubler ring shall be made as fully encircling sleeves with the longitudinal welds made with backing strips and avoiding penetration into the main pipeline material. Other welds shall be continuous and made in a manner to minimise the risk of root cracking.
H. Material and Process Specific Requirements H 100 Internally clad/lined carbon steel and duplex stainless steel Modify to read
Welding consumables for clad/lined carbon steel
103 Welding consumable shall be chosen taking into account reduction of alloying elements by dilution of the carbon steel. In addition, corrosion properties of weld deposit shall be superior to that of the clad material. The two following options can be considered when welding lined/clad pipelines:
• Option 1: Only one welding consumable is used.
• Option 2: Three welding consumables and the “buffer layer technique” are used (possibly
required to reach mechanical properties for X65, X70 backing steels with UNS N06625, UNS N08825, UNS 31603 and UNS 31703 CRA claddings).
• Option 3: Two welding consumables but both inner side and outer side welding are used.
Option 1 shall be the base case. Option 2 can be critical in terms of welding and shall be considered on a case by case basis and only when there are design issues due to lateral buckling, thermal expansion, etc. Experience with option 2 shall be fully detailed at the bid stage
C-Mn CRA
One welding consumable
C-Mn CRA
Welding consumable 1: CRA weld metal
Welding consumable 3: Carbon steel filler metal
Welding consumable 2: Pure Fe/ERNi-1
C-Mn CRA
Welding consumable 2: CRA weld metal
Welding consumable 1: Carbon steel filler metal
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 68 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
if this is the proposed option. The option 3 shall be justified by a track record of qualification and production experiences.
Backing and shielding gas
105 Back purge protection shall be made with argon welding quality inert gas or appropriate mixture approved by company. Backing gas protection during qualification tests as well during production shall be maintained until completion of the first 3 passes or a minimum of 8 mm of deposited weld metal. Duration of backing gas application before welding shall be recorded during qualification time and monitored during production.
Before starting production, the Contractor shall send relevant back purging and oxygen level measurement methods for Company approval. These proposed methods could be continuous or discontinuous with a minimum frequency to be agreed by Company.
The oxygen content on back side gas shall be less than 500 ppm during welding. The oxygen shall be checked and recorded during the qualification tests until the end of weld performance.
During the fabrication, the oxygen level shall be checked until backing gas protection is maintained. In production, the oxygen level shall not be higher than the level obtained during the qualification tests.
Internal checking point of oxygen level shall be located in the upper quadrant (12 o'clock position) of the pipe, unless proved technically impossible.
The addition of hydrogen in shielding and backing gas is prohibited.
Shielding and back purge gas shall be of welding quality with the following requirements in addition of those stated in ISO 14175:
• Purity > 99.999%
• Dew point shall not be higher than - 30°C
• Oxygen < 2 ppm
• CO₂ < 10 ppm
• Hydrocarbon < 1 ppm.
Contractor shall obtain Manufacturer gas analysis certificate for each batch used for the job and for each rack of bottles.
Production
106 Welding of clad/lined carbon steel shall be performed by the welding processes listed in A 200.
For the duplex stainless steel, only the following processes are authorised:
• Shielded Metal Arc Welding (SMAW) for fillet weld only
• Manual and automatic Gas Tungsten Arc Welding (GTAW)
• Automatic Submerged Arc Welding (SAW). Any other process that a Contractor would intend to use shall receive company approval. Autogenous welding is forbidden in both cases, except for tack welding. 108 The bevels shall be prepared by machining, but a preparation by automatic plasma cutting is acceptable. The heat-affected zone shall then be removed by grinding. Oil, moisture, rust,
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 69 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
scale, paint or other foreign matter shall be removed from the weld surface and at least 50 mm of adjacent base metal prior welding. De-greasing with solvent free from chloride shall be performed. Contamination of surface, weld bevel and surrounding areas with low melting point metals such as Copper, Zinc, etc., are not acceptable.
114 The interpass temperature shall be measured directly where a weld run will start and terminate. The maximum interpass temperature as recorded on the WPQR shall be considered as an essential variable. In no case the temperature shall be greater than 150°C for all CRAs, except for 25% super duplex stainless steel, where the maximum allowable interpass temperature is 100°C.
Additional for welding of duplex steel
116 The heat input must be controlled to avoid detrimental weld cooling rates. Stringer beads shall be used to ensure a constant heat input, and any weaving of the weld bead should be limited to maximum 3X filler wire/electrode diameter. The welding shall be performed with the heat input within the range 0.5 - 1.8 kJ/mm and avoiding the higher heat input for small wall thicknesses. For the root pass, the heat input shall be higher than for second pass.
For the 10 first production welds, welding parameters shall be recorded and then, shall be monitored for the others. Records shall be submitted to Company’s Inspector for review.
117 Post Weld Heat Treatment is not required.
Add
Essential variables
For the duplex stainless steel, the following essential variables shall also be applied:
• Any change in travel speed or in electrode Run Of Length outside the qualified range ± 10%
• Any change of welding parameters more than:
- ± 10% (I,U) in manual processes
- ± 5% (Heat Input) in automatic processes
- ± 5% (Ipeak, Ibackground, Heat Input, U) in pulsed current.
• Welding procedure qualification with a 22% Cr stainless steel (known as duplex stainless steel) does not qualify welding procedure on a 25% Cr stainless steel (known as super duplex stainless steel).
Welding consumables for duplex steel
Super duplex consumables shall not be used for weld filling and capping on duplex base metal.
Production
Cutting shall be carried out only by plasma or by mechanical sawing (chloride content in machining oil shall be limited to 1.0 ppm).
Preheat is not required, however, the pipe wall temperature shall be such that the pipe is free from condensation. The humidity shall be eliminated by using hot air blowers and/or by controlled induction heating. To prevent any oxidation the use of air/gas torch is prohibited. Ambient temperature shall not be less than 20°C.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 70 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
For clad/lined pipelines, when three welding consumables are used, only Gas Tungsten Arc Welding (GTAW) or Gas Metal Arc Welding (GMAW) STT are allowed for the welding of the pure Fe/Ni buffer layer. The maximum allowable dilution of the pure Fe/Ni buffer layer in the CRA weld metal is 30% and any change of ± 5% of the dilution shall be considered an essential variable. This dilution shall be determined from metallographic investigation on test coupon with only CRA weld metal and buffer layer (no carbon steel weld metal).
For automatic welding process, the following shall be specified:
• Amplitude of weave
• Frequency of weave
• Dwell time.
All parts of line-up clamps in contact with the CRA shall be made of stainless steel or non metallic parts.
When used of clamp is not possible, tack welding may be carried out with controlled backing gas protection. Tack welding procedure shall be submitted to Company for approval prior to any work commences.
For clad/lined pipelines, the use of PWHT shall be avoided as much as possible due to contradictory PWHT optimum conditions (temperature, time, heating and cooling speeds) between C-Mn steel and CRA. In a case where PWHT is deemed necessary, Company shall be informed as soon as possible (at the BID stage for example) so that all relevant tests can be performed to set the right PWHT conditions.
Additional for welding of duplex steel
A reception site certificate shall be filled-in before the start of fabrication and shall be periodically reviewed to follow the fabrication quality.
Correction of deflexion by flame straightening is prohibited.
Before welding, bevels and adjacent inner and outer surfaces and TIG wires shall be cleaned with acetone and fluffiness fabric.
Whichever the welding process used for filling on no back welding sequence, the two first passes shall be carried out using the GTAW process.
All manual GTAW shall use a high frequency start and a post-purge gas flow for the torch. Whenever the welder stops welding, the welding current shall be gradually decreased by use of the remote current control. The torch shall be held in position close to the weld pool until the gas shielding post-purge flow is completed to prevent oxidation.
Whenever the welder stops welding, the welding current shall be gradually decreased by use of the remote current control.
The torch shall be held in position close to the weld pool until the gas shielding post-purge flow is completed to prevent oxidation.
Any ground surface, external weld surface and adjacent base metal shall be pickled and passivated after grinding or welding, according to a procedure submitted to Company for approval. In case of oxidation of the inner surface (for example: root pass made by SMAW or SAW process), internal pickling and passivation should be required by Company. GS EP PVV 175 shall be applicable for internal pickling and passivation.
Paint and markers containing zinc or chloride are prohibited.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 71 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
A Quality Control from Contractor shall monitor the welding of duplex and super duplex materials in accordance with minimum following items, but not limited to:
• Degreasing of the weld preparation and adjacent base metal shall be properly monitored
• For the first production weld of each welder, welding parameters of root, hot and filling passes shall be monitored and recorded
• Every five prefabrication production weld of each welder shall be 100% monitored and recorded. Welding parameters of root, hot and filling passes shall be properly monitored and recorded
• For each installation weld welding parameters of root, hot and filling passes shall be monitored and recorded off all materials
• Reference shall be made to the relevant weld procedure
• Measuring equipment used for weld monitoring shall have valid calibrated certificate
• Monitoring checklist shall be used to record the welding parameters; it is mandatory that actual values be recorded
• Whilst the monitoring of welding is being carried out particular attention must be paid to:
- The cleanliness of weld preparation and consumables
- The content of oxygen back purge, All pass temperatures measured by Digital Contact Thermometer with close monitoring of root and hot passes
- Actual recorded heat input value
- Run-out-lengths.
• All completed weld monitoring check lists shall be issued to the Contractor welding department for Company review
• Welders found to be working outside of the welding procedure parameters or unable to maintain the required heat input values shall be immediately replaced. Immediate corrective action shall be taken and Company shall be informed.
During production, the ferrite content shall be measured on a 20% random sampling of all production welding using the magnetic induction method, and the portable device for measurement (e.g. FISHER Ferritscope MP30E) shall be approved by company. Measurements shall be taken on both, weld metal caps and HAZ. Each measurement shall be the average of three measurements and the averages values obtained shall be within the Ferrite content range of 35% to 65%. The measurement shall be performed as follows:
• 3 locations around the pipe at 120° (one at 12 O’Clock position)
• For each location, 3 measurements shall be taken on HAZ area and 3 measurements shall be taken on weld metal area
• For each area (weld metal or HAZ) on each location, the average of 3 measurements shall be done.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 72 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
H 200 13Cr Martensitic stainless steel Modify to read
This section is not applicable.
H 300 Pin brazing and aluminothermic welding Modify to read
Repair of welded/brazed anode leads
309 Welded/brazed anode leads not meeting the requirements of the section F 500 shall be removed by grinding and inspected by MPI to ensure the absence of any crack.
Add
For duplex stainless steel, electrical connecting welds as thermit welding or pin brazing are not permitted in a weld junction for anodes or other components. The weld profile shall be submitted to Company on the case by case basis for approval.
Production requirements for welding/brazing of anode leads
Junctions of anode shall be carried out by using doubler-plates which shall be previously welded onto pipe bodies. However, in the case of pipes having a yield stength lower than 418 MPa (grade 60), the junctions may be carried out without using doubler-plates.
Care shall be taken to the dimensions of the anodes, which could be damaged during their passage on the rollers of the stinger or in the tensioners during laying.
The appropriated methods of anode connections onto the pipe shall be done as tabulated below for the low alloy steels.
Welding of anode pad is always preferred, but in some case, the brazing by electrical discharge method may be authorised if the conditions of the following table are fulfilled.
For all other laying offshore and/or other electrical connection methods, doubler plates are required with the associated requirements indicated in the note under the table.
For all laying onshore method, electrical connection shall be made through doubler plates.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 73 of 110
Appendix C
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
In case of internal coating, the doubler plate method shall be always required:
Laying method
Concrete coating Position of electrical connection Pipe
grade Electrical discharge pin brazing
S-LAY
Yes Pipe mill or coating mill < X60 Note 1
≥ X60 On doubler plate
No
On board before tensioning All Unauthorised
On board after tensioning < X60 Note 1
≥ X60 Note 1 + on doubler plate
On piggy back method < X60 Note 1
≥ X60 On doubler plate
J-LAY
On board before tensioning All Unauthorised
On board after tensioning < X60 Note 1
≥ X60 Note 1 + on doubler plate
REEL-LAY
On board before tensioning All Unauthorised
On board after tensioning < X60 Note 1
≥ X60 Note 1 + on doubler plate
Note 1: Pin brazing by electrical discharge may be authorised if the Supplier demonstrates that the anode does not move onto the pipe when the anode goes through the stinger.
In H2S service (sour service), the following statements shall apply:
• Method of anode connection onto the pipe shall be through doubler plate method only
• Electrical connection of anode onto doubler plate shall comply with relevant GS EP COR 401.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 74 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Appendix D Non-Destructive Testing (NDT)
A. General A 400 Non-destructive testing methods Add
The following guideline shall be considered for NDT method selection:
Guideline for NDT method selection
Surface Examination Volume Examination
Hydrotested welds Workmanship criteria
Visual DPI MPI ET RT MUT AUT
Main line welds X DPI, MPI or ET RT or AUT*
RPR X / /
TTR or TTRR X DPI, MPI or ET RT or MUT**
PTR or PTRR X DPI, MPI or ET RT or MUT**
CR or CRR X DPI, MPI or ET RT or MUT**
Hydrotested welds ECA based acceptance criteria
Visual DPI MPI ET RT MUT AUT
Main line welds X DPI, MPI or ET AUT*
RPR # X / /
TTR or TTRR X DPI, MPI or ET AUT or MUT***
PTR # or PTRR X DPI, MPI or ET AUT or MUT***
CR or CRR X DPI, MPI or ET AUT or MUT***
Golden welds Workmanship criteria
Visual DPI MPI ET RT MUT AUT
Main line welds X DPI, MPI or ET RT and AUT*
RPR X / /
TTR or TTRR X DPI, MPI or ET RT and MUT**
PTR or PTRR X DPI, MPI or ET RT and MUT**
CR or CRR X DPI, MPI or ET RT and MUT**
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 75 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Guideline for NDT method selection
Surface Examination Volume Examination
Golden welds ECA based acceptance criteria
Visual DPI MPI ET RT MUT AUT
Main line welds X DPI, MPI or ET RT and AUT*
RPR X / /
TTR or TTRR X DPI, MPI or ET RT and MUT***
PTR or PTRR X DPI, MPI or ET RT and MUT***
CR or CRR X DPI, MPI or ET RT and MUT***
Note: * AUT can be according to the Zone Discrimination Technique or by a combination of ToFD and
pulse echo phased array. PoD and sizing accuracy of the system and the related procedure shall be previously established.
** MUT shall combined ToFD and pulse echo for at least cap and root inspection. *** MUT shall combined ToFD and pulse echo and PoD as well as sizing accuracy shall be previously
established. MUT shall be performed using a hand driven probe holder (fully manual UT is not accepted). If PoD and sizing accuracy cannot be determined, then any indication shall be considered as it has a height of minimum 2.5 mm.
# RPR or TTR not applicable to fatigue sensitive lines.
For clad and lined pipe girth welds only two weld inspection strategies shall be considered:
Strategy 1 Strategy 2
RT after root and hot pass RT after weld completion
AUT after weld completion
If RT is performed only after weld completion then root+hot pass acceptance criteria shall apply to the full weld volume.
All NDT procedures shall be submitted to Inspector’s approval and shall be qualified on the welding procedure qualification test welds.
Each joint shall be thoroughly cleaned using power driven wire brushes, and all slag, spatter, etc., removed prior to weld examination. Any bonding media, or any inks or dyes used for crack detection, shall be removed. All completed circular welds shall be examined visually internally (as far as practicable) and externally to the pipe prior to being examined by radiography. All tie-in welds shall be witnessed and the fit-up and weld quality visually examined in full, by the Inspector.
Ultrasonic, MPI and liquid penetrant testing equipment shall be available on Site to supplement radiography on any doubtful area nominated by the Inspector.
Where quality and/or interpretation of radiograph is affected by the presence of a cable inside the pipe (buckle detector …), an alternative NDE technique such as manual UT shall be qualified and used to inspect the area.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 76 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
A 500 Personnel qualifications Modify to read
Manual or semi-automatic NDT
501 Personnel performing manual or semi-automated NDT and interpretation of test results shall be certified to Level 2 by a Certification Body or Authorised Qualifying Body in accordance with ISO 9712 or CSWIP scheme. ASNT personnel qualification is not acceptable unless the qualification is certified by Third Party Inspection. Personnel qualification to an employer based qualification scheme as SNT-TC-1A may be accepted if the employer’s written practice is reviewed and found acceptable and the Level 3 is ASNT Level III or ACCP Professional Level III and certified in the applicable method. Company appointed Level 3 is not accepted.
Ultrasonic operators performing testing of welds including austenitic or duplex stainless steel material, shall be specially trained and qualified for the purpose according to ISO 9712 or equivalent scheme.
The qualification of each member of the NDT team shall be subjected to approval of the Inspector.
Add
Manual or semi-automatic NDT
All NDT operators/technicians shall have at least two years experience on pipeline working in the NDT grade qualified.
B. Manual Non-Destructive Testing and Visual Examination of Welds B 100 General Add
In case of dispute, the Inspector’s interpretation of the NDT results shall prevail.
Reporting
All radiographic and ultrasonic examination records shall be suitably stored in fire proof cabinets by Contractor for a period of ten years and shall be handed over to Company at its request.
B 200 Radiographic testing of welds Modify to read
201 All radiographic techniques and procedures as well as quality of films shall comply with ISO 19232-1, ISO 17636, ISO 5579, EN 1435, ISO 11699-1 and this specification.
Classification of radiographic techniques
204 The radiographic technique shall comply with EN 1435 Class B.
Image Quality Indicators
206 Only wire type Image Quality Indicators (IQI), type single (according to ISO 19232-1) or duplex (according to ISO 19232-5) shall be used. The sensitivity across the weld, using a source side penetrameter, shall be demonstrated as required by the code. IQI's shall be placed so that each film has at least two: one within 25 mm from interpretable film extremity and one at center of film. When a complete girth weld is radiographed in a single exposure (panoramic exposure), four IQIs shall be placed 90° apart.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 77 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Radiographic procedure qualification
208 Each radiographic procedure and the consumables used shall be qualified by making radiographic exposures of a welded joint or base material with the same or typical configuration and dimensions, and of material equivalent to that which shall be used in production radiography.
The exposure shall such that density through the weld is between 2.0 and 3.5. Viewing conditions and facilities shall be such that film densities up to 4.0 can be viewed and interpreted. A densitometer (with valid calibration) shall be available on site at all times.
Processing and storage
210 All radiographic films shall be dried thoroughly prior to viewing and shall be processed and fixed to allow storage of the films without image deterioration for at least 10 years. All films shall be refixed onshore to achieve the specified minimum archival life (unless the Contractor can demonstrate by routine residual thiosulphate testing offshore that the original fixing and washing was sufficient to guarantee the specified life).
Digital Radiography and Radioscopic testing
212 Computed radiography or radioscopy may be considered by Company. In that case, it shall be qualified and used in production as per GS EP PLR 431 requirements.
Add
For duplex stainless steel, due to a lower penetration of X and Y-rays when compared to carbon steel, the practicability of radiographic examination for thickness above 35 mm shall be questioned with Company.
Contractor shall supply all labour and materials necessary to perform 100% radiography on all circular welds. Each radiograph shall cover the entire weld. For weld repair, the film shall cover 100 mm on either side of weld area of repair.
When agreed by Company in some specific cases, the gamma rays examination shall be performed using film system C2 according to ISO 11699-1 and shall be followed by ultrasonic inspection. Double film technique is recommended by Company to limit operator’s exposure.
The film system shall be C5 according to ISO 11699-1, fine grain or ultra fine grain high contrast, direct type, i.e. KODAK INDUSTREX MX or AGFA Grade 7, or company equivalent.
The film overlap shall be 50 mm minimum.
Inspection set-up shall be determined so that geometric unsharpness is maximum 0.25.
Radiographic performance shall comply with the relevant Country and Project safety codes and radiation acts. Attention is drawn to the necessity for audible and visual warning arrangements and for regular monitoring or radiation levels.
At least one certified level 2 (minimum) radiographer shall be present on each shift for film interpretation.
Radiographic procedure qualification
For qualification purpose (WPQ, welder qualification), radiographic technique shall comply with EN 1435 class B using film system class C2 according to ISO 11699-1.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 78 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
A lead number “B” of appropriate thickness shall be placed at the back of the cassette to check the back scatter. If the image of “B” appears on the radiograph, the weld shall be reshoot and remedial action must be taken to improve the back scatter
Intensifying screens of the lead type shall be used for welder and welding procedure qualifications, and tie-ins. The use of fluorometallic screens is acceptable for offshore pipelaying, except tie-ins, provided that the required sensitivity is easily met and that Contractor agrees to replace them on Inspector’s request. Fluorometallic screens shall not be permitted with gamma-rays sources. Salt screens shall not be used.
The radiographic procedure qualification test shall be repeated at the discretion of the Inspector whenever any change is made to the operating techniques, or whenever production films differ appreciably from the sensitivity, contrast or density of the qualification radiographs.
Processing and storage
Final film interpretation shall be carried out on dry film.
All films shall be protected in individual plastic bags and stored in aluminium boxes closed with tight fit lids before delivery to the Company. All film boxes shall be individually numbered and indexed (arrangement of films to be stated) on their top.
Reporting
As a minimum, the film identification shall include:
• Project Identification (as previously agreed with Company)
• Line Size and Identification
• Joint Number
• Date (Day, Month, Year)
• Radiographic Location.
The zero datum shall be located at the 12 o'clock position. The direction of numbering on tape shall be clockwise when looking in the direction of flow. Defect location shall be in the metric system. Each radiograph shall have reference markers at 100 mm (minimum) intervals.
Specific requirements to radiography of installation girth welds
On lay barge, no weld shall be moved past the repair station until the radiograph is completed and the weld is judged satisfactory.
Unless otherwise approved by Inspector, coating and wrapping of the joint shall not begin until the weld is judged satisfactory.
B 300 Manual ultrasonic testing of welds in C-Mn/low alloy steel with C-Mn/low alloy steel weld deposits Modify to read
301 Ultrasonic examination procedure of welds shall be as per ASME BPVC Section V, ISO 17640 or equivalent standard.
Ultrasonic testing techniques
306 Ultrasonic testing techniques shall be in accordance with ASME PBVC Section V, ISO 17640 or equivalent standard.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 79 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Add
Ultrasonic procedures, where required, shall be submitted to Company for approval prior to use.
The Inspector reserves the right to test proposed UT operators on a test weld prior to accept them on the job.
The Company shall require ultrasonic examination of welds in the following cases:
• To verify minimum acceptable pipe wall thickness after grinding (refer to material specifications for the minimum acceptable wall thickness)
• To verify weld defects not fully defined by radiography
• To cross-check weld defects dimensions not fully defined by radiography (length) and check if that defect height is acceptable
• To double check welds made by mechanized GMAW.
B 400 Manual ultrasonic testing of welds with CRA (duplex, other stainless steels and nickel alloy steel) weld deposits Modify to read
401 Ultrasonic examination procedure of welds shall be as per ASME BPVC Section V, ISO 17640 or equivalent standard.
407 The probes shall include normal compression wave and 45 degrees, 60 degrees and 70 degrees shear wave angle probes, single and twin crystals 4-5 MHz.
Table D-3 Reference Block Dimensions
Matherial thickness (t) Thickness of
reference block (T) in
Diameter of side drilled hole in mm
Position of side drilled holes
t < 15 mm 15 mm or t 1.5 ± 0.1
t/4, t/2 and t3/4 15 mm ≤ t < 35 mm 25 mm or t 3.0 ± 0.2
35 mm ≤ t < 50 mm 45 mm or t
50 mm ≤ t < 100 mm 75 mm or t
3.0 ± 0.2
The distance between the two outer holes and the nearest surface shall not exceed 12 mm.
100 mm ≤ t < 150 mm 125 mm or t
Add
Ultrasonic procedures, where required, shall be submitted to Company for approval prior to use.
The Inspector reserves the right to test proposed UT operators on a test weld prior to accept them on the job.
The Company shall require ultrasonic examination of welds in the following cases:
• To verify minimum acceptable pipe wall thickness after grinding (refer to material specifications for the minimum acceptable wall thickness)
• To verify weld defects not fully defined by radiography
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 80 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
• To cross-check weld defects dimensions not fully defined by radiography (length) and check if that defect height is acceptable
• To double check welds made by mechanized GMAW.
B 500 Manual magnetic particle testing of welds Modify to read
501 Contractor shall supply a MPI procedure based on ASTM E709 or equivalent for review and approval by Company.
Add
General
The following cases shall be Magnetic Particle Inspected:
• All repair weld excavations
• All welds to fittings
• All fillet welds on steel grade X60 and above
• All arc strike outside weld groove area.
Magnetic particle testing procedures
Inspector reserves the right to test the proposed MPI procedure prior to acceptance.
Magnetising equipment
Electromagnetic (a.c.) yoke and/or adjacent cable techniques shall be used.
Calibration blocks and approved magnetic flux indicators shall be available on Site at all times.
B 600 Manual liquid penetrant testing of welds Add
General
The following welds shall be 100% inspected by liquid penetrant testing (chloride free):
• All repair weld excavations
• All welds to fittings
• All fillet welds and incomplete penetration welds.
When DPI is applied, no cracks or crack like defects are permitted. Any indications revealed by DPI shall be investigated and removed by grinding or pipe re-cutting, as necessary.
Contractor shall supply a DPI procedure for review and approval by Company.
Company reserves the right to test proposed DPI procedure prior to acceptance.
B 800 Visual examination of welds Add
For clad and lined pipelines, visual inspection of the weld root area from inner side shall be performed with an endoscope or a video camera. No trace of oxidation shall be evidenced.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 81 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
B 900 Acceptance criteria for manual non-destructive testing of welds with nominal strains < 0.4% and no ECA Modify to read
Pipeline girth welds
904 The acceptance criteria given in Table D-4, Table D-5, and Table D-6 are applicable for nondestructive testing of pipeline girth welds exposed to nominal strains < 0.4%.
The acceptance criteria of the Table D-6 is valid for the V preparations. When performing a manual ultrasonic testing of a girth weld which was made in a J bevel, all the levels of the Table D-6 shall be displaced - 4dB (i.e. decrease 4 dB).
Table D-4 Acceptance criteria for visual examination and surface method testing of welds 1) 2)
Visual examination
External profile (not relevant for SAWL in pipe mills)
The welds shall merge smoothly with the parent metal and shall not extend beyond the original joint preparation by more than 2.5 mm (4.0 mm for SAW welds).
Cap and root reinforcement height (Double sided girth welds)
Cap: 1.0 mm ≤ Height ≤ 3.0 mm. Root: Height ≤ 3.0 mm. 90° re-entrant angles and overlap are not permitted.
Cap reinforcement (Single sided welds)
1.0 mm ≤ Height ≤ 3.0 mm. For duplex stainless steel: 1.0 mm ≤ Height ≤ 0.2 t (but max 3.0 mm)
Root penetration (Single sided welds)
Height ≤ 0.2t (but 3.0 mm), although occasional local slight excess of penetration is allowable (25 mm maximum). 90° re-entrant angles and overlap are not permitted. For clad/lined, where the pipeline is fatigue sensitive, the root profile shall be scanned and plotted by laser inspection. The maximum root bead into the bore of the pipe shall be max 1 mm.
Root concavity Permitted up to 1.2 mm in depth if there is no lack of root fusion and the thickness of the weld is not less than the specified wall pipe thickness.
High/low on root side of single sided girth welds
Maximum: 2 mm. For welds in clad/lined material the offset shall not reduce the effective thickness of the cladding/lining in the root area. For duplex stainless steel, high/low shall be less than 0.1 t but 1.3 mm max.
Undercut Cap Undercut: Depth shall not exceed 0.5 mm. If exceeds, shall be removed by grinding. Grinding shall not reduce the wall thickness below the minimum specified. Root Undercut: Depth shall not exceed 0.4 mm. Length shall not exceed 25 mm in any continuous weld length of 300 mm (or 100 mm for duplex stainless steel).
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 82 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Table D-4 Acceptance criteria for visual examination and surface method testing of welds 1) 2)
Visual examination
Lack of penetration/lack of fusion Not permitted in case of fatigue services. Not permitted for welds in duplex stainless steel, CRAs and clad/lined steel. Individual acceptable length: maximum 25 mm. Accumulated length in any 300 mm length of weld: maximum 25 mm. Accumulated length of indications exceeds 8% of the weld length in any weld less than 300 in length.
In H2S service: Individual acceptable length: maximum 10 mm. Accumulated length in any 300 mm length of weld: maximum 20 mm.
* The acceptance criteria which were not modified in this table remain applicable.
Table D-5 Acceptance criteria for radiographic testing of welds 1) 2)
Type of defect Acceptance criteria 1) 2) 3) 10) 11)
Individual discontinuities Maximum accumulated size of in any 300 mm weld length for each type of discontinuity
Porosity 1) 2) Scattered Cluster 5) Wormhole Hollow bead Isolated 6) On-line 7)
An isolated pore greater than 0.2 t or 3.0 mm (0.2 t or 2.0 mm for duplex stainless steel), whichever is smaller, in any direction, shall be considered unacceptable. Wormholes shall not be acceptable. Hollow bead (elongated porosity in root run) shall not be acceptable. For duplex stainless steel, cluster and scattered porosity are not permitted.
When projected radically through the weld, porosities shall not exceed 2% of any 600 mm2 of projected weld area. In H2S service: When projected radically through the weld, porosities shall not exceed 1.5% of any 600 mm2 of projected weld area.
Slag 1) 2) 3) 8)
Isolated Single lines Parallel lines
Isolated: Width < 3 mm (1.5 mm for duplex stainless steel) Single lines: Width < 1.5 mm Parallel lines: Width < 1.5 mm
Isolated: Length 12 mm, but max. off separated by min. 50 mm Single lines: Length 2 t, but max 50 mm (for duplex stainless steel, length 2 t, but max 25 mm) Parallel lines: Length 2 t, but max 25 mm
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 83 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Table D-5 Acceptance criteria for radiographic testing of welds 1) 2)
Type of defect Acceptance criteria 1) 2) 3) 10) 11)
Individual discontinuities Maximum accumulated size of in any 300 mm weld length for each type of discontinuity
Inclusions: Tungsten Copper, wire
Diameter < 0.5 t, but max. 3 mm. For duplex stainless steel, diameter < 0.1 t, but max. 3 mm. No surface breaking tungsten inclusions are permitted on inner and outer surfaces. Not permitted.
Max. 2 per weld and separated by min 50 mm.
Lack of penetration 1) 2)
3) 8) Not permitted in case of fatigue services. Not permitted for welds in duplex stainless steel, CRAs and clad/lined steel in surface areas (root, hot and cap). Length maximum: 25 mm. In H2S service: Length maximum: 10 mm.
Maximum: 25 mm. Accumulated length of indications exceeds 8% of the weld length in any weld less than 300 in length. In H2S service: Maximum: 20 mm.
Root Embedded 9)
Length: t, but max. 25 mm. Length: 2t, but max. 50 mm. For duplex stainless steel, Length: t, but max. 25 mm.
Length: t, but max. 25 mm Length: 2t, but max. 50 mm For duplex stainless steel, Length: t, but max. 25 mm
Lack of fusion1) 2) 3) 8) Not permitted in case of fatigue services. Not permitted for welds in duplex stainless steel, CRAs and clad/lined steel. Length maximum: 25 mm. In H2S service: Length maximum: 10 mm.
Maximum: 25 mm. Accumulated length of indications exceeds 8% of the weld length in any weld less than 300 in length. In H2S service: Maximum: 20 mm.
Surface Embedded 9) Length: t, but max. 25 mm Length: 2t, but max. 50 mm
Length: t, but max. 25 mm Length: 2t, but max. 50 mm
Total accumulation of discontinuities (excluding porosity) - The aggregate length of indications in any continuous 300 mm of weld length shall not exceed
50 mm - The aggregate length of indications shall not exceed 8% of the weld length. Total accumulation of discontinuities (excluding porosity) on duplex stainless steel - The aggregate length of indications in any continuous 300 mm of weld length shall not exceed t/2 but
max. 8 mm for surface indication and 2% of the weld length in case of embedded indications.
* The acceptance criteria which were not modified in this table remain applicable.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 84 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Add
The graphics hereafter shall also be considered as acceptance criteria for manual ultrasonic testing of welds.
Note 1: For J bevels, all the reference levels of the graphic shall be displaced - 4 dB (i.e. decrease 4 dB).
Note 1: For J bevels, all the reference levels of the graphic shall be displaced - 4 dB (i.e. decrease 4 dB).
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 85 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
B 1000 ECA based non-destructive testing acceptance criteria for pipeline girth welds Add
General
At the bid stage the following critical defect size can be considered to evaluate the repair rates:
SWEET SERVICE - Critical defect size to be considered
CAP SIDE Root surface breaking Embedded Cap surface breaking
HEIGHT LENGTH HEIGHT LENGTH HEIGHT LENGTH
General case Workmanship criteria
εl,nom ≥ 0.4% (non fatigue sensitive) 3.0 mm 10.0 mm 3.0 mm 20.0 mm 3.0 mm 15.0 mm
FS1 line 2.0 mm 10.0 mm 2.5 mm 20.0 mm 2.0 mm 15.0 mm
ROOT SIDE Root surface breaking Embedded Cap surface breaking
HEIGHT LENGTH HEIGHT LENGTH HEIGHT LENGTH
General case Workmanship criteria
εl,nom ≥ 0.4% (non fatigue sensitive) 2.0 mm 10.0 mm 2.5 mm 20.0 mm 3.0 mm 15.0 mm
FS1 line No indications 2.0 mm 15.0 mm 2.0 mm 15.0 mm
SOUR SERVICE - Critical defect size to be considered
CAP SIDE Root surface breaking Embedded Cap surface breaking
HEIGHT LENGTH HEIGHT LENGTH HEIGHT LENGTH
General case Workmanship criteria
εl,nom ≥ 0.4% (non fatigue sensitive) 3.0 mm 10.0 mm 2.5 mm 20.0 mm 2.0 mm 15.0 mm
FS1 line 2.0 mm 10.0 mm 2.0 mm 15.0 mm No indications
ROOT SIDE Root surface breaking Embedded Cap surface breaking
HEIGHT LENGTH HEIGHT LENGTH HEIGHT LENGTH
General case Workmanship criteria
εl,nom ≥ 0.4% (non fatigue sensitive) 2.0 mm 10.0 mm 2.5 mm 20.0 mm 2.0 mm 15.0 mm
FS1 line No indications 2.0 mm 15.0 mm No indications
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 86 of 110
Appendix D
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
C. Manual Non-destructive testing and Visual Examination of Plate, Pipe and Weld Overlay C 200 Plate and pipe Add
Ultrasonic testing for detection of laminar flaws
After the field bevel, the ultrasonic examination of pipe ends shall be carried out according to ASTM A578. On the bevel face and on a zone extending 10 mm of the bevel, the blue zone in the schema below, planar defects shall not be acceptable whatever their sizes. On the zone marked in red, any discontinuity (e.g. lamination) causing a reflection echo exceeding 50% and accompanied by a 50% loss of back reflection shall be considered as rejectable when the discontinuity area exceeds 100 mm2.
Propose: no indication shall be permitted within 100 mm from pipe ends.
Magnetic particle testing
When MPI is applied on parent material, e.g. following pipe re-bevelling, no cracks are permitted. Any indications revealed by MPI shall be investigated and removed by grinding or pipe re-cutting, as necessary.
The finished weld bevel shall be Magnetic Particle Inspected following field cut back of pipe, at least when this cut back is located within a range of 25 mm from original bevel.
Liquid penetrant testing
DPI shall be applied on pipe re-bevelling or finished weld bevels, and no cracks are permitted. Any indications revealed shall be investigated and removed by grinding or pipe re-cutting, as necessary.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 87 of 110
Appendix E
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The information contained in this document does not substitute to the applicable laws and regulations.
Appendix E Automated Ultrasonic Girth Weld Testing
E. Field Inspection E 400 Acceptance criteria Modify to read
401 Acceptance criteria given in Table E-1 are applicable for automated ultrasonic testing (AUT) of pipeline girth welds in sweet service exposed to total nominal strains <0.4%, with a wall thickness 15 mm ≤ t < 150 mm. The acceptance criteria of Table E-1 assumes a height sizing accuracy within ±1 mm. The acceptance criteria of Table E-1 are therefore only valid as long as the height sizing accuracy is documented to be within ±1 mm upon the qualification.
For wall thickness 8mm ≤ t < 15 mm, the maximum accumulated length of indications is 8 mm, and the allowable heights of indications listed in Table E-1 are applicable.
Under sour service, the maximum heights of indications listed in Table E-1 are also applicable. For wall thickness 8mm ≤ t < 15 mm, the maximum accumulated length of indications is 8 mm. For wall thickness 15 mm ≤ t < 150 mm the requirements of Table E-1 are applicable for root and embedded indications, but in case of surface defects on the sour side, the maximum accumulated length of indications shall be 10 mm.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 88 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Additional Sections
1. Flux dryness Flux management procedure Supplier shall issue a dedicated procedure for flux management as described below. This procedure shall cover all steps from flux purchasing to “ready-to-used” step (welding heads).
This procedure shall be submitted to Company for review at the bid stage.
Pipe Manufacturer shall guarantee the flux dryness (The resulting diffusible Hydrogen in weld deposit shall be 5 ml / 100 g max.) 1 - Procurement of flux At the time of flux packing, the diffusible hydrogen content in SAW weld deposit shall be checked on a sample of the batch of flux and shall be lower than 5 ml / 100 g of weld deposit.
(This measurement may also be done through moisture content measurement, when evidence of correlation for the flux, intended to be used, can be provided by flux Manufacturer. This correlation curve shall be based on previous comparative tests of diffusible Hydrogen versus flux moisture content. The “Karl Fisher” method shall be applied).
For diffusible hydrogen testing or for moisture measurement, neither pre- drying nor any pre-heating of flux sample will be carried out before testing.
(Tests shall be carried out with the flux as it is at the time of sampling. Moisture measurement will be carried out at 982°C approx., carrier gas shall contain 10% minimum of oxygen).
Results of diffusible hydrogen or moisture measurement shall be reported on the 3.1 flux certificate for each batch. The testing conditions, as specified above, shall be confirmed on the certificate.
Packing shall be of humidity proof type Acceptable packing shall be:
• Metallic/stiff plastic drums with rubber gasket for top tightness
• Double polymer top welded bags
• PEHD-aluminium-PEHD top welded bags.
The packing shall be designed to guarantee no significant humidity absorption during storage of one year.
2 - Storage of flux Flux shall be stored in a controlled hygrometry room where the relative hygrometry shall be permanently maintained below 60%. The maximum duration of storage shall be one year (after the date of packing). Over one year, a spot check of diffusible hydrogen / moisture content shall be required.
3 - Use of flux Drums/bags shall be checked before use. They shall be undamaged.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 89 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
They shall be opened just before pouring the flux in the welding machine hooper where the temperature shall be maintained between 120 and 150°C.
In case of welding stop, the remaining flux stored in hoopers shall be scrapped after 12 hours maximum.
The system of feeding, downstream the hoopers, shall be drained off before welding restart when welding has been interrupted 2 hours max.
The feeding from hoopers shall be done by gravity where possible. Where pressurised air is used for flux conveying, the said air shall be dried with adequate equipment.
4 - Flux recycling Recycling of flux is not permitted.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 90 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
2. Additional welding procedure qualification program in the case of girth welds subject to total nominal longitudinal strain ≥ 0.4% (i.e.: reeling) In these cases, an additional welding procedure qualification program shall be developed to address the mechanical characteristics of circumferential welds after cycled deformation.
That program shall consist of a full scale deformation of circumferential welds butting two (2) pipes.
Full scale straining shall represent the strain history ending up in tension.
Full scale straining can be replaced by small scale reeling simulation provided the test procedure is submitted to Company approval at the bid stage.
The welds shall be subject to the cycles of deformation generating the plastic strain generated during fabrication and installation (the proposed cycles shall be subject to Company’s approval).
After deformation, specimens for mechanical testing (including CTOD, segment specimens, FCGR …) and SSC tests (where applicable) shall be extracted from both extended and compressed sectors such as:
• 6 O’clock (12 O’clock position is defined as the top of weld when reeling on)
• 12 O’clock position.
The specimens shall be extracted for a full scale bending test simulating the successive bending cycle of pipeline form the first spooling till final laying.
The bending scheme, equipment and relevant procedure shall be previously approved by Company.
The samples shall be artificially aged at 250°C for one hour before testing.
The following testing shall be conducted before straining and after straining and ageing:
• One weld metal tensile testing (all weld)
• One transversal tensile test (across the circumferential weld)
• Hardness test
• Four sets of Charpy V-notch impact toughness testing (transverse specimen) in Weld Metal (WM), Fusion Line (FL) & HAZ (FL + 2 mm and FL + 5 mm).
Note: Test temperature shall be addressed in the PPS.
CTOD and FCGR tests may be required by PPS.
That specific welding qualification program is required for both Main line welding & repair welding procedures.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 91 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
3. Specification for sulfide stress cracking tests on welds (SSC tests)
3.1 General This specification applies to the testing of circular welds and repair welds of pipelines by means of sulfide stress cracking tests using the 4-point bending test method (method B of EFC Publication No. 16).
The Supplier shall prepare a fully detailed test procedure proposal based upon this specification and submit it to the Company for prior approval.
SSC tests are not required for sweet and mild sour service.
3.2 Specimen preparation Each set shall consist of three specimens.
Six sets of specimens shall be removed transverse to the weld:
• At 12, 3 and 6 o’clock position (or at one position for 1G and 2G position)
• For through thickness repairs and mid-thickness repairs.
Each set shall consist of three specimens.
Each specimen shall be prismatic with the following dimensions: 115 to 140 mm long, 15 mm wide and 5 mm thick.
It is reminded here that only samples free from defects should be used. Regardless of the pipe wall thickness (WT), the set of specimens shall be cut as close as possible to the pipe surface in contact with the effluent containing H2S (Root or Cap) and at mid-thickness with a minimum depth of machining to obtain flat surfaces.
For Partial Thickness Repair (PTR), sampling shall be carried out at the root of the repair weld. The extracted specimen shall include about 1/3 of the Heat Affected Zone located right under the root of repair as shown in Figure 2.
Moreover, the sampling at mid thickness of repair weld may be avoided (See Figure 2) provided welding parameters at mid thickness of weld repair shall be the same for both Through Thickness Repair (TTR) and Partial Thickness Repair (PTR) which means within the same essential variable ranges.
All specimen surfaces shall be prepared to a consistent repeatable finish with Ra ≤ 0.2 µm. The test specimen shall be made carefully at an appropriate machining rate to avoid overheating and undesirable cold work of the surface.
Test identification shall be marked on each specimen by an approved method.
3.3 Test required Round bar tensile specimens shall be machined in the base metal and parallel to the pipe axis. The test specimens shall be cut on either side of the qualification weld.
Then, a tensile test shall be carried out and the Yield Strength (0.2% proof stress) and Ultimate Tensile Strength shall be recorded.
The lowest Yield Strength value shall be taken as the reference for the Actual Yield Strength (AYS) mentioned below.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 92 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
This AYS of base material shall be the reference for calculating the stress level of the SSC tests.
Spare test specimens shall be available in case additional tests are needed.
Figure 1 - Removal of specimens in girth welds
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 93 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
Figure 2 - Removal of specimens in Through and Partial Thickness Repair (TTR and PTR)
For severe sour services applications and if specified in the PPS, circumferential SSC tests shall be performed. Test set-up and testing conditions shall be mutually agreed at the bid stage.
3.4 Test set up Test arrangement and loading of specimens shall be as per Appendix 2 of EFC Publication No. 16. All SSC tests shall be conducted at the %AYS of pipe base material. The measurement of applied stress shall be made using ISO 7539-2 § 5.4.1.4.4. Either electrical strain gauges or the deflection method (accuracy shall be ± 0.010 mm) can be used provided that the calculation procedure is validated against strain gauge measurements made on the specimen being tested.
The outer and inner rollers shall be made with materials which do not creep when subject to the sustained loads (glass or ceramic rods) and avoiding galvanic coupling with the specimen.
Stress applied to specimens shall be adjusted as stated here above and in paragraph 3.
3.5 Test conditions The Contractor shall choose between the two following options unless any specific requirement stated in the PPS.
Whenever the field conditions are more severe than the NACE solution, then SSC tests shall always be performed in an environment representative of field conditions.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 94 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
3.5.1 Solution NACE TM 0177 The test solution shall be NACE solution “A” as described in NACE TM 0177. This test solution is applicable for all field conditions under 1 bar of PH2S at atmospheric pressure.
The Supplier shall ensure that both the deaeration and H2S saturation is obtained as described in § 9.6.5 of NACE TM 0177. The H2S saturation shall be maintained at the required level during the test by continuous bubbling. Hydrogen sulfide concentration in the solution shall be measured by the iodine titration method as per NACE TM 0284 at start and at the end of the test.
The temperature of the solution shall be maintained at 24°C ± 3°C and regularly recorded from start to test completion.
The pH of the solution shall be recorded at the start and at the end of the test. The pH values shall be within the limits of NACE TM 0177 (i.e. initial pH = 2.7 ± 0.1 and pH max = 4.0 at the end of test).
Tests shall have a minimum duration of 30 days (720 hours under full H2S saturation).
SSC Tests Conditions
PIPELINE (1) SOUR SERVICE AREA (1) PIPELINE
EFFLUENT TEST CONDITIONS STRESS LEVEL (%AYS)
Mild 1 All NA NA
Intermediate & severe
2 & 3 All NACE TM 0177 pH = 2.7 - PH2S = 1 bar
80
Note 1: Refer to definitions in specification GS EP COR 170.
3.5.2 Specific application Application-specific testing shall be carried out following the principles of ISO 15156-2 Option 2 in an environment according to EFC Publication No. 16 procedure.
The test environment shall be assessed and provided by Company.
The environment shall correspond to the worst case estimated service environment in terms of in situ pH and H2S partial pressure for the pipeline including transient situations.
The applied stress shall be 90% AYS.
EFC Publication No. 16 test solutions shall consist of 50 g/L NaCl + 4 g/L of sodium acetate (CH3COONa) in distilled or deionized water. At pH greater than 4.5, the solution may be buffered through an addition of NaHCO3 in order to reach the required pH values.
Throughout the test, pH shall be measured, recorded and periodically adjusted to the specified pH with an allowance of ± 0.1 by addition of HCl or NaOH.
H2S gas purity shall be 99.5% minimum.
The Supplier shall ensure that both the deaeration and H2S saturation is obtained as described in § 9.6.5 of NACE TM 0177. The solution shall be saturated by using H2S + CO2 gas mixtures to obtain the desired H2S partial pressure and shall be maintained at the required level during the test by continuous bubbling.
Hydrogen sulfide concentration in the solution shall be measured by the iodine titration method.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 95 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
The H2S concentration of the solution shall be recorded after initial H2S saturation at the start of the test and at the end of the test.
The value shall correspond to the estimated H2S concentration corresponding to the applied H2S partial pressure.
The temperature of the solution shall be maintained at 24°C ± 3° and regularly recorded from the start to the end of the test.
The volume of test solution to the total exposed surface area of test specimens shall be 30 ± 10 ml/cm2 minimum.
Tests durations shall be of 30 days (720 hours under full H2S saturation) minimum.
3.6 Specimen examination Following failure or at the end of the test (whichever happens first), visual examination and photographs shall be made at x1 and x10 magnifications of the stressed surfaces of each specimen further to cleaning, dye penetrant and MPI examination.
Whenever a crack is found, the specimen shall be cross sectioned, polished and etched at the crack location. Photographs shall be made at a suitable magnification before and after etching.
Any cracks in weld shall be categorized by location namely: Base Metal, HAZ and Weld Metal.
The metallurgical features shall be documented with photomicrographs.
3.7 Test acceptance criteria Test specimens shall be evaluated for any evidence of hydrogen cracking including surface breaking and sub-surface cracks. All cracks shall be considered regardless of whether it is interpreted as sulfide stress cracking (SSC), stress-oriented hydrogen induced cracking (SOHIC), soft zone cracking (SZC) or hydrogen induced cracking (HIC).
No crack (or rupture) shall be accepted in any of the tested specimens (in HAZ, weld or base metal) within the 30 days period for any of the tests carried out.
Samples not broken containing welding defects clearly identified that may have generated cracks with length not exceeding 0.5 mm in the through thickness direction can be considered as acceptable.
Samples not broken with surface breaking or embedded cracks with length not exceeding 0.5 mm in the through thickness direction shall be considered as acceptable.
Small grooves or pits caused by corrosion shall not be considered, in mutual agreement between Supplier and Company.
3.8 Reporting At the end of the test, the Supplier shall provide a test report giving the following information:
a) Measurement of the actual applied stress (strain gauges, etc.)
b) Individual result for each specimen tested per set, with photographs and photomicrographs (when applicable)
c) Type of solution used for the tests. pH of solution at start and end of test and during the test for EFC Publication No. 16 solutions. H2S concentration at start and end of test
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 96 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
d) Location and dimensions of specimens
e) Mill certificates of materials tested showing full chemical analysis and mechanical properties
f) Testing procedure specification.
Conclusions and pertinent explanations (where needed) or concluding information. Any failure shall be analyzed by the Supplier and the cause of failure made clear to the Company before any re-test or remedial actions.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 97 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
4. Model applicable for the PPS The PPS shall be a collection of datasheets. A datasheet shall be issued for each line. The following datasheet format shall be used.
Project: Welding datasheet number:
Reference of the line:
Estimated number of welds:
1. Service condition
Onshore: Offshore: Water depth:
Sweet: Sour level 1: Sour level 2: Sour level 3:
Gas: Oil: Multi-phases: Water:
Installation (S-lay, J-lay, Reel-Lay, Towing…):
2. Pipe material
2.1. Inner pipe
Purchasing specification:
Grade: OD: WT:
ID tolerance: ID OoR: WT tolerances:
End preparation (V-bevel, Square cut …)
Cut-back length:
Clad or liner material (if applicable):
Clad or liner thickness:
Length of overlay:
2.2. Outer pipe (if applicable)
Purchasing specification:
Grade: OD: WT:
ID tolerance: ID OoR: WT tolerances:
End preparation (V-bevel, Square cut …):
Cut-back length:
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 98 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
3. Fatigue requirements (if any)
Fatigue sensitive lines are all lines exhibiting fatigue damage > 0.05 considering a safety factor of 10 as required in GS EP PLR 100 (It corresponds to a fatigue life below 20 times the field lifetime).
Location Riser RBS, Flowlines, spools
Period (year)
Environment DNV-RP-C203 SN curve
Period (year)
Environment DNV-RP-C203 SN curve
ROOT (inner pipe)
CAP (inner pipe)
ROOT (outer pipe)
CAP (outer pipe)
4.Testing requirements
4.1 Impact tests
Test temperature: Minimum single value
WM FL HAZ
Minimum average value
WM FL HAZ
4.2 CTOD tests (if required by Company)
Limitation in test provisions:
(to cope with project schedule issues)
Test environment: Refer to section 3 of the datasheet
Test temperature: 25°C Minimum values WM FL HAZ
4.3 FCGR tests (if required by Company)
Limitation in test provisions:
(to cope with project schedule issues)
Test environment: Refer to section 3 of the datasheet
Test temperature: 25°C Requirement: Refer to section F 300 of the GS.
4.4 Full scale fatigue tests (if required by Company)
Limitation in test provisions:
(to cope with project schedule issues)
Test environment: Refer to section 3 of the datasheet
Test temperature: 25°C Requirement: Refer to section 3 of the datasheet and section F 300 of the GS.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 99 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
4.5 Strip tests fatigue tests (if required by Company)
Limitation in test provisions:
(to cope with project schedule issues)
Test environment: Refer to section 3 of the datasheet
Test temperature: 25°C Requirement: For information only.
5. Project specific requirements
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 100 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
5. Model for quality control plan (qualification and production) The following Quality Control Plans (QCP) shall be fulfilled by the contractor for qualification and production. No contractor specific QCP shall be used.
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 101 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
A. JOB PREPARATION
a1 Applicable documents.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Review applicable documents.
Documents available for CPY review at least one week before the Kick off Meeting: • List of applicable documents • List of clarifications and granted
deviations/qualifications. • Document explaining the welding and
NDT philosophy (process, consumables...).
R
a2 Define material quantities for WPQ. Identify relevant pipe(s) for WPQ.
List of required material quantity. Pipe certificates.
Documents available for CPY review at least one week before the Kick off Meeting.
R
a3 Establish WPQ schedule.
WPQ schedule. Document available for CPY review at least one week before the Kick off Meeting.
R
a4 Kick off Meeting (KoM).
M.O.M of KoM. The scope of work, the welding and NDT philosophy and the applicable documentation shall be agreed.
H
B. PREPARATION OF WELDING PROCEDURE QUALIFICATION(S)
b1 Supply of welding consumables.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Welding consumables certificates. Internal checking report (conformity)
Welding consumables purchased according to GS EP PLR 426 rev 00 requirements. Certificates transmitted to CPY for review and approval before PPM.
R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 102 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
b2 Storage of welding consumables.
Procedure for welding consumables storage.
Procedure shall be transmitted to CPY for approval before PPM.
W/R
b3 Supply of materials for welding procedure qualifications.
Material (pipes...) certificates. Internal checking report (conformity, surface conditions...).
Pipes purchased according to GS EP PLR 426 rev 00 requirements. Certificates shall be transmitted to CPY for review and approval before PPM.
R
b4 Material cutting and marking.
Material cutting sheets and marking requirements.
Cutting sheets and marking requirements shall be transmitted to CPY for review and approval before PPM.
W/R
b5 Preparation of welding documentation;
PPS XXX GS EP PLR 426 rev 00
pWPS. Girth welds cutting sheets. ITP for WPQ. Procedure for welding parameters recording and heat input calculation.
Documentation transmitted to CPY before PPM.
R
b6 NDT documentation.
Prepare NDT documentation. Documentation transmitted to CPY before PPM: • Visual inspection procedure. • MPI procedure. • RT procedure • UT procedure • List of NDT operators and
certifications.
R
b7 Pre-Production Meeting (PPM).
MoM of PPM. All procedures shall be agreed. H
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 103 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
C. WELDING QUALIFICATION (MAINLINE PROCEDURE)
c1 Check bevel preparation.
pWPS XXX NDT report (dimensional and MPI)
Bevel according to approved joint design. No indications.
W/R
c2 Check pipe length. Internal record. Length according to pWPS requirements.
W/R
c3 Check welding equipment calibration.
Checking report. The equipments shall be rightly calibrated.
W/R
c4 Check line-up. pWPS XXX Line-up report: hi-lo measurements (minimum 4 locations).
hi-lo according to GS EP PLR 426 rev 00 requirements.
W/R
c5 Check welding consumables (filler wire, gas...).
pWPS XXX Recording of welding consumables used for WPQ.
Welding consumables certificates stamped “Acceptable for use”.
W/R
c6 Check preheating temperature.
pWPS XXX GS EP PLR 426 rev 00
Record of welding temperature.
W/R
c7 Root welding. pWPS XXX GS EP PLR 426 rev 00
Internal visual inspection. Record any defect.
No lack of penetration. No root defects.
W/R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 104 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
c8 Procedure Qualification Record
pWPS XXX GS EP PLR 426 rev 00
WPQR with: • Welding parameters • Pass distribution • Preheat temperatures • Interpass temperatures
All required information is recorded. H
c9 Specific test for copper shoes (if applicable).
pWPS XXX GS EP PLR 426 rev 00
Test report. Requirements as per GS EP PLR 426 rev 00.
H
D. WELDING QUALIFICATION (REPAIR PROCEDURE)
d1 Check preparation. pWPS XXX Bevel according to approved joint design. No indications.
W/R
d2 Check welding equipment calibration.
Checking report. W/R
d3 Check line-up (for TTR).
pWPS XXX Line-up report: hi-lo measurements (minimum 4 locations).
hi-lo according to GS EP PLR 426 rev 00 requirements.
W/R
d4 Check welding consumables (filler wire, gas...).
pWPS XXX Recording of welding consumables used for WPQ.
Welding consumables certificates stamped “Acceptable for use”.
W/R
d5 Check preheating temperature.
GS EP PLR 426 rev 00 pWPS XXX
Record of welding temperature.
W/R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 105 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
WPQR with: • Welding parameters • Pass distribution • Preheat temperatures • Interpass temperatures
All required information is recorded. H
E. WELDING PROCEDURE QUALIFICATION TESTING
e1 Visual inspection (cap).
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Inspection reports. W/R
e2 MPI examination of coupons.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Inspection reports. W/R
e3 RT examination of coupons.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Inspection reports. W/R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 106 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
e4 UT examination of coupons.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Inspection reports. W/R
e5 Specimen sampling for testing.
Cutting sheets XXX Specimens stamped according to cutting sheets.
W/R
e6 Testing. PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
Test report including: • Test pieces dimensions, • Calibration of equipments, • Tests conditions
(temperature...) • Tests results
As per PPS XXX and GS EP PLR 426 rev 00 requirements.
W/R
e7 Welding book. Welding book including: • pWPS • WPQR (mainline and
repairs procedures)
As per PPS XXX and GS EP PLR 426 rev 00 requirements.
H
F. PREPARATION OF PRODUCTION WELDS
f1 Prepare WPSs for production.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
WPSs In accordance with WPQR. R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 107 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
f2 Prepare equipments.
List of required equipments for site welding.
Available for review. R
f3 Prepare consumables.
List of required welding consumables: type and quantity for site welding.
Available for review. R
G. WELDER QUALIFICATION
g1 Prepare WPS for welder qualification.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
WPS R
g2 Welding of qualification coupons.
PPS XXX GS EP PLR 426 rev 00 DNV-OS-F101 October 2013
According to WPS. W/R
g3 Marking/Identification of the coupon
g4 Visual inspection. Test report. Operator certification.
As per PPS XXX, GS EP PLR 426 rev 00 and DNV-OS-F101 October 2013 requirements.
W/R
g5 RT inspection. Test report. Operator certification (min level II).
As per PPS XXX, GS EP PLR 426 rev 00 and DNV-OS-F101 October 2013 requirements.
W/R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 108 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
g6 Mechanical tests Test report. As per PPS XXX, GS EP PLR 426 rev 00 and DNV-OS-F101 October 2013 requirements.
W/R
g7 Welder certification Welder certificate Specify the qualification range. H
H. PRODUCTION WELDING
h1 Check bevel preparation.
pWPS XXX NDT report (dimensional and MPI)
Bevel according to approved joint design. No indications.
W/R
h2 Check residual magnetism
pWPS XXX GS EP PLR 426 rev 00
Residual magnetism below 25 Gauss W/R
h3 Check welding equipment calibration.
pWPS XXX GS EP PLR 426 rev 00
Checking report. W/R
h4 Check line-up. pWPS XXX GS EP PLR 426 rev 00
Line-up report: hi-lo measurements for all welds (minimum 4 locations).
hi-lo according to GS EP PLR 426 rev 00 requirements.
W/R
h5 Check preheating temperature.
pWPS XXX GS EP PLR 426 rev 00
Record of welding pre-heat temperature.
Above the minimum qualified. W/R
h7 Visual inspection after root welding.
Any indication shall be grinded. W/R
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 109 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
n° Step Related procedures Responsible Activity Acceptance criteria/Deliverables Inspection
CTR 2nd P 3rd P CPY
h8 Check welding parameters and heat input.
Welding parameters shall be displayed and recorded in an electronic format.
Shall be within the range of qualified parameters.
W/R
h9 Check interpass temperature.
Shall not exceed the maximum interpass temperature qualified.
W/R
h10
General Specification GS EP PLR 426
Site welding of carbon steel and CRA pipelines (sweet and sour service, onshore and offshore) according to DNV-OS-F101
Rev.: 01 Effective date: 10/2015 Page: 110 of 110
This document is the property of TOTAL S.A., it contains confidential information which may not be disclosed to any third party, reproduced, stored or transmitted without the prior written consent of TOTAL S.A.
The information contained in this document does not substitute to the applicable laws and regulations.
6. Overview of ECA
* Shall be performed for embedded, inner and outer surfaces breaking flaws. ** In any case most stringent criteria between ECA and workmanship shall apply.