* bp wai Sey ANDREW DEVELOPMENT PROJECT SPECIFICATION ial 380001.1 WELDING AND NDT OF CARBON STEEL [10'S LINEPIPE TO BS 4515-1(2004) bid WG DOCUMENT NO. _ | 37AND-F041G7001-Y-SD-0039-000 BP DOCUMENT NO. _| ADP-ME-SPE-8014-000 [er [ aaeanie | iSsuED Fon consTaUeTION = ie #(COMMENTS SHEET REVISION al or DATE ‘a0107/2012 zaoerzot2 ‘COMMENTS ISSUED FOR REVIEW/COMMENT ISSUED FOR CONSTRUCTION ‘STAND-FO41G7001-Y-$0-0089-000 Rev C1[BP Exploration Operating Company Lid ‘Andrew Development Project WGIM: ‘and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) WELDING AND NOT OF CARBON STEEL LINEPIPE TO BS 4515-1(2004) ‘Table of Contents 1.0 INTRODUCTION. 4.1. Purpose of Document 5 12 Solely 5 13. Detintions. nnn 14 Abbreviations. 6 1.5 HSEQ for Pipeline Welding Operations 8 1.6 Pre-Produetion Consutation 8 4.7 Duties of CONTRACTOR 8 18 Quality Conformance... — 8 1.9 Records sn so 8 1.40 Contractor's Personnel 10 2.0 NORMATIVE REFERENCE! 241 Specification Compliance, 12 22 Confit of Information 13 23 Revisions... 13 24 Referenced Documents 13 25 Codes and Standards 13 3.0. TERMS AND DEFINITIONS. 31 General 16 3.26 Batch (lot) oA 3.28 Quality plan 7 7 — son 4.0 INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED. .nnnssnnnseenne 4.1. Information to be Supplied by COMPANY. . 7 Page Tof7@ _ STAND.FOATG700%-Y-SD 008000) Rev G1[BP Exploration operating Company Lia ‘Andrew Development ret wain Se Wotding and NOT Carbon Ste Uneppe to BS 418-1(2009 20 42 50 6 61 62 70 m4 72 80 a1 82 88 9.0 ea 92 100 toa 102 104 105 108 107 110 Items subject to approval by COMPANY - EQUIPMENT. - 28 WELDING PROCESSES. General. —— 27 ‘Automatic (Mechanised) Welding 27 WELDING CONSUMABLES. General 29 Storage and Handling 30 ‘TESTING, QUALIFICATION AND ACCEPTANCE OF WELDING PROCEDURES. FOR BUTT WELD: General sos 92 Changes Affecting Qualification and Approval (Essential Variables) of Butt Welds...96 Destructive Testing of But Welds and Full Penetration Repair Welds. a2 ‘TESTING, QUALIFICATION AND APPLICATION OF WELDING PROCEDURE FOR FILLET WELDING. Non-Destructive Tasting of Filet Welds. 48 Destructive Testing of Filet Wolds 43 TESTING, QUALIFICATION AND APPROVAL OF WELDERS. General 49 Butt Joints. . 49 Fillet Welds for Sleeves, Sockets, Slip-on Flanges or Other Attachments. 50 (Changes Affecting Qualification and Acceptance (Essential Variables) of Welders .50 Non-Nastnieve Testing 50 Destucve Testing 50 PRODUCTION WELDING. Pronmity of Welds ol el 74 S7AND.FOAG7O01-V-SD-o0a-000 Rev Gt PaWelding and NDT of Carbon St tos 4515-1(2009) spt onrngconrny wai Se f 11.2. Pipe End Preparation 113. Fusion Faces. 52 114 Alignment... sn 52 11.5 Line-Up Clamps and Pipe Support. 52 116 TackWelds. 53 118 Stay Ares. 54 11.9 Weather Conditions. nnn 54 11.10 Preheating and Post Weld Heat Treatment. 55 THAT Branches nn 87 11.12 Intor-un Cleaning 58 11.13 Partaly Completed Joints snneeSB 11.44 Filet Weld Attachments 58 TAB ReC0188 so nn 58 12.0 INSPECTION AND TESTING OF WELDS. 121 General 60 122. Personnel Qualification et 124 Radiographic Testing - sn 425 Manual Utrasonic Testing —— een 126 Automatic Utrasonic Testing sn or 127 Magnetic Paticle Testing or 128 Liquid Penetrant Testing 18.0 ACCEPTANCE AND RECTIFICATION OF WELDS..... 13.1 Non-Destructive Testing Acceptance Criteria 182 Rectification of Welds. ANNEX H ADDITIONAL REQUIREMENTS FOR PIPELINES SUBJECT TO HGH ‘STRAIN LEVELS Page sof —_-SYAND FOATGTOOI-V-SD 0080.00) Rev GF{sP exploration Uperating Company Lta Aro Boepmen le wai Sey 7 ‘Welding and NDT of Carbon Steel Linepipe to BS 4515-1(2004) Ht Introduction ——— H2 General = er HS Weld Procedure Qualfication Testing pT 4 Production Welding = Pagedol7@ __ STAND.FO#IG7O01-¥-S0.0000.000 Rev GrBBP Exploration Operating Company Lid ‘Andrew Development Project WGIM ‘Welding and NDT of Carbon St 2008 1.0 INTRODUCTION 1.1 Purpose of Document This specication when read in conjunction with the referenced standards, specications, cotter sted documents and relevant data sheets, defines the minimun technical requirements for the field welding and NOT of carton steo nepipe in accordance with BS 4815-1: 2004 fr sour and non-sour service conditions (applicable t seal grades upto XE Paragraph numbers in this specication corespond to BS 4516-1: 2004. Modifications to 'BSA515-1: 2004 are dented as Add cr Mosifed to lad inthis specttion, It is notte intention of this document to be applied to anything other than the anticipated \worksoope contained within the Caisson Breakout to the platform and is epaciiealy rot Intended as guidance or implementation of ary kind in relation to rgid subsea fowines/pipeines. 12. Satety [All ricks to personnel and the environment resulting from the Andrew Project chould be AS Low As Reasonably Practcable (ALARP). Safety is the primary consideration during design and all risks associated with the design shall be minimized by adhering to the relevant governing design codes, and COMPANY Intemational procedural requirements 1a Definitions Approval Consent given in writing, on behalf of COMPANY in advance of an event, by a person wih appropriate authotty. Approval by COMPANY doos not relieve CONTRACTOR from any ofits contractual ebigtions or from having to make good any pat of the item to be elivered found to be defective sutsequent to COMPANY'S approval. comPANY [BP Exploration Operating Company Lid or any ofits ubsiciari or representative agents ‘CONTRACTOR ‘Tho Party contacted by COMPANY to be responsible for the welding and NOT. Lnepipe Generic statement covering spools, flanges and fitings. Shat Incicates mandatory requirements Page 50174 STAND FOATG7O0I-V.S0.0060.00) Rev GI[BP Exploration Opersting Company Ltd ‘Andrew Development Project WGIM 4 Indicates preferred course of action. SUPPLIERIMANUFACTURER A party which supplies materials, equipment or services EMPLOYER Abbroviations accor ALARP ANS! ASNT as™u aws Ban BaAS-CSWIP BINoT Bs cen cei 00, oswir pling wo! owst ECA EWE maw esFcaw to CONTRACTOR, Road COMPANY. [ASNT Central Ceriicaton Programme ‘As Low as Reasonably Practoable American National Standard Insite ‘American Society for Non-Destructive Testing “American Society for Testing and Materials American Welding Society Federal institute for Materials Research and Testing (Germany) British Gas Approval Scheme — Certification Scheme for Welding and Inspection Persona British Instiute of Non-Destructive Testing Brish Standard Chartered Engineer ‘Carbon Equivalent (Internationa Institute of Welding Formula) Carbon Dioxide CCetfication Scheme for Welding and Inspection Persornel Charpy V Noten Diploma ingeniour (Europe) Double Wall Double Image Double Wall Single Image Engineering Coal Assessment European Welding Enginoer ‘Gas Metal Are Welding Gas Shielded Flux Cored Are Weiding Page6ol7#__ STAND.FOATG700%-¥-S0 0008.00) Rev G1BP Exploration Operating Company Lid ‘Andrew Development Project WGIM ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) craw {Gas Tungsten Arc Welding Haz Heat Atfected Zone HSE Heath and Sately Executive HsEO Heath, Safety, Environmental and Quality HV Vickers Hardness 1a Image Qualty Incicator 180 International Standards Organisation we International Welding Engineer Mer Magnetic Particle Testing or Minimum Design Temperature mm atimetres ur Manual Utrasonie Testing Nor Non-Destructive Testing nist National Institue of Standards and Technology (USA) o Oxygen, Pb Lesa Pom lto-Bessyo Formula Carbon Equivalent PON Personne! Certlication in Non-Dastuctve Testing POMAW Pulsed Gas Metal Are Welding POR Procedure Qualification Record pwPS Preliminary Welding Procedure Spectcation RE Fadiographic Examination RT Radiographic Testing RMS Foot Mean Square saw ‘Submerged Are Welding sMaW Shiolded Meta Arc Welding sms Spoctod Minimum Yield Strongth Swe Single Wall Examination Page Tel 7a SYAND-FON107001-¥-S0-0080-009 Rev G1BBP Exploration Operating Company Ltd Andrew Development Project WGIM ‘Welding and NDT of Carbon Stee! Linepipe to BS 4516-1(2004) sw Single Wall Viewing swt Single Wall Single Image ™ Tho Welding institute (UK) ur Utrasonie Testing ve Visual Examination w Visual Inspection wes Wilding Procedure Specification wea Wilding Procedure Qualicaton wear Welding Procedure Qualification Test 1.5. HSEQ for Pipeline Welding Operations, Welding, cuting, NDT, and associated operations shall be undertaken in a safe manner and with due regard to individual heath and safety, and the minimisation of environmental Impact consistent with COMPANY requirements. Welding, cuting, NDT activites, and associated operations shall feature in CONTRACTORS operational safety planing and in the safety aut schedule, ANS! 249.1 or similar codes shouldbe followed, Measures shall be taken to ensure adoquate ventilation and contol the quality of breathing air during welding operations. ‘As a minimum, radiography operations shall conform tothe lensing Raclation Regulations 1980 (SI 1999 No. 2282) and the Approved Code of Practice and Guidance - Working with lonising Radiation: lonsing Regulations 1998. Environmental guidance shal be taken from BS EN 14717 when undertaking welding and its associat processes. 1.8 Pre-Production Consultation Pre-produetion meetings shall be held with COMPANY and any appropriate third-party Inspection personne in odor to ensure that all partis fully understand the requirements. “Those mectngs shall be held botore wong procedure qualification toting and before ‘commencement of fabrication ‘COMPANY Welding Engineer shal be consulted at he folowing stages: + During bid evaluation to agree the basic welding and NDT methods proposed and to advise on acceptably. Page @ oT STAND-FOATG7O0I-¥-SD.0000000 Rev G1BP Exploration Operating Company Lid ‘Andrew Development Project WGIM ‘Welding and NDT of Carbon Stee! Linepipe to BS 4516-1(2004) ‘+ Before weld procedure qualification for approval of the proposed welding procedures (ewes), ‘+ Batore production welding for approval of the fal WPS. 1.7 Dulles of CONTRACTOR Construction, welding and pipoday shall be card out by a well tained and qualified ‘workforce employing reliable, modem, and well maintained equipment and shall also be fuly ‘compliant with safe and environmental sound wesking practices ata times. Unless advised otherwise by COMPANY welding and associated equipment including, but rot limited to: heating equipment, fluxes, gases, filer metals, welding units, mechanical handing, testing equipment, and NDT equipment shall be supplied and appropriately calibrated. Be responsible fr the compliance of sub-contractors with this specication 1.8 Quality Conformance CONTRACTOR shall demonstrate tothe satisfaction of COMPANY that his acivites within ‘he scope of this document comply with ISO 3834 Parts 1 and 2 and the relevant sectons of BS EN ISO 9001, Prior tothe commencement of work, CONTRACTOR shall submit to COMPARY for rviow ‘and approval, a Quality Plan and procedural specications, which shall include procedures for storage and contol of materials and welding consumables, welding and nor-destuctive testing and supporting qualification records, The Qualty Plan shall defne all sub- contractors involvement within the werk, "Names of indvduals Weling Engineers / Welding Inspectors responsible fr implementation ‘of qualty assurance and quality contol functions shal be included. 1.9 Records Documents required by his specication shall be gathered, colated, indexed, stored, and finally presented to COMPANY for secut long term storage. ‘Ag identiying, by number, each pipe or fing and identifying the weld nunbers joining thom to other tems shal be compile. Each circumferential weld (whether a feld joint or shop-mado weld) shall be allocated a Unique number, which shal be used for reference tothe weld in reports and test documents. ‘Al documentation shall be avalablo in an agreed, good qual, elctroni format Page 978 SYAND-FONTG700%-¥-S0-0008 000 Rev GT[BP Exploration Operating Company Ltd ‘Andrew Development Project Welding and NDT of Carbon Stee! Li 1.10 Contractor's Personnel 1.0.1 General Personnel associated with welding including engineers, welders, welding operators, welding inspectors and non-destructive testing technicians shall be propery trained and qualified to recognised industry standards by examination andor by individual ast 1.10.2 Welding Engineers ‘A competent and sultably qualified Welding Engineer shall be employed. The Welding Enginoor shall be responsible for the technical aspects of all welding op the following: jens inclucing Selection of welding processes, equipment and consumables; Preparation and qualification of welding procedures; ‘Qualticaton of woiders; Providing technical oversight ofthe production welding: LUaison with COMPANY and the NDT SUB-CONTRACTORS. ‘The minimum experience and qualification level for the Welding Engineer should be: Chartered Enginwer (C Eng / ipl Ing) holding as a minimum a dogree in engineering, ‘metallurgy or materials science and having specialised training in welding technology. The requirements of ISO 14731(FDIS) / EN 719 shoud be met as demonstrated by the European Welding Engineer (EWE) or Intemational Welding Engineer (IWE) qualification Professional Membership of The Welding Institute (UK) is desirable and a minimum of 5 years relevant experience in the pipeline welding or fabrication industry is deemed ‘essential 1.10.3 Welding Inspectors Competent and certificated welding inspection personnel shall be employed in sufficient humors to ensure that all welding rlated activi are adequately inspected Welding Inspectors shall have @ sound knowedge of welding processes and thelr pplication to pipeline welding, and possess the knowadge and sks to carryout the tasks ‘ven inthe accepted Quality Plan, including thase necessary forthe follwing: + Conduct of routine inspections and checks on ste or at SUPPLIER'S in a systematic + Production of accurate records and reports Welding Inspectors shal, 2s a minimum, hold current certification to any of ‘he folowing standards: Page 100174 STAND.FOMTG7O0I-Y-SD 0050.00) Rev GtBP Exploration Operating Company Ltd Meret Semone tes wee, Welding and NOT of 110.4 on Steel Lineplpe to BS 4515-1(2004) CSIP (TW, UK) — Welding Inspector, BGAS.CSWIP (TWI, UK) ~ Welding Inspector, PON (BINDT, UK) ~ Wold Inspection Level 2; [AWS QC (1996 or later editon) ~Ceritod Welding Inspector (CW, ‘Alternative Walding Inspector catiiation is unacceptable unless aocopted by COMPANY. A Senior Welding Inspector shall be employed to supervise the work of the welding Inspectors. The role of senior welding Inspector requires at least 10 years relevant experience and sound knowedge of welding processes and thelr application. Formal engineering taiing through apprenticeship and technical college education are required. Senior Welding Inspectors shal, as a minimum, hold curent coriication to any of the following standards: ‘© CSWIP (TW, UK) - Senior Welding Inspector, ‘+ BGAS-CSWIP (TW, UK) ~ Senior Welding Inspector (SWI) or Senior Pipeine Inspector (SP); ‘+ PCN (BINDT, UK) — Weld inspection Level; ‘+ AWS QC (1996 or later ecton) ~ Senior Certiid Welding Inspector (SC NDT Personnel NDT personnel shall hold current Level 2 certification (or equivalent), specific to weld testing, for the appropriate NDT methods o any ofthe following standards as a minimum: SMP (TW, UK); BGAS-CSWIP (TW, UK) PON (BINDT, UK}; [ACCP (ASNT): SNT-TC-1A(ASND) NDT personel certificated to the requirements of a Written Practice under the rues of 'SNT-TC-1A shall not be used, unless the Wren Practce and the personne certification hhas boon reviewed and accepted by COMPANY forthe speciic work. Personnel engaged in AUT shallbe qualified in accordance with GIS 43-339 Page 11 of 74 S7AND.FONTG7O01-¥-80 0000000 Rev Gi[BP Exploration Operating Company Ltd Andrew Development Project WwGIM ‘Welding and NDT of Carbon Stoo! Li 2008 20 NORMATIVE REFERENCES 21 Specification Compliance ‘This specticaion has been wren to be in ful compliance wih the aprroprate BP Engineering Technical Practices (ETP) and Group Instruction for Supely(GIS's for Pipeline Wielding in accordance with BS 4516-1 2004 CONTRACTOR be in complete compliance with the requirements ofthe flowing GIS ‘documents unless instructed thers by this speciation: aisasait Longtusinal or Helical Seam Submerged Are Welded Linepipe in Grades up to X80 ~ Supplement to API SL, 43" Edtin 30 May 2007. ais 4aa12 High Frequency Inducton (HF) or Electic Resistance Welded (ERW) Linopipe in Grades up to X70 - Supplement to API SL, 43° Ealion, 30" May 2007. Gis 43.313 ‘Seamless Linepipe in Grades up to X60 ~ Supplement to API St, 4rd Eation, 90” May 2007. cis 43-393, Guidance on Industry Standard for BS 4515-1 Pipeline Welding, 20" July 2006 ais 43-399 ‘Automated Ulrasonic Testing of Pipeine Gith Welds, 30" October 2007, ais 18-012 Guidance on Industry Standard for Storage and Control of Welding Consumables, $1" October 2007 ‘Within the GIS documents CONTRACTOR shal replace the words ‘mus’ and ‘should with ‘shal to read as mandatory requirements. Any ‘hall’ or ‘must in commentary (txt in bie itais) does not speci an ETP requitement Note 2: Techical deviations, non-applicable paragraphs and clauses of GIS 43-383 to this specication are detailed within technical deviation (PK-DR-002), In addon, CONTRACTOR shall comply in ful with the latest issues of relevant codes, statutory regulations and other documents referenced within the contrat and hein CONTRACTOR is responsible forthe quality of materials and workmanship in performance ofthe work Page (Bal 74 SYAND-FOW1G7001-¥-SD 0000-009 Rev G1BP Exploration Operating Company Lid ‘Andrew Development Project toBs 451 200 22 Confliet of Information Inthe event of any confi, inconsistency or ambiguity between the contact documents, this SSpectcaton or any cther specication and associated data sheets, of wih any of the ‘ppliable codes, standards and regulations CONTRACTOR shall immediatoly inform COMPANY in wing and recoWve writen clarification trom COMPANY belore proceeding with the work, 22:1. Project Documents “The folowing documents pertaining tothe Andrew Project ave related or applicable to this ‘Speciation DEV-AADMP.SPPK-XXXX _Speccation or Lnepipe DEV.AAD-MP-DSUPK.1055 Carbon Stel Induction Bends Speciation DEV.AAD-MP-SP-JPK-1056 Spectleation for Carbon Stool Fanges, Ftings and Bukheads 23° Revisions ‘The latest issues forthe relevant standards, codes, stator regulations and epectcations referenced hersin shall be applied to the work, unless othenvis stated 24 Relerenced Documents, Itis the responsibilty of CONTRACTOR to ensure that he has received from COMPANY all specifications, ete which are referenced within applicable specifications to enable him to understand and comply with all aspecs of the work to be performed for COMPANY. 28 Codes and Standards CONTRACTOR is responsible for the qualily of the work and compliance with the requirements of the applicable International Codes, Statutory Reguations and Spoctcations as listed. Tho following Codes, Standards and Specifications with their latest published amendments shal apply. Statement does not apply 1 BS 4515-1: 2008 25.1. American National Standards Insitute (ANSI) / American Welding Socioty (AWS) ANSUAWSAAS Standard Methods for Determination of the Difusible Hydrogen Content of Martensitc, Bainic, and Ferric Steel Weld Motal Produced by Arc Welding Page 130174 STAND-FOATG7O0I-Y-S0-000800) Rev GIBBP Exploration Operating Company Ltd ‘Andrew Development Project weim Welding and NDT of Carbon Stoel Linepipe to BS 4515-1(2004) ANSVAWSAS:32 Specification fr Welding Shieting Gases ANSVAWSC8.3 Recommended Practices for lr Carbon Are Gouging ard Guting ANSVAWSAC1 Standard for AWS Cerficaton of Welding Inspectors ANSVAWS 249.1 Safetyin Welding Cutting, and Aliod Processes, 252 American Society for Testing Materials, ASTM E562 ASTME1A15.06 Standard Teet Mathod for Ciaeication of Fim ‘Systeme for Industrial Radiography 25. Bish Standards and Reguatlons BS 4515-1 (2008) _Spectication for welding of steel pipelins on land and cfshore Carton and carbon manganese steel pipelines BSEN 280.9 Specication and Approval of Welding Procedures for Metalic Materials BSEN 1043 Destructive Testing on Welds in Metalic Materials ~ Hardness “Testing Part 1 — Hardnoss Tosts on Welded Joints SEN 10045 Charpy Impact Testing of Metalic Materials SEN 10204 Metalic Products ~ Types of Inspection Document BSEN 12074 Welding consumables. Quality requirements for manufacture, supply and distibution of consumables for welding and allied processes BSEN 1435 Non-Destructive Examination of Welds. Radiographic Examination cof Welded Joints BSENISO 14175 Welding consumables. Gases and gas mistues for fusion welding and alled processes BSEN 14717 Welding and alied processes. Environmental check list BSEN ISO 156091 Specification and qualiication of welding procedures for metalic materials, Welling provedure specicaion. A welling BSENISO 8001 Quality Management Systems ~ Requirements ‘SI 1999 No. $282 The lonising Faciations Regulations 1999 Page 1gal74__ S7AND-FO4IG7OOT-Y-50-0080-000 Rev CiBP Exploration Operating Company Ltd maecinoaeace wom &, Welding and NDT of Carbon Steel Linepipe to BS 4515-1(2004) 2.5.4 Intemational Standards Organisation 150.2504 180.3690 180 3834 808173 180 5580, 180 6507-1 180 11690-1 180 14731, 180 17636 150 17638, Radiography of Welds and Viewing Conditions for Fims.— Utilstion of Recommended Pattoms of Image Quality Indicators (Qs) ‘Welding and Alied Processes ~ Determination of Hydrogen Content In Feritc Stoel Are Welds Quality Requirements for Welding. Fusion Welding of Motalc Materials, Parts 1-6, Destructive Tests on Welds in Metalic Materials ~ Bond Tests Non-Destructive Testing ~ Industrial Radiographic Muminators — Minimum Requirements Metalic Materials. Vickers Hardness Test Test Method [Non-Destructive Testing ~ Industial Radiographic Fims ~ Part t: Classification of Film Systams fr Industial Radiography ‘Welding Coordination, Tasks and Responsibities Non-Destructive Testing of Welds ~ Radiographic Testing of Fusion ‘Welded Joins Non-Destructive Testing of Welds ~ Magnetic Particle Testing Page 15174 STAND-FO#IG7OOT-¥-50-0090-00) Rev C1Be Exploration Operating Company Lid nave Development ajc wai Sey ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) 30 TERMS AND DEFINITIONS 21 General ‘This document shall be read hereafter in conjunction with BS 4516-1: 2004 as clated, ‘amended or supplemented below. The clause numbers used rellect conespondinly rumbered sections within, ‘The following terms shall be Mosiied to Roa 3826 Batch (lo) Acingle heat of ter wire, a single blend of flux, or for covered electrodes or cored wie, the cambination ofa single heat of cored wire with a single dry blend of fux cover cr cor. 3.28 Quality plan Document spectving which procedures and associated resources shall be applied by whom and wen to @ spect project, produc, process or contract. Page 160174 S7AND.FO#TG700%-Y-80 0088.00 Rov G1BBP Exploration Operating Company Ltd Andrew Development Project wei Welding and NDT of Carbon Steel Linepipe to BS 4515-1(2004) 4.0 INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED 4.41 Information to be Supplied by COMPANY Information to be supplied by COMPANY Is given as additions or carficatons to the appropiate Sections of BS 4515-1: 2008. ‘CLAUSE 'BS 4515-1: 2008 ‘SUPPLEMENT | Whether batch testing of ‘Bach testing of electrodes and filer materiale lectrodes andiler materiatss | required. See secton 7.1 of BS 45151: 2004 required. ‘and as modtiod by secon 72.1 of is spectication, Production welding shal ulise the same batches ‘of consumables as those Used for welding ‘procedure qualification. See section 7.1 of BS {S515-1: 2004 and az modified by secon 722 of this specication, > | Whether specie compostional | _Allwelding consumables wil be proposed by controls arb tobe applied tothe | CONTRAGTOR and subject to COMPANY ‘oposited weld matal approval. Se section 7.1 of BS 4515-1: 2004 {and as modiied by sections 42 a and 71 ofthis speciation, © | The degree of yield strength “The yield strengih of welding consumables shal ‘overmatching for welds pipe | overmaich the SMS at ambient and elevated mates where installation Temperatures unless otherwise agreed by methods invalve plastic ‘COMPANY. Soe secon 7.1 of BS 4515-1: 2008 {deformation ofthe pipe or for ‘and as modified by secton 8.3.2 of his \Waldsin pipe of spectiod minimum | spacicaton. el trength (SMS) 500- s0Nmm ‘| Whether atferent batches of Diflerent batches of electrodes and Mr materials electrodes and ler mateais aro | shall be Individually identfied and completly tobe incivdualy denfiable and | separated. Soe section 72 of BS 4SI5-1: 2004, completely separated, | Thetype andnumber of reieste | _Re-tosing is permied subject to CCMPANY required inthe event of fale approval, provided CONTRACTOR can ‘uring tating and qualification of || demonstrat that te test failure was due to error welding procedures. In test procedure, specimen preparation or defect in the mechanical test specimen, See section 8.1 Of BS 4515-1: 2008, | Whether an atrate location i= |” No alfonative locations ara required pair spectid forthe excavation {est weld, See section 8.1 of BS 4515: 2008, locaton forthe ropair weld test. {| Whether stain ageing data andlor | The use of historical data may be permitted adaonal tess ae roguired as the | subject to meeting the roquiremonts ofthis basis fr weling procedure ‘specication and agroed by COMPANY. See approval for pipe-eolng ‘Annex Hof tis specication Page 1774 S7AND-FO«TG7001-Y-S0 0080-00 Rav G1[BP Exploration Operating Company Ltd ‘Andrew Development Project ‘Welding and NOT of Carbon Stee! Lin WGIM 10 BS 4515-1(2004) ‘CLAUSE BS 4515-1: 2004 ‘SUPPLEMENT | Whether specimens shoud be lowed to coal for curation othor than 24 hours before testing ‘Specimens shall be allowed 1 cool» ambient temparature for 24 beter testing unless an alternative duration is spectied by COMPANY. ‘See section 1 of BS 4515-1: 2004, T___| The method of weld renal testing wen a minimum weld metal yield strength requirement is specie. ‘All weld tensile testing shallbe performed in ‘accordance withthe method spectied by ‘COMPANY. No fattening of test pieces shal be permitted. Soe section 3.2 of BS 4815-1: 2004 land a8 modified by secon 8.3.2 of tis ‘Spocticaton, ‘Charpy toughness and test temporature for conditions othor than pipe and wall thicknesses up to and including 25mm, minimum design temperatures not ower than 10°C and pipe material wth a specified minimum yield strength ‘ot greater than S5ONnm Impact requirements as per section €8.2 of BS 4515-1: 2004 and as medi by section 8.3.2 of this specification, | Whether adlonal NDT methods {or filet welds apply. “There are no addional NDT requirements to sual and MPE for filet welds. See ection 9.1 of this specication, ‘Whether the hardness values of {est specimens excoed those given in Tab 4 “Tho hardness values ofthe test spedmen shall not exceed those given in Table 4 of 35 4515-1 2008. See section 9:2.4,1 of BS 4515-1: 2008, im | Whether proposed change to a welding procedure wil require re- ‘quaifcaton ofthe welders. ‘Al changes fom approved weld procedures/specticatons shal be subject to prior ‘wlan COMPANY approval an, where necessary and appropriate, othe sucessful e- ‘qualticaon of WPS andlor weldors. Soe section 40.5 of BS 4515-1: 2008 and as mocted by ection 10.5 o this specication, | Whether prevaiing weather ceondttons are such that quay of ‘he competed weld would be impaired. ‘When necessary, measures shal be taken, 6.9 by covering the pipe ends, to prver: water or other extraneous mater being chanelle into the wold region. Soo socton 11.9 of 3S 4515-1 2004 and as madiied by section 10 of hs spectication, (© | The methods) and requency of visual inspection and non- destructive testing ‘See section 12:1 of BS 4516-1: 2008 and as madiied by section 12.1 of his spectcation, P| Whether competed welds aT bbe ground. ‘See eoaton 121 of BS ABTS: 2000 @ | Whether allemative techriques are tbe used for racographic testing ‘See sodton 12.4.1 of BS 4515-1: 2034 and as ‘medifieg by section 12.4.1 ofthis spectioation, of welded but joints, | Utrasons testing aoooptance ‘S60 section 125. of BS 4515-11 2004 and as criteria edied by secon 12.5.3 ofthis specication. ‘SAND. FOAIGTOOI-Y SD. 0050-009 Rev GT Page 18at74[BP Exploration Operating Company Ltd ‘Andrew Development Project wom&e Welding and NBT of Carbon Stee Linepipe to BS 4515-12008) ‘CLAUSE BS 4516-1: 2008 ‘SUPPLEMENT | Whether NDT acceptance citeria | See section 18.1.1 of BS 4515-1: 2008 ana are tabe based on quality control | madiied by eacton 13.1.3 ofthis epestication. orengineetng crical assessment. 1 | Whether the maximum planar Planar daects are ot acceptable. See Section defect dimension so beless than | 13.12 of 8S 4518-1: 2004 and as mecsied by 25mm, Section 18.1.2 of ths specication. | Whethera more stingent limit for | Nott exceed Sm. I service condos root penetration is requird, ocesstato a more stingont ei, tis shall bo Spectied by COMPANY. | Whether eliffrent hardness ims | Hardness shall be in aocordance wah the lie for anode bonding joinis are ‘utined within his specication. reajulted or anage bonding joints. ‘Ww | The composton and thickness of | Not applisable tha pipe corrosion resistant aloy Ai x | The method of nepipe Not applicable ‘manufacture, inciting seal weld andongtudnal weld dtals whore these tems are presenti CRA clad and ined pipelines. ¥ | The maximum agen content of | Not applicable, backing gs during welding or the corrsion tess thatthe wed is required to pass, 2 | Whether the strength conibution | Not applicable, ‘ofthe GRA ayer has been used in the dosign, ‘aa | Whether adctional hardness ‘Not applicable. traverses are roquired in CRA clad and ined pipetines. ‘25 | Hardiness limits for GRA porions of | Not applicable the woldment. ‘a> | The composition imi for chemical | Not applicable, analysis ofthe weld in CRA clad and ned pipatines. ‘ad | Whethera chemicalanaiyisis | Not applicable, required for seal weld quafiation (CRA cad and lined pietines. ‘a2 | Whether intemal weld or cuting | Notappieable, spatter in CRA clad and ined Pipelines requires removal andthe ‘method tobe used, Page 190174 ‘TAND-FO4IGTO01-¥-SD-GO30-00) Few CT[BP Exploration Operating Company Ltd ‘Andrew Development Project Welding and NDT of Carbon Stee! Linepi WGIM: to BS 4515-1(2004) ‘CLAUSE BS 4575-1: 2004 ‘SUPPLEMENT ‘at | Whether weld oot acceptance | Not applicable, criteria more onerous than those in ‘Table 5 are required in CRA clad and ined pipaines. ‘29 | Whethortul penetration repars | Not applicable. ‘are permitted in GRA cia and lined pipelines. a ‘ah | Whether pre-qualficaion Vals of | Full details of oring technique and associated welding processes are required | equipment for brazing and aluminatheic ‘woldng of anode bonding leads should bo ‘Submited 0 COMPANY ‘or approval pir to use land should conform to MANUFACTURER'S recommendations. See section 6 of his ‘spectcation ‘@l__| Whether addtional hardness “The hardness surveys shall be undertaken on surveys on macre-sectone are_| each of the macro-examinalion epocmens, Soe requiod Seaton 8.3.4 at this specication, ' | Whether addtional Gharpy test | See section 83.5 of his epecticatior. locations are requited 42 Items subject to approval by COMPANY “The items to be approved by COMPANY are included inthis Specification as addons or latiicatons or amendments tothe appropriate Sections of BS 4515-1: 200. 's required testing of electrodes and filer materials ‘CLAUSE BS 4516-1 2008 ‘SUPPLEMENT | Welding consumables tobe used. ‘Only welding consumables which “have received the prior approval ol COMPANY ‘hall be used. Seo section 7.1 ¢f BS 4515-1: £2004 and as mosified by section 7.1 of tis ‘spectcaton >| The defiiton of a batch when batch | A single heat of filer wire, a single blend of ‘ux, oF for covered electrodes cr cored wie, the combination of a single Raat of cored wire with a single dy blend of flux cover or parent metal The tensile strength of weld metal for Jains betwoen agsimiar materials, ‘ther than that of the higher trength Tn the case of dissimilar metl welds, the ‘weld metal shall have strength atleast equal {0 the minimum spectied for the parent ‘materal. See section 7.1 of BS 4515-1 2008, age 20078 {TAND-FO41G7O001-¥-S0-0030-000 Fev C18p Exploration Operating Company Lid WGIM ‘CLAUSE BS 4515-1 2008 ‘SUPPLEMENT | The ype and number of elects of a| Atesls of a welding procedire shall be welding procedure when they are] _speciied by COMPANY. permite © | Test weld production on pipes sharter| Any proposal to cary out the teat welds on than tl length. Pipes loss than 12m long shall be subject to COMPANY approval. See section 8.1 of BS 4815-1: 2004, 1 | Use of ot weldng ol welding shall only be used with the COMPANY'S approval. Seo secton 8.1 of BS 4515-1: 2004, @ [Use of a test weld for desiucie| An explanation shall be provided to testing or re-nelding to the same | COMPANY before approval is given for the procedure folowing NDT fair. {est piece to ba subject to destructive testing ‘or alematwvely re-welding the test plece. See ‘ection 81 of BS 4515-1 2008 | Welding procedure. qualification test | WPOT to be caried out in accordance wih dotais” and welding procedure | BS 4515-1: 2004 and winessod by an specication fr producten welding. | independent inspectox. See secton 8.1 of BS 4516-1, 2008 7 | Simulation of filet weldjoint using flat | Shall only be used. with prior approval of Plat filet welds. COMPANY. Soe section 104.1 of BS 4515- 12004 7 | Allemative methods of NOT for welder| Shall only be used with prior approval of test piece, COMPANY, See section 10.6 ccf BS 4515-1 2004, k | Giving @ welder second opportunity | A welder may be given a secone opportunity, to gain approval subject 10 COMPANY agreement, to gain [APPROVAL as defined inthe fist paragraph of Clause 10.8 of BS 4515-1: 2004, This ‘pion does nat, however, apply when estrucive test falures have occurred. In these circumstances, tho welder shall be trained prior to retesting 1 [Al documentation relating to welder| All documentation relating to welder ‘ualiaton tests, ‘qualification tests. shall be. spprovod by COMPANY; prior to the welder sommencing production ‘work Welder recons. shall be Iretuded within the as-bull documentation fand. issued to COMPANY i electronic format, Welder reoorda sha b> Kept for a patod of ton years. See section 10.9 of BS 4515-1: 2004, im | Use of manual thermal cuting for pipe fend beveling and the ability of the operator. ‘Manual thermal cuting shal not be used for beveling the pipe ends for welding. See second paragfaph of socton 11.2 of BS 4515-1: 2004, Page 23 0174 ‘STAND-FO4TGTOO1-¥-S0-0059-00) Rev CTBP Exploration Operating Company Ltd Andrew Development Project. WGIM: ‘Welding and NOT of Carbon Stee Li CLAUSE BS 4515-1: 2008 ‘SUPPLEMENT | The blending out by grinding of minor | With the approval of COMPARY the joint impertections within the joint | _ shall bo re-prepared by grinding to eliminate preparation area. ‘small s00re marks, indentations, sto being ‘resent within the joint preparation area. See section 11.2 a of BS 4515-1: 2004, (© | Method of marking datum points on a The method of marking ultrasonic datum Joint for utasonic testing points shall be inchided in the ultrasonic procedure for weld examination and shall be subject to APPROVAL by COMPANY. See section 11.2 ofthis specticaton P| Method of obtaining minimum | Only rotation ofthe pipes shall be used for misalignment, ther than rotation of the | obtaining minimum misalignment. See Pipes. section 11.4 ofthis specication. @ | Method of aigament of pipes other| Alignment methods other than the use of than intral inp clamps. intemal line-up clamp shall be subject to approval by COMPANY. Seo section 11.5.1 Ot this specication “The elage at which Ine-up clamps are removes Internal line-up camps shall note removed ntl after 100% competion ofthe root run ‘and hot pass, Exteral line-up slamps shall fot be removed unt af least 50% of the CGrcumference of the joint unfarmiy spaced has Been filed. Soe Section 115.1 of ts ‘specticaton. “The stage at which the pipe is lowored ‘onto skids or Supports removed from titings. For subsea spools, pipes shall ot be moved ox fed unt at least @ 1/3" of he weld has been deposited, unless it canbe demonstrated as__ acceptable through talelation, See Section 1152 of the speciation, ‘Areas showing stay ares may only be paired by mechanical removal of the elective material, blending of the fexcavation, checking by -MPE and Confirmation that the thickness ofthe pipe or fiting ' within permed toleravces, Repair of parent material by weling shall not be permitted. See Section 11.8. o1 BS 4515+ 2004 and Section 11.8 of his spsctcation, ‘Means of appving preheat. ‘Approval of the proposed method of pre: heating shall be Included with review of re ‘wold procedure specification. See Section T1102. of BS 4515-1: 2006 and Section 1110.2 ofthis specication Page 2274 ‘SAND. FOMIGTOOH-¥-SD.0030-000 Rev CTBBP Exploration Operating Company Ltd ‘Andrew Development Project wei Sey Wading wdnBre urn Ste Uepipero es esisscamoy WIM ‘CLAUSE BS 4515-1: 2008 “SUPPLEMENT Methods of attaching and removing ‘thermocouples, “Thermocouples shal be attached tothe pips by the eapadtance discharge rathos. Aor use, the thermocouples junctions shal be removed by gindng and. tte aroa_of fatiachment ‘shal be examined. by MPE. Methods ot thermocouple. attachment and removal shall be subject to review by COMPANY. See Section TI,10.401 BS 4518. 4%: 2004 and Secon 1.104 of bis -spectiaton ‘The welding procedure for branch connections inhere the angle botwoen the main and branch is less than 60° For branch welds where the angla between ‘ho main ino and branch is unavoidably less than 60°C, the welding procedure shall be subject 10 approval by COMPANY. See Section 1.174 of BS A541 2004, Willen _uvasonio examination Procedure for pipe material around a Planned cutout Wiiten procedure —shall_be submited COMPANY for approval. See So:ton 11.113 Of BS 4515-1: 2008, ‘Al nondestructive testing procedures to be used ‘AI NDT procedures used for examination of procedure quafication and producton welds shall bo qualffed and than subject. to ‘approval by COMPANY. See Sesion 12.1 of BS 4515-1, 2004 and Secon 12.1 of his spectication ‘All inpection personnel ‘Tho qualification concatos of all NOT| personnel shall be subject to review and approval by COMPANY. Soe Section 12.2 of BS 4515-1: 2004 and Section 12.2 of this specication “The technique in BS EN 1435 to be sed fr raciographic examination, Only class techniques of 150 17636 shall be used, unless geometric consrants oblige relaxation to class A. The welding CONTRACTOR shal provide explanation for ‘any nonuse of clase 8. techniques and demonstrate ther accepabity 10 COMPANY. See Section 12.1 0 BS 4516-1 2004 and Section 12.1 ofthis speciation, ‘Any method for magnetic particle testing to be used at above ambient tomporatre Wel methods of MPT shal alvaye be used at ambient temperatures. Dry powder may be Used for repair groove” inspection. See Beaton 12.7 of BS 4516 1: 2004 and Seaton 127 ofthis spectcaton “Any proposal to repair weld ‘COMPANY shal approve all weld repairs See Section 132.1 of BS 4515-1 2004 and Section 122.1 ofthis epectiatin, Page 2374 {IAND-FOAIGTOO1-¥-SD.GO09-00) Fev CTBBP Exploration Operating Company Ltd Andrew Development Project WGIM ‘Welding and NDT of Carbon Stee! Linepipe to 8S 4515-1(2004) CLAUSE BS 4515-1: 2004 ‘SUPPLEMENT ‘2d | Any allerative imiis on repair weld | The iis fo the longih of wold repair shall length be as speciod in Section 18.2.1 of BS 4515- 1,1. 30% of the weld length maximum for @ Patil penetration repair no ful penetration repair allowed ‘26 | Use of root sealing or single run repair| Root sealing or single run repairs are not epost. acceptable, ‘| More than one alompt ata ropa Two attempts may be made at a paral penetvation repair of carbon manganese See! welds provided that the repair procedure is qualified by two simulated Fepairs. See Section 13.2.4 of BS 4515+ 2004 and Section 12.2.4 af this specication ‘39 | The postion of the longitudinal seam| Not applicable, Relates 10 hyperbaric wold it applicable) on the subsea | welding Pipeline at the hyperbaric weld tocaton ‘ah | Joining technique and equipment tor| Applicable. Pin brazing shall be used unless brazing or aluminothermic welding of | otharviso directed by COMPANY. ‘anode bonding leads. Procedures for attachment af arade bonding leads shall bo approved by COMPANY. See Section Bi of BS 4515-1: 2008, ‘a | Proposed brazing or aluminothermic | Refer to ah, welding procedure specication [Method of chemical analysis of but | Not applicable. Welds in CRA clad and lined pipeines. ‘ak | The locaton, elements to be analysed, | Not applicable, method and acceptance citeria_for Soal wold chemical analysis in CRA, lad and ined pipelines. ‘al [Whotner grinding, wire brushing or | Not applicable, fling of the intemal surtace of CRA ‘lad and lind ppetines is permite. ‘am [Cessation of oxygen monitoring | Not appicabie Immediataly prot to completion ofthe root passin CRA clad and lined Pipelines ‘an | The method of flaw removal in CRA| Notappicable, lad and ind pipelines ao [A reduction in the number of Notapplcable ‘mechanical test samples. for {uaificaton of repair weld procedures | CRAGad andiined pipelines. ‘ap | Use of automatic and eemi-aulomatc | See eecton 6 of hs epecticatio. welding systems {AND-FO4iGTO01-¥-SD.0090-009 Rev CT Page 4 0174[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM {Welding and NDT of Carbon Steel Linepipe to BS 4515-1(2008) CLAUSE BS 4515-1 2004 ‘SUPPLEMENT ‘aq [Approval of wolding consumable | See section 72 of this epecticain handing and storage procedure ‘ar | The mixing of ACO, shielding gas at| See socion 7.2 ofthis epecticaton. site ‘as | The type of weld monitoring equipment | See secon 8.1.4 ofthis specication {or use during WPO testing ‘at |The forms used for recording for WP | See speciation 8.1.6 of his epeccalion, intormatn ‘au__| The re-use of exating WPS: ‘See secon 81,7 ol his speciation. ‘av | Atornatveetchants to Nal See secon 8.3.5 of his speciation. ‘aw [Acceptance of enisting_welder| See secon 10.1 a his spectieaon ‘qualitcatons ‘&__| Method of removing end coatings ‘See section 11.2 of tis epecticaon ‘ay _| The solvent for grease removal ‘Soe section 118 ofthis specication ‘az | Use of itomal tapering ‘See section 11 of this specteaion ba [Resta of welding folowing | Soe secion 13.21 ofthis pectieaton suspension due to cracking bib |Full scale bend procedure (H3.1) ‘See eecion HA. of his speciation, age as of 78 STAND-FaaiG7e01-¥-SO-0080-000 Rav GT Page 25 74[BP Exploration Operating Company Ltd ‘Andrew Development Project ‘Welding and NDT of Cat 50 EQUIPMENT Add Independent calibrated instrumentation shall be provided to measure all relevant parameters during WPQT and production, The use of permanent or consumable backing rings isnot permited. An exception is the outer pipe welds in a pipe-inpipe system. Non-consumable temporary backing as an Integral permanent feature on an intemal clamp Is permitted subject to satsactory demonstration ofthe process. 'SMAW electrode holders shall be fuly insulated. Welding return cables connections shall be of sufclent cross-sectional area to pravent concentration of current and shall be securely attached to prevent arc bums. In the case of semi-automatic and mechanised /automatie welding, the welding unt, the Welding power supplies, and the associated contra! software used for procedure ualification shall be of the same typsimodelversion as those used in production. The ‘manufacturer's model and type of equipment and sofware shall be iderified in the procedure qualification record Independent calibrated instrumentation shal be proved to measure relevant parameters, such as current, votlage, welding speed, preheat, and inter-pass temperatures during production, Gauges for measuring the weld preparation, wold bead profile, and the profile of wold repair excavations shal also be provided Copper contact tubes shall be visually checked after each weld pass to ensure that they ‘are not being fused int the weld pol Page 260174 STAND-Fo4TG700I-¥-S0-0039-000 Rev CTBBP Exploration Operating Company Ltd ‘Andrew Development Project WGI ‘Welding and NDT of Carbon Stee! Linepipe to BS 4516-1(2004) 60 WELDING PROCESSES en 61 General Mechanised and automate welding processes are preferred and should be used whenever possible for pipaline gith welding. Main tin welding should be by mechanised or automatic (985 metal arc welding (GMAW) which may include single, mul-orch, or tandem-are variants of the process and the use of cored wires. I the uses of mechanised or automated GMAW processes are impracticable, altemative processes may be used. In such Instances, welding may be performed by shielded mota arc welding (SMAW), manual or ‘automated gas tungsten arc welding (GTAW), semiautomatic GMAW processes using old or cored wires, or @ combination ofthese processes, Limitations onthe use of cellulosic SMAW electrodes are specie in Section 71.1. Solf shielded cored wire welding techniques sh not be used For double or multipa jointing, gith welds should be mado using submerged are welding (SAW) whenever possible. It SAW cannot be used, the alemative mainine processes sted above may be utilised either alone orn combination with SAW. Welding techniques requiing the use of permanent backing rings shal ot be used. ‘The welding of pipelines by the oxy-acetyene process or by the flash-butt welding process (FW) or by anyother process not defined above isnot permite. \When applicable the welding process or combination of processes proposed fr the pipelay welding operation shall be spectid in the bid, Manual processes, semiautomatic or ‘automatic welding systems may be offered, Ifa process or system Is proposed of which COMPANY has no previous experionce, COMPANY will specify welding and NOT tials \which shal be undertaken and completed succasstuly before the proposed tezique can be approved for qualification testing. Separate qualification of a SMAW procedure may also be required, for possible use in the event of falure of semiautomatic or automatic equipment in production welding. 62 Automatic (Mechanised) Welding I mechanised or automatic processes are proposed for mainline welding, tein welding or ‘muttple jointing of pipeline subassemblies, the bid shall include ful deals. of the processes to be used, the associated welding equipment, and the proposed area of ‘application. Page 27 of 74 ‘STAND-F061G7001-Y-S0-0089-00) Rev C1BP Exploration Operating Company Lid ‘Andrew Development Project weim Welding and NBT of Carbon Stee Linepipe to BS 4515-1(2008) For mainline welding applications, the proposal shall Ist the number of weling stations {roet pass to final capping pass) ether on the fring line (ofshore lay barge) oF spool base: ‘and deta the equipment and number of welders and other personnel required to operate ‘each station. Ful deals ofthe welding shelters shall also be provided. ‘Asimilar love of detail shall be provided for ein welding and mutipe jointing Mechanised 26 or 5G walding equipment should be operated in conjunction with data logging facies capable of recording the essential variables associated with the arc, Incluting wie feed speeds and travel speeds. The equipment shall record all parameters for each pass of every weld ata minimum rate of once per 10 degrees of angular rotation ‘and shall incScate the angular poston of each measurement. This data shill be readily retrievable for monitoring purposes and shall form part of the pipeline constuction data package. Data logging Is mandatory i welding with other mult torch or multi wee systoms ‘and for girth welds made in 2 XB0 grade inepipe Each mechanised (automatic) welding station shall be demonstrated tobe ful operational bofore it is employed to wold any joints that will be incorporated into the pipeline. For ‘example, fora spraad of welding stations this domonstation may consist of wo ful gith welds made consecutively, each weld being required to meet the production acceptance ‘fteria without the need for any repair. NDT shall ullse the agreed ppeline NOT techniques and equipment. Internal welding equipment shall also require operational omonstration. Each of these pre-construction welds shall be uniquely identified and reserved for possible mechanical evaluation by COMPANY, [NDT shal utilise the agreed pipeline NDT techniques and equipment. Internal welding equipment shall also require operational demonstration, Each ofthese pre-construction welds shall bo uriqualy ienttied and reserved for possibla ‘mechanical evaluation by COMPANY. ‘This operational demonstration shall be repeated as agreed with COMPANY but should, as 2 minimum, be repeated after interuptions © 7 days in pipeline welding and when a \wolding spread is dsassombled and transfered from one section ofthe line to another. "he proposal shall also detail tne intended level of technician support for equipment ‘maintenance and lst the principal spares that will be available in order to maintain ‘equipment serviceability forthe duration of the pipelay. ‘The proposal shall also advise if @ manual welding procedure is to be qualified for ‘Production or repair welding, Page28 174 STAND-FO4IG7O0T-¥-50-0090-003 Rev C1BBP Exploration Operating Company Ltd ‘Andrew Development Project WGIM' Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) 7.0 WELDING CONSUMABLES TA General Ass: “The selection of electrodes, flr materials and wiraflux combinations shal be approved by ‘COMPANY, In principe, the yiald strength ofthe weld metal shouldbe selected to ensure tat the yield strength ofthe depesited pipeline gith welds overmatches the actual yield strangth ofthe parent pipe material. The deposited weld metal shall also meet the specified ductity, toughness, and limiting hardness criteria in accordance with this specification. “The definition ofa batch (lot of consumablas hal be that stated in section 2.1, lem 3.26. 7.1.1 imitations of use for cellulosic electrodes. Closic costed electrodes shall nat be used for: Pipe grades nd thicknesses beyond those shown in Table 71. Pipelines subject to high sian (2.9, reeled pipeline). ‘Strain based design pipelines. ‘The welding of titngs, anges, and valves. Flot welding (og for anode doublor plato attachment. For applications where cellulosic SMAW electrodes are being evaluated tor use, the pssitility of employing low hydrogen vertical dowm electrodes shall be considered CClulosic electrodes shall nether be baked nor died and shall be used straight from the ‘orginal packaging TABLE 7A (GRADE AND THICKNESS LIMITS FOR CELLULOSIC ELECTRODES PIPE GRADE: PIPE GRADE] waxinta WAC (130 3183) (EN 10208) (Pit) [THICKNESS (A'6) SLA50. 265 1 Zon Lass 70 “ram wih Es 0 passes ore wi EBOTO ssa Ts co eo and ht past ony ‘3 EDTO or EDIT eetvosee maybe ued or ook pass welding proved sliciont cera wold stengh and oughness is 2aned by Prehoat shall be applied oceloale wold (see 1.10) ag 0178 STAND FONT TOOI-Y-SD 0050.00) Rev GI[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM: ‘Welding and NOT of Carbon Steel Linepipe to BS 4516-1(2008) 7412 Consumable selection fr root welding In some instances, it may be necessary to select a root welding consumatie having spectic chemical analysis in order to provide resistance to preferential weld metal corrosion. The pipeline designer will provide advice on any such requiement. Ita weld ‘etal compesiion is speci, then one root weld metal chemical analysis shall be Conducted for each WPS and each full penetration or intemal weld repair procedure to ‘check tha the requted composition has been achioved, 713 Welding Gases {Gases employed for shielding and purging shall comply with EN 439 or ANSVAWS AS.32 and have a dew point of 50°C or lower, Gases shall be pre-mixed and bottled by the supplier and have cetiicates of compliance ‘Gases shall be held inthe containers in which thoy re supplied and stored, wth adequate ‘suppor in a secured are. ‘Subjoct to COMPANY APPROVAL, standard Ar]COs compostions may be miced at ste the mixing is part of @ mechanized process which utiizs a fail eafe cut off when the ‘ropotons fal outwith those specified in the approved welding procedu Gas mixes containing Hydrogen shal not be used for ether shielding or purging. 7.2 Storage and Handling Add, ‘The storage and handing of welding consumables shal bein accordance with GIS 18-012 ‘A dotalled consumable storage and handing procedure or plan shall be submitted for COMPANY review and acceptance, ‘Shielding gases shall meet EN 439 or AWS A 5.32. Gases shall be pre-mixed and bottled by SUPPLIER and shall have certificates of compliance. The cetficates shall show the composition and dew point. Subject fo COMPANY’ approval, standard A/C, gases may bbe mixed at site 7.2.1. Consumable Batch Testing by Contractor Ads: Each boatchlot of welding consumables shall have a consumable MANUFACTURER'S ‘centicate conforming tothe relevant EN, !SO or AWS filer metal specication The testing of each batch shal include actual deposited weld metal chemical compositor, tensile and CCN tes; of to GIS 18-012 and section 7.2.2 of this specication, Page 00174 S7AND.FOATG7O0I-¥-S0.0000000 Rev GT[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM: Weal 722 3nd NOT of Carbon Steel Linepipe to BS 4515-1(2004) For low hydeogen SMAW consumables (610 2510 82.4 Weld Preparation For narrow gap welding, any change in bevel angle boyand 21°, root face boyend 150%, or root gap 0.6mm, constitutes an essential varabo. Any wold proparation with an included angle of less than 20° shall be considered tobe narrow gap welding For all ether welding, any changes in bevel angle by more than 25°, or variation in root ‘gaproot face by more than 250%, constitutes an essential variable. Page 40ol74 __STAND.FO#1G7001-V-S0. 000.000 Rav G1BP Exploration Operating Company Ltd ‘Andrew Development Project ‘Welding and NDT of Carbon Stea! 10.88 451 (2008) For pipe grades above LS55 (X80), it may be necessary to impose more stringont its on the Joint design for mechanised welding than those quoted above as minor changes can osu in signticantotferences in mechanical properties of the gith welds 8.25. Type of Joint Use or deletion of temporary suppot forthe root pass, eg. copper, backing rings or shoes hall be considered an essential variable ‘Change from a gith weld toa filet weld shall constitute an essential variable, Filet welds ‘shall be qualified separately. “The configuration, shape, and size of branch weld test places shall be the same as the ‘branch welds to be made in production. “The qualification of branch welds shal include an addtional but wel qualification to prove the mecharical properties ofthe ont. 8.26 Fler Metal The following changes shal require re-approval ofthe WPS: + Ay change in ter metal designation ter metal MANUFACTURER, wandering ‘+ Any change in consumable diameter por pass; ‘ Achange in batch ruber if consumable batch contro has been specfiod(s90 7.2.2). 8.2.7. Welding Machines ‘The welding unt, power supply lype, MANUFACTURER, model number end software version number shall constitute essential variables for semi-automatic, mechanised and automatic welding 82.8 Typo of Curent For pulsed welding, the typeof curent includes the pulse rato, pulse shapo and maximum ‘and minimum current. 8.2.9. Preheat Temperature ‘The method of preheat appication shall bean essential variable, 8.2.10 Interpass Temperature “The use of rapid cooling of welds constitutes an essential variable unless simulated in wrar. ag at of 8 S7AND-FOATG7OOT-¥-8D-0000-000 Rev GT[BP Exploration Operating Company Ltd ‘Andrew Development Project wei ‘Welding and NDT of Catbon Steel Linepipe to BS 4515-1(2008) 8.2.11 Time Interval When welding with non‘nydrogen controlled consumables or processes, the time lapse between the start ofthe root pass and the start ofthe second pass shall not exceed the time lapse recorded during welding ofthe test piece. For hydrogen controlled processes, an increase inthe maximum time between completion ‘of the root pass and the stat ofthe second pass shall nat exceed the time lapse recorded uring welding ofthe test piece. 8.2.12 Other Parameters CChanges tothe following require re-quaiication of the WPS: '+ Head angle, electrode spacing from top dead centre and direction of rotation for 16. rotated welding: + Electrode spacing for welding procedures utizing multiple electrodes e.g andem wire ‘SAW, or mechanized tandem vite or Wn torch processes, 183 Destructive Testing of Butt Welds and Full Penetration Repair Welds As ‘The blanks from which the mechanical test pisces are machined may be cut from the ualfication weld using oxyfuel gas cuting; but its dimensions shall be sufient to alow the material of the final machined test piece to remain unaffected by the heat from the ceuting operation. ‘Test specimens shall not be subjected to any elevated temperature degassing reatment, ‘The type and extent of mechanical testing shal be in accordance with Table 8.3. The tost place locations shall be as shown in Figures 8.1 and 8.2 Page a2 a7 STAND-FO#IG7O0T-Y-50-0080-00) Rev C1[BP Exploration Operating Company Lid ‘Andrew Development Project Weim ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) Table 89 INSPECTION AND TESTING OF THE TEST PIECES FOR GIRTH WELDING FULL TVPE OF | eurrweio PENETRATION | IusPECTIONTEST ae Zama | ‘3239m0m) Tranavere Tensio Test acre 2 >5239m) ‘NIWeld Tense Test ° * Tnpact Test oF o ‘Side Bends z 2 ‘Macro examination and hardness tat =” * roo * * notes: 12. When an ECA is used to determina defect acceptance lava, @ minimum of three all weld metal specimens shal be taken. Additonal sets of Charpy Impacts may be fequited by COMPANY Welding Engineer. For example, if very thick pipe isto be ulised or the combination of processes or consumables has not been adequately sampled by the spectiod locations. ‘For thicknesses greater than 20mm, a total of 9 cots shall be required. The ‘addtional sets hall be taken ftom the outer surface (ebe Figure SBS 286-9), WN, FL and FL¥2mm locations. 4. Impact testing is not required for pipe sizes below 60.3mm clameter with thicknesses less than 12.7mm, f. Ske bonds are only required for GMAWIPGMAW and GSFCAW (Verteally ‘own welding processes. For Wt >25mm four side bends shal be conduc, For fll and partal penetration rpais two side bonds are required, 1. Adtional macro-examinatons and hardness tests are reqred for long seam ‘Tntersoctons (600 8.3.3) 9+ ey nour ees he runbr of acess voy maybe eed eo 834) fh. GTOD tosts shall comprise a minimum of one set of wold metal and two sas of {son line samples. |. Tosts ara oniy required for niptinos with ECA bast required by the pipeline designer. S00 71.1 for wold chemical anal test requirements. accoptance citer ait Page 43 of 74 ‘STAND-F041G7001-¥-SD-6089-000 Rev C1[BP Exploration Operating Company Ltd ‘Andrew Development Project weim Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) Figure 8.1 UPWARDS WELDING Key Tate fr "ete spocinen "ear Ao =e ert rn eRe oo a en eR an wall Sen esto Figure 82 LOCATION OF TEST SPECIMENS FOR A FIXED POSITION GIRTH WELD PIPE FOR DOWNWARDS WELDING Koy. Resist enen hea stor Ingato spocenons (CL, FLA FL+2n) ‘aera opoctnon “Aetna et epeomens tego sawasion a Spacers Manes tole (632.9) sraobtiat ne ~tiacrotet pecan Hansen 323.200) roa tet specimens (WEL PLE FL2nm) Pago #4174 STAND.FO#IG7O0I-Y-S0. 0060-000 Rev GtBBP Exploration Operating Company Lid Andrew Development Project WGIM Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) CCTOD and adkitional all weld tensile specimens may be taken from available material around the weld. The locations shal be agreed with COMPANY. More than one weld may be required o provide suficient material for testing. 83.1 Transverse Weld Tensile Tt Ad The results of all tarsverse weld tensile tests shall meet or exceed the speciiod requirements for the pipe (base metal) with respect to specified tensle_ strength, Transverse weld tensile specimens shall fll ata location within the HAZ or base metal Failure in the weld meta is unacceptable, base metals of ferent strength levels are used, then acceptance ertera shall be based on the tower strength base metal 8.32 Weld Metal Tensile Te Aas ‘Weld metal overmaiching of the typical pipe yield strength is considered desirable. The ‘wold metal strength shal be considered in elation tothe actual pipe yield stengths when ‘ing ‘an ECAis used or when required bythe pipeline design, 8.3 Macro-Examination Ass: “Thrae macro-examination test piaces shall be taken from each WPQ. The lations shall be at 12, 3 and 6 olclock (see Figures 8.1 and 82). When gith welding SAW-welded linepipe, an adxtonal macro-examination specimen shal be extracted from the gith weld {atthe Tntersetion region between the gith wold and seam wald. ‘All macro-examination specimens shall be polished to @ metallographic (1h) fnish anc ‘tched In @ 2-10% Nital solution, oF other suitable COMPANY accepted etchant. The ‘etched specimens shall be thoroughly examined at 10 times magnification “The prepared surface shall exhibit no cracks or lack of fusion defects. Volur tic defects shall be investigated and shall not exceed the acceptance eteria of Section 19.0. Original photo-macrographs of macro-examinaton specimens at approximately 3 to § times ‘magnification shall be included in the POR documentation. “Page a5 of 74 ‘STAND-FO41G7001-Y-80-0099-000 Rev C1[BP Exploration Operating Company Lid ‘Andrew Development Project Welding and NDT of Carbon Steel Ling 834 Hardness Testing Ads, Harcness testing shall be in accordance with EN 1043-1 ° 180 6507-1. ‘The hardness surveys shall be undertaken on each of the macro-examinalon specimens specifiodin 9.3.3. Each eurvey shal consist of thee rows of indents, One traverse shall be located below the ‘cap, one above the root (or intemal surface) and one al midthickness. The fostons are shown in Figure 8.9. The midhickness traverse may be waived for single sided welds below 12.7mm, COMPANY Welding Engineer may require adaltional hardness indent positions, eg. when a consumable type has not been sampled by the three speciiod traverses, GGIRTH WELD HARDNESS INDENTATIONS notes: ‘+ Parent material indontatons shal be at east 20mm from the fusion tne. ‘The frst HAZ indentation shal be placed as close to the fusion le as possible. Further Indentatons into the HAZ shall be separated by approximately 05mm, romevor the minimum cente-to-cente separation requirement of 3 times the mean diagonal ofthe nearest indentation shall be maintained (et. 1S0 6507-1), +The same survey pattern shall be applied to double-sided weds ‘The macrophotographs shall show the poston of each hardness indent and shall bo Induged inthe POR along with tabulation or lagram shoting the result ard location of {Sach inert, The maximum and minimum values shal be sented. AB Impact Testing aificaton: Forgas pipelines the impact test temperature shall be no higher than minus 10°C, Cacticaton; ‘Sample preparation shal be conducted in accordance with BS EN 10045 Part 1 Pages 174 STAND-FO4iG700T-V-SD-0090-003 Rev CtBP Exploration Operating Company Lid Andrew Development Project weim ‘elaing and NDT of Carbon Steel Linepipe to BS 4515-1(2008) Ad Impact tests shal be carried out in the fusion line + 2mm locations. The impact test equiroment for all pipebenditingtorging is 50 minimum average and 404 minimum Individual, for 3 spacimans at the MOT. 1836 Crack Tip Opening Displacement (CTOD) Testing When required by Section 12.0 of this speotfication, fracture toughness tests shall be conducted at the MOT. Tho required minimum CTOD value shall be 0.t8mm unless otherwise justified through an ECA CTOD testing shall be undertaken in accordance with BS 7448 Parts 1 and 2by a testing laberatory specifically approved for CTOD testing by COMPANY. Testing shall be based on the use of through thickness notched, single edge notched bend (SENB) spocimens (BS 7448 Part 1 paragraph 5.1) inthe NP orientation, unless agreed ‘otherwise by COMPANY. Test specimens shall be notched and fatigue cracked to sample the microstus ‘Wold conte ine and inthe coarse grained HAZ adjacent to the fusion tne atthe ‘The numberof valid test resuits employed to determine the characteristic CTOD ofthe wold ‘metal and HAZ microstructures shall comply wth BS 7910 paragraphs K2.3 and 7.1.5.5. ‘This may require a greator number of CTOD specimens than sted Table 8.8 Post test metallography shall be used to identiy the ination point and the associatod microstructure on @ minimum of thvee HAZ specimens selected by COMPANY. The Ination point of bitte events shall be identified by metalography. The specimen is considered qualtiedit ‘The pre-crack tip isnot more than 0.5mm from the fusion kine; Grain coarsened HAZ microstructure is present within a region confines by @ plane perpendicular othe erack plane through the crack tp and a paral plane (mm ahoad tthe crack i. Page 774 STAND.FOsTG7O0I-¥-SD 0008000 Rev G7BP Exleraton Operating Company Lid Karo Gevaert es wen ey Weigand NST arb Sel Lineppe to 451612009) 80 TESTING, QUALIFICATION AND APPLICATION OF WELDING PROCEDURE FOR FILLET WELDING 8.1 Non-Destructive Testing of Fillet Welds Catication: There are no addtional NOT requirements to visual and MPE for flet welds 9.2 Destructive Testing of Filet Welds Ak mechanical properties are relevant to the application, an addtional qualification shall be ‘made, .g. abutt wold Page 4@ol74__STAND.FOATG7O0I-¥-SD 0050.0 Rev GT[BP Exploration Operating Company Ltd Andrew Development Project WGIM: ‘Welding and NDT of Carbon Stee! Line 4515-1(2008) 10.0 TESTING, QUALIFICATION AND APPROVAL OF WELDERS 10.1 General Ads Welders shall be qualified pir to welding onthe pipeline. Previous welder qualfeations tests may be accepted by COMPANY provided they ar fully documented, supported by production records demonstrating satistacory welder performance, and are less than 6 months old, These tests shall have been conducted Uutizing a WPS substantially the same as that for the curtent work and for automatic, ‘mechanised or semiautomatle welding procedures, utling the same type, MANUFACTURER and model number of welding unit and power supply. Additionally, these tests shall have been conducted by the same fabrication CONTRACTOR and witnessed by COMPANY, or have been conducted by a COMPANY accepted independent testing laboratory. In adtion to the practical welding test and prior to the commencement cf production \wolding, all welders shall be required to attend a briefing session arranged jointly by CONTRACTORS and COMPANY welding engineer. This briefing wil detalthe elements of ‘good welding practice and the specication requirements applicable to producion welding, “These roquiromonts shall be futher emphasized during regular tooLbox sessions and gach older shal also be issued with a card or booklet summarizing these requtements, the ‘contents of which shall be agreed between CONTRACTOR and COMPANY. ‘Any welder who, in the opinion of COMPANY ie either consistently ignoring good welding Practice or specication requirements or is responsi for a high level of repairs during production shall be removed from the work, and shall undergo @ re-raining programme ‘accepted by COMPANY before a retest may be considered 102 But Joints Acs Welder qualification teats shall be carried out on full ameter project pipe nipples. Test 1 around the ful circumference. Al qualification welding shall be carried out In the presence of a COMPANY representative. COMPANY's decision on acceptance is final been comp ‘Welders shall weld a least S0% ofthe circumference ofthe tat pipe. Page ao 174 STAND-FO4IG7O0T-Y-S0-0090-00) Rev C1[BP Exploration Operating Company Ltd {Andrew Development Project WGIM: ‘Welding and NDT of Carbon Stoel Linepipe to BS 4515-1(2004) 104 Fillet Welds for Sleeves, Sockets, Slip-on Flanges or Other Attachments Catication; “The simulation of filet weld joint using Hat plate weld shal not be permite Ads Procedures for welding and NOT of filet welded attachments to pipelines shal be subject, to acceptance by COMPANY. “The pipe area surrounding filet weld shall be tested for laminations using NUT up to a stance of 100 mm surrounding the projected locations ofthe weld toes. Any laminations ‘ound shall comply wth the applicable project ine pipe specication. ‘Where any filet welds are to be made using mutiple passes, the fst pess shall be ‘deposited mainly on the pipe andthe fnal wel pass shall not touch the pipe Completed filet welds shall be examined by visu tamination and MPE. 105 Changes Affecting Qualification and Acceptance (Essential Variables) of Welders Moda to Rea 105 Non-Destructive Testing Ad NDT of welder test-pieces for butt welds shall Include VE, MPE, RE and MUT/AUT it GMAW/PGMAW and GSFCAW (Vortcal down) is used. Where SMAW, GTAW or SAW or GSFCAW (Vertical Up) is used VE, MPE, and RE shall bo used 1 the application of AUT for the inspection of pipeline girth welds has beon agreed by ‘COMPANY, t may be used fr the assessment a the welder qualification welds in place of radiography. However section 13.1.2 of his specication, rather than an ECA based cfterion. the acceptance critorion used shall be BS 4515-1 Table 6 and 107 Destructive Testing 107.2 Butt joints Ads: Macro-examinaion shall bo undertaken, Additionally, for welding using GMAWPGMAW land GSFCAW (Verical Down) welding processes, bend testing in accordance with ISO 5179 shal alo be performed. age 074 STAND-FO4iG700T-¥-S0-0090-000 Rev GTBP Exploration Operating Company Ltd ‘crow Sovelopment Moje wai Se ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) no PRODUCTION WELOING Adis ‘Any weld suspected of not having been produced in accerdance withthe accepted welding procedure shall be cut out, and may be subject to inveetigation at the discretion of COMPANY, Proximity of Welds Ass ‘Tho distance betwoon pipoie girth welds shal not be loss than twice the outside diameter othe pipe. ‘The distance between pipeline girth and branctvatachment welds shall not be less than one pipe diamator “The distance between branchattachment welds on the pipeline shall not be less than one Pipe diameter. Pipe End Preparation Aas, Pipe ends shall be bevelled to the dimensions specified in the WPS, Weld bevels shall be prepared by machining with a floating head cutter. The beveling ‘machine shall follow the ID surface contour in order to ensura a consistent root face dimension, Mechanised thermal cuting may be accepted for tien welds. The cut surface shall be ground back nominally 2mm. Manual culting of fied bevels isnot permite. {Any protective coating on the end bevel shal be removed prior ta welding by a COMPANY accepted method, Weld repairs to pipe ends shall not be permitted. COMPANY may formit minor Impertections in the pipe ends to be repaied by grinding, prior to assembly for welding, provided the remaining wall hicknass is acceptable as confirmed by MUT, IW AUT is to be used, a reference ine at a speciied distance from the root lace shall be setbed onto the pipe surface to allow the exact location ofthe root bead tobe Kentifiad, i ‘On pipe whichis to be cut back, a zone extending 100mm from the proposed poston ot ‘the now fill bevel shall be examined by VE, and MUT to check for laminations tothe requirements ofthe appropiate linepipe matoial specification Paget ol7@ _ S7AND.FONGTOOI-¥-SD 0080-000 Rev GrBBP Exploration Operating Company Lid ‘Andrew Development Project WGIM' Welding and NDT of Carbon St 10.8 4515-1(2004 113 Fusion Faces Ads ‘Surfaces contaminated with oll or grease shall be cleaned utlizing solvent. Degreasing of base metal shall extend at least SOmm from the edge of the fusion faces on both IO and (00 surfaces. Al cleaning solvents shall be used from a sutable container, stall have all necessary documentation avalablo and be accopted by COMPANY as HSE compliant. 114 Alignment Mosiied to Reads Pipes shall be aligned with care. The alignment of sbuting pipe ends shall minimize the Internal offset between surfaces, Any offset greater than 1.5mm, provided its caused by dimensional variations within spectied tolerances, shall be equally distributed around the Circumference of the pipe or fitings. Misalignment shall be reduced to a minimum by ‘otaon of the pipes to obtain the bes ft Maximum misalignment shall be mm, Ad, Heat ehall not be used to correct excessive misalignment. Internal tapering shall not be permitted ifthe tapering interferes with ultrasonic inspection. Longitudinal welds shall le within the top half of the pipe circumference and shall be separated by a minimum of 100mm, 11.5 Line-Up Clamps and Pipe Supports 11.5.1 Use of Line-Up Clamps Modified to Read: Powered internal alignment clamps shal be used for pipe-to-ppe but welds, Where access ‘does not permit the use ofan internal cam fr pipe-o-pipe welds, an extemal clamp shall be used. For small diameters (<150mm), the use ofan external clamp may be proposed for COMPANY acceptance. A welding seauence that distibutes the stesses zs evenly as possible shal be used, eg. wo welders working dametricaly opposite each other. Ian intemal ine-up clamp is used, the root run shall be 100% complete before the clamp | removed. When an external line-up clamp is used, the root run shall be at least 50% ‘complete bela the clamp Is removed, “Page a of? S7AND-FO41G700%-¥-S0-0058000 Rev CTBP Exploration Operating Company Ltd ‘Andrew Development Project Welding and NOT of Carbon Stee! Linepipe to BS 4518-1(2004) 1182 Line-up clamps or other devices for maintaining line-up shall be ofthe same ype as used ‘during the welding of test pieces for WPS approval. The slage at which line-up clamps are removed shall be stated in the WPS and qualified subject to the approval ot COMPANY. “The line-up clamp shall be designed to prevent damage to the pipe anc costings. Straps, brackets, cleats, or similar plate sections shall not be atlachad to the pipe by welding forthe purposes af agent Removal of pipe supports Modifies to Re Intomal tine-up clamps shal not be removed until the completion of the root and hat pase ‘Atamatvely CONTRACTOR shall present a case, supported by stress analysis, which proves that a weld with only the root pass in place will not be adversely affected by movement, an intemal clamp incorporates a copper back-up bar, the backing bar shal be subject toa {ul circumferential VE at last once every ten welds to ensure no fusion of copper is taking place. Ad ‘COMPANY shall accept Iine-up methods for tings and flanges. ‘Tack Welds: Ads: ‘All tack welds (fused) shall be deposited by qualified welders using low hydrogen welding in accordance with an accepted welding specification. Where preheat Is speed, it shall be applied prior to tack welding and be effective over a distance equal to thee times the wall thickness or 75mm whichever isthe greatest and shall be maintained unl the jan Is compete ‘Alignment by tacking for fabrication weld, 69. for pipe to flange joints, shal be subject to acceptance by COMPANY. The following shall apply when tacking is used! ‘Thine tn tka wl ba aorta sma: {Tack welding to bo undertaken by qualfiad weldors in accordance wih Section 100; ‘The preheat vel required for the main WPS shall be applied for tacking and shall be not less than 60°C; ‘+The preferred method is bullt tacking, The bullets shall be made fron compatible Tnepipe material + Avminimum of four tacks shall be used for dlamatars >100mm, More tacks may be requ for diameters >300mm; + Alwelding shal be confined tothe weld preparation and not impinge onthe roc area: Page Sd 174 S7AND-FOAIG7O01-¥-SD.0000-000 Rev C1[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM' Welding and NDT of Carbon Steel Linepipe to BS 4515-1(2004) ‘Tacks shall be removed by grinding as root welding progresses around the but; + tftack welds ae to be incorporated in othe final weld, they shal be at least 25mm long land shall be thoroughly cleaned of slag and tape ground a each end to ensiro completo root contin, + The intended method of tacking to be used in production shall be incorprated in the wear, COMPANY may agree to waive MPE of the ground area folowing tack removal 11.8 Stray Ares A COMPANY shall have the option to require removal of weldments wih more tan one are bum from the pipeline ‘Ropair of parent material by weding isnot permitted If blending to remove the affects of arc bums reduces the wall thicknoss below the ‘pecfiod minimum, the defective pipe section shall be cutout andthe pipe re-tevelled and re-wolded, Welding shall not be used to repair arc bums. For non-esled applcation, if a nipple Is used to replace the defective section, its length shall be at lesst two pipe diameters. Welding return cables shal be of sufficient cross-sectional area to prevent concentration of current and shall be securly attached to prevent stray arcing, Atachment by welding shall not be performed (Cerifeaton: ‘Areas showing stray arcs may only be repaid by mechanical removal of tio detective ‘material and blending of the excavation. MPE together with confmation that pipe a iting wall thickness is within specified tolerances shal be confirmed. 11.9 Weather Conditions Acs: ‘When necessary, measures shall be taken, e.g by covering the pipe ends, to prevent water Cor other extraneous matter being channelled into the weld region, COMPANY shall decide i the protection given from the weather is adequate and that it wil not affoct the qualty ofthe complotod wel. Page 540174 STAND.FOATGTO0I-Y-SD 0000.00) Rev G1Br Exploration Operating Company Ld Andreu Bovapmont Paes wei Sey 415-204 aN ‘Welding and NDT of Carbon Stoo! Li 11.10 Preheating and Post Weld Heat Treatment tit04 11.402 Gonerat Modi to Rea Prebeat and interpass temperatures shel be in accordance with COMPANY approved WPS, [As @ minimum the preheat temperature shall be selected to ensure that The pipe is dry prior to welding: ‘The metal temperature is greater than 90°C, or greater than S0°C when moisture Is present on th pip, or when the ambient temperature is below 5°C; ‘+The hardness requirement of Section 8.34 is met for the weld and HAZ, It the weld isto be cooled rapidly to allow immediate AUT, this shall be simuated during \WPOT, Assisted cooing shall nat commence uni the weld temperature ha ecoled without Interterence to below 300°C. reheating Ass: Preheating shall be applied by gas or oloctical equipment. Induction heating is preferred {or pipeline welding and is mandatary for welding of pipe diameters greater tan 500mm, Hand! held gas torches shall not be used for welding when prehests greater ran 80°C aro required. Welding or cutting torches shall not be used for preheating puposes. The preheating equipment shall maintain a satisfactory temperature dstibution end shall not Interfare with the welding operation. are shall be taken to avoid damage to any coatings and interference withthe welding, Preheating shall be applied uniformly on both sides of the joint preparation around the ‘entire periphery. Local preheating may be used for repair welding. Corect preheat ‘temperatures shal be maintained throughout the welding of the joint ‘The preheat temperature shall be measured at @ minimum distance of 75mm trom each ledge ofthe weld bevel at a minimum of four coumterential locations, each spproximataly oo er a time interval following the removal ofthe heat source to allow for temperature ‘equalisation. The time interval she per 12:7 mm of wall thiciness, eg. 2 ‘minutes for 25mm thick material, The preheat temperature shall be confirmed immediately ‘rot tothe commencement of welding and around the whole jint whist welling is taking plac. pat. Prohea! temperature measurement shall be made onthe heated face ofthe pipe be 1 minut Pages fT S7ANO-FO#1G7OOI-¥-S0.0090-000 Rev GTWeal 1.103 [BP Exploration Operating Company Ltd Andrew Development Project WGIM. ‘and NOT of Stee! Lit .4515-1(2008) Interpass temperature shall be measured on the parent material atthe edge ofthe weld bevel near the weld start location. The temperature shall be measured immatdately bolore the passage of the are and the maximum speciiedInterpass temperature shall not bo excoaded. For continuous rotated welding, interpass temperature shall be measured at last once per compete revolution Temperature indicating crayons which melt on ataining the specie temperature may be sed to check prehest and inorpass temperature, but shall not be marked on wold bevels, wold beads ot surfaces to be welded. Temperature indicating crayons or faints which Indicate tomperature by colour change shall not be used. Altativey, suitably stached {and calrated) thermocouples, or calibrated contactor optical pyrometers, maybe used to check preheat and inorpass temperatures. ‘When pipe-o-pipe joins are to be lett partly completed, the joint shall be wrapped in cry insulating, heat-ressting material with a waterproot backing and shall be coold ata stow Uniform rate, Preheat shall be re-appiiod and the speciied temperature attained before recemmencement of weling Post weld heat treatment temperatures Ads It any form of post-wold heat treatment or delayed cooing ofthe weld is 1o be use, it shall be specified in the WPS. The method and technique of post wold heat treatrent shall be subject to the approval of COMPANY. It post heating or post weld heat treatment Is ‘specified, the pipe shall be heated fora minimum distance on both sides of th jint equal to 2.5(A1% (where Ris the external radius and tis the wall thickness of th pipe). The temperature at the edge of this heated band shall be nat less than elf the peak {emperatur. The method and technique of post weld hea treatment shal be subject tothe ‘approval of COMPANY. Thermocouples shall bo used for recording post weld heat ‘reatment temperatures and shall be postioned to give a true measure of the joint temperature, AS a minimum, thermocouples shall be positioned at the 6 and 12 ollock postions. For blbe sizes above 600mm. thermocouples shall also be placed a the S and 9 lock postions. The thermocouples shal be in metalic contact wi the material being heat treated and shall be socurely attached. Thermocouple wires and junctions shall be protected from direct heat Pagess fT S7AND-FO#IG7OOT-Y-50-0080-003 Rev C1[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM: ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) m0 nun nn naa ‘Thermocouple Attachment and Junctions Ass: ‘Thermocouples shall be atlached to the pipe by the capacitance discharge method. After use, the thermocouples junctions shall be removed by grinding and the area o! attachment shall be examined by MPE. Branches Aa Procedures for cutting, joint proparation, soting-up, welding and NDT shall be subject to COMPANY acceptance, Forged ttings shall be used for branches and other pressure containing attachments unless otherwise accoptod by COMPANY. Spacing of Branches Ad Refer to 11.1 Welding Ads SSotin Fiting Welds ‘Sotin ting wold shall be inspected as follows: ‘+ accessible and folowing competion of th full wed, the root bead shal be ground fish ‘on the Inside ofthe pipe ts location clearly marked with indelible pen and inspacted by VE and MPE; ‘Wold caps tobe subjoctod to VE and MPE; ‘The full welds shall be examined with radlography using the SWE/SWV technique with the fm inside and radiation source outside, using @ minimum source tof stance of 00mm. A minimum of four equidistant spaced separate exposures shal be used for branches 150mm nominal bore. The DWEISWV technique may only be used it accepted by COMPANY. In each event the centre ragation beam shall pass trough ‘bach weld region being tested at normal incidonce to the weld fac. ‘Sot onfiting welds shall be inspacted as flows: ‘+ The root bead and weld cap shall be examined by VE. VE of the root tore shall bo Undertaken through the bore of thefiting trom the outside ofthe pipe: ‘+ Weld caps shal be examined by MPE. Whero access allows MUT shall be undertaken from the Inside surface of te iting PageS7 of 74 STAND-FONIG7O0T-Y-SD.0000-000 Rev G1BBP Exploration Operating Company Ltd ‘Andrew Development Project weim Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2008) 11.12 Inter-run Cleaning Aas Contact tips shall not be fused into the weld metal, A VE shal be undertaken between wold ‘passes to conf no copper has been deposited, 11.13 Partially Completed Joints Ags, ‘Ofshore pipeline welds or welds on fitings, ton weld, or repairs shall nat b> allowed to ‘cl below the specified minimum preheat temperature before weld compton. No welds ‘hall be allowed to cool below preheat temperature botoce the completion four full circumferential passes. [Al welds shal be completed by continuous welding 11.14 Fillet Weld Attachments Procedures for welding and NDT of filet welded attachments to pipaines shall be subject to ‘approval by COMPANY. The pipe surrounding filet weld shall be tested for laminaone using UT up to a distance of 100mm surrounding the projected locations of the weld toes. Any laminations found (Ividual or cluster) shal not exceed a total area of S00mm! No lamination regardless of size shall be permitted within 25mm ofthe projected wel oes. I any filet welds are to be made using multiple passes, the frst pass shall be deposited ‘mainly on the pipe and te final weld pass shall nt touch the pipe. Complete filet weld eal be examined by VE and MPE. 11.45 Records A {All documentation required by this specication and BS 4515-1 shall be collate, indexed, stored safely and presented to COMPANY. ‘A\og ldenttying, by number, each pipe or ting and Identiying the weld numbers Jotning ‘them to ther items shall be compiled. Each circumferential weld (whether afl joint or ‘shop-made wold) shal be allocated a unique number, which shall be used for reference to the weld in all reports, radiographs and test documents. (Quality records shall include the folowing: Page 8 of 8 S7AND-FO41G7001-¥-80.0039-003 Rev G1[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM: ‘Welding and NDT of Carbon Steel Linepipe to BS 4516-1(2008) Record of conractiesgn review, Material cortfcatos; Consumable coticatos; Wieder name and/or number ws; Wielding procedure acceptance test records; ‘Welder or welder operator acceptance certificates; Nondestructive testing personnel cerficates; Heat treatment records; ‘Non destructive testing and destructive testing procedures and reports; ‘Dimensional por; Fecord of pair and other non-confomity reports; ‘Site o technical queries pertaining to welding and NDT. ‘The above documentation shall be traceable back to individual weld numbers, where applicable. The accepted WPS and POR packages shall also be available in a good quality cloctroni format. Page 60 174 S7AND-FOAIG7O0T-¥-SD.0000-000 Rev CTBP Exploration Operating Company Ltd ‘Andrew Development Project weim ‘elaing and NDT of Carbon Steel Linepipe to BS 4515-(2008) 120 INSPECTION AND TESTING OF WELDS 121 Gene Cacticaton; Every pipeline weld shall be subject to individual examination and non-destructive test Using reliable, madern, and proven techniques, and shall be shown to mest the design code acceptance criteria in al respects before the pipeline is put into sevice, [An ECA and CTOD tests are mandatory when pipeline instalation is by roaling or S-Lay, no (CTOD/ ECA are required for bundle applications. For the fabrication of spools CTOD'S and ECA only required where the MOT is lower than -86°C and or thicknesses >40mm. The use ofan ECA shal not be required on pipe dameterss 6" andiorwte1 0mm “The use of narow gap welding techniques (with an inclusive bevel angle < 20°) dictates that AUT chal be required. ach production butt weld shal be subjected to @ VE (external), AT and supplementary UT FAUT examination ora combination of both, unless otherwise agreed with COMPANY. For wall thickness above 25mm, AUT isthe preferred NDT technique. For manual o semi-automatic welding processes using a conventional bevel configuration, ‘one ofthe fotiowing NOT methodologles may be adopted subject to COMPANY review and approval: “+ Where FIT is the primary NDE method, MUT shall be used to supplement FTF when Planar defects are detocted during production welding. MUT shall be used to establish ‘Setect size, height and positon. An ECA (when raqured) shall bo used to develop the ‘wold NDE acceptance standard taking cognizance ofthe NDE sizing accuracy ‘+ Alomatvely, VE and AT may bo considered, provided CONTRACTOR can demonstrate ie ality detect the defects defined within tha workmanship acceptancs crteria, as Getaled in tis specication and Table § (BS 4515.2) and Section 181.2 of ths specication, The acceptance ertera shall be no cracks or planar defects within the weld Le. surface breaking of within the body ofthe weld, RT and single wal techniques shall nly be used fo NDE of gith welds. Te avoid repairs or cut-out its recomrended tata MUT be qualfied to assist AT. As Faaiographic procedures shall be qualified on test welds containing representative detects ‘hich are subjected to sectioning to confi defect sizes and NDT by additonal methods. CONTRACTOR shall domonstate that his NDT production methods and procedures can detect the dfects defined within he acceptance crea Page GDol7 _ S7AND-FOAIG7O01-¥-S0-0000-00) Rev Gt[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM' ‘Welding and NDT of Carbon Steel Linepipe to BS 4516-1(2008) Proposed NOT procedures shall be submited in wriing to COMPANY for approval All procedures shall be qualified and approved by COMPANY before u The ful ength of pipali Hatt and 11.14 branch and filet welds shall be examined In acccrdance with ‘The use of automatic ultrasonic testing (AUT) shal be subject to approval by COMPANY. It the use of AUT has boon approved, testing hall be performed in accordance with GIS 43- £389. The use of AUT i not permite in place of radiography forthe folowing wold les: ‘+ Welds connecting pipes with an internal taper, ‘Butt welds to valves, flanges and oer fitings [MUT and MPE equipment and personnel shall be available at ste forthe ful duration of pipeline construction, ‘COMPANY shall have the right to inspector test any weld by non-destructive or means, This inspection may be made during the welding or after the weld has been completed. The right of inspection may inde NDT undertaken by COMPANY personne! in addon to any NOT undertaken by CONTRACTOR. For example, COMPANY may ‘choose to inspect welds by MUT. rctve (On a plpe-laying barge, the weld shall not be moved past the weld repair station unt the Interpretation of the radiograph and all other NOT is complete and the wed has been judged satisfactory Coating! wrapping of a welded joint shall not bogin unl the wold has been judged satisfactory, unless otherwise approved by COMPANY. Cantication: ‘Completed welds may be ground when agreed with COMPANY to facitate NOT provided tho wall thickness complies with the minimum specified limit. Grinding shal ensure no stress raisers and a smooth transition exits. 122 Personnel Qualification Modi 1 Roast NOT personnel shall hold current Level 2 certification (or equivalent), speiic to weld ‘esting, for he appropriate NDT metnods 1 any o the folowing standards as & minimum: CSWIP (TW UK) BGAS.CSWIP (TW, UX PCN (BINDT, UK} ACCP (ASNT); 'SNT-TO-1A (ASNT. Page i ol74__ SYAND-FONGTOOI-Y-S0-005000 Rev G1[BP Exploration Operating Company Ltd Andrew Development Project WGIM: ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(200) NOT personnel certicated to the requirements of a Whitten Practice under the rules of SSNT-TC-1A shall not be used, unloss the Writen Practice and the personnel cetfication has been reviwed and accepted by COMPANY forthe spectic work. Personnel engaged in AUT shal be qualified in accordance wih GIS 43-839 124 Radiographic Testing 124.1 Gonoral Ak AAT shall be conducted using X-ray equipment. Where the use of Xray equipment is Impracticablo, dium 192, Ytorbium 169 or Selenium 75 may be used subject to ‘acceptance by COMPANY. Other sources of gamma rays are not permite. Radiographic practice shal be in accordance with this specication and 180 17536, 12.42 Approved Radiographic Procedu Ads, 12.42.1 General {As part of the radiographic procedure qualification, test radiographs shall be produced Using each radiographic procedure planned for use; these shall be made on the welcing procedure qualification welds or welds made wih the production WPS. The ful ‘reurference of each test wold shall be raciographed. Fim type shall be ISO 11699-1 Class T2 or ASTM E1815-96 Class |, e.g. Agla Structrix DS or Kodiak Industrex 7200, o finer grain (slower) fm. Where its shown that exposure times would exceed 2 minutes using X-ray equipment with this fm, the use of [SO 11690-1 (Class TS or ASTM E1815-96 Class II may be permitted atthe discretion of CONPANY. Lead (Pb) intensifying screens shall be used. COMPANY may accept the use of ‘luorometalic screens, as an atemativ, where CONTRACTOR is able to demonstrate that ‘test procedures and results are ofa standard acceptable to COMPANY. 12.4.2.2 Procedure Speciication (Addon) ‘Specticatons of radlographic procedures shall where relevant, define the following Pipe diameter and wall thickness; Radiation and eoure X-ray equipment MANUFACTURER, model ram and number; “Technique (equipment rating, n vlge, extemal or intemal equipment); Page 620174 STAND FOsTG7O0%-Y-S0-0050-00) RevBBP Exploration Operating Company Ltd Andrew Development Project Welding and NDT of Carbon Stee! Linepipe to BS 451 (2004) ‘+ Geometric relationships (source focal-size, fim focus dstance, object-fim distance, radiation angle with respect o weld and in); ‘+ Penumbra or geometric unsharpness; ‘Flim type (rade name, designation and dimensions); ‘+ Intonstying sevens (rant andor back, material thickness, ters); ‘Exposure conditions (voltage, curent and duration, Curiemminutes and Gigabecquereh mites) ‘+ Processing (developing timeemperature,stop-bat,faton, washing, dying, manual or ‘automatie processing, MANUFACTURER and type of equpmen); “+101 type and sonstiites, in percent of wal thickness, based on source-and fln-side indicators, respectively); + Fim density; + Fim overap; ‘| Reterence to actual WPS; {Temperature of welds during inspection; Archival 1 Inia! source strength 12.423 Exposure Geometry SSource-weldim arrangements shall comply with ISO 17696 except that the eliptical technique shall be usod on al gith welds on pipe <88.9mm dlamoter. The perpendicular technique (straight through) exposures shall not be usod unless accepted by COMPANY. ‘The single wall exposure for single wall viewing (SWEISWY) technique withthe raiation source located inside the pipe! fing shall be the preferred technique for radiography of ith welds. 12.424 Type of mage Qualty Indicators Only wir type las (ISO 2504 oF COMPANY accepted equivalent) shall bo used 12.425 Selection of image Qualty Indicators For radiographic procedure qualification, wite type IQs shall be placed across the weld on both the source side and the fm side of the area being examined. The sensitivity level, jblained using the fim side 101, shall be no worse than that gen in Table 12.1. The corresponding sensitivity for the source side 1Ql shall be recorded. I any test radograph shows one visible wire more on the fim sido IOI, compared to the source side 10 COMPANY has the option to reject the radiographic procedure, Page@3 0174 S7AND-FO#1G7O0I-¥-S0-0000-000 Rev GtBP Exploration Operating Company Ltd [dren Devslpmant Project welm {eling and NOT Carbon tet Lineppeto BS 4515-120 ‘Table 12.1 SENSITIVITY REQUIREMENTS THICKNESS | paoiocnarny Cana RADIOGRAPHY (mm) ‘swst Dws! wor ‘swst pwsi | DWDI 4560 | 20% | 25% | aon | 20x | 2m | ae se080 | 17% | 20% | son | een | 2m | are sa040 | 18% | 10% | Nows | 2q% | an | Nowe Sores | tam | 17% | NA | 20% | aes [NA sras260 [13% | 178 | NA | 17% | 20% | NA >ee0400 | itm [17% | NA | 18% | 1@% | NA ~400 | Noto | Naws | Now | Now s | News | Noes [NOTE 1: Thickness for SWS! and DWS! is estimated fora single wold thickness. NOTE 2: Sensitivity chal be no worse than the values given In this table. Sensiity shall be calulated using the formula: Thickness of thinnest wire visible in weld area Sensitivity Thickness [NOTE 3: Sonstity requiroment fo be agroed with COMPANY following production of test rachographs. “The procedure test radiographs shall be submitted to COMPANY for acceptance prior to the stat of production. New procedure test radiographs may be requested atthe cscretion ‘of COMPANY whenever ary change is made in operating technique or whenever ‘production raciographs difer appreciably from the deta, contrast, definition or density of ‘the qualifying radiographs. Procedure test radiographs shall be readly avallable for comparison purposes in each arkroom used for radiographic vowing 12.426 Film Density Exoept for small localized areas caused by weld weave or discontinultes, the radiographic density shall be between 2.0 and 3.2 inthe weld area. If tis density range cannot be ‘achieved within the full weld width in single exposure, then the above densi range shall bo achioved by producing two radiographs ofthe weld area at diferent exposures or by using the sandwich technique, unless otherwise agreed by COMPANY. Page 640174 STAND.FOATG7O01-¥-S0. 0000000 Rew GTBP Exploration Operating Company Ltd ‘Andrew Development Project ‘Welding and NDT of Carbon Steet Li WGIM to.BS 4515-1(2008 Densitometers shall be used for measuring density and shall be calibrated using a donsity strip (density reference scale) of known denstes. A density stip cerited within the last 3 yoars toa recognized standard, e.g. NIST or BAM, shall be present on ste, Tb save wear land tear on the calibrated density sti, a working density stip may be used for checking ing densitometer; this shall be chocked agains the cortiad densly stip at no ‘more than 3 monthly intervals. and cal 124.27 Information on racfograph ‘The radlegraphs shall contain the following information Project name, project number, and pipeline identification Weld number. Whether the radiograph i ofa repair weld, ofa replacement weld ora re-shaot Markers) incating the poston ofthe racfograph in relation to the weld Pipe diameter and thickness. Material grad Date, WPS number. 12.428 Fim Viewing Equipment ‘The viewing facies shall provide subdued lighting of an intensity that will not cause ‘troublesome reflections, shadows or glare on the raciograph, The viewing equipment shal Produce sutciont brightness forthe iuminated raciograph to be satistactorly interpreted ‘and shall maet the requirements of ISO $580. The Image shall be free fiom fog and processing iregularies that could mask the image of actual imperections.Allradiographic fir shall be died thoroughly prior to viewing 124. Fim Storage Aa For the main production pipeline and when agreed with COMPANY, radiographic flm shall bo digtized using methods that give adequate resolution and stored in lectenic media in ‘an agrood manner with COMPANY. ‘All radiographic fim shall be dried thoroughly porto viewing and shal be processed to allow storage ofthe film without deterioration fora minimum period of 5 years 'At the discretion of COMPANY, the radiographic CONTRACTOR shall satstactoniy ‘demonstrate that the fim can be processed, using the site facties, to have a fg level not rear than 03. {AND Fo41G7001-¥-SD-0000-005 Few G1BBP Exploration Operating Company Ltd ‘Andrew Developmer Project WGIM Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2008 1s 1254 1253 (One radiograph in every 100 shall be subjected to a residual thiosuphate tet, to ensure that the fim has been suitably processed for 5 yoars storage. The procedure for this tost shall form part ofthe radiographic procedure package for COMPANY approval Radiographs shall be stored in an environment that wil ot detimentally affect the radiographs. Boxes shall be used to store radiographs in multiples of 25, 50 or 100 wold. ‘The weld numbers that apply to the stored raciographe that each box contains shall bo clearly visible on each box. Manual Utrasonic Testing Goneral A MUT shal comply withthe requirements of ISO 17840. Specifications for MUT procedures shal dain the folowing Type of UT equipment; “Type and dimensions of transducers; Range of frequencies; Method of calibration; Felerence Bock daving Surface requirements; Coupling medium; Examination techniques; Weld identfeation math Reporting requirements; Reference tothe applicable WPS; “Temperature range of weld during examination, FRporting and Evaluation A Discontinuly indications having amplitude above the reference level shal be assessed against th requirements of Table 6 of BS 4515-1 andthe following: racks are unacceptable, regardless of size, location in the weld; * Unear indleatons other than cracks) interpreted to be open to the surface are ‘unaozeptabie t they exceed a length equal to tho wal hickness but not exceeding 25mm in foal ength in continuous 300mm length of wold or 8% of tho weld length; + Linear indications interpreted to be buried within the weld are unacceptable they excood 2 length equal to but not exceeding 50mm in total length in a continuous 302mm of weld (Or 15% of the wel, ‘+ ndvdual detects witha height greater than one pass height (determined ater reviewing ‘2 macrosecton from the main line WAIT) but not greater than 4mm and before interaction assessment shal ot be permitted, Page Gb 174 STAND.FOATGOOT-¥-S0.0030-00) Rev GT[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM: ‘Welding and NDT of Carbon Steel Linepipe to BS 4516-1(2008) 12.6 Automatic Uitrasonie Testing Ad, “The use of automatic ultrasonic testing shall be subject to COMPANY approval in each instance. The qualification ofthe AUT procedures and production testing shall comply with als 43-339, 127 Magnetic Particle Testing Ade [MPT shall comply with the roquiroments of ISO 17638, ‘The non-fluorescent wet method of MPT using white contrast paint and an AC yoke (110V) shall bo used. Dry powder MPT may be used for repair groove inspection. The AC yoke shall be capable of liting 4.5 kg at 150mm pole spacing. Poles shall make maximum contact wit te test surface during inspection. DC prods shal not be used, ‘AL MPT procedures, including the method for determining adequate Hux levels in the test ‘area, shall be qualified 128 Liquid Penetrant Testing When roquired Penotrant Testing (PT) shall bo applied as described in ISO 3452. An ‘examination procedure shall be submited to COMPANY for approval bolore ‘commencement of WPQT programme and shall be qualified during this tet programme. During testing the surface temperature willbe inthe range 15-95 degrees centigrade Inications that cannot be removed by ight burr grinding to a maximum depth of 0.5mm shall be cause for rejection of the weld and shall be subject to an agreed weld repair technique. ‘AND. FOATGTO01-¥-SD- 0030-000 Rew GT[BP Exploration Operating Company Ltd ‘Andrew Development Project weim ‘and NDT of Carbon Steel Linepipe to BS 4515-1(2004) 130 ACCEPTANCE AND RECTIFICATION OF WELDS 1.1 Non-Destructive Testing Acceptance Criteria 13.1.1 General Ads, ‘The acceptance standards defined in Secton 13.1.2 below shall be the minimum requirement in which redography is the primary NOT method. Where marual or sami- ‘aulomate welding processes are adopted with a conventional bovel configuration and FT is the primary NDE method, MUT shall be used to supplement RT when cracks or planar otects are detected during production welding. MUT shall be used to establish defect size, height and poston. I the use of AUT has besn approved by COMPANY, Section 13.1.2 below shall be augmented by an ECA in accordance with BS 7910 (Level 3} lo determine flaw chmensions and acceptance levels which shal be subject to COMPANY approval refer te Section 13:1. of this spectator). ‘When unacceptable flaws occur in more than five consecutve welds or when, in the ‘opinion of COMPANY, a particular faw type becomes repetitive in terms ofits size andlor location, the cause of the flaws wll be investigated by the Welding Engineers working on behalf of CONTRACTOR and COMPANY. If necossary, welding wil be terminated unt the ‘cause of unacceptable flaws has been estabishod and sallstactorly resolve. 18.1.2 Accoplance Criteria Based on Quality Control Ad In areas of weld preparation such as pipe ends, fusion faces and branches, planar defects are not acceptable Ag (BS 4515-1 Table 6k) Tungeten inclusions shall not exceed two per weld and shall bo ‘separated by @ minimum of SOmm. The maximum dimension of a tungsten inclusion not to ‘exceed Sm oF §0% ofthe wal thickness, whichever is smaller. (8 4815-1 Tabla Copper inclusions atm not prema. Ads: (8S 4515-1 Table 6) The maximum length of infor run fusion and lack of side fusion in any Continuous 300mm weld length s limited to but not exceeding SOmm, Page 6Sol7a__S7AND-Fo41G700%-Y-S0-0059-00 Rev G1[BP Exploration Operating Company Ltd ‘Andrew Development ‘Welding and NDT of 1318 1314 132 1321 (88 4515-1 Table 6g) Cracks or crack Ike defects are unacceptable, In the event that such fects are detected the complete weld shal be cut from the pipeline and the cause ofthe ‘racking shall bo established to the satistaction of COMPANY. ‘Acceptance Criteria Based on Engineering Cical Assessment (ECA) Ada. ‘Tho use of atemative acceptance standards for gith welds shall be subject tc COMPANY approval beloce contact award, The ECA method and testing shall be proposed for COMPANY approval before the commencement of WPAT. ‘The output of the ECA shall be used to develop the weld NOT acceptance standard. The wold acceptance standard shall include an appropriate NDT sizing allowance (ee GIS 43- 380) which shall be clearly documented, In adation tothe limits derived rom the ECA, the following restrictions on defect size shall apply “+ Inividual defects with height greater than 4mm (before interaction assossment) shall not be permit ‘+ No acceptance of any dofect »4mm shall be permitted, even If demonstrated trough the ECA; + Irespective of defect height, detects witha length grester than 7 tes wal thickness (ater intaracton assessment) shall not be ported, COMPANY reserves the right to modily the ECA acceptance tra Ada: Suspected Welds [Any wld suspected of not having been produced in accordance with the approved welding procedure shall be cut out, and may be subject 0 Investigation at the sictetion of COMPANY, Rectification of Welds Removal of Flaws Ads: AWPS for ropairwolding chall bo in accordance wth Section 8 ofthis spesiticstion, Defects shall not be repaired in any part of the weld without prior acceptance by COMPANY. Al repairs shall be witnessed by COMPANY, and the relevant NOT records shall be made avaiable to COMPANY at that ime. Page 6d 17a S7AND-Fo41G700%-Y-S0-0009-00 Rev GtBBP Exploration Operating Company Ltd Andrew Development Project WGIM Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) Internal weld ropars shall not be permited except for pipe-tositing welds were the repair can be undertaken fom the open and ofthe pipe or fiting, subject to successful welding procedure qualification [No more than two separate repairs are alowed in any single weld. ‘Welds with cracks (other than small rater cracks <émm in length) shall be removed trom the pipatin. The wong procedure shall be suspended untl the cause is identified and ‘remedial measures implomonted to prevent further occurrence. Production welding with the ‘suspanded WPS shall only recommence following acceptance from COMPANY Welding Engineer, ‘Smal erator cracks shall bo removed by local grinding and repaired, For repair of arc buns, see 11.8, 13.22 Preparation for Re-Welding Ad ‘The minimum allowable repair langth shall not tobe less than 50 mm at the bottom ofthe ‘g100v8. Metal may be removed by thermal gouging followed by grinding. Grinding shall bo used for the last 3mm through to the root, Ai-are gouging shall be controlled by a procedure documenting the allowed variables as required by AWS C5.3. Iv there are significant loads or deformation atthe weld repair tation, veied calculations |usttying the excavation size shal be submitted for COMPANY approval 1824 Re-Welding Ads Internal weld repairs shall not be permited except for pipe-ositing welds where the repair ‘can be undertaken from the open end of the pipe or fiting, subjct to successful welding procedure quaifcation. When a root rapa weld in a pipeline falls to comply with Section 18, the entire Circumferential weld shall be cutout and the pipe ends shal be re-bevolled and re-welded, necessary, second repair may he atamptad forall raginns apa from the root this ‘second repair falls to mest Section 13, the entire crcumferenial weld shall be cut out. Ono {ull penetration repair is permitted subject to successful welting procedure qualification ‘Two paral penetration repairs are permited subject to successful welding procedure {qualfication. Partial penetration repairs are not permited within mm ofthe pipe intemal surface, Page 700174 S7AND-FOATGTO0%-Y SD 000900 Rev G1BBP Exploration Operating Company Ltd Andrew Development Project WGIM: Welding and NDT of Carbon Steel Linepipe to BS 4518-1(2004) COMPANY may require th ful cicumference of repaired welds to be re-examined by the ‘Same examination method which located the defect. ‘Aull record o ll pais shal be maintained by CONTRACTOR. The recor shall be made ‘seach defects discovered, and shall include te following The weld number; ‘The type and siz of defect; ‘The crcumferentialocation (defined to an accepted syst); ‘An estimate ofthe depth (assessed by UT where possible); Mimic taken of ropairprotie and sketch included detaling (depth, postion relative to ‘ginal weld, with and length of excavation) "Name andor numberof the welder who produced the defect; Repair welsing procedure number, ‘Name andlor number of repair welder Copy ofthe ingpeetion repart forthe rol Date o repair. Page7i of 74 S7AND-FOAIG7O01-¥-S0-0000-000 Rev G1[BP Exploration Operating Company Ltd ‘Andrew Development Project WGIM ‘Welding and NDT of Carbon Stee! Linepipe to BS 4515-1(2004) ANNEX H ADDITIONAL REQUIREMENTS FOR PIPELINES SUBJECT TO HIGH STRAIN LEVELS. HI Introduction This section applies to pipelines subject to plastic deformation during installation, 6 Instalation by roving, \When evaluating the amount of stain atthe weld expected during installation, the ‘misalignment, pipe strength variation, and coating stiness shal be considered cts of 12 General H21 Linepipe Pipstins welded in accordance with this appendix shall use linapipe that complos with the ‘addtional high strain requirements of GIS 43-311, GIS 43-812, or GIS 43-813, H22 Welding Processes Welding processes not previously used by CONTRACTOR wit the proposed installation method shall require ful scale qualification tials. The extent of the tras shall be

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