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AMENDMENTS / SUPPLEMENTS

TO
DEP NO. : 61.40.20.30 - Gen

DEP Date : June 1993 + DEP circular 20/00 + 41/04

DEP Title : Welding of Pipelines and Related


Facilities

THIS DOCUMENT IS INTENDED FOR USE BY ADCO AND ITS NOMINATED CONSULTANTS, CONTRACTORS, MANUFACTURERS AND SUPPLIERS

ORIGINATOR:
ENGINEERING SUPPORT DEPARTMENT
Date of Issue:
ADCO DOCUMENT No. 30-99-00-0041-1 Rev. 2
Oct. 2006
DOCUMENT CLASSIFICATION: GENERAL
MASTER
REVISION RECORD

REV. DATE ORIGINATOR REVIEWED APPROVED DESCRIPTION

1. 20-03-06 M. Muthuraman M. Muthuraman E. Al Romaithi Revised after 20th edition of API 1104

2 15-10-06 SE(M&W) SE(M&W) HE(JD/ FG) Updated to DEP Version 23

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 2 OF 21


TABLE OF CONTENTS

1 Ref. Section 5
Part I INTRODUCTION 5
1.1 Scope 5
Part II AMENDMENTS/SUPPLEMENTS TO API STANDARD 1104 5
New API section 4.1 Equipment 5
1.5.1 (New API section 4.2.1) Pipe and fitting 5
1.5.2 (New API section 4.2.2) Filler Metal 6
1.5.2.1 (New API section 4.2.2.1) Type and size 6
1.5.2.2 (New API section 4.2.2.2) Storage and handling of filler metals and fluxes 6
1.5.3 (New API section 4.2.3) Shielding Gases 6
1.5.3.1 (New API section 4.2.3.1) Types 6
1.5.3.2 (New API section 4.2.3.2) Storage and handling 7

2 (New API section 5)-Qualification of Welding Procedures for welds Containing Filler Metal
Additives 7
2.1 (New API section 5.1) Procedure Qualification 7
2.3.2.10 (New API section 5.3.2.10) Time between passes 8
2.3.2.13 (New API section 5.3.2.13) Pre-and Post-heat treatment 8
2.3.21 (New API section 5.3.2.17) New: Welding Procedure Specification 9
2.3.22 (New API section 5.3.2.18) New: Records 9
2.5 (New API section 5.5) Welding of Test Joints Butt Welds 9
2.6.9 (New API section 5.6.9) New Clause 10
2.9 (New API section 5.9) New clause other requirements 11
2.9.1 (New 5.9.1) 11
2.9.2 (New 5.9.1) 11
2.9.3 (New 5.9.1) 11

3 (New API section 6) Qualification of Welders 11


3.1 (New API section 6.1) General 11
3.6 (New API sub-section 6.6) Radiography Butt welds only 12

4 (New API section 7) Design and Preparation of a joint for Production Welding 12
4.1 (New API section 7.1) General 12
4.1.1 (New API section 7.1.1) New Section Pipe Cleaning 12
4.2 (New API section 7.2) Alignment 13
4.3 (New API section 7.3) Use of Line-up clamp for Butt Welds 13
4.5 (New API section 7.5) Weather Conditions and Protection 13
4.10 (New API section 7.10) Identification of Welds 13
4.11.1 (New API section 7.11) PRE and Post-heat treatment 14
4.11.2 (New API section 7.11.1) Preheating and Interpass temperature control and measurement 14
4.11.2.1 (New API section 7.11.1.1) General 14
4.17 (New API section 7.12) New section other requirements 14
4.17.1 (New API section 7.12.1) Tack Welds 14
4.17.2 (New API section 7.12.2) ARC Strikes 14
4.17.3 (New API section 7.12.3) End Protection 15

5 (New API section 8) Inspection and testing of production welds 15


5.1 (New API section 8.1) Right of Inspection 15
5.2.1 (New API section 8.2.1) General 15
5.2.2 (New API section 8.2.2) Radiographic examination 15

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 3 OF 21


5.2.3 (New API section 8.2.3) Ultrasonic examination 15
5.2.5 (New API section 8.2.5) Magnetic Particle Examination 16
5.3 (New API sub-section 8.3) Qualification of inspection personnel 16
5.4 (New API sub-section 8.4) Certification of Non-destructive Testing Personnel 17
5.5.3 (New API section 8.5.3) Inspection after welding 17

6.11 (New API section 9.8) New clause Defect Acceptance Levels 17

7.1.2 (New API section 10.1.2) Removal of defects and repair 18


7.1.2 (New API section 10.1.2.1) General 18

8 (New API section 11) Procedures for non-destructive testing 18


8.1.1 (New API section 11.1.1) Radiographic test methods - General 18
8.1.7 (New API section 11.1.7) Production radiography 18
8.1.13 (New API section 11.1.13) Radiation Protection 18

9 (New API section 12) Mechanized Welding with filler wire metal additions 19
9.5.2 (New API section 12.5.2) Changes requiring re-qualification 19
9.8 (New API section 12.8) Inspection and testing of production welds 19
11 (New API section 14) New Records 20
III REFERENCES 21

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 4 OF 21


Welding of Pipelines and Related Facilities
Amendments/Supplements to DEP 61.40.20.30-Gen

Ref. Section

Part I : INTRODUCTION

1.1 Scope
Second paragraph: This specification is based on API Standard 1104, twentieth edition,
Nov 2005. Though the DEP refers to the 17th edition, the corresponding sections of the 20th
edition shall be applicable. For ease of reference, the amended sections of the DEP and
the applicable sections of both 20th edition (new) and the 17th edition (old) are indicated
in this standard. Clauses which are not amended by this specification shall remain
applicable as written.

Part II Amendments/Supplements to API Standard 1104

New API section 4.1 Equipment:

Add the following:


All welding machines, line up clamps, beveling machines, cutting torches and other equipment,
tools and supplies used in connection with welding work shall be kept in good mechanical
condition. Sufficient meters, portable or permanent, shall be provided to calibrate machines and
to regulate voltage and amperage as may be needed. Ground clamps shall be dependable and
not arc the pipe. The clamps shall be located close to the point of welding.

The welding equipment used in production welding shall be the same type and model used
during welding procedure qualifications.
The welding machines shall be periodically calibrated as per the approved calibration schedule.
Calibration records shall be maintained and the calibration status shall be displayed by means of
a sticker on the machine.

A detailed procedure for operation of automatic welding equipment outlining set-up and
sequence of operation shall be submitted for Company approval. This shall include the following:
Input welding parameter detail and maximum/ minimum programmed tolerances
Method statement for the control of the welding parameter cartridges at all weld stations.
Maximum/ minimum welding operator adjustment control limits
Procedure for adjusting welding parameters at the welding console, including report sheet.

1.5.1 (New API section 4.2.1) - Pipe and fittings:

Add the following:


The residual magnetism on the line pipe shall not exceed 25 gauss. Contractor shall ensure that
residual magnetism does not impede welding. Residual magnetism in excess of the specified
value shall be removed by demagnetization. A detailed procedure for de-magnetization shall be
submitted for Company review and approval.

1.5.2 (New API section 4.2.2) Filler Metal


Project No.: MASTER
DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 5 OF 21


Sub-section 1.5.2.1 (New API section 4.2.2.1) Type and size

Add the following:


Electrodes conforming to E7010-P1 and E8010-P1 of AWS A5.5 shall be used in place of
E7010-G and E8010-G respectively.
The level of testing for all electrodes shall be Schedule K of ANSI/AWS A5.01 which shall be
taken as Schedule J plus chemical analysis for the particular electrode sizes which are not
required to be chemically analyzed by ANSI/AWS A5.5. For alternative electrodes, the level of
testing shall be at least the same.
The batch classification shall be C3 of ANSI/AWS A5.01.
Electrode inspection certificates for each batch shall be in accordance with ISO 10474 Type
3.1B/ EN10204 Type 3.1 certification.
For sour service, the electrodes shall not deposit weld metal containing more than 1.0 weight %
Nickel.
The Molybdenum content of electrodes, filler metals and fluxes shall not exceed 0.5% and shall
not be deliberately added.
Details on Nickel and Molybdenum shall be included in Manufacturers certification.
Electrodes shall have type approval by a certifying authority such as Lloyds or DNV.
Each electrode shall have the AWS or other appropriate classification marked on the flux near
the grip end. Electrodes which do not have this marking shall be removed from the job site to the
satisfaction of the Company.
All welding consumables used during production shall be the same manufacturer, brand and
AWS type as those used and approved during welding procedure qualifications.

1.5.2.2 (New API section 4.2.2.2) Storage and handling of filler metals and fluxes

Add the following:


All welding consumables shall be stored and handled in accordance with the Manufacturers
recommendations, as a minimum. The Contractors procedures for storage, issue and handling
of welding consumables shall be submitted for Company review and approval.
Sufficient quantities of each lot of welding consumables shall be purchased by the Contractor to
complete the work.
Contractor shall maintain a system of traceability whereby the batch number of the welding
consumables can be related to the weld number for any particular joint.

1.5.3 (New API section 4.2.3) Shielding Gases

1.5.3.1 (New API section 4.2.3.1) Types

Add the following:


When specified in the WPS, the shielding gas or gas mixture to be used, and gas quality shall be
qualified in the welding procedure qualification.
Shielding gas shall be of welding grade and shall meet the following requirements:

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 6 OF 21


CO2 for gas metal arc welding (GMAW):
Carbon dioxide : 99.5% minimum
Residuals : 0.5% maximum
Moisture : 97 ppm max at minus 34 degrees C dew point.

Argon for gas tungsten arc welding (GTAW) ands GMAW:


Argon : 99.995% minimum
Moisture : 10.5 ppm max at minus 60 degrees C dew point

Where mixed gases are to be used, the specification, composition and purity shall be subject to
Company approval.

1.5.3.2 (New API section 4.2.3.2) Storage and handling:

Add the following:


Each container of gas shall be identified with the gas type, mixture and purity. Unmarked
containers and/or contaminated gases shall be removed from the work site. The shielding gas
manufacturer shall issue certificates of compliance to the specified purity levels with details of
gas composition.

Section 2: (New API section 5) Qualification of Welding Procedures for


Welds Containing Filler Metal Additives

2.1 (New API section 5.1) : Procedure Qualification

Add the following requirements:


Welding procedures are required to cover all production welding including butt welds, fillet welds
and all associated repairs.
In each case where an automatic welding process or system is approved for use, a manual
welding procedure shall be qualified as a back-up.
The use of semi-automatic self shielded flux cored welding process shall not be permitted.
Welding progression should be downhill for mainline welding with an internal clamp.
For all tie-in welds, for joints where an external clamp is used and for full thickness repairs, the
root bead shall be deposited in the uphill progression.
No single pass welds, internal back welding or internal root sealing welds shall be allowed,
except for an automatic root pass applied internally that is an integral part of the welding
procedure when approved by the Company.
A minimum of two welders shall be employed on girth welds for pipe diameters 6 NPS and
above.
Both partial penetration and full penetration repair procedures shall be qualified by testing.
The contractor shall notify the Company of the date and location of the welding procedure
qualification testing at least five (5) working days before the start of any test. All welding
procedure and welder qualification tests shall be witnessed by the Company Engineer/Inspector.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 7 OF 21


Separate welding procedures shall be submitted and qualified for the following:
- Pipeline welding
- Tie-in welding
- Welding of fittings
- Welding of weldolets
- Repair welding
- Fillet welds
- Attachment of saddles / split sleeves
- CP attachments
- Cap, partial thickness and full penetration repair procedures shall be qualified.
Roll welding shall only be acceptable when using a fully automatic welding process.
Contractor shall be responsible for developing and obtaining Company approval of all welding
processes, equipment and procedures.

2.3.2.10 (New API section 5.3.2.10) Time between passes


The maximum time lapse between the root pass and hot pass shall be recorded on the welding
procedure specification and shall be qualified during weld procedure qualification. This time shall
be kept to a minimum.

2.3.2.13 (New API section 5.3.2.13) Pre- and Post-heat treatment


Add the following:
The minimum preheat temperature shall comply with the requirements of BS EN 1011 Part 2 for
ferritic steels and applicable part of BS EN 1011 for the material to be welded.
Preheat shall be specified on the WPS when it is required and shall be qualified during welding
procedure qualification testing.
For pipe diameter 12 inch NPS & above and wall thickness over 18 mm, electrical resistance
preheating shall be carried out.
For pipe diameter 12 inch NPS & above and wall thickness up to 18 mm, full encirclement ring
type burners may be used in lieu of electrical resistance preheating.
For pipe diameter below 12 inch NPS and greater than 6 inch NPS, hand-held, fuel gas torches
of adequate size may be permitted provided a minimum of two torches are used when
preheating manually.
The use of oxyacetylene gas for preheating shall not be permitted
All tie-in welds, repairs, fillet welds and fitting-to-pipe welds shall be preheated to a temperature
at least 50oC above that required for similar pipe-to-pipe butt welds. The inter-pass temperature
shall not exceed 250oC.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 8 OF 21


Tie-in welds shall be welded in one cycle without any interruption with a minimum pre-heat and
inter-pass temperature of 100 degrees C. Root pass shall be deposited with an uphill welding
progression and time lapsed between the completion of the root pass and the commencement of
the second pass shall not exceed five minutes. A minimum of two welders shall be engaged on
each girth weld to comply with the above requirements.
If post weld heat treatment (PWHT) is required, it shall be specified on the WPS and shall be
qualified during welding procedure qualification. A separate PWHT procedure shall be submitted
for Company approval. The procedure shall include details of thermocouple placement and
PWHT cycle. Acceptable PWHT methods are electrical induction and electrical resistance
heating.

2.3.21 (New API section 5.3.2.17) New: Welding Procedure Specification


In addition to the requirements of API 1104, the following minimum details shall be included in
the Welding Procedure Specification:
1. Project identifications
2. Consumables trade names, type and lot number
3. Weld preparation and fit-up tolerances
4. Preheat temperature and method
5. Time lapse between end of root bead and start of hot pass
6. Inter-pass temperature
7. Nozzle diameter for automatic welding
8. Oscillation width and frequency for automatic welding
9. Electrode stick-out length
A tabulated list of proposed welding procedures with details of pipe diameter, wall thickness,
welding process, consumables and intended application in the project work scope shall be
submitted along with welding procedures for COMPANY review.
2.3.22 (New API section 5.3.2.18) New: Records
Each revision of a WPS shall be given a new number in sequential order and revisions marked in
order to identify changes.

2.5 (New API section 5.5) Welding of Test Joints- Butt Welds
Add the following:
Pipe to be used for welding procedure qualification shall be selected from the heat exhibiting the
highest carbon equivalent.
Cap, partial penetration and full penetration repair procedures shall be qualified.
For mechanized welding equipment, a minimum of three consecutive complete test joints are to
be made. Automatic monitoring equipment shall be available for measuring amperage and
voltage at the welding heads to verify that programmed parameters are being achieved.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 9 OF 21


A 1.6 mm root misalignment, if necessary using a 1.6 mm shim, shall be induced in one of the
three welds.
All three joints shall pass the required NDE. One of the welds shall be used for repair
qualifications. Cleaning between weld passes may not be required if demonstrated satisfactorily
during welding procedure qualification.

2.6.9 (New API section 5.6.9) New Clause

Add the following:

Full ring CAPCIS tests


For longitudinally welded API 5L X 60 and higher pipe grades in sour gas service, the welding
procedure qualification tests shall include full ring CAPCIS testing at the design stress or 72% of
specified minimum yield strength (SMYS) whichever is higher. Test coupons for this test shall be
selected from the heat having the highest carbon equivalent and heaviest pipe wall thickness for
each pipe manufacturer. One test weld each for the main line welding procedure, tie-in
procedure and a full thickness repair procedure shall be subjected to this test. The test method
shall be as per Offshore Technology Report OTI 95 635 published by Health and Safety
Executive, UK. The test solution shall be NACE TM0177 test solution i.e. 0.5% acetic +5% NaCl
+ H2S with a constant PH of 3.2. For acceptance criteria, according to TM 0177, no crack or
rupture in 720 hours shall be permitted.

SULPHIDE STRESS CRACKING (SSC) TEST


Pipe grades API 5L X 60 and higher for sour service conditions shall require sulphide stress
cracking (SSC) tests to be carried out on all weld and repair procedures.
The SSC procedure shall consist of transverse weld, four-point bend tests as per ASTM G 39
specification using solution A of NACE TM0177. Applied deflection shall correspond to 80% of
specified minimum yield strength of the base material. A total of 12 specimens shall be taken
from the 6 oclock position to include the weld metal and HAZ from the weld root, mid thickness
and cap. There shall be no cracking after 720 hours of exposure.

CRACK TIP OPENING DISPLACEMENT TESTS (CTOD)


Crack tip opening displacement tests (CTOD) shall be conducted at 0oC on all procedure tests
(except fillet welds) in accordance with ISO 12737 and BS 7448, Part 1 & Part 2 using the SENB
geometry specimen (a). Test specimens shall be taken from the weld metal and at the fusion
line at the 12 oclock, 3 oclock and 6 oclock positions as per API 1104. Each test shall consist
of three specimens.
The welding procedure shall be qualified to a minimum fracture-toughness requirement of
0.12mm.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 10 OF 21


2.9 (NEW API section 5.9) New Clause - OTHER REQUIREMENTS
2.9.1 (New 5.9.1)
CONTRACTOR shall review, witness and submit all non-destructive and destructive testing
procedures for Company approval. All mechanical testing shall be carried out by an accredited
testing facility subject to the approval of COMPANY.
All procedure qualification welding and testing shall be witnessed and certified by COMPANY
Engineer/Inspector.

2.9.2 (New 5.9.1)


A register of all welding procedures to be used in production, shall be maintained by
CONTRACTOR prior to the start of any production welding, and shall be subject to COMPANY
approval.

2.9.3 (New 5.9.1)


For partial penetration weld repair qualification weld, the following mechanical tests shall be
done:
Tensile tests - 2 specimens
Side bend tests - 2 specimens
Macro and hardness survey - 1 specimen
Charpy test - to specification
SSC test - 3 specimens from base of repair
For cap repairs, the following mechanical tests shall be done:
Side bend tests - 2 specimens
Macro and hardness survey - 1 specimen

Section 3 (New API section 6) Qualification of welders

3.1 (New API section 6.1) General

Add the following:


All welders and welding operators employed by CONTRACTOR shall be required to pass a
welding test for the type and methods of welding he will perform, including attachment welds. No
welder shall work on any phase of the pipeline unless he has been tested and approved by
COMPANY. For pipe diameters over 12 NPS, a welder may be qualified on half the pipe
circumference, this shall include the 12 and 6 oclock positions. Automatic Welding operators
shall have previous experience/ qualification on proposed equipment prior to testing. All
automatic welding operators will require re-qualification before production on all the appropriate
pipe sizes/thicknesses.
Welder tests shall simulate production conditions, with the distance between the bottom of pipe

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 11 OF 21


and the ground being between 40 60cms.
The quality of the test welds shall be determined by radiographic testing, using the approved RT
procedure, and in addition, for GMAW welding, the approved UT procedure. Welds passing NDT
shall be finally qualified by destructive testing as per API 1104.
Each welder/operator shall be given a unique number which shall be marked in paint on all welds
produced by him. Paint quality shall be approved by COMPANY.
A list of qualified welders shall be kept up to date and available for COMPANY inspection. This
shall include a welders competence certificate that references the corresponding WPS number,
the essential variables, validity date and test results for each welder or welding operator for each
test.
Each qualified welder and welding operator shall be given a badge with details of the range of
qualification and applicable welding procedures for which he is qualified. Should a welder or
welding operator leave the job, his number shall not be duplicated.
Any welder found responsible for an unacceptable level of defects/repairs, shall, at COMPANY
request, be removed from production. At the discretion of COMPANY, the welder in question
may be retested after an agreed upon period of retraining.

3.6 (New API sub-section 6.6) Radiography Butt welds only

3.6.1 (New API sub-section 6.6.1) General


Delete this section and add the following:
Butt welded test coupons for welder qualifications shall be subjected to radiographic examination
prior to destructive testing. Only when the test welds are acceptable by radiography, they shall
be subjected to subsequent destructive testing.

SECTION 4 (New API section 7) Design and Preparation of a joint for Production Welding
4.1 (New API section 7.1) GENERAL
Add the following requirements:
On pipe which is to be cut back or sectioned, a zone extending 100mm for the proposed position
of the new field bevel shall be examined visually and by ultrasonic testing to the acceptance
requirements of the appropriate pipe material specifications. In addition, the finished new bevel
shall be magnetic particle tested.
During welding production, each automatic welding head shall have its welding parameters
checked on a random basis by the approved metering equipment. All results shall be subject to
COMPANY approval.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 12 OF 21


4.1.1 (New API section 7.1.1) New Section pipe Cleaning
Add the following requirements:
Each joint of pipe shall be swabbed along its full length, immediately prior to alignment
with the pipeline.
Swabbing shall remove all loose dirt, mill scale, and other foreign substances inside the
pipe.
The swab shall incorporate a steel disc, minimum 0.25 inch (6.4mm) thick, with a
diameter 0.4 inch (10mm) less than the nominal inside pipe diameter (ID).
In the event that the steel disc will not pass through a joint of pipe with the plane of the
disc at right angles to the pipe wall, that joint shall be rejected and shall not be installed in
the pipeline. Each rejected joint of pipe shall be clearly marked as a reject and removed
from the job site.
4.2 (New API section 7.2) ALIGNMENT
Add the following:
Force shall not be used to correct misalignment other than the normal force associated with the
use of conventional line-up clamps.

4.3 (New API section 7.3) Use Of Line-Up Clamp For Butt Welds
The second paragraph of SHELL DEP clause 4.3 is deleted and is replaced by the following:
Internal line-up clamps shall not be removed before the completion of the first pass.
The pipes on both sides of the weld joint shall not be raised, lowered, or otherwise moved, until
both the root pass and the second pass (hot pass) have been completed, unless CONTRACTOR
can demonstrate to the satisfaction of COMPANY that the root pass alone is adequate to resist
deformation and cracking. This shall include a stress calculation. In this case, the root pass shall
be inspected by magnetic particle examination to confirm the absence of cracks prior to
subsequent welding.
External line-up clamps may be removed when the root pass is at least 50 per cent complete and
equally spaced around the pipe circumference, subject to the pipe remaining adequately
supported.
4.5 (New API section 7.5) WEATHER CONDITIONS AND PROTECTION
Add the following:
The welding procedures approved by COMPANY shall be strictly adhered to at all times with
regard to welding parameters and environmental conditions. Welding shall not be performed
when, in the judgment of COMPANY, the quality of the completed weld would be impaired by the
prevailing weather conditions. These conditions include, but are not limited to, airborne moisture,
sand or dirt particles and high winds. Windshields and enclosed welding stations may be used
when practical.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 13 OF 21


4.10 (New API section 7.10) IDENTIFICATION OF WELDS
Add the following:
CONTRACTOR shall paint the weld number on the pipe adjacent to the weld at a point where it
shall remain visible after welding and filed joint coating. The weld number shall be a minimum
10mm high and legible.

4.11.1 (New API section 7.11) PRE AND POST-HEAT TREATMENT

4.11.2 (New API section 7.11.1) PREHEATING AND INTERPASS TEMPERATURE


CONTROL AND MEASUREMENT
4.11.2.1 (New API section 7.11.1.1) GENERAL
Add the following:
Preheating and inter-pass temperature requirements shall be qualified on welding procedure
qualification testing. For automatic welding (other than SAW), preheat trials shall be conducted
to ensure specified hardness requirements are obtained.
Unless otherwise agreed by COMPANY, the preheat for repair welds shall be at least 50 degrees
C above that qualified for the original weld, but in no case shall be less than 100oC, and shall be
applied uniformly around the full circumference of the welds.
Any requirements for post-weld heat treatment shall be established during welding procedure
qualification tests. In such cases, the specific requirements for heat treatment shall be included
in the welding procedure specification.

4.17 (New API section 7.12) NEW Section - OTHER REQUIREMENTS


Add the following clauses to this section:
4.17.1 (New API section 7.12.1) TACK WELDS
Tack welds when approved by COMPANY shall be a minimum of 50mm long, and shall be
welded with the same Welding Procedure Specification used for the root pass and by a qualified
welder.
All tack welds shall be welded vertical up.
Preheat of tack welds shall be the same as the approved welding procedure specification for that
pipe or fitting grade, size and thickness.
Tack welds incorporated into the final weld shall be ground to a feather edge at each end to
ensure adequate fusion on the root pass.

4.17.2 (New API section 7.12.2) ARC STRIKES


Arc strikes shall not be permitted outside the weld bevel.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 14 OF 21


4.17.3 (New API section 7.12.3) END PROTECTION
Pipe ends shall be adequately protected during transportation, handling and fabrication and
installation.
Bevel protectors, where provided, shall remain in place until fabrication commences.
On completion of stage fabrication or end of work shift or end of the day, secure end caps or
plugs shall be placed over open ends. Welding to pipeline material is not permitted. End caps
and plugs shall be approved by COMPANY.

5 (New API section 8) Inspection and testing pf production welds

5.1 (New API section 8.1) Rights of Inspection

Add the following:

The Contractor shall submit an Inspection and test plan (ITP) incorporating the requirements of
this specification for Company review and approval. The type, extent and frequency of inspection
shall be as per the approved ITP.

5.2.1 (New API section 8.2.1) GENERAL


Add the following:
Each weld shall be cleaned by a power brush to remove all slag, splatter, etc., before inspection.
All welds shall be inspected 100 per cent by visual inspection.
All butt welds shall be inspected 100 per cent by radiographic inspection.
Non-destructive Testing (NDT) procedures shall be submitted for COMPANY approval and shall
be qualified individually on the welding procedure qualification tests, or when agreed to by
COMPANY, on a production weld.

For UT, at least one ASNT Level III certified inspector shall be available for overall supervision.

5.2.2 (New API section 8.2.2) Radiographic examination


Add the following:
Internal X-ray crawlers shall be used for radiographic examination of pipelines for pipe diameter
6 NPS and above. For pipe sizes below 6 NPS, low energy Gamma radiography using Isotopes
such as Seleinium-75 may be allowed in lieu of X-ray subject to procedure qualification and
Company approval. Wire type IQIs shall be used in all cases.
Contractor shall supply all labour and materials necessary to perform radiographic inspection.
Any weld which, in Companys opinion, is not satisfactory as indicated by radiographic inspection
shall be repaired or cut out and re-welded at Contractors expense.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 15 OF 21


5.2.3 (New API section 8.2.3) ULTRASONIC EXAMINATION
The first two paragraphs of SHELL DEP clause 5.2.3 are deleted and replaced by the following:
Ultrasonic examination shall be required as follows:

(i) After re-beveling due to pipe cutting, pipe damage and/or cut outs a 100mm wide band
extending from pipe end.
(ii) A zone 100mm wide around planned cut-outs for nozzles, branches, etc.
(iii) To verify minimum wall thickness after grinding
(iv) All tie-in welds
(v) Initial testing of automatic welds

At the commencement of welding with an approved automatic process, in addition to


radiography, all welds shall be tested 100% by ultrasonic examination until COMPANY is
satisfied that the process is under complete control (minimum of 50 welds). The level of UT
examination may then be reduced with Companys approval, when a satisfactory level of
confidence in the automatic process and quality of the welding has been reached.
A detailed UT procedure shall be required which includes a test block with known defects for
calibration purposes.
(vi) Where radiographic inspection does not clearly show compliance with this specification.
Excluding (iv) and (v), acceptance shall be in accordance with the relevant pipe material
specification.
Where there is a conflict in the test result between radiography and UT inspection, the more
stringent criteria shall be applied and the weld area shall be repaired accordingly.
Ultrasonic inspection procedures shall be submitted to COMPANY for approval, prior to use.

5.2.5 (New API section 8.2.5) Magnetic Particle Examination


Contractor shall submit a magnetic particle examination (MT) procedure for Company review.
Wet method MT with AC yoke shall be used. Prod type technique as per ASME Section V, Article
7, T-743 is not permitted.
Magnetic particle inspection shall be required for the following:
(i) Re-beveling due to pipe cutting / pipe damage.
(ii) On removal of arc strikes

5.3 (New API sub-section 8.3) Qualification of inspection personnel

Add the following:


Personnel performing welding inspection shall have a valid AWS CWI or CSWIP 3.1 certification
in welding inspection and a minimum of five years experience in welding inspection.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 16 OF 21


5.4 (New API sub-section 8.4) Certification of Nondestructive Testing Personnel

Delete sub-section 8.4.1 and replace DEP 5.4.1 with the following:

All NDT personnel shall have ASNT or PCN Level II certification in the applicable NDT method
and type with a minimum of 5 years experience. ASNT Level II personnel shall have been
examined and certified by ASNT Level III examiners. Certifications by Contractor appointed
Level III examiners who do not have valid ASNT Level III certification in the relevant method shall
not be acceptable.
Personnel interpreting radiographs shall have valid CSWIP or PCN certification in interpretation
of radiographs or ASNT Level III certification in radiography and shall have a minimum of 5 years
experience in film interpretation after the certification.
Ultrasonic testing operators shall have valid CSWIP or PCN Level II certification for butt weld
configuration. COMPANY reserves the right to test proposed UT operators prior to acceptance
using the approved procedures on a test weld.

5.5.3 (New API section 8.5.3) Inspection after welding

Add the Following:


Production weld Hardness Testing
10% of the girth welds in sour service shall be subjected to hardness testing using Kraut Kramer
Microdur MIC 2 or MIC 10. A set of 5 hardness readings shall be taken on the weld and the
heat- affected zone on either side at 12 Oclock position. The readings on the HAZ shall be taken
within 0.5 mm from the fusion line/weld toes. The weld surface shall be prepared by grinding,
filing and polishing with emery paper (300 grit or better) prior to hardness testing. A procedure
for surface preparation shall be submitted for Company approval.

6.11 (New API section 9.8) New Clause DEFECT ACCEPTANCE LEVELS
All defect acceptance limits specified below are in addition to those specified in API Standard
1104 and SHELL DEP 61.40.20.30-Gen.
The external weld reinforcement shall be uniform and in no area shall the weld cap be lower
than the adjacent pipe wall.
Burn-through is not acceptable. All burn-throughs shall be repaired to the satisfaction of
COMPANY.
The aggregate length of all indications of Hollow-Bead Porosity (HB) shall not exceed 3% of
the weld length.
Tungsten inclusions shall be treated as individual inclusions and shall not exceed 2 per weld
and 3 mm in size separated by a minimum distance of 50 mm.
No arc strikes are permitted outside the weld bead. Repair by welding of arc strikes is not
permitted.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 17 OF 21


Removal of arc strikes shall be at the discretion of COMPANY. When removal is allowed, it
shall be done by careful grinding only. The ground area shall be examined by magnetic
particle inspection to ensure freedom from defects and the remaining wall thickness shall be
checked by ultrasonic testing. If grinding to remove the effects of arc strikes reduces the wall
thickness below the specified minimum wall thickness of the pipe, the defective pipe section
shall be cut off.
Where Magnetic Particle Inspection is applied on parent pipe bevels following re-beveling, no
linear defects or laminations are permitted. Any indications revealed by MT shall be
investigated and removed by grinding or cutting, and again re-beveling.

7.1.2 (New API section 10.1.2) Removal of defects and repair

7.1.2 (New API section 10.1.2.1) General

Add the following:


Weld repairs to the pipe body or to the body of fittings or bevels are not permitted. Single pass
repairs shall not be permitted. Repairs to the weld root by welding from the inside of the pipe
shall not be permitted. Repair procedures shall be qualified as per relevant clauses of this
specification.

8 (New API section 11) PROCEDURES FOR NON-DESTRUCTIVE TESTING

8.1.1 (New API section11.1.1) Radiographic test methods General

Add the following:


All pipeline girth welds for pipe sizes 6 NPS and above shall be radiographed with X-ray crawler.
Gamma ray radiography is not acceptable.
Radiographs shall be made using film conforming ASTM E94 Type 1 or Type 2 except for pipe
size 8 NPS or less, for which only Type 1 film shall be used.

8.1.7 (New API section11.1.7) Production radiography

Personnel interpreting radiographs shall have valid CSWIP or PCN certification in interpretation
of radiographs or ASNT Level III certification in radiography and shall have a minimum of 5 years
experience in film interpretation after the certification.

8.1.13 (New API section11.1.13) Radiation protection

Add the following:


The contractor shall fully comply with applicable Company safety regulations on radiation safety.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 18 OF 21


9 (New API section 12) - Mechanized Welding with filler wire metal additions

9.5.2 (New API section12.5.2) Changes requiring re-qualification

For Mechanized GMAW process, the following shall be applicable.


A change in the batch number of electrode shall constitute an essential variable. Batch test
certificates for each batch of GMAW wire /electrode shall be provided from the manufacturer as
per ASME Section II - Part C.
For procedure qualification, additional indentations, on weld metal and heat affected zone shall
be required by the COMPANY during Vickers (HV10) hardness survey of weld cross sections.
This shall be advised by the COMPANY at the time of procedure qualifications following a review
of the proposed WPS.
The procedure qualifications test welds and welding operator test welds shall be ultrasonically
examined in addition to radiography prior to destructive tests.

9.8 (New API section12.8) Inspection and testing of production welds

Add the following:


Initial testing of automatic welds: At the commencement of welding with an approved automatic
process, in addition to radiography, a minimum of 50 welds shall be tested 100% by ultrasonic
examination until COMPANY is satisfied that the process is under complete control.
Subsequently at least 5% the remaining welds shall be ultrasonically examined as advised by the
COMPANY. Cracks of any size and lack of fusion defects in excess of the specification detected
by ultrasonic examination shall be cause for rejection.
When there is a dispute between radiography and ultrasonic examination, production welds shall
meet the requirements of both radiography and UT. Following repair, the welds shall be
examined by both radiography and UT.
The COMPANY reserves the right to ask for ultrasonic examination to supplement radiography to
confirm the absence of crack like defects and lack of fusion in GMA welds.
Production weld hardness testing: 10% of production welds in sour service shall be subjected to
hardness testing. In addition to the weld, the heat affected zone on both sides of the weld shall
be hardness tested using Kraut Kramer Microdur MIC 2 or MIC 10. The weld reinforcement shall
be dressed and the surface adequately prepared to facilitate hardness testing. The readings on
the HAZ shall be taken within 0.5 mm from the fusion line/weld toes.
One production weld out of the first 100 production welds made by mechanized GMAW process
shall be submitted to destructive testing as per the welding procedure qualification requirements.
Additional production welds may be required to be destructively tested as required by
COMPANY Engineer.
Repair welding procedures shall be qualified. Manual (SMAW) repair procedure on automatic
GMAW welds shall be carried out with low hydrogen electrodes with vertical uphill progression.
The use of cellulose coated electrodes for repair of GMA welds shall not be permitted.
Mechanized GMA welding shall be carried out with full environmental protection from rain,
draught, dust etc.

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 19 OF 21


11 (New API Section 14) New Records

Permanent records shall be made with full supporting information of all welds, including repairs
and re-welds. Records shall include a pipe tracking system or field drawing which identifies the
final location co-ordinates of each pipe and weld.
All welding repair rates shall be reported to Company weekly per welder/ per line/ per automatic
machine, with an analysis of the type of defects occurring. This shall be presented in a software
package format (e.g. Excel / Access).

In addition to hard copies, all approved project welding procedures (WPS and PQR), NDT
procedures and approved Inspection & test plans (ITPs) shall be furnished on CD ROM format
(2sets).

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 20 OF 21


PART III REFERENCES

The following Reference Codes, Standards and Specifications are added:


AMERICAN STANDARDS
Test Methods and definitions for Mechanical ASTM A370
Testing of Steel Products

Preparation and Use of Bent-Beam ASTM G39


Stress-Corrosion Test Specimens

Laboratory Testing of Metals for resistance NACE TM0177


To Sulfide Stress Cracking in H2S Environments

Personnel Qualification and Certification RP SNT-TC-1A


In Non-Destructive Testing
BRITISH STANDARDS
Fracture mechanics toughness tests welds BS 7448, Parts 1 & 2

EUROPEAN STANDARDS
Metallic Products Types of Inspection EN 10204
Documents

ISO STANDARDS
Materials for use in H2S containing
Environments in oil and gas production ISO 15156-182
Metallic materials determination of
plane strain fracture toughness ISO 12737

Offshore Technology Report published by

Health and Safety Executive, UK OTI 95 635

Project No.: MASTER


DOCUMENT TITLE: ADCO DOC. NO. 30-99-00-0041-1
Welding of Pipelines and Related Facilities
REV. 2 DATE :Oct. 2006

DEP No. : 61.40.20.30 PAGE 21 OF 21