8384-2602-SQ-0720 B1 Spec Welding and NDT

Provision of FEED for PLD
Development Project, Block

06.01, Vietnam
Prepared for: ROSNEFT VIETNAM B.V.
Doc Ref: 8384-2602-SQ-0720
Rev: B1
Date: June 2017
SPECIFICATION FOR WELDING AND NDT OF

CARBON STEEL PIPELINE COMPONENTS AND
PIPELINES TO API 1104
Provision of FEED for PLD Development Project, Block 06.01, Vietnam
SPECIFICATION FOR WELDING AND NDT OF CARBON STEEL PIPELINE
COMPONENTS AND PIPELINES TO API 1104
Table of Contents
1.0 Introduction ....................................................................................................................... 9

1.1 General ..................................................................................................................................... 9
1.2 Scope and Purpose of this Document .................................................................................... 10
1.3 Definitions ............................................................................................................................... 11
1.4 Abbreviations .......................................................................................................................... 11
1.5 Units ........................................................................................................................................ 13
2.0 Codes and Standards, regulations and Project Documents ........................................ 14

2.1 General ................................................................................................................................... 14
2.2 Conflict of Information ............................................................................................................. 14
2.3 Vietnamese Regulations ......................................................................................................... 14
2.4 COMPANY BOD and Project Documents .............................................................................. 14
2.5 Applicable Codes and Standards ........................................................................................... 15
2.6 Order of Precedence .............................................................................................................. 18
3.0 HSE and Quality Assurance / Quality Control ............................................................... 19

3.1 General HSE Requirements ................................................................................................... 19
3.2 General Quality Assurance / Quality Control requirements .................................................... 19
4.0 Specifications (API 1104:2016 Section 4) ...................................................................... 20

4.1 General (New) ........................................................................................................................ 20
4.2 Welding processes (New) ....................................................................................................... 20
4.3 Equipment (API 1104:2016 Section 4.1) ................................................................................ 20
4.4 Materials (API 1104:2016 Section 4.2) ................................................................................... 21
4.4.1 Pipe and Piping Components (API 1104:2016 Section 4.2.1) ............................................ 21
4.4.2 Filler Metals and Fluxes (API 1104:2016 Section 4.2.2)..................................................... 21
4.4.3 Shielding Gases (API 1104:2016 Section 4.2.3) ................................................................ 23
5.0 Qualification of Welding Procedures with Filler Metal Additions (API 1104:2016
Section 5) ......................................................................................................................... 24
5.1 Procedure Qualification (API 1104:2016 Section 5.1) ............................................................ 24
5.1.1 General (New) ................................................................................................................... 24
5.1.2 Welding Procedure Parameters (New) .............................................................................. 24
5.2 Record (API 1104:2016 Section 5.2) ...................................................................................... 25
5.3 Welding Procedure Specification (API 1104:2016 Section 5.3) .............................................. 25
5.3.1 General (API 1104:2016 Section 5.3.1) ............................................................................. 25
5.3.2 Specification Information (API 1104:2016 Section 5.3.2) ................................................... 25
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5.4 Essential Variables (API 1104:2016 Section 5.4) ................................................................... 29

5.4.2 Changes Requiring Requalification (API 1104:2016 Section 5.4.2).................................... 29
5.5 Welding of Test Joints – Butt welds (API 1104:2016 Section 5.5) .......................................... 32
5.5.1 Test Pipe for WPQT (New) ................................................................................................ 32
5.6 Testing of Welded Joints – Butt Welds (API 1104:2016 Section 5.6) ..................................... 33
5.6.1 Preparation (API 1104:2016 Section 5.6.1)........................................................................ 33
5.6.2 Tensile Strength Test (API 1104:2016 Section 5.6.2) ........................................................ 35
5.6.3 Charpy V-Notch Impact Testing (New) .............................................................................. 37
5.6.4 Macro Section (New) ......................................................................................................... 39
5.6.5 Hardness Testing (New) .................................................................................................... 40
5.6.6 Weld Metal Tensile Testing (New) ..................................................................................... 41
5.6.7 ECA Mechanical Testing (New) ......................................................................................... 42
5.7 Welding of Test Joints – Fillet welds (API 1104:2016 Section 5.7) ......................................... 42
5.8 Testing of Welded Joints – Fillet welds (API 1104:2016 Section 5.8) ..................................... 42
5.8.1 Preparation (API 1104:2016 Section 5.8.1)........................................................................ 42
5.8.2 Method (API 1104:2016 Section 5.8.2) .............................................................................. 42
5.8.3 Requirements (API 1104:2016 Section 5.8.3) .................................................................... 43
6.0 Qualification of Welders (API 1104:2016 Section 6) ...................................................... 44

6.1 General (API 1104:2016 Section 6.1) ..................................................................................... 44
6.2 Single Qualification (API 1104:2016 Section 6.2) ................................................................... 45
6.2.2 Scope (API 1104:2016 Section 6.2.2) ................................................................................ 45
6.3 Multiple Qualification (API 1104:2016 Section 6.3)................................................................. 45
6.4 Visual Examination (API 1104:2016 Section 6.4) ................................................................... 46
6.5 Non-Destructive Testing (NDT) – Butt Welds Only (API 1104:2016 Section 6.6)................... 46
7.0 Design and Preparation of a Joint for Production Welding (7)..................................... 47

7.1.1 Weld Proximity (New) ........................................................................................................ 47
7.2 Alignment (API 1104:2016 Section 7.2) .................................................................................. 47
7.3 Use of Line-up clamp for Butt Welds (API 1104:2016 Section 7.3) ........................................ 48
7.3.1 General (New) ................................................................................................................... 48
7.3.2 Tacking (Tack Welding) (New) ........................................................................................... 48
7.4 Bevel (API 1104:2016 Section 7.4) ......................................................................................... 48
7.4.1 Mill Bevel (API 1104:2016 Section 7.4.1) ........................................................................... 48
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7.4.2 Field Bevel (API 1104:2016 Section 7.4.2) ........................................................................ 48

7.4.3 Bevel Condition (New) ....................................................................................................... 49
7.4.4 Inspection and Treatment of Bevels (New) ........................................................................ 49
7.5 Weather Conditions (API 1104:2016 Section 7.5) .................................................................. 49
7.6 Clearance (API 1104:2016 Section 7.6) ................................................................................. 49
7.7 Cleaning Between Beads (API 1104:2016 Section 7.7) ......................................................... 49
7.8 Identification of Welds (API 1104:2016 Section 7.10)............................................................. 50
7.9 Preheat and PWHT (API 1104:2016 Section 7.11) ................................................................ 50
7.9.1 Preheat and Interpass Temperature (New) ........................................................................ 50
7.10 Weld Interruption (New) .......................................................................................................... 51
7.11 Branches (New) ...................................................................................................................... 51
7.11.1 General ............................................................................................................................. 51
7.11.2 Set-in Type Fittings............................................................................................................ 51
7.11.3 Set-on Type Fittings .......................................................................................................... 52
7.12 Fillet Weld Attachments (New) ............................................................................................... 52
8.0 Inspection and Testing of production Welds (API 1104:2016 Section 8) ..................... 53
8.1 Rights of Inspection (API 1104:2016 Section 8.1) .................................................................. 53
8.2 Methods of Inspection (API 1104:2016 Section 8.2) .............................................................. 53
8.2.1 NDT General (New) ........................................................................................................... 53
8.2.2 Method (New) .................................................................................................................... 53
8.2.3 Timing of NDT (New) ......................................................................................................... 54
8.3 Qualification of Inspection Personnel (API 1104:2016 Section 8.3) ....................................... 55
8.4 Certification of Welding Engineer (New) ................................................................................. 55
9.0 Acceptance Standards for NDT (API 1104:2016 Section 9) .......................................... 57

9.1.1 Visual Acceptance – Weld Profile (New) ............................................................................ 57
9.2 Radiographic Testing (API 1104:2016 Section 9.3) ................................................................ 57
9.2.1 Inadequate Penetration due to High-Low (API 1104:2016 Section 9.3.2) .......................... 57
9.2.2 Internal Concavity (API 1104:2016 Section 9.3.6).............................................................. 57
9.2.3 Burn-Through (BT) (API 1104:2016 Section 9.3.7) ............................................................ 58
9.2.4 Porosity (API 1104:2016 Section 9.3.9) ............................................................................. 58
9.2.5 Cracks (API 1104:2016 Section 9.3.10) ............................................................................. 58
9.2.6 Undercutting (API 1104:2016 Section 9.3.11) .................................................................... 58
9.2.7 Accumulation of Imperfections (API 1104:2016 Section 9.3.12)......................................... 58
9.2.8 Tungsten Inclusions (New) ................................................................................................ 58
9.2.9 Copper Inclusions (New) ................................................................................................... 59
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9.3 Ultrasonic Testing (API 1104:2016 Section 9.6) ..................................................................... 59

9.3.1 Acceptance Standards (API 1104:2016 Section 9.6.2) ...................................................... 59
9.4 Visual Acceptance Standards for Undercutting (API 1104:2016 Section 9.7) ........................ 59
9.4.1 Acceptance Standards (API 1104:2016 Section 9.7.2) ...................................................... 59
9.5 Suspect Welds (New) ............................................................................................................. 59
10.0 Repair and Removal of Welds Defects (API 1104:2016 Section 10) ............................. 60
10.1 General (API 1104:2016 Section 10.1) ................................................................................... 60
10.2 Authorization for Repair (API 1104:2016 Section 10.2) .......................................................... 60
10.2.1 Company Authorization (API 1104:2016 Section 10.2.1) ................................................... 60
10.2.2 Crack Repairs (API 1104:2016 Section 10.2.2) ................................................................. 60
10.2.3 Repairs of Defects Other Than Cracks (API 1104:2016 Section 10.2.3) ............................ 60
10.3 Repair Procedure (API 1104:2016 Section 10.3) ................................................................... 61
10.3.1 Types of Repair Procedures (API 1104:2016 Section 10.3.2) ............................................ 61
10.4 Arc Burns (New) ..................................................................................................................... 62
11.0 Procedures for Non-Destructive testing (NDT (11)........................................................ 64

11.1 Radiographic Test Methods (API 1104:2016 Section 11.1) .................................................... 64
11.1.1 General (API 1104:2016 Section 11.1.1) ........................................................................... 64
11.1.2 Detail of procedure (API 1104:2016 Section 11.1.2) .......................................................... 64
11.1.3 Exposure Geometry (API 1104:2016 Section 11.1.3) ........................................................ 64
11.1.4 Type of IQIs (API 1104:2016 Section 11.1.4) ..................................................................... 65
11.1.5 Selection of IQIs ( API 1104:2016 Section 11.1.5) ............................................................. 65
11.1.6 Identification of Images (API 1104:2016 Section 11.1.8) .................................................... 65
11.1.7 Storage of Film and Other Imaging Media (API 1104:2016 Section 11.1.9) ....................... 66
11.1.8 Film Density (API 1104:2016 Section 11.1.10) .................................................................. 66
11.1.9 Image Processing (New) ................................................................................................... 66
11.2 Magnetic Particle Test Method (API 1104:2016 Section 11.2) ............................................... 66
11.3 Ultrasonic Test Method (API 1104:2016 Section 11.4) ........................................................... 67
11.3.2 Scanning and Evaluation Level (API 1104:2016 Section 11.4.7) ....................................... 67
12.0 Mechanized Welding with Filler Additions (API 1104:2016 Section 12) ....................... 68
12.1 Acceptable Processes (API 1104:2016 Section 12.1) ............................................................ 68
12.2 Procedure Qualification (API 1104:2016 Section 12.2) .......................................................... 68
12.3 Record (API 1104:2016 Section 12.3) .................................................................................... 69
12.4 Welding Procedure Specification (API 1104:2016 Section 12.4) ............................................ 69
12.5 Essential Variables (API 1104:2016 Section 12.5) ................................................................. 69
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12.6 Qualification of Welding Equipment and Operators (API 1104:2016 Section 12.6) ................ 69
13.0 Automatic Welding Without Filler Metal Additions (API 1104:2016 Section 13) .......... 70
Appendix A CTOD Testing ..................................................................................................... A-1

A.1 General ................................................................................................................ A-2
Appendix B Pin Brazing and Aluminothermic Welding of Anode or Continuity Leads ..... B-1
B.1 Pin Brazing and Aluminothermic Welding of Anode or Continuity Leads .............. B-2
B.1.1 Joining Technique ................................................................................................ B-2
B.1.2 Specification and Approval of Procedure .............................................................. B-2
Appendix C Requirements for AUT ....................................................................................... C-1

C.1 Introduction .......................................................................................................... C-2
C.2 System Requirements .......................................................................................... C-3
C.2.1 General ................................................................................................................ C-3
C.2.2 Agreed Items ........................................................................................................ C-3
C.2.3 Equipment Requirements ..................................................................................... C-4
C.2.4 Inspection Procedure ........................................................................................... C-7
C.2.5 System Configuration ........................................................................................... C-7
C.2.6 Mode of Use......................................................................................................... C-8
C.2.7 Set-Up and Calibration ....................................................................................... C-10
C.2.8 AUT Operators ................................................................................................... C-11
C.2.9 System Qualification .......................................................................................... C-12
C.2.10 Verification ......................................................................................................... C-14
C.2.11 Change to Qualification ...................................................................................... C-15
C.2.12 System Checks .................................................................................................. C-15
C.2.13 Documentation ................................................................................................... C-15
C.2.14 AUT Application ................................................................................................. C-15
Appendix D Requirements for Procurement, Storage and Control of Welding .................. D-1
D.1 Basic requirements .............................................................................................. D-2
D.2 Procedure Checklist ............................................................................................. D-5
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List of Figures
Figure 1.1 Phong Lan Dai Development ....................................................................................... 10
Figure 5.1 Location of Test Pieces Extracted from Pipe Butt Welds .............................................. 36
Figure 5.2 Charpy V-notch (CVN) Locations ................................................................................. 38
Figure 5.3 Locations of Hardness Indents ..................................................................................... 40
Figure 5.4 Fillet Weld Hardness Indent Locations ......................................................................... 42
Figure 11.1 IQI Sensitivity Levels .................................................................................................. 65
Figure D.1 Example Flowchart for Typical Consumable Control Procedure ................................ D-9
List of Tables
Table 2.1: Project Documents ....................................................................................................... 14
Table 5.1: Diameter and Test Pipe Thickness Range of Approval ................................................. 26
Table 5.2 (API 1104:2016 Table 2) Modified Types and Number of Test Specimens for Welding
Procedure Qualification Test ......................................................................................................... 37
Table 5.3 Charpy Impact Test Requirements ................................................................................ 38
Table 5.4 Maximum Permissible Weld and HAZ Hardness Values (HV10) ................................... 41
Table 10.1 Type and Number of Test Specimens for Repair Welding Procedure Qualification Test
..................................................................................................................................................... 62
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1.0 Introduction
1.1 General
Rosneft Vietnam B.V. (hereby referred to as “COMPANY”) is the operator of the existing
Block 06.1 Lan Tay platform that feeds gas through the Nam Con Son Pipeline (NCSP) to
the Dinh Co Gas Processing Terminal in Southern Vietnam.
The Lay Tay field was developed in 2002 by tying back 5 deviated subsea well completions
and horizontal subsea tees to the Lan Tay manifold (LTM). The LTM can allow tie-in of 6
wells. One 16.75-inch 13% chrome flowline and one main electro-hydraulic umbilical were
used to connect the LTM to the Lan Tay platform. The flowline and umbilical are
approximately 4.5km long and lie at a water depth of approximately 125m.
In 2012, the Lan Do field was developed by tying back 2 vertical subsea well completions
and horizontal subsea trees to the Lan Tay platform. The wells (LD-1P & LD-2P) are located
approximately 2.6km apart at a water depth of approximately 190m and tied back via a 12-
inch 28km predominantly 13% chrome flowline to a 12-inch Inconel 625 clad steel riser at
the Lan Tay platform. In line, the flowline includes a subsea isolation valve (SSIV), an inline
sled (ILS) and pipeline end termination (PLET) structures and has 35-off Inconel 625 CRA
clad carbon steel joints installed along its length for anode placement. A combined main
and SSIV umbilical and infield umbilical with associated control equipment and subsea
umbilical termination (SUT) structures were also part of the scope.
The Phong Lan Dai Development Project will develop the Phong Lan Dai (PLD) field.
Development of the PLD field is fundamental to COMPANY’s strategy in Vietnam of
continuing to develop a material gas business, to improve returns for co-venturers and to
retain its leadership of Vietnam’s emerging gas market. Key decisions have been made on
the scope and particularly the pace of the development which is influenced by both
competitions for the gas market and market demand.
COMPANY has recently completed a pre-FEED work programme for the development of
the field, with a reference case development for achieving first gas in 3Q 2018.
To achieve this date, FEED for the Phong Lan Dai Development Project is planned to
commence in 1Q 2017.
The reference case for development is based on 2-off subsea wells. See Figure 1-1
overleaf. One well (PLD-1P) will be located at the PLD field, while the other well (LD-3P) will
be located at the Lan Do field. PLD-1P will lie in a water depth of approximately 160m and
be located approximately 20km North East of the LTM and 10km North West of LD-3P.
Similar to the existing Lan Do wells, LD-3P will lie in a water depth of approximately 190m.
The wells will be tied back via a carbon steel flowline to the PLD SSIV.
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Figure 1.1 Phong Lan Dai Development
1.2 Scope and Purpose of this Document
This Specification details the minimum requirements welding processes, consumable

materials, testing, operators and inspection for welding of Carbon Steel pipelines, and
related facilities. The scope of this Specification includes the welding of Carbon Steel
Induction Bends, Valve pups, pipelines Flanges and Fittings.
It is the responsibility of the Contractor to meet the requirements of all referenced
Regulations, Specifications, Codes and Standards listed in this Specification and any
deviation will be treated as a non-conformance.
This specification is not applicable to installation by reeling and assumes that installation
tensile stress levels will be controlled within elastic design limits (<0.4% nominal longitudinal
strain).
This specification is applicable for elastic design and not strain based design (<0.4%
nominal longitudinal strain).
This Specification applies specific requirements for sour service conditions, except for ECA
(HOLD 01).
The welding of Alloy 625 clad components is not included in this Specification.
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1.3 Definitions
In and throughout this document, unless the context otherwise requires the
following definitions apply:
COMPANY : Rosneft Vietnam B.V.
CONTRACTOR : The party to which the Contract for welding and inspection is
awarded and who shall be responsible for conformity to this
Specification.
PROJECT : Provision of Front End Engineering Design (FEED) Services for
Phong Land Dai (PLD) Development Project, Block 06.1, Vietnam.
1.4 Abbreviations
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASNT American Society of Non-destructive Testing
ASTM American Society for Testing and Materials
AUT Automated Ultrasonic Testing
AWS American Welding Society
BS British Standard
CSWIP Certification Scheme for Welding and Inspection Personnel
CTOD Crack Tip Opening Displacement
CVN Charpy V-Notch
ECA Engineering Critical Assessment
EN European Norm
EWE European Welding Engineer
FL Fusion Line
FBW Flash Butt Welding
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
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HV10 Hardness Vickers with a 10 kg load
H2S Hydrogen Sulphide
IQI Image Quality Indicator
ISO International Standards Organisation
ITP Inspection and Test Plan
IWE International Welding Engineer
MPT Magnetic Particle Testing
MUT Manual Ultrasonic Testing
NDT Non Destructive Testing
PD Published Document
PE Professional Engineer
PO Purchase Order
pWPS Preliminary Weld Procedure Specification
RMS Root Mean Square
RT Radiographic Testing
RTR Real-Time Radiography
SAW Submerged Arc Welding
SI International System of Units
SMAW Shielded Metal Arc Welding
SMTS Specified Minimum Tensile Strength
SMYS Specified Minimum Yield Strength
SWSI Single Wall Single Image
UT Ultrasonic Testing
VT Visual Testing
WM Weld Metal
WPQR Welding Procedure Qualification Record
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WPQT Welding Procedure Qualification Test
WPS Welding Procedure Specification
1.5 Units
The International System of Units (SI) will be used throughout the design, however in
accordance with standard industry practice; the following units may be used as shown
below.
°C Degrees Celsius
in Inches
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2.0 Codes and Standards, regulations and Project Documents

2.1 General
The welding and inspection shall be carried out in accordance with the requirements of this
Specification, other project specifications where referenced in the Contract, and the latest
editions of the following codes, standards and regulations and other documents referenced
therein.
It is the responsibility of the CONTRACTOR to meet the requirements of all referenced
Regulations, Specifications, Codes and Standards listed in this Specification and any
deviation will be treated as a non-conformance.
This specification is complementary to the requisition for individual item(s) of equipment,
legislative requirements and guidance notes issued by any relevant authority and
specifications referenced herein. Particular notice of the requirements of SI 1996: 825 and
PD 8010-2 shall be taken.
2.2 Conflict of Information
If there is any conflict between this specification or any other specification and related
datasheets, or with any applicable codes, standards and regulations, CONTRACTOR shall
inform COMPANY in writing. Written clarification must be given by COMPANY before
CONTRACTOR commences work.
2.3 Vietnamese Regulations
Where Vietnamese Regulations exist, their requirements shall apply. A list of relevant
Vietnamese Regulations and Standards are located in Company document Codes,
Standards and Recommended Practices. The Vietnamese regulations shall not be applied
for manufacturing works outside Vietnam.
2.4 COMPANY BOD and Project Documents
It is the responsibility of CONTRACTOR to ensure that it has received from COMPANY all
specifications and associated datasheets, etc., which are referenced within applicable
specifications, to enable it to understand and comply with all aspects of work it is performing
for COMPANY.
The list of relevant project documents is provided in the following Table 2.1.
Table 2.1: Project Documents

Document No. Document Title
[1] 8384-2602-SW-0001 Linepipe Specification
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[2] 8384-2602-KW-0001 Linepipe Data Sheet
[3] 8384-2603-SW-0001 Pipeline Bends Specification
[4] 8384-2603-SW-0004 Pipeline Fitting Specification
2.5 Applicable Codes and Standards
The requirements of the latest edition of the Codes and Standards located in Company
document Codes, Standards and Recommended Practices, and the additional Codes and
Standards listed below shall be interpreted as the minimum requirements applicable to the
subject work.
In the case of conflict between this Specification, its associated specifications, data sheets,
Codes and Standards, the Contractor shall bring the matter to the Company’s attention for
resolution and approval in writing. No statement contained in this Specification shall be
construed as limiting the work to such minimum requirements.
American Standards
API 1104:2016 Welding of Pipelines and Related Facilities.
Section IX. Qualification Standard for Welding, Brazing, and Fuzing

ASME/BPVC SEC IX Procedures; Welders; Brazers; and Welding, Brazing, and Fusing Operators -
Welding, Brazing and Fusing Qualifications.
Standard Test Method and Definitions for Mechanical Testing of Steel

ASTM A370
Products.
This Standard Covers the Method and Equipment for the Determination of
ASTM E21 Tensile Strength, Yield Strength, Elongation, and Reduction of Area of Metallic
Materials at Elevated Temperatures.
ASTM E23 Standard Test Methods for Notched Bar Impact Testing of Metallic Materials.
Standard Test Methods for Vickers Hardness and Knoop Hardness of Metallic
ASTM E92
Materials.
ASTM E164 Standard Practice for Contact Ultrasonic Testing of Weldments.
ASTM E709 Standard Guide for Magnetic Particle Testing
Standard Practice for Design, Manufacture and Material Grouping

ASTM E747
Classification of Wire Image Quality Indicators (IQI) Used for Radiology.
Standard Test Method for Classification of Film Systems for Industrial

ASTM E1815
Radiography.
Standard Methods for Determination of the Diffusible Hydrogen Content of

AWS A4.3
Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc Welding.
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AWS B4.0 Standard Methods for Mechanical Testing of Welds
Welding Consumables - Gases and Gas Mixtures for Fusion Welding and
AWS A5.32M/A5.32
Allied Processes.
AWS C5.3 Recommended Practices for Air Carbon Arc Gouging and Cutting.
AWS QC1 Standard for AWS Certification of Welding Inspectors.
British Standards
Guide to Methods for Assessing the Acceptability of Flaws in Metallic

BS 7910 +A1
Structures.
BS EN 10204 Metallic Materials - Types of Inspection Documents.
Welding Consumables - Quality Requirements for Manufacture, Supply and

BS EN 12074
Distribution of Consumables for Welding and Allied Processes.
Non-destructive testing - Characterization and verification of ultrasonic

BS EN 12668-1
examination equipment Part 1: Instruments.
Non-destructive testing - Characterization and verification of ultrasonic

BS EN 12668-2
examination equipment Part 2: Probes.
Non-destructive testing Characterization and verification of ultrasonic

BS EN 12668-3
examination equipment Part 3: Combined equipment.
BS EN ISO 148-1 Metallic Materials - Charpy Pendulum Impact Test Part 1: Test Method.
Quality Requirements for Fusion Welding of Metallic Materials Part 1: Criteria

BS EN ISO 3834-1
for the Selection of the Appropriate Level of Quality Requirements.
Quality Requirements for Fusion Welding of Metallic Materials Part 2:

BS EN ISO 3834-2
Comprehensive Quality Requirements.
BS EN ISO 4136 Destructive Tests on Welds In Metallic Materials - Transverse Tensile Test.
BS EN ISO 6507-1 Metallic Materials - Vickers Hardness Test - Part 1: Test Method.
BS EN ISO 6508-1 Metallic Materials - Rockwell Hardness Test - Part 1: Test Method.
Metallic Materials - Tensile Testing Part 2: Method of Test at Elevated

BS EN ISO 6892-2
Temperature.
BS EN ISO 9001 Quality Management Systems — Requirements.
Destructive Tests on Welds in Metallic Materials. Impact Tests. Test Specimen

BS EN ISO 9016
Location, Notch Orientation and Examination.
BS EN ISO 9606-1 Qualification Testing of Welders - Fusion Welding Part 1: Steels.
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BS EN ISO 9712 Non-destructive Testing - Qualification and Certification of NDT Personnel.
Non-Destructive Testing - Industrial Radiographic Film - Part 1: Classification of

BS EN ISO 11699-1
Film Systems for Industrial Radiography.
Welding Consumables. Gases and Gas Mixtures for Fusion Welding and Allied
BS EN ISO 14175
Processes.
Petroleum and Natural Gas Industries - Materials for Use in H2S-Containing

BS EN ISO 15156-2 Environments in Oil and Gas Production Part 2: Cracking-Resistant Carbon
And Low-Alloy Steels, and the Use of Cast Irons.
Non-Destructive Testing - Ultrasonic testing. Time-of-flight diffraction technique

BS EN ISO 16828
as a method for detection and sizing of discontinuities.
General Requirements for the Competence of Testing and Calibration

BS EN ISO 17025
Laboratories.
Non-Destructive Testing of Welds - Radiographic Testing - Part 1: X- and

BS EN ISO 17636-1
Gamma-Ray Techniques With Film
BS EN ISO 17637 Non-Destructive Testing of Welds. Visual Testing of Fusion-Welded Joints
BS EN ISO 17638 Non-Destructive Testing of Welds. Magnetic Particle Testing
Non-Destructive Testing of Welds - Ultrasonic Testing - Techniques, Testing

BS EN ISO 17640
Levels, and Assessment
Non-Destructive Testing - Image Quality of Radiographs - Part 1:

BS EN ISO 19232-1 Determination of the Image Quality Value Using Wire-Type Image Quality
Indicators
PD 8010-2 Pipeline Systems – Part 2: Subsea Pipelines – Code of Practice
International Standards
Non-Destructive Testing - Industrial Radiographic Illuminators - Minimum

ISO 5580
Requirements.
Welding and Allied Processes - Classification of Geometric Imperfections in

ISO 6520-1
Metallic Materials - Part 1: Fusion Welding.
Non-Destructive Testing - Ultrasonic Inspection - Evaluating Electronic

ISO 12710
Characteristics of Ultrasonic Test Instruments.
DNV-OS-F101 Submarine Pipeline Systems.
Pipeline regulations
SI 1996: 825 Statutory Instrument Number 825. The Pipeline Safety Regulations 1996
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2.6 Order of Precedence
In event of any conflict or doubt between this Specification for Welding and NDT of Carbon
Steel Pipeline Components and Pipelines to API 1104 and base code API 1104: 2016; the
following order of precedence in relation to the project will be followed:
1. This Specification;
2. API 1104: 2016;
3. Other codes and standards listed in section 2.2 of this specification.
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3.0 HSE and Quality Assurance / Quality Control

3.1 General HSE Requirements
Supplier/ Contractor shall ensure that all requirements of the Acts and Regulations of
Vietnamese Government applicable to performing the services are strictly adhered to at all
times. Supplier shall be responsible for HSE related matters of the performance of the
Services and shall protect the work, personnel, environment, public and all other persons or
property based on the HSE Managements System and requirements set forth under ITT
document.
3.2 General Quality Assurance / Quality Control requirements
The quality assurance of the welding and NDT shall be in accordance with API 1104:2016
and any project specific quality requirements.
CONTRACTOR shall operate a quality system, covering the scope of supply, to ensure that
the requirements of this specification are met. Unless otherwise stated in the Purchase
Order, CONTRACTOR's quality system shall be in accordance with BS EN ISO 9001, or
approved equivalent.
The effectiveness of the quality system and CONTRACTOR’s compliance with it will be
subject to continuous monitoring by COMPANY, and in addition, may be audited.
A Quality Manual shall illustrate the Organisation and methods of the quality assurance and
quality control systems employed by CONTRACTOR for manufacture and supply of
linepipe. The Quality Manual shall be submitted to COMPANY and approval obtained
before commencement of fabrication.
All testing and inspection activities shall be indicated in the ITP.
CONTRACTOR shall ensure that all documents relating to this specification and the
purchase order are collated, indexed and retained for subsequent presentation to
COMPANY.
All documents associated with welding and NDT shall be reviewed and approved by
COMPANY before the commencement of the WPQT and the start of production, i.e. WPS,
ITP, associated welding procedures etc.
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4.0 Specifications (API 1104:2016 Section 4)

Add:
4.1 General (New)
To demonstrate compliance in terms of welding operations; CONTRACTOR shall

demonstrate that their quality requirements and systems meet the guidelines in
BS EN ISO 3834-2. Alternative standard shall be by COMPANY approval.
Any certifications of approval to BS EN ISO 9001 and BS EN ISO 3834-2, if produced by a
third party, must at the date of any review by COMPANY, have at least 6 months validity
before expiry. If due to expire before contract end such certification shall be renewed in time
to have continuous effect. Evidence of these arrangements should be demonstrated to
COMPANY.
Detailed requirements for welding shall be contained in CONTRACTOR’s project specific
plans.
Add:
4.2 Welding processes (New)
Mechanised welding processes are preferred and should be used whenever possible for
pipeline girth welding (e.g. by mechanised GMAW). If the use of mechanised GMAW
processes is impracticable, alternative processes may be used. In such instances, welding
may be performed by Shielded Metal Arc Welding (SMAW), manual or mechanised Gas
Tungsten Arc Welding (GTAW), semi-automatic GMAW processes or Submerged Arc
Welding (SAW). Self-shielded cored wire welding techniques shall not be used.
The root and hot pass of single sided girth welds shall be deposited by GTAW or GMAW
welding process. The root and hot pass of branches and fittings may be completed by
GMAW or SMAW.
For double or multiple jointing, girth welds should be made using Submerged Arc Welding
(SAW) whenever possible. If SAW cannot be used, the alternative mainline processes listed
above may be utilised either alone or in combination with SAW.
The welding of pipelines by the oxy-acetylene process or by the Flash Butt Welding process
(FBW) or by any other process not defined above is not permitted.
4.3 Equipment (API 1104:2016 Section 4.1)
Add:
Welding equipment shall be independently calibrated and maintained in good order that
ensures continuity of operation and that the production of welded joints consistently meet
the quality standard detailed in this specification. Certificates showing that equipment
calibration is valid for the period of use shall be made available to COMPANY when
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requested.
All GTAW equipment shall use either high frequency starting unit or an approved alternative
programmed touch starting unit together with a crater-eliminating slope-out control. A
current decay device should also be fitted, together with a gas lens, to improve gas
shielding of weld pool.
Welding return cables connections shall be of sufficient cross-sectional area to prevent the
concentration of current and shall be securely attached to prevent arc burns.
Gauges for measuring the weld preparation configuration, weld bead profile and the profile
of weld repair excavations, etc., shall be provided by CONTRACTOR.
During welding operations, adequate ventilation shall be provided and the quality of
breathing air shall be controlled.
Radiography operations shall conform to local regulations regarding the dangers of ionizing
radiation, e.g. in the UK radiography should be undertaken in accordance with the Ionising
Radiation Regulations 1999 (SI 1999 No. 3232) and The Approved Code of Practice and
Guidance – Working with Ionising Radiation: Ionising Regulations 1999.
Environmental guidance shall be taken from BS EN 14717 when undertaking welding and
its associated processes.
4.4 Materials (API 1104:2016 Section 4.2)
4.4.1 Pipe and Piping Components (API 1104:2016 Section 4.2.1)
Clarification:
Pipe and pipeline components shall be compliant with relevant COMPANY project
specifications and data sheets.
4.4.2 Filler Metals and Fluxes (API 1104:2016 Section 4.2.2)
4.4.2.1 Types (API 1104:2016 Section 4.2.2.1)
Add:
All consumables will be proposed by CONTRACTOR and subject to COMPANY for
approval.
Only low hydrogen welding consumables shall be used.
Use of cellulosic electrodes shall not be permitted.
The use of consumable inserts shall not be permitted.
The root welding consumable shall be selected in order to provide resistance to preferential
weld metal corrosion.
Use of welding consumables, with deliberate additions of nickel shall be subject to
COMPANY approval and limited to 1% maximum. This would be subject to use of
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consumable with no deliberate addition of Nickel in the root and fill portion of the weld to the
depth of the pipe corrosion allowance.
The weld metal diffusible hydrogen content for welding consumables shall be 5.0 ml/100g
maximum.
Welding consumables shall be selected to ensure that the yield strength and ultimate tensile
strength of the as-deposited weld metal either meets or exceeds the SMYS and SMTS of
the parent pipe material.
If required, the deposited weld metal shall be tested at the maximum design and shall
exceed the SMYS specified in the applicable component datasheet(s).
The recorded weld metal strength shall be confirmed as sufficient if an ECA is carried out.
The ECA shall consider the recorded weld metal strength for the cases of line pipe with
upper bound tensile properties in addition to minimum specified tensile properties.
Where dissimilar materials are joined, the tensile properties of the weld metal shall meet or
exceed the SMYS and SMTS properties of the lower strength material.
Consumables shall provide adequate impact toughness at the temperature advised by
COMPANY (not higher than minus 10 deg°C).
When required to support the project ECA, the CTOD testing of batch of consumables shall
be carried out by welding CONTRACTOR using a production WPS (see Section 5).
4.4.2.2 Storage and Handling (API 1104:2016 Section 4.2.2.2)
Clarification:
The storage and handling of welding consumables shall be in accordance with Appendix D
of this Specification.
Add:
Welding consumables shall be fully traceable by batch and used sequentially with new
batches being opened only after consumption of the preceding batch. Different batches of
consumables shall be individually identified and separated.
Add:
4.4.2.3 Consumable Lot Testing by Supplier (New)
Welding consumables shall be purchased from Manufacturers operating a quality system

based on BS EN ISO 9001 or BS EN 12074. Each lot of welding consumables shall have a
manufacturer certificate conforming to BS EN 10204 (Type 3.1). The testing of each lot shall
include: actual deposited weld metal chemical composition, tensile and CVN impact tests.
For SMAW consumables, manufacturer’s certificate shall include average-diffusible-
hydrogen level as determined and reported in accordance with AWS A4.3.
SAW filler wire shall be tested in combination with the same brand and classification of flux
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as that to be used during production welding.

Add:
4.4.2.4 Additional Lot Testing (New)
Only the lots of consumables mechanically tested shall be used for production welding.
Testing shall be conducted to attain approval for additional lots of consumables and testing
shall be undertaken on a weld made in accordance with the production WPS and shall
include:
 Two (2) all-weld tensile tests;

 Two (2) sets of weld metal CVN impact tests;
 One (1) macro-section and hardness survey sampled from the 3 o’clock position;
 One (1) chemical analysis;
The testing shall be in accordance with section 5.6.
When an ECA is performed, weld metal CTOD shall also be performed.
4.4.3 Shielding Gases (API 1104:2016 Section 4.2.3)
Add:
4.4.3.1 Compliance (New)
Shielding gases shall comply with BS EN ISO 14175 or AWS A5.32M/A5.32 and be
supplied with certificates of compliance.
The gas containers shall be clearly labelled with the grade and brand name as specified in
the WPS.
Gases shall be pre-mixed and bottled by Supplier and the cylinders shall be clearly labelled
with the gas composition.
The certificates shall show the composition and dew point exceeding -20˚C.
Subject to COMPANY approval, Ar / CO2 gases may be mixed at site provided that the
mixing is a part of a mechanised process that utilises a fail-safe cut off when the proportions
fall outside of those specified in the approved WPS. Alternatively documented QC
monitoring of the digital gas mix display shall be carried out. Gas mixtures containing
hydrogen shall not be used for shielding unless approved by COMPANY.
Flow meters appropriate to the gas mixture composition or type shall be used in production
to control shielding and backing gas flow rates. The flow meters shall be of the same gas
mixture type as those used in the corresponding WPQT.
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5.0 Qualification of Welding Procedures with Filler Metal Additions

(API 1104:2016 Section 5)
5.1 Procedure Qualification (API 1104:2016 Section 5.1)
Add:
5.1.1 General (New)
The WPS / WPQR packages shall be made available for COMPANY review and approval
and in good quality electronic format, and shall be approved prior to commencement of
production.
A pWPS shall be submitted for COMPANY approval prior to commencing with the WPQT
program.
Welding procedures, including fillet welds and repair procedures shall be qualified as
detailed in this specification.
Welding, NDT and mechanical testing of the WPQT weld(s) shall be witnessed by
COMPANY or an approved Third Party. The witnessing of mechanical tests shall include
the positioning of the notches for Charpy and CTOD tests (including location of fatigue
crack growth).
A WPS with more than one (1) supporting WPQR shall not permit optional processes, but
shall uniquely specify the process for each type of pass e.g. root, hot pass, fill and cap.
Previously-qualified WPSs are not acceptable.
Add:
5.1.2 Welding Procedure Parameters (New)
During weld procedure qualification, relevant procedure data irrespective of whether the
item is a listed essential variable shall be captured and recorded. Sufficient information shall
be recorded to allow complete replication of the procedure qualification welds.
With respect to mechanised welding systems, the welding power supplies adopted for
procedure qualification shall be the same type and model to be used in production.
For all welding processes and systems, the power supply manufacturer, model and type
shall be identified in the WPQR.
The methods of measuring the welding parameters shall be agreed with COMPANY.
Following qualification, the pWPS shall be revised to reflect the parameters recorded during
qualification.
The final WPS shall state parameters for each pass. However, if fill passes (i.e., passes
other than root, hot pass, and cap) have similar values, the parameters may be combined
on the WPS.
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5.2 Record (API 1104:2016 Section 5.2)
Clarification:
The details of each procedure shall be recorded.
Add:
Forms to be adopted in order to record details contained within the WPS and WPQT report
shall contain the relevant information as defined in this specification and the format shall be
subject to approval by COMPANY.
The WPQR documentation package for each welding procedure shall contain the following
information / data:
 Geometric details of joint preparation;

 Alignment method & tacking details;
 Record of welding parameter data (WPQR);
 Weld preparation diagram & run sequence;
 NDT results;
 Mechanical test results including photo-macrographs, showing locations of hardness
indents;
 Welding Consumable certification including gas;
 Base material certification;
 Details of equipment used in the WPQT.
The following data shall also be available if requested by COMPANY:
 Calibration certificates for equipment and measuring devices;

 NDT procedures/written practices;
 Welding Inspector and NDT personnel certification;
 NDT procedure qualification records;
 Test-house approval certification;
 The identity of any anti-spatter liquid used.
5.3 Welding Procedure Specification (API 1104:2016 Section 5.3)
5.3.1 General (API 1104:2016 Section 5.3.1)
Add:
The relevant COMPANY approved WPS shall be displayed at each work location and shall
be readily available to each welder.
5.3.2 Specification Information (API 1104:2016 Section 5.3.2)
5.3.2.1 Materials (API 1104:2016 Section 5.3.2.2)
Clarification:
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Pipe and pipeline components from different sources or in different supply conditions shall
require separate procedure qualification as detailed in Section 5.4.2.2.
5.3.2.2 Diameters and Wall Thicknesses (API 1104:2016 Section 5.3.2.3)
Clarification:
The ranges of diameters and wall thicknesses over which the procedure is approved are
identified in Table 5.1 below:
Table 5.1: Diameter and Test Pipe Thickness Range of Approval

Test Pipe Diameter (mm) Range of Approval (mm)
D < 60.3 < 60.3
60.3 < D ≤ 323.9 60.3 to 323.9
323.9 < D ≤ 610 323.9 to 610
D > 610 > 610
Test Pipe Thickness = t 0.75t to 1.5t
5.3.2.3 Joint Design (API 1104:2016 Section 5.3.2.4)
Add:
The use of permanent or consumable backing rings is not permitted.
Non-consumable temporary backing as an integral permanent feature on an internal clamp
should be permitted subject to satisfactory demonstration of the process.
5.3.2.4 Filler Metal, Flux, and Number of Beads (API 1104:2016 Section 5.3.2.5)
Add:
The brand name, electrode or wire name, designation and welding consumable
classification shall be stated in the WPQR.
5.3.2.5 Electrical characteristics (API 1104:2016 Section 5.3.2.6)
Add:
The following parameters (if applicable) shall be specified in the WPS:
 Welding current (including pulse rate, pulse shape or dwell time, and max / min current
for pulsed welding procedures);
 Diameter of electrodes or welding wires and number of wires;
 Wire-feed speed (and pulse rate or frequency for pulsed wire procedures);
 Arc energy for each pass. For multiple (electrically isolated) welding processes
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incorporating tandem electrodes (e.g. SAW and P-GMAW) the effective arc energy per
pass shall be calculated as the sum of the individual arc energies for each electrode.
For pulsed procedures the effective arc energy shall be calculated on the basis of RMS
values. Voltage and current shall be determined with calibrated meters and recorded
for each pass during WPQT welding using suitable COMPANY approved data
monitoring equipment.
 Type, diameter and angle of tip for GTAW tungsten electrodes;
 Hot wire diameter, feed speed, current and voltage;
 Head angle, electrode spacing from top-dead centre and direction of rotation for 1G-
rotated welding;
 Contact tip to work-piece distance;
 Electrode spacing and individual angles relative to pipe surface (applicable to welding
with multiple electrodes);
 Torch separation and angle for multiple torch welding;
 Torch oscillation frequency for mechanised welding;
 Shroud / gas-cup diameter;
 The welding unit, power supply type, manufacturer, model number and software
version number shall be stated for mechanised welding procedures;
5.3.2.6 Position (API 1104:2016 Section 5.3.2.8)
Add:
The welding position shall be as specified in the WPS and WPQR documents.
5.3.2.7 Time between Passes (API 1104:2016 Section 5.3.2.10)
Add:
The time between completion of the root bead and commencement of deposition of the hot-
pass shall not be greater than that qualified in the WPQT and should not be greater than 10
minutes.
5.3.2.8 Type and Removal of Lineup Clamp (API 1104:2016 Section 5.3.2.11)
Add:
Where internal alignment clamps are used, they shall not be released until 100% of the root
pass is completed.
For short sections and small diameters (< 150mm), the use of an external clamp may be
proposed for COMPANY approval.
If access does not permit the use of an internal clamp, e.g. on tie-in welds, an external
clamp shall be used.
External clamps shall not damage the external pipe coating, and visual inspection of
external coating shall be performed on removal of the clamps to ensure the coating surface
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is free of holes, disbondments or cracks.

Details of the alignment clamp proposed for the production welds shall be submitted for
COMPANY approval before the commencement of the WPQT program. The same type of
clamp to be used in production shall also be used during WPQT.
Where external clamps are used the root run shall be deposited using an uphill welding
technique and shall be at least 50% complete before the clamp is removed.
In either case, the pipes on either side of the partially welded joint shall not be raised,
lowered or otherwise moved axially until the root and the hot pass / second run have been
completed, unless it can be demonstrated to the satisfaction of COMPANY that the root run
alone is adequate to resist deformation under load.
For onshore welding, bullets may be used if approved by COMPANY.
5.3.2.9 Preheat and Postweld Heat Treatment (PWHT) (API 1104:2016 Section 5.3.2.13)
Add:
As a minimum, a pre-heat temperature shall be selected to ensure that:
 The pipe is dry prior to welding;

 The metal temperature is greater than 20°C;
 The metal temperature is greater than 50°C if moisture is present on the pipe and / or if
the ambient temperature is below 5°C;
The minimum preheat shall be calculated in accordance with BS EN 1011-1 and BS EN
1011-2 using the maximum Carbon Equivalent (CE) allowed for the material to be welded.
The duration the weld temperature is below preheat temperature (i.g. during a breakdown or
a stoppage on the barge) shall be qualified during WPQT and shall be limited to 40 minutes
maximum. The preheat shall be re-applied prior to the re-commencement of welding
operations.
The interpass temperature shall be qualified during WPQT. The inter-pass temperature
shall not exceed 300°C. Preheat and interpass temperatures shall be measured in
accordance with section 7.9.1.
If delayed cooling of the welded joint is to be adopted, the details shall be specified in the
WPS. If the weld is to be cooled rapidly to allow immediate AUT, then this shall be
simulated during the WPQT Project. Assisted cooling shall not commence until the weld has
cooled naturally without interference to below 400°C.
5.3.2.10 Shielding Gas and Flow Rate (API 1104:2016 Section 5.3.2.14)
Clarification:
Shielding gas type, composition and flow rate (for each torch in multi-torch systems) shall
be specified in the WPS.
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Add:
5.3.2.11 Bead Map (New)
A sketch of the weld cross-section illustrating the bead sequence shall be detailed in each
WPS.
If bead deposition is by a weaving technique, this practise shall be designated on the WPS.
Low hydrogen SMAW electrodes shall not be weaved by more than three (3) times the
nominal electrode core wire diameter.
Add:
5.3.2.12 Period of Validity for Welding Procedures (New)
New detailed welding procedure specifications shall be prepared for the project.
5.4 Essential Variables (API 1104:2016 Section 5.4)
Add:
An approval of a WPS obtained by CONTRACTOR is valid in workshops or sites operated
by CONTRACTOR under identical or equivalent technical and quality control. Welding
procedures shall not be transferred from CONTRACTOR to another party without
requalification.
5.4.2 Changes Requiring Requalification (API 1104:2016 Section 5.4.2)
5.4.2.1 Welding Process or Method of Application (API 1104:2016 Section 5.4.2.1)
Add:
Any change from a single torch per motorised head to multiple torches, or vice-versa, shall
constitute an essential variable.
Any change of wire delivery system for SAW or mechanised GMAW or GTAW system,
including single to double or multiple wires and / or from cold to hot wire systems, or vice
versa, shall constitute an essential variable.
Add:
5.4.2.1.1 Line-up Clamps (New)
A change from internal to external line-up clamp or vice versa shall constitute an essential
variable.
Removal of the line-up clamp at an earlier stage than that qualified during the WPQT
Project constitutes an essential variable.
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Add:
5.4.2.1.2 Weld or Joint Backing (New)
The adoption or removal of copper backing rings or shoes, or combination of these, shall be
considered an essential variable.
Add:
5.4.2.1.3 Number of Welders or Welding Operators (New)
The number of welders shall be at least as many as was utilised during the WPQT and shall
be considered as an essential variable for each pass.
5.4.2.2 Base Material (API 1104:2016 Section 5.4.2.2)
Clarification:
The test material shall be project material. The following constitute essential variables:
 Change in make, source, or grade

 Change of steel making, forging or pipe manufacturing process or manufacturing
procedure revision.
 A change in composition resulting in a change greater than +0.01 or -0.03 CEIIW or
greater than +0.01 or -0.02 Pcm value.
CEIIW and Pcm are defined as follows:
Mn Cr  Mo  V Ni  Cu
CEIIW  C   
6 5 15
Si Mn  Cu  Cr Ni Mo V
Pcm  C       5B
30 20 60 15 10
Where the chemical elements are expressed in % of mass.
When both heat and product analyses are available, the product analysis shall be used for
the calculation of CEIIW and Pcm values.
5.4.2.3 Joint Design (API 1104:2016 Section 5.4.2.3)
Add:
For narrow gap welding (e.g. mechanised GMAW) any change in bevel angle beyond ± 1°,
root face beyond ± 50% or root gap – 0 mm /+ 0.5 mm shall constitute an essential variable.
Any weld preparation with an included angle of less than 20° shall be considered to be
narrow gap welding.
For other welding techniques, any change in bevel angle by more than ± 5°, or variation in
root gap / root face by more than ± 50%, shall constitute an essential variable.
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5.4.2.4 Position (API 1104:2016 Section 5.4.2.4)
Add:
A change of welding position shall constitute an essential variable. Welding positions 5G
and 2G shall be qualified separately. 6G qualification shall be required if the angle of the
pipe is between 25° and 65° to the horizontal.
5.4.2.5 Wall Thickness (API 1104:2016 Section 5.4.2.5)
Clarification:
Any change out the grouping ranges of pipe by diameter and wall thickness designated in
section 5.3.2.2 shall constitute an essential variable.
5.4.2.6 Filler Metal (API 1104:2016 Section 5.4.2.6)
Clarification:
The following changes in filler metal constitute essential variables:
 Any change in filler metal designation, filler metal manufacturer, manufacturing location
or brand name;
 Any change in welding consumable or size;
5.4.2.7 Electrical Characteristics (API 1104:2016 Section 5.4.2.7)
Add:
Any change in the following shall be considered as essential variables:
 For pulsed current welding either a change of the pulse rate, pulse shape and max /
min current recorded in the WPS or a change outside the RMS current range specified
in the WPS (1);
 Head angle, electrode spacing from top dead centre and direction of rotation for 1G
rotated welding;
 Electrode spacing for welding procedures utilising multiple electrodes (e.g. tandem-wire
SAW, or mechanised tandem wire or twin torch processes;
 For mechanised welding, the welding unit, power supply type, manufacturer, model
number and software version number.
5.4.2.8 Shielding Gas and Flow Rate (API 1104:2016 Section 5.4.2.10)
Add:
Any change in shielding gas flow rate greater than ± 10% of that qualified shall constitute an
essential variable.
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5.4.2.9 Shielding Flux (API 1104:2016 Section 5.4.2.11)
Add:
Any change of shielding flux manufacturer, manufacturing location, brand or type
constitutes an essential variable.
5.4.2.10 Speed of Travel (API 1104:2016 Section 5.4.2.12)
Add:
A change in speed of travel beyond the range of the approved WPS constitutes an essential
variable.
5.4.2.11 Preheat (API 1104:2016 Section 5.4.2.13)
Add:
Any change in the preheat application method shall constitute an essential variable.
Add:
5.4.2.12 Arc Energy per Pass (New)
The values for current, voltage and travel speed for each pass shall conform to one of the
following:
 Within the range recorded during the WPQT (preferably established by means of
‘envelope’ trials at minimum and maximum arc energy). Transient or anomalous values
shall not be used to establish the range,
Or
 The mean value ±10% for each parameter, with ±10% change of calculated heat input;
unless otherwise agreed with company.
The arc energy shall be calculated using the recorded values of current, voltage, and travel
speed without the addition of a percentage.
Add:
5.4.2.13 Interpass Temperatures (New)
An increase in the specified interpass temperature shall constitute an essential variable. A

change in rapid cooling of welds constitutes an essential variable.
5.5 Welding of Test Joints – Butt welds (API 1104:2016 Section 5.5)
Add:
5.5.1 Test Pipe for WPQT (New)
The WPQT shall simulate the production welding.
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If an internal line-up clamp will be used in production welding, the length of the nipples used
in the WPQT shall be sufficient to accommodate the full length of the clamp. The minimum
length of any nipple piece used during qualification should be 1m or 1.5 pipe diameters
whichever is the greater.
The minimum length of test rings for the WPQT of fittings and flanges shall be subject to
agreement with COMPANY.
The test rings shall be made from project material and shall be supplied in the same heat
treated condition as the finished component.
The number and the minimum length of the test rings for the WPQT tests are specified in
the PO or the component datasheet(s).
5.6 Testing of Welded Joints – Butt Welds (API 1104:2016 Section 5.6)
5.6.1 Preparation (API 1104:2016 Section 5.6.1)
Add:
Refer to Figure 5.1 presented in this specification.
The blanks from which the mechanical test pieces are machined may be cut from the
WPQT weld by the use of plasma or oxy-fuel gas cutting, but its dimensions shall be
sufficient to allow the material of the finally machined test specimen to remain unaffected by
the heat from the cutting operation. This shall be a minimum of 3 mm left before machining.
Add:
5.6.1.1 Non-Destructive Testing of WPQT Welds (New)
WPQT welds shall be visually inspected as soon as is possible after completion of welding
with 100% coverage of surfaces of welds. WPQT welds shall meet the same requirements
regarding weld profiles and visual inspection as that specified for production welds.
Visual examination shall include examination of internal surface of weld, if possible, using
suitable optical instruments (e.g. mirror, remote camera).
The full circumference of WPQT welds shall be examined by radiography testing (RT),
ultrasonic testing (AUT or manual UT), and magnetic particle testing (MPT).
When UT scanning (AUT or manual UT) is applied, transverse probes shall be included on
WPQT welds for transverse defect assessment.
For WPQT welds there shall be a minimum delay time of 24 hours between completion of
welding and NDT.
The NDT procedures for WPQT welds shall be qualified and subject to approval by
COMPANY.
Acceptance criteria shall be in accordance with API 1104:2016 and this Specification.
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When ECA is used, acceptance criteria shall be in accordance with the project ECA, if more
stringent than the acceptance criteria defined in API 1104:2016 and this Specification.
Acceptance by COMPANY shall be required before sectioning WPQT welds for mechanical
testing.
Add:
5.6.1.2 Mechanical Testing (New)
Mechanical testing shall be performed by a certified (BS EN ISO 17025) testing laboratory
approved by COMPANY.
Test specimens shall be extracted from WPQT welds as detailed in Figure 5.1.
Test weld mechanical testing locations and specimen types/ numbers shall be in
accordance with Table 5.2.
Repair test weld mechanical testing locations and specimen types/ numbers shall be in
accordance with Table 10.1.
Test specimens not presented in Figure 5.1 (e.g. CTOD specimens, all Weld Metal tensile)
may be taken from any position around the weld where spare material is available; however
the exact locations should be agreed in each instance with COMPANY.
When ECA is used, additional testing may be required by the project ECA.
If any specimen fails to meet the test requirements, two sets of retests, for that particular
type of test, may be performed. The results of both retest specimens shall meet the
specified requirements. All the results shall be reported and be a part of the WPQR
package.
Add:
5.6.1.3 Test Temperature (New)
Destructive mechanical testing shall be performed at ambient temperature, except for CVN
impact, elevated tensile testing or CTOD testing.
When required, elevated hot tensile testing shall be conducted by CONTRACTOR in
accordance with BS EN ISO 6892-2, ASTM E21 or an approved equivalent. The test
temperature and the required tensile strengths at elevated temperature shall be advised by
COMPANY.
Add:
5.6.1.4 Repair of WPQT Welds (New)
Weld repairs to WPQT welds are not permitted, except if the purpose is to qualify a welding
repair procedure.
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5.6.2 Tensile Strength Test (API 1104:2016 Section 5.6.2)
5.6.2.1 Preparation (API 1104:2016 Section 5.6.2.1)
Add:
Transverse weld tensile testing shall be carried out in accordance with BS EN ISO 4136,
AWS B4.0 or an approved equivalent.
Preparation of the tensile test specimens shall be configured as detailed API 1104:2016,
Figure 4, except that the internal and external weld reinforcement shall be removed before
testing.
The position of failure shall be recorded (i.e. weld metal, HAZ or base metal).
Clarification:
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5 6 6 5
1 2 4
3 2
4
< 60.3mm (2.375”) 5
> 114.2mm (4.500”) 5 3 2

but < 323.9mm (12.750”) 6 5
4 3 5 6
2 1 3
2 4
5
> 60.3mm (2.375”) but
< to 114.3mm (4.500”)
5
Also, < 114.3mm (4.500”) when
wall thickness > 12.7mm (0.500”)
5 6
4
2
3 1 3
4 2
2 3
1 4 5
Greater than 323.9mm (12.75”)

5
6
3 1
4 4
2 2
1 3 Key:
1) Face or side bend
5
2) Transverse tensile
3) Root or side bend
4) Nick-break
5) Macrosection
6) Charpy V-Notch
Figure 5.1 Location of Test Pieces Extracted from Pipe Butt Welds
Clarification:
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Table 5.2 (API 1104:2016 Table 2) Modified Types and Number of Test Specimens for
Welding Procedure Qualification Test
Number of Specimens for Wall Thickness ≤ 12.7mm
Tensile Bend
Pipe OD
Nick break CVN Test Macro / HV10 CTOD
(mm) X- All-
(5) Root face Side
weld weld
(1)
< 60.3 0
1 0
(3)
60.3 – 114.3 (2) 2
2 2 2
(4)
0 3 3
> 114.3 –
2
323.9 (3)
1 4
(2)
> 323.9 4 4 4 4
Number of Specimens for Wall Thickness > 12.7mm
(3)
< 114.3 2 2
(2)
2 2
> 114.3 – (4)
1 0 0 4 3 3
323.9 (3)
4
(2)
> 323.9 4 4 8
Notes: 1. One (1) nick-break and one (1) root-bend specimen shall be extracted from each of two (2) test welds
2. Nick break tests are not required for mechanised welding processes.
3. CVN impact tests shall comprise of (a) WM and (b) FL specimens machined from the pipe OD. Pipes with wall thicknesses > 20 mm shall
have additional specimens machined from the ID (at root).
4. CTOD tests are only required for pipelines with ECA based acceptance criteria. CTOD tests shall be as per the project ECA requirements.
5. An additional all-weld tensile specimen shall be tested at the maximum design temperature (if required)
5.6.2.2 Requirements (API 1104:2016 Section 5.6.2.3)
Clarification:
The results of transverse (cross weld) weld tensile tests shall meet or exceed the specified
requirements for the applicable component data sheet(s).
Transverse weld tensile specimens shall fail at a location within the HAZ or base metal
(outside of the weld or fusion zone).
If base metals of different strength levels are adopted, the acceptance shall then be based
on the lower strength base metal.
Add:
5.6.3 Charpy V-Notch Impact Testing (New)
5.6.3.1 Scope
WPQT welds shall be subjected to CVN impact testing. Weld procedure tests conducted on
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material less than 6 mm thick need not be impact tested. However, such procedure tests
shall not qualify for thickness greater than 6 mm.
5.6.3.2 Preparation
The test pieces shall be prepared and tested in accordance with BS EN ISO 148-1 and BS
EN 9016 or ASTM A370 and ASTM E23.
A set of CVN impacts shall comprise three (3) specimens. Sets of CVN impact specimens
shall be extracted from the locations presented in Figure 5.1.
Specimens shall be notched with the axis of the notch perpendicular to the pipe surface.
The position of the notch for each set shall be as presented in Figure 5.2.
5.6.3.3 Method
The CVN impact test temperature shall be - 29°C.
A (i) Weld Centreline
A (ii) Fusion Line (FL)
Figure 5.2 Charpy V-notch (CVN) Locations

Notes: 1. Specimens shall be positioned between 1 and 2 mm from the pipe outer surface. Additional specimens for pipe thicknesses greater than 20
mm shall be positioned within 1 to 2 mm from the inner surface.
2. Fusion line Charpy specimens shall sample 50% weld metal and 50% HAZ.
5.6.3.4 Requirements
CVN impact values shall meet or exceed the values given in Table 5.3.
Table 5.3 Charpy Impact Test Requirements

Minimum Average Energy Minimum individual Energy
50 40
For specimens below 10mm in thickness (set as full size), the energy requirement shall be
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reduced as follows:
 83% of full size energy values for 10 × 7.5 mm CVN specimens;

 67% of full size energy values for 10 × 5 mm CVN specimens.
Ductile shear area shall be recorded for each CVN specimen and shall exceed 50% in all
Weld Metal and Fusion Line, and 75% in parent metal.
Individual samples may be replaced if there is evidence of a weld defect on the fracture
surface. Re-testing may be permitted following discussions with COMPANY.
Test results, including percentage ductile shear area, shall be recorded.
Add:
5.6.4 Macro Section (New)
5.6.4.1 Method
Macro-sections shall be extracted from procedure qualification test welds at three (3)
locations approximately 90° apart. For welds containing any pass made in the 5G position,
macro-sections shall be extracted as close as practicable to the 12 o’clock, 3 o’clock and 6
o’clock positions.
When girth welding seam-welded linepipe, an additional macro-section shall be extracted
from the girth-weld at the T-intersection region between the girth weld and seam weld.
Macro-sections shall be polished to a metallographic (1 µm) finish and etched in a 2 to 10%
Nital solution, or other suitable COMPANY approved etchant. The etched specimens shall
be thoroughly examined at times ten (×10) magnification.
Original photo-macrographs of macro-sections at approximately three (3) to five (5) times
magnification shall be included in the WPQR documentation.
5.6.4.2 Acceptance Criteria
When examined at times ten (x10) magnification the macro-section shall reveal:
 No cracks.
 Complete fusion between adjacent layers of weld metal and between weld metal and
base metal.
 Complete fusion at the root.
 No lack of penetration.
 No undercut (unless weld surfaces are to be ground smooth). If weld surfaces are to be
ground flush, minor undercut may be removed by the surface grinding operation. If the
undercut is of such depth that its removal would result in encroachment of the minimum
specified thickness of the pipe, it shall be deemed unacceptable.
 No excess cap reinforcement exceeding 1.6mm above the base metal surfaces (for
weld surfaces not specified to be ground flush) except when welding in the 5G position,
where a cap height of 3.0 mm is acceptable.
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 Weld reinforcement shall blend smoothly into the adjacent base metal.
 No penetration of the root bead into the bore exceeding 3.0 mm.
 At no point shall the weld external or internal surfaces lay below (under-flush) the
adjacent base metal.
Add:
5.6.5 Hardness Testing (New)
5.6.5.1 Preparation
In accordance with BS EN ISO 15156-2, the hardness testing technique shall be the Vickers
method with an applied load of 10kg in accordance with BS EN ISO 6507-1 or ASTM E92.
The ASTM A370 (Vickers test method) will be acceptable as an alternative provided that a
calibration procedure is provided for COMPANY approval. The use of Rockwell method
(HRC) in accordance with BS EN ISO 6508-1 will be acceptable as an alternative provided
that a calibration procedure is provided for COMPANY approval. The hardness surveys
shall be undertaken on each of the macro-section specimens.
5.6.5.2 Method
Each survey shall consist of three (3) rows of indents. One (1) traverse shall be located
below the cap, one (1) above the root (or internal surface) and one (1) at mid-thickness. The
positions of the hardness indents are shown in Figure 5.3.
The mid-thickness traverse shall be waived for single sided welds below 12.7mm thick.
COMPANY shall require additional hardness indent positions in the case where a
consumable type has not been sampled by the specified three (3) traverses.
Figure 5.3 Locations of Hardness Indents

Notes: 1. Parent material indentations shall be at least 20 mm from the Fusion Line (FL).
2. The first HAZ indentation shall be positioned as close to the FL as possible. Further indentations into the HAZ shall be separated by
approximately 0.5 mm; however, the minimum centre-to-centre separation requirement of 2.5 or 3 times the mean diagonal of the nearest
indentation shall be maintained (Ref. BS EN ISO 6507-1 and ASTM E92).
3. The same survey pattern shall be applied to double sided welds.
4. All indentations shown in the grey area shall be entirely performed in the HAZ, and as close as possible to the fusion boundary between the
weld metal and the HAZ.
The macro photographs shall show the position of each hardness indent and shall be
included in the WPQR along with tabulation or diagram showing the result and location of
each indent. The maximum and minimum values shall be identified.
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5.6.5.3 Requirements
In accordance with BS EN ISO 15156-2, the individual hardness values permitted to qualify
shall not exceed the values presented in the Table 5.4 below:
Table 5.4 Maximum Permissible Weld and HAZ Hardness Values (HV10)
Location Maximum Hardness values
Weld
Inside surface and mid-
250
thickness
HAZ
Weld
Outside Surface 275
HAZ
Add:
5.6.6 Weld Metal Tensile Testing (New)
Weld metal tensile test specimens shall be in accordance with DNV-OS-F101 unless
otherwise specified by the project ECA. No Flattening of test pieces shall be permitted.
When advised by COMPANY, an additional all-weld tensile specimen shall be tested at the
maximum design temperature in accordance with BS EN ISO 6892-2 and shall meet the
requirements stated in the component data sheet(s).
Specimen for elevated tensile test shall be extracted adjacent to the specimen extracted for
ambient temperature tensile test.
For narrow gap welds where the width of the weld bead is insufficient to permit a
conventional all-weld metal tensile test piece to be prepared, the geometry of the test piece
shall be agreed with COMPANY.
The longitudinal axis of the tensile test specimen shall coincide with the procedure
qualification test-weld axis. The tensile specimen shall be prepared by machining and its
dimensions and orientation shall be such that the gauge length consists of only weld metal.
The weld metal yield strength and ultimate tensile strength shall exceed the specified
minimum requirement of the parent pipe. If parent metals of different strength levels are
used, then acceptance criteria shall be based on the lower strength parent metal.
The weld metal strength in relation to the actual base metal yield strength shall be
considered where an ECA is conducted. In this case, weld metal strength shall exceed the
parent pipe maximum strength (based on production data) unless otherwise agreed with
COMPANY.
Acceptance criteria for the elevated temperature tensile test shall be as per ambient
temperature unless otherwise specified by the component data sheet(s).
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Add:
5.6.7 ECA Mechanical Testing (New)
When ECA is used, Mechanical Testing (e.g. CTOD) shall also be compliant with Appendix
A. It is assumed that effects of H2S may be excluded from ECA considering that the H2S
levels. CONTRACTOR shall request COMPANY’s confirmation.
5.7 Welding of Test Joints – Fillet welds (API 1104:2016 Section 5.7)
Add:
The tests specified in Section 5.8 do not provide comprehensive information on the
mechanical properties of the joint. If mechanical properties are relevant to the service
application, then an additional qualification in the form of a butt weld, etc., is required.
Simulation of a fillet weld joint using flat plate fillet welds is not permitted.
5.8 Testing of Welded Joints – Fillet welds (API 1104:2016 Section 5.8)
5.8.1 Preparation (API 1104:2016 Section 5.8.1)
Add:
Two (2) macro-sections shall be extracted from the test weld at locations agreed with
COMPANY. The specimens shall be prepared and examined in accordance with Section
5.6.4.
5.8.2 Method (API 1104:2016 Section 5.8.2)
Add:
One (1) of the macro-sections shall be subject to hardness testing. The test method shall be
Vickers with an applied load of 10kg in accordance with BS EN ISO 6507-1 or ASTM E92.
The survey shall consist of two (2) traverses with the positioning of indentations shown in
Figure 5.4.
1 – 2 mm
Figure 5.4 Fillet Weld Hardness Indent Locations

Notes: 1. Parent material indentations shall be at least 20 mm from the Fusion Line (FL).
2. The first HAZ indentation shall be positioned as close to the FL as possible. Further indentations into the HAZ shall be separated by
approximately 0.5 mm; however, the minimum centre-to-centre separation requirement of 2.5 or 3 times the mean diagonal of the nearest
indentation shall be maintained (Ref. BS EN ISO 6507-1 and ASTM E92).
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A macrograph shall clearly show the positioning of each hardness indent and a copy shall
be included in the WPQR in conjunction with a tabulation or diagram showing the measured
value and location of each indent. The maximum and minimum values shall be identified.
5.8.3 Requirements (API 1104:2016 Section 5.8.3)
Add:
If the fillet weld is on the outside of the pipe wall and therefore not in contact with the
process fluids, then the acceptance criteria for ‘outside surface’ presented in Table 5.4 shall
apply.
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6.0 Qualification of Welders (API 1104:2016 Section 6)

6.1 General (API 1104:2016 Section 6.1)
Add:
Welder qualification tests shall be carried out on full diameter Project pipe nipples. Welders
and welding operators’ tests shall be witnessed by a recognised independent body to be
Welders shall be qualified for each welding process that they will use in production. Welders
shall complete at least 50% of the circumference for the passes they are being qualified for.
For mechanised or semi-automatic welding, each welder shall be qualified for each type,
manufacturer, and model number of the welding unit(s) and power supplies to be used in
production welding.
Welders shall be qualified before production welding commences.
Welders making tack welds and temporary attachments shall be qualified.
Welders for repair and fillet welding shall be required to make qualification test welds in
accordance with the approved repair and fillet weld WPS’s.
A welder who has satisfactory completed a procedure qualification test is automatically
qualified for that procedure.
Existing current welder qualifications meeting the minimum requirements of
BS EN ISO 9606-1, ASME/BPVC SEC IX or an approved equivalent may be proposed by
CONTRACTOR provided they are less than 6-months old and subject to COMPANY
approval. In this case, it is mandatory that an independent 3rd party shall have endorsed the
certificates. These tests shall have been conducted utilizing a WPS substantially the same
as that for the current work and, for automatic, mechanised, semi-automatic or manual
welding procedures, utilising the same type, manufacturer, software package, 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 approved third
party.
For offshore welding, in addition to the practical welding test and before the commencement
of production welding, welders shall be required to attend a briefing session arranged jointly
with COMPANY. This briefing shall detail the elements of good welding practice and the
specification requirements applicable to production welding.
Any welder who, in the opinion of COMPANY, is either consistently ignoring good welding
practice or specification requirements or is responsible for a high level of repairs during
production shall be removed from the place of work, and shall undergo a re-training Project
approved by COMPANY before a retest may be considered.
CONTRACTOR shall operate a scheme for welder qualification certificates and welder
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identification, which shall be submitted to COMPANY for approval.

Welder qualification records shall be retained and made available for inspection as required.
6.2 Single Qualification (API 1104:2016 Section 6.2)
Add:
Qualification welds shall be assessed by VT, MPT and RT. The agreed NDT regime shall
reflect production NDT if more stringent than workmanship and shall examine the full weld
circumference.
Qualification welds with wall thicknesses > 20mm shall be assessed by VT, MPT, RT and
UT (including examination for transverse defects).
Qualification of welders using GMAW shall be by VT, MPT, RT, MUT, and mechanical
testing to include face and root bends or side bends. In the case of manual welds, nick
break tests are also required.
If the application of AUT for the inspection of production girth welds has been agreed by
COMPANY, it may be used for assessment of the welder qualification welds in place of RT.
The acceptance criterion used shall be workmanship rather than an ECA based criterion
unless if more stringent.
The position of the pipe used in the test shall determine the extent of qualification as
follows:
- Horizontal pipes shall be used to qualify for welds between pipes positioned within 25°
of the horizontal.
- Vertical pipes shall be used to qualify for welds between pipes positioned within 25° of
the vertical.
- Pipes at 45° to the horizontal shall be used to qualify for welds between pipes
positioned at intermediate angles between 25° and 65° to the horizontal.
6.2.2 Scope (API 1104:2016 Section 6.2.2)
Clarification:
c. For SMAW process, a change of electrode manufacturer and brand

name.
6.3 Multiple Qualification (API 1104:2016 Section 6.3)
Clarification:
Multiple qualification of a welder shall not be permitted.
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6.4 Visual Examination (API 1104:2016 Section 6.4)
Clarification:
Filler wire protruding into the pipe bore shall not be permitted.
6.5 Non-Destructive Testing (NDT) – Butt Welds Only (API 1104:2016 Section 6.6)
Clarification:
RT (or AUT) shall be performed on the qualification welds.
Testing procedures and acceptance criteria shall be subject to approval by COMPANY.
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7.0 Design and Preparation of a Joint for Production Welding (7)

Add:
Any protective coating on the end bevel shall be removed prior to welding by adopting a
COMPANY approved method.
Prior to welding, the pipe end shall be cleaned inside and outside utilising power driven wire
brushes, grinders or another method approved by COMPANY, for a minimum distance of
40mm from the edge of the weld bevel.
If AUT is to be adopted, a reference line at a specified distance (100 mm minimum) from the
root face shall be scribed onto the pipe surface in order to define the location of AUT
equipment relative to the exact location of the root bead.
Attachment of welding return cables by welding shall not be permitted.
Repair of the pipe body or forging material by welding shall not be permitted.
Add:
7.1.1 Weld Proximity (New)
The distance between pipeline girth welds shall not be less than 2 pipe diameters or
500mm, whichever is the larger.
The distance between a girth weld and a branch / attachment/forging weld shall not be less
than one (1) pipe diameter.
The distance between branch / attachments welds on the pipeline shall not be less than one
(1) pipe diameter.
In case of welding piping structures, shorter minimum distances may be acceptable if
7.2 Alignment (API 1104:2016 Section 7.2)
Clarification:
Pipe ends shall be aligned by rotating pipes, avoiding pipe end bevel damage.
The misalignment between the internal surfaces and the misalignment between the external
surfaces shall not exceed the lesser of 3.0 mm or 1% of the pipe internal diameter at any
point. For small diameter pipes (e.g. < 150mm) alternative acceptable misalignment may be
The longitudinal (or spiral) weld ends shall be separated, at the circumferential weld, by 90°
or a circumferential distance of 250 mm, whichever is the smaller.
Longitudinal welds shall lie within the top half of the pipe circumference.
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If abutting pipes have the same outside diameter with different nominal bores, the smaller
bore shall be machined, ground or filed, to produce an internal taper no steeper than 1 in 4.
Internal tapering shall be subject to COMPANY approval if the taper will interfere with
ultrasonic inspection. Internal tapering may not be used with AUT.
Heat and hammering shall not be used to correct excessive misalignment.
7.3 Use of Line-up clamp for Butt Welds (API 1104:2016 Section 7.3)
Add:
7.3.1 General (New)
A welding sequence that distributes the stress and limits distortion as evenly as possible
shall be used (e.g. 2 welders working diametrically opposite each other).
Add:
7.3.2 Tacking (Tack Welding) (New)
Tack welds, shall be deposited by qualified welders in accordance with an approved WPS.
If preheat is specified, it shall be applied before tack welding and be effective over a
distance (from the edge of the weld bevel) equal to three (3) times the wall thickness or
75mm, whichever is the greater and shall be maintained until the joint is complete.
The following shall apply when tacking is used:
 Tacks shall be deposited using low-hydrogen welding consumables;

 The joint to be tacked shall be adequately supported;
 The preheat level required for the main WPS shall be applied for tacking and shall not
be less than 50°C;
 Tack welding shall be of the bullet type. The bullets shall be made from compatible
linepipe material and shall be removed as welding progresses;
 A minimum of four (4) tacks shall be used;
 Welding shall be confined to the weld preparation and shall not penetrate the root;
 Tacking shall be incorporated into the WPQT phase if it is to be adopted in production.
7.4 Bevel (API 1104:2016 Section 7.4)
7.4.1 Mill Bevel (API 1104:2016 Section 7.4.1)
Clarification:
Mill bevelled ends will be provided as specified in the component data sheet(s).
7.4.2 Field Bevel (API 1104:2016 Section 7.4.2)
Clarification:
Weld bevels shall be prepared by machining. Mechanised thermal cutting may be accepted
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for tie-in welds. The cut surface shall be ground back nominally 2mm. Manual cutting of field
bevels is not permitted.
Add:
7.4.3 Bevel Condition (New)
Surfaces to be welded shall be free of primers, paints or coatings. Anti-spatter compounds

shall not be applied to surfaces to be welded.
Fusion faces and adjacent material shall be free from fins, planar defects or cracks, tears,
moisture, scale, rust, grease or any other foreign matter immediately prior to welding .
Surface contamination by the presence of oil or grease, etc., shall be removed. Degreasing
of the base metal shall extend to a minimum distance of 50mm from the edge of the fusion
faces on both the ID and OD. Solvents adopted for cleaning shall be dispensed from a
suitable container and be approved by COMPANY as being HSE compliant with necessary
documentation available.
Add:
7.4.4 Inspection and Treatment of Bevels (New)
On pipe that is to be cut back, a zone extending 100mm from the proposed position of the
new field bevel shall be visually inspected and ultrasonically tested in accordance with the
requirements of the applicable base metal specification(s).
Welding repairs to the base metal ends shall not be permitted.
7.5 Weather Conditions (API 1104:2016 Section 7.5)
Add:
All welding shall be performed under conditions where protection from adverse weather
conditions is assured. When necessary, measures shall be taken, e.g. by covering the pipe
ends, to prevent water or other extraneous matter being channelled into the weld region.
7.6 Clearance (API 1104:2016 Section 7.6)
Add:
Full and adequate clearance to the joint shall be provided for the welders so that the full
circumference is readily accessible without hindrance to the welding operation.
7.7 Cleaning Between Beads (API 1104:2016 Section 7.7)
Add:
Contact tips shall not be fused into the deposited weld metal. A visual inspection shall be
undertaken upon completion of the weld by the operator / welder in order to confirm that no
copper has been deposited.
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The use of manual slag hammers, chisels and light weight vibrating tools for the removal of
slag and spatter is permitted and is not considered as peening. Weld peening is not
permitted.
7.8 Identification of Welds (API 1104:2016 Section 7.10)
Add:
Accurate records to identify the extent of work conducted by each welder shall be
maintained and a weld identification system, detailing each weld with a unique identification
number shall be submitted.
Pipework shall be identified by indelible marking that is free from sulphur, chloride, and
other halogens.
7.9 Preheat and PWHT (API 1104:2016 Section 7.11)
Add:
7.9.1 Preheat and Interpass Temperature (New)
Preheating shall be applied by gas or electrical equipment. Electrical preheating method is

preferred, (e.g. by induction) for larger/thicker size pipes. Alternatives may be proposed by
agreements with COMPANY. For offshore pipeline welds, during a breakdown or stoppage
of the pipelay the use of gas torches is acceptable to apply heat to maintain the pipe
temperature. The use of gas torches for heating the pipe shall be qualified during WPQT
phase. Welding or cutting torches shall not be used for preheating purposes.
The preheat temperature shall be measured at a minimum distance of 75mm from each
edge of the weld bevel at four circumferential locations, each approximately 90 apart.
Preheat temperature measurement shall be made on the heated face of the pipe after a
time interval following the removal of the heat source to allow for temperature equalisation.
The time interval shall be 1 minute per 12.7mm of wall thickness (CONTRACTOR can
demonstrate effects of reduced time intervals for preheat measurement during welding
procedure qualification for COMPANY approval). The preheat temperature shall be
confirmed immediately before the commencement of welding and around the whole joint
whilst welding is taking place.
Damage to coatings shall be avoided. Preheating shall be applied uniformly on both sides of
the joint preparation around the entire periphery. Local preheating may be used for repair
welding. Correct preheat temperatures shall be maintained throughout the welding of the
joint.
The preheat temperature shall not exceed the minimum preheat temperature qualified
during the WPQT by more than 50°C.
In order to facilitate production welding, forced air or water jackets may be used to
accelerate cooling. When used in production, forced cooling shall be qualified during
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WPQT. Direct water cooling may be permitted and the maximum temperature of the weld
before water-cooling, measured on any location of the weld cap using a digital thermometer,
shall be qualified during WPQT (see also section 5.3.2.9).
The interpass temperature shall not be less than the preheat temperature and shall not
exceed the highest value recorded during WPQT welding.
For continuous welding, interpass temperature shall be measured once per complete
revolution around the weld circumference prior to the next pass. Interpass temperature shall
be measured at the edge of the weld bevel near the weld start location.
Temperature indicating crayons which melt on attaining the specific temperature may be
used to check preheat and interpass temperature, but shall not be marked on weld bevels,
weld beads, or surfaces to be welded and shall be used in conjunction with calibrated
contact digital thermometers/pyrometers. Temperature indicating crayons or paints, which
indicate temperature by colour change, shall not be used. Alternatively, suitably attached
(and calibrated) thermocouples or calibrated contact or optical pyrometers may be used to
check preheat and inter-pass temperatures.
If girth welds are to be left partly completed, the joint shall be wrapped in dry insulating,
heat-resisting material with a waterproof backing and shall be cooled at a slow uniform rate.
Preheat shall be re-applied and the specified temperature attained before recommencement
of welding.
Add:
7.10 Weld Interruption (New)
For offshore pipeline welds, during a breakdown or a stoppage of the pipe lay, it is
acceptable that for the weld to cool below the preheat temperature provided that the root
pass is fully completed and the joint fully supported.
Add:
7.11 Branches (New)
7.11.1 General
Branch welds shall be sited away from other welds on the pipeline (see section 7.1.1).
The pipe area surrounding a branch weld shall be tested for laminations / inclusions using
UT up to a distance of 100 mm surrounding the projected locations of the weld toes. Any
laminations found (individual or cluster) shall not exceed a total area of 500 mm2. No
lamination, regardless of size, shall be permitted within 25 mm of the projected weld toes.
7.11.2 Set-in Type Fittings
Set-in type fittings shall be attached to the pipe using a low hydrogen welding process.
If accessible and following completion of the full weld, the root bead shall be ground flush
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on the inside of the pipe, its location clearly marked with indelible pen, and inspected with
VT and MT.
Weld caps shall be subjected to VT and MT.
The full welds shall be examined with RT using the SWE/SWV technique with the film inside
and the radiation source outside, using a minimum source to film distance of 600 mm. A
minimum of four (4) equidistantly spaced separate exposures shall be used for branches ≤
150 mm nominal bore; a minimum of six (6) equidistantly spaced separate exposures shall
be used for branches > 150 mm nominal bore.
The DWE/SWV technique may only be used if approved by COMPANY.
In any event, the centre of the radiation beam shall pass through each weld region being
tested at normal incidence to the weld face.
7.11.3 Set-on Type Fittings
All welding shall be using a low hydrogen welding process.

The root bead and weld cap shall be examined by VT. The weld cap shall also be examined
with MT. If access allows, UT shall be undertaken from the inside surface of the fitting.
Add:
7.12 Fillet Weld Attachments (New)
The pipe area surrounding a fillet weld shall be tested for laminations/ inclusions utilising UT
up to a distance of 100mm surrounding the projected locations of the weld toes.
Any laminations found (individual or cluster) shall not exceed a total area of 500mm2. No
lamination, regardless of size shall be permitted within 25 mm of the projected weld toes.
If any fillet welds are to be deposited with multiple passes, the first pass shall be deposited
mainly on the pipe, and the final weld pass shall not come in contact with the pipe.
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8.0 Inspection and Testing of production Welds (API 1104:2016

Section 8)
8.1 Rights of Inspection (API 1104:2016 Section 8.1)
Add:
The right of inspection includes NDT undertaken by COMPANY personnel, in addition to
any NDT undertaken by CONTRACTOR.
8.2 Methods of Inspection (API 1104:2016 Section 8.2)
Add:
8.2.1 NDT General (New)
Each joint shall be thoroughly cleaned utilising power driven wire brushes and hand tools
following welding and before inspection. Spatter and extraneous material shall be removed.
Proposed NDT procedures shall be submitted in writing to COMPANY for approval.
Qualification of NDT procedures shall be performed on WPQT weld(s) or welds made in
accordance with COMPANY approved WPS, unless otherwise agreed by COMPANY.
Add:
8.2.2 Method (New)
All completed welds shall be fully visually inspected (for offshore welding, external side
only) in accordance with BS EN ISO 17637 immediately upon completion of welding.
Adequate lighting (1000 lux minimum) shall be provided for this inspection which shall apply
for both internal and external inspection.
The full circumference of all pipe butt welds shall be examined 100% by RT or AUT.
100% UT shall be used for wall thicknesses > 20mm and repair welds deeper than 20 mm.
The primary method shall by AUT for wall thicknesses above 25mm.
The use of AUT shall not be permitted in place of radiography for the following weld types:
- Welds connecting pipes with an internal taper;
- Butt welds to valves, flanges and other fittings;
100% MUT shall be used to supplement RT with GMAW or cored wire systems.
When AUT is not adopted, the full circumference of all butt welds shall be examined 100%
by MT unless if agreed otherwise by COMPANY.
All fillet welds shall be subject to 100% MT.
Repairs shall be subject to the same NDT as the original weld. The full length of the weld
shall be examined (i.e. original weld plus the repaired length).
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If AUT is adopted for the original welds, additional MUT shall be conducted for the repair
welds and shall be approved by COMPANY. After excavation of the repair area and prior to
the start of welding, the excavation shall be MT inspected, with the exception of the burn
through repair.
RT shall be used for the following types of welds:
 Welds connecting pipes with an internal taper;

 Butt welds to valves, flanges and other fittings.
If for practical reasons RT is being adopted to examine welds produced by GMAW or cored
wire systems, in place of AUT, manual UT shall be adopted to supplement RT.
Manual UT and MT equipment and qualified personnel shall be available at site for the full
duration of the scope of work.
Evaluation of welding defects shall be final responsibility of CONTRACTOR. COMPANY
reserves the right to reject any weld it deems unacceptable.
If a defect is detected in a weld, COMPANY reserves the right to require additional NDT of
the weld joint (RT, UT and/or MPT). In cases where examinations reveal the presence of
other non-acceptable defects, not discovered by RT or AUT, the use of RT, UT, and/or MPT
shall be continued for a minimum of the next 10 production welds. In addition, the cause of
the problem shall be identified and corrective measures shall be taken. All AUT records, RT
records and the relevant evaluation software and hardware shall become property of
COMPANY.
The NDT records shall be clearly identified using CONTRACTOR’s name, unit number
location, etc. NDT records of any weld repair shall be identified by having the letter “R”
added to the weld identity number. The NDT records including type, location and extent of
defects should be part of the tracking system.
COMPANY shall have the right to inspect individual welds and NDT operations. This
inspection may be made during the welding or after the weld has been completed. The right
of inspection may include NDT undertaken by COMPANY personnel in addition to any NDT
undertaken by CONTRACTOR. For example, COMPANY may choose to inspect welds by
MUT to assist in defect sizing.
Completed welds may be ground when required and agreed with COMPANY to facilitate
NDT provided the wall thickness complies with the minimum specified limit. Grinding shall
ensure no stress raisers and a smooth transition exists.
Add:
8.2.3 Timing of NDT (New)
Mechanised welds shall be visually inspected immediately upon completion of welding.

For all welds conducted onshore (including repair welds), there shall be a minimum of 24
hours between completion of welding and commencement of NDT.
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8.3 Qualification of Inspection Personnel (API 1104:2016 Section 8.3)
Add:
All personnel using NDT equipment shall have a thorough knowledge of the operation of the
equipment to be used. All NDT operators shall be qualified to Level 2 by a Certification
Body or Authorising Qualification Body in accordance with BS EN ISO 9712 or the ASNT
Central Certification Programme. An examiner qualified to CSWIP-WI-6-92 Level 3 or
equivalent in all NDT techniques shall also be available.
NDT personnel certificated to the requirements of a Written Practice under the rules of SNT
TC 1A shall not be used, unless the Written Practice and the personnel certification has
been reviewed and accepted by COMPANY for the specific work.
AUT personnel qualification shall be in accordance with Appendix C of this Specification.
Welding Inspectors shall hold current certification to, as a minimum, any of the following
standards:
 CSWIP (TWI, UK) – 3.1; Welding Inspector;

 BGAS-CSWIP (TWI, UK) – Welding Inspector;
 PCN (BINDT, UK) – Weld Inspection Level 2;
 AWS QC1 (1996 or later edition) – Certified Welding Inspector (CWI);
 EWI-S, IWI-S, NS 477 – Certified Welding Inspector.
A Senior Welding Inspector shall be employed to coordinate and supervise the work of the
Welding Inspectors. Senior Welding Inspectors shall, as a minimum, hold current
certification to any of the following standards:
 CSWIP (TWI, UK) – 3.2; Senior Welding Inspector;

 BGAS-CSWIP (TWI, UK) – Senior Welding Inspector (SWI) or Senior Pipeline
Inspector (SPI);
 PCN (BINDT, UK) – Weld Inspection Level 3;
 AWS QC1 (1996 or later edition) – Senior Certified Welding Inspector (SCWI).
Add:
8.4 Certification of Welding Engineer (New)
A competent and suitably qualified Welding Engineer shall be employed. The Welding
Engineer shall be responsible for the technical aspects of welding operations including the
following:
 Selection of welding processes, equipment, and consumables;

 Preparation and qualification of welding procedures;
 Qualification of welders;
 Providing technical oversight of the production welding;
 Liaison with COMPANY and the NDT sub-contractors;
The minimum experience and qualification level for the Welding Engineer should be:
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In USA: Professional Engineer (PE) holding as a minimum a degree in engineering,

metallurgy or materials science and having specialised training in welding technology.
Membership of American Welding Society (AWS) is desirable and a minimum of 5 years
relevant experience in the pipeline welding or fabrication industry is essential.
In Europe/Rest of the World: Chartered Engineer (CEng/ Dipl Ing) holding, as a minimum, a
degree in engineering, metallurgy or materials science and having specialised training in
welding technology. The requirements of 5.2.2, ISO 3834 should be met as demonstrated
by the European Welding Engineer (EWE) or International 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
essential.
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9.0 Acceptance Standards for NDT (API 1104:2016 Section 9)

Clarification:
The acceptance standards defined in this section shall be the minimum requirements for
COMPANY pipelines in which RT is the primary NDT method.
If the use of AUT has been approved by COMPANY, the maximum allowable flaw sizes
shall be confirmed by ECA unless specifically approved by COMPANY. This would be
subject to restriction of planar flaw individual (non-interacting) actual height to 4 mm and
lengths to those of workmanship criteria specified in API 1104:2016 and in this
Specification.
ECA shall not be used to relax workmanship criteria specified in API 1104:2016 and this
Specification, unless approved by COMPANY. The above stated flaw height restriction is
applicable.
For AUT inspection, flaw dimensions shall be reduced to account for AUT sizing accuracy
proven by AUT qualification and verification program.
The ECA method and assumptions shall be defined in a CONTRACTOR method statement
and subject to COMPANY approval prior to conducting analysis.
Add:
9.1.1 Visual Acceptance – Weld Profile (New)
Completed welds shall have a uniform appearance without excessive change in profile and
shall blend smoothly into the parent material. At no point shall the penetration of the root
bead (into the bore) exceed 3.0 mm.
Welds are not required to be grounded flush except if specified by the project ECA.
9.2 Radiographic Testing (API 1104:2016 Section 9.3)
Clarification:
This section, where relevant, is also applicable to NDT conducted by UT.
9.2.1 Inadequate Penetration due to High-Low (API 1104:2016 Section 9.3.2)
Clarification:
The length of an individual indication of inadequate penetration due to High-Low (IPD)
exceeds 25mm.
9.2.2 Internal Concavity (API 1104:2016 Section 9.3.6)
Clarification:
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Internal concavity (IC) up to 25% of the total length of weld is acceptable provided the
density of the radiographic image of the IC does not exceed that of the thinnest adjacent
base metal.
9.2.3 Burn-Through (BT) (API 1104:2016 Section 9.3.7)
9.2.3.1 Small Diameter Pipe (API 1104:2016 Section 9.3.7.3)
Clarification:
For all pipe diameters, a burn-through (BT) shall be considered a defect if any of the
following conditions exist (See conditions listed in API 1104:2016).
9.2.4 Porosity (API 1104:2016 Section 9.3.9)
Add:
The total area when projected radially through the weld shall not exceed 2% of the
projected weld area in the radiograph. The area shall be the length of the weld affected by
the porosity (with a minimum length of 150mm) times the maximum width of the weld.
9.2.5 Cracks (API 1104:2016 Section 9.3.10)
Clarification:
Any form of crack or suspected crack shall be unacceptable and welds containing cracks
(other than crater cracks ≤ 4 mm in length) shall be removed from the pipeline.
9.2.6 Undercutting (API 1104:2016 Section 9.3.11)
Clarification:
The aggregate length of internal undercut (IU) exceeds 25mm in any continuous 300mm of
weld length. Irrespective of length, undercutting shall not be sharp.
9.2.7 Accumulation of Imperfections (API 1104:2016 Section 9.3.12)
Add:
c. The total aggregate length of all indications, including incomplete penetration due to
High-Low and undercutting, exceeds 15% of the weld length.
Add:
9.2.8 Tungsten Inclusions (New)
Tungsten inclusions shall not exceed two (2) per weld and shall be separated by a minimum
distance of 50mm.
Add:
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9.2.9 Copper Inclusions (New)
Not permitted.
9.3 Ultrasonic Testing (API 1104:2016 Section 9.6)
9.3.1 Acceptance Standards (API 1104:2016 Section 9.6.2)
9.3.1.1 General (API 1104:2016 Section 9.6.2.1)
Clarification:
b. Manual Ultrasonic Testing (MUT) and Automated Ultrasonic Testing (AUT) acceptance
criteria shall be approved by COMPANY.
Add:
When applicable, the ECA shall be used to develop the weld NDT acceptance criteria. In
addition to the limits derived from the ECA, the following restrictions shall also apply:
- For Defects with a height greater than 4mm (before interaction assessment) shall not be
permitted. No acceptance of these defects shall be permitted even though the ECA may
show safe defect heights in excess of 4mm.
- Irrespective of defect height, defects with a length greater than 7 times wall thickness
(after interaction assessment) shall not be permitted.
9.4 Visual Acceptance Standards for Undercutting (API 1104:2016 Section 9.7)
9.4.1 Acceptance Standards (API 1104:2016 Section 9.7.2)
Clarification:
All undercuts shall be smooth.
Weld cap undercutting exceeding a depth of 0.4 mm shall not be permitted and shall
therefore be removed by light grinding prior to performing NDT. If the pipe wall thickness is
reduced below the specified minimum, the entire circumferential weld shall be cut out and
the pipe ends re-bevelled and the joint re-welded accordingly.
Add:
9.5 Suspect Welds (New)
Any weld suspected of not having been produced in accordance with the approved welding
procedure shall be cut out.
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10.0 Repair and Removal of Welds Defects (API 1104:2016 Section 10)
Add:
Weld repairs shall be performed in accordance with a COMPANY approved repair welding
procedure.
10.2 Authorization for Repair (API 1104:2016 Section 10.2)
10.2.1 Company Authorization (API 1104:2016 Section 10.2.1)
Add:
A full record of repairs shall be maintained and a report shall be initiated as each defect is
discovered and shall include the following information:
 The weld number

 The type and size of defect.
 The circumferential location (defined to an approved system).
 An estimate of the defect depth (assessed by ultrasonic testing, if practical).
 Name of welder who produced defective weld.
 Repair welding procedure number.
 Name of repair welder.
 Inspection report number (Copy of report shall be attached).
 Date of repair.
Defects shall not be removed / repaired in any part of the weld without the prior approval of
COMPANY.
10.2.2 Crack Repairs (API 1104:2016 Section 10.2.2)
Clarification:
The welding procedure shall be suspended until the cause is identified and remedial
measures implemented to prevent further occurrence.
Small / shallow crater cracks with length ≤ 4 mm shall be removed by local grinding and
inspected after grinding by MPT. Cracks shall not be repaired by welding.
10.2.3 Repairs of Defects Other Than Cracks (API 1104:2016 Section 10.2.3)
Clarification:
Weld repairs shall be performed in accordance with a COMPANY approved repair welding
procedure.
Weld repair coverage shall be limited to:
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 30% of the circumferential weld length in situations where repairs do not open the root,
or
 20% of the circumferential weld length in situations where repairs do open the root, or
 20% of combination of the above.
Further restrictions on weld excavation may be required if the weld is under load at the time
of the repair (i.e. beyond the tensioners of a lay-barge, etc). In such cases, verified
calculations justifying the extent of excavation shall be submitted for COMPANY approval.
If a root repair weld fails, the entire circumferential weld shall be cut-out and the pipe ends
re-bevelled are re-welded accordingly. If necessary, a second repair may be attempted for
all regions of the weld, except for the root region. If a second repair fails, the entire
circumferential weld shall be cut out.
With respect to the repair of arc burns, refer to Section 10.4.
Internal weld repairs shall not be permitted except for pipe-to-fitting welds where the repair
can be undertaken from the open end of the pipe of fitting.
No more than two (2) separate repairs, with a minimum separation of 50 mm between repair
locations, are permitted in a single butt weld circumference. The total length of weld repair
shall not exceed that specified above.
10.3 Repair Procedure (API 1104:2016 Section 10.3)
10.3.1 Types of Repair Procedures (API 1104:2016 Section 10.3.2)
Clarification:
Weld repair procedure qualification is required.
It is not necessary to make a full circumferential repair weld. It is only required to make
sufficient repair weld to provide material for mechanical testing. The radial position of the
test repair weld shall be approved by COMPANY.
Single pass repairs shall only be permitted for weld cap defects.
Each repair type of those listed below that are considered to be adopted during production
shall be qualified separately:
 Full penetration
 Partial penetration
 Partial penetration – re-repair. Partial penetration - re-repair may be used to qualify
partial penetration repair if agreed by COMPANY.
 Cap repair
 Internal repair (if permitted by COMPANY)
The repair weld procedure qualification shall be tested by the following techniques:
 Visual inspection (VT)

 Magnetic particle testing (MPT)
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 Manual ultrasonic testing (UT)

 X-Radiographic testing (RT)
Type and Number of test specimens for repair welding procedure qualification test shall be
performed in accordance with Table 10.1.
Hardness testing shall be performed in accordance with section 5.6.5.
Table 10.1 Type and Number of Test Specimens for Repair Welding Procedure Qualification
Test
Type of ‘X’ Weld All-Weld CVN Impact
Bend Macro / HV10 CTOD
Repair Tensile Metal Tensile Tests
(1)
Single pass 0 0 0 0 0
(3+4)
Partial 5 1
(2) (5) (2)
2 1 2 2
(3+4)
Full Pen. 3
Notes: 1. If the strength of the weld may be significantly affected (e.g. adoption of low strength repair electrode on thin-wall pipe) a transverse / cross
weld tensile test shall be undertaken.
2. CTOD and all-weld tensile testing shall be undertaken only if required by ECA. Testing shall be as per the project ECA.
3. One (1) set (of three (3)) CVN impact specimens shall be located in the (i) repair weld metal, (ii) associated parent metal HAZ at the fusion
line (FL) and (iii) FL + 2mm. For partial penetration repair welds only, a further two (2) sets of CVN impact specimens shall be notched to
sample the repair weld metal (WM) and associated original weld metal HAZ at the fusion line (FL) and FL + 2mm (FL +2 mm) positions.
4. For partial penetration and full penetration welds with a depth in excess of 20 mm, additional sets of weld metal (WM), fusion line (FL) and
fusion line + 2 mm (FL +2 mm) shall be located at the inner surface of the repair weld (i.e. root location).
5. The bend specimen type shall be selected in accordance with Section 6.6 based upon the thickness and diameter of the weld.
Separate repair weld procedure qualification excavations at different locations per welded
joint shall be separated by a minimum distance between repair locations of 50 mm. Each
separate repair shall be excavated and fully welded prior excavation of the next repair.
Add:
The portion of the weld cut out for repair shall be tapered at the sides and ends in order to
give adequate access for re-welding. Metal may be removed by thermal gouging followed
by grinding.
Grinding shall be performed for the removal of the final depth of 3 mm through to the root.
Air-arc gouging shall be controlled by a procedure documenting the permitted variables as
required by AWS C5.3.
The minimum allowable repair length shall be 50 mm at the bottom, of the groove.
Add
Partial repair of single or accumulated defects is not acceptable. Excavations associated
with the partial thickness repair of planar imperfections shall be evaluated by MT in order to
confirm the complete removal of the defect.
Add:
10.4 Arc Burns (New)
Arc burns outside of the weld groove shall not be permitted. Remedial action on arc burns
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shall consist of careful grinding until visible signs of arc burn are removed. Welding shall not
be used to repair arc burns. The dressed area shall blend smoothly into the surrounding
base metal and shall be examined by visual inspection and MT to ensure freedom from
defects. The remaining wall thickness shall be checked with UT.
If blending to remove the effects of arc burns reduces the wall thickness below the specified
minimum, the defective pipe section shall be cut out and the pipe re-bevelled and re-
welded.
In addition, etching with 5% nital or ammonium per-sulphate shall be performed on the arc
burns to ensure the complete removal of the hardened layer. Each arc burn removal and
the relevant inspections shall be recorded in the repair record.
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11.0 Procedures for Non-Destructive testing (NDT (11)

11.1 Radiographic Test Methods (API 1104:2016 Section 11.1)
Add:
The procedure / test radiographs shall be submitted to COMPANY for approval prior to the
start of production.
RT shall be performed using X-ray equipment. If the use of X-ray equipment is deemed to
be impractical, Gamma ray sources such as Iridium 192 may be adopted subject to
approval by COMPANY.
Radiographic practice shall be in accordance with this Specification and BS EN ISO 17636-
1 (class B only).
For RT procedure qualification, wire type IQI’s, meeting the requirements of ASTM E747 or
COMPANY approved equivalent shall be positioned across the weld on both the source and
the film sides of the area being examined.
Acceptable film types shall be categorised as BS EN ISO 11699-1 class T2 or ASTM E1815
Class I, e.g. Agfa Structurix D5 or Kodak Industrex T200), or finer grain (slower) film. If it is
shown that exposure times would exceed two (2) minutes using X-ray equipment with this
film, the adoption of BS EN ISO 11699-1 Class T3 or ASTM E1815 Class II may be
permitted at the discretion of COMPANY.
11.1.2 Detail of procedure (API 1104:2016 Section 11.1.2)
11.1.2.1 Film Radiography (API 1104:2016 Section 11.1.2.2)
Add:
a. Also to include brand name, including specific model name / number of X-ray equipment.
e. Exposure conditions:
 For X-ray: Exposure time, mA and kV.

 For Gamma: Curie-minutes and Gigabecquerel-minutes.
f. Also to include type and brand of each processing chemical and process temperature.
11.1.3 Exposure Geometry (API 1104:2016 Section 11.1.3)
11.1.3.1 Film Radiography (API 1104:2016 Section 11.1.3.1)
Clarification:
Source-weld-film arrangements shall comply with BS EN ISO 17636-1. The perpendicular
technique (straight through) exposures shall not be considered unless approved by
COMPANY.
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The single wall exposure for single wall viewings (SWE/SWV) technique with the radiation
source located inside the pipe or fitting shall be preferred technique for RT of girth welds.
11.1.4 Type of IQIs (API 1104:2016 Section 11.1.4)
Add:
Wire type IQI’ in accordance with BS EN ISO 19232-1, ASTM E747 or an approved
COMPANY equivalent shall be adopted.
11.1.5 Selection of IQIs ( API 1104:2016 Section 11.1.5)
Clarification:
IQI Sensitivity requirements shall be as given in Figure 11.1.
Figure 11.1 IQI Sensitivity Levels
11.1.6 Identification of Images (API 1104:2016 Section 11.1.8)
Add:
The individual radiographs shall contain the following information:
 Project name, Project number and COMPANY system identification;

 Weld number;
 Status of radiograph (i.e. a shot of a repair weld, a replacement weld or re-shoot of a
radiograph, etc.);
 Marker(s) indicating the position of the radiograph in relation to the weld reference
position(s);
 Pipe diameter and thickness;
 Material grade;
 Date;
 WPS number;
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 Welder Numbers (WPQR and Welder qualification only).
11.1.7 Storage of Film and Other Imaging Media (API 1104:2016 Section 11.1.9)
11.1.7.1 Film (API 1104:2016 Section 11.1.9.1)
Add:
All unexposed film shall be stored in a clean, dry environment where the surrounding
conditions will not detrimentally affect the emulsion.
Digital storage of radiographs is preferred to storage of films.
Where COMPANY agrees to storage of films the film shall be processed to allow storage
without deterioration for a minimum of five (5) years. One (1) radiograph in every one-
hundred (100) shall be subjected to a residual thiosulphate test, (e.g., Inch Hypo or Thio-
Test) to ensure that the film has been suitably processed for long term storage.
11.1.8 Film Density (API 1104:2016 Section 11.1.10)
11.1.8.1 General (API 1104:2016 Section 11.1.10.1)
Clarification
Except for small localised areas caused by the weaving technique or areas containing
discontinuities, the radiographic density shall be between 2.0 and 3.0 in the weld area.
11.1.8.2 Film Viewing Equipment (API 1104:2016 Section 11.1.10.2)
Add:
The brightness of the illuminated radiograph shall be such that it can be interpreted
satisfactorily. Illuminators shall meet the requirements of ISO 5580.
Add:
11.1.9 Image Processing (New)
Radiographic film shall be dried thoroughly before viewing. Films shall be processed in
order to facilitate storage without deterioration for a minimum period of five (5) years. One
(1) radiograph in every one-hundred (100) shall be subjected to a residual thiosulphate test.
11.2 Magnetic Particle Test Method (API 1104:2016 Section 11.2)
Add:
MT shall comply with BS EN ISO 17638 or ASTM E709.
MT procedures, including the method for determining adequate flux levels in the test area,
shall be qualified.
The non-fluorescent wet method of MT utilising white contrast paint and an AC yoke (110 V)
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shall be adopted. Dry MT may be proposed to COMPANY for inspection of repair

excavations.
The AC yoke shall be capable of lifting 4.5kg at pole spacing of 150mm.
A minimum of 1000 lux shall be used when visible particles are used.
11.3 Ultrasonic Test Method (API 1104:2016 Section 11.4)
Add:
Manual UT shall comply with BS EN ISO 17640 or ASTM E164.
11.3.2 Scanning and Evaluation Level (API 1104:2016 Section 11.4.7)
11.3.2.1 Automatic Ultrasonic Weld Testing (API 1104:2016 Section 11.4.7.3)
Add:
The adoption of AUT systems requires qualification and production testing / calibration in
accordance with the requirements of Appendix C.
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12.0 Mechanized Welding with Filler Additions (API 1104:2016 Section

12)
12.1 Acceptable Processes (API 1104:2016 Section 12.1)
Add:
If mechanised processes for main line welding, tie-in welding or for multiple jointing of sub-
assemblies are proposed, the bid proposal shall include full details of the processes to be
used, the associated welding equipment, and the proposed area of application.
The proposal shall list the number of welding stations (root pass to final capping pass and
detail the equipment and number of welders and other personnel required to operate each
station.
The proposal shall also detail the intended level of technician support for equipment
maintenance and list the principal spares that will be available in order to maintain
equipment serviceability for the duration of the welding applications.
The proposal shall also advise if a manual welding procedure is to be qualified for
production or repair welding.
Mechanised welding equipment should be operated in-conjunction with data logging
facilities capable of recording the essential variables associated with the arc including wire
feed speeds and travel speeds. The equipment shall record all parameters for each pass of
every weld at a minimum rate of once per 10 degrees of angular rotation and shall indicate
the angular position of each measurement. This data shall be readily retrievable for
monitoring purposes. Data logging is mandatory if welding with either multi torch or multi
wire systems.
Each mechanised welding station shall be demonstrated to be fully operational before it is
employed to weld any joints that will be incorporated into the pipelines. This demonstration
shall consist of the first two full girth welds made consecutively, each weld being required to
meet the production acceptance criteria without the need for any repair. These two welds
shall have the parameters monitored to the satisfaction of COMPANY using calibrated
gauges independent of the gauges built into the welding machines. NDT shall utilise the
agreed NDT techniques and equipment. Internal welding equipment shall also require
operational demonstration. Each of these pre-construction welds shall be uniquely
identified. If production is interrupted for a period of ≥ 7 days, COPANY reserves the right to
require repeat of this operational demonstration.
12.2 Procedure Qualification (API 1104:2016 Section 12.2)
Clarification:
The requirements for the qualification and testing of a WPS utilising mechanised welding
have been incorporated in section 5.1.
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12.3 Record (API 1104:2016 Section 12.3)
Add:
Additional requirements for mechanised welding have been incorporated in section 5.2.
12.4 Welding Procedure Specification (API 1104:2016 Section 12.4)
Add:
The requirements for the development of a WPS utilising mechanised welding have been
incorporated in section 5.3.
12.5 Essential Variables (API 1104:2016 Section 12.5)
Add:
The requirements for a mechanised welding have been incorporated in section 5.4.
12.6 Qualification of Welding Equipment and Operators (API 1104:2016 Section 12.6)
Add:
The requirements for mechanised welding have been incorporated in sections 4 and 6.
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13.0 Automatic Welding Without Filler Metal Additions (API 1104:2016

Section 13)
Clarification:
Mechanised and automatic welding without filler metal additions shall not be permitted.
-o0o-
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Appendix A CTOD Testing
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A.1 General
CTOD testing shall be undertaken in accordance with ISO 15653 by a testing laboratory
specifically approved by COMPANY for CTOD testing.
Testing shall be based on the use of Bx2B through thickness notched, single edge notched
bend (SENB) specimens (ISO 15653) in the NP orientation, unless agreed otherwise by
COMPANY. An alternative specimen geometry such as B×B surface notched may be
required when specified by COMPANY.
Test specimens shall be notched and fatigue cracked to sample the microstructures at the
weld centre line and in the coarse grained HAZ adjacent to the fusion line.
The number of valid test results employed to determine the characteristic CTOD of the weld
metal and HAZ microstructures shall comply with BS 7910 paragraphs K.2.3 and 7.1.5.5.
The test temperature shall be MDT unless otherwise specified.
Post-test metallography shall be used to identify the initiation point and the associated
microstructure on a minimum of three HAZ specimens selected by COMPANY. The
initiation point of all brittle events shall be identified by metallography.
Alternative requirements may be specified by COMPANY to meet requirements for ECA.
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Appendix B Pin Brazing and Aluminothermic Welding of Anode or

Continuity Leads
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B.1 Pin Brazing and Aluminothermic Welding of Anode or Continuity Leads
B.1.1 Joining Technique

Full details of the joining technique and associated equipment should be submitted to
COMPANY for approval prior to use.
B.1.2 Specification and Approval of Procedure

General
A procedure specification shall be submitted for COMPANY approval, this shall include
requirements for surface preparation, pre-heating, visual inspection, coating repairs, etc.
Before qualification, the parameters and information to be recorded and shown on the final
WPS shall be proposed for COMPANY approval. Relevant details of the test, including
serial of catalogue numbers of the components and tools used, shall be recorded. For
brazing, this shall include the electrical settings of the power supply.
The procedure should be qualified by making three (3) consecutive test joints in the
presence of COMPANY, on material to be used in production. The test material should be
selected by COMPANY to represent the upper quartile of the carbon equivalent range.
The electrical resistance of each weld should be measured and should not exceed 0.1Ω.
The mechanical strength of the weld should be tested by means of a sharp blow from a 1
kg hammer.
The test welds should be sectioned and prepared for metallographic examination. The
following tests should be performed on the sections.
Copper Penetration Measurements
The depth of copper penetration below the surface of the pipe material should be measured
metallographically. The fusion line of the weld or braze should not be more than 1mm below
the pipe surface. Intergranular copper penetration of the pipe material shall not exceed 0.5
mm beyond the fusion line when a specimen is examined at a magnification not exceeding
times fifty (x50).
Hardness Survey
Each test section should be tested using an applied load of 10kg. A transverse should be
made across the weld zone. The transverse should consist of at least six impressions; two
in the HAZ each side of the weld / braze and one in the parent meal each side of the weld /
braze.
The hardness values should not exceed 275 Hv10 for pipe thickness less than 9.5mm, 300
Hv10 for pipe thickness above 9.5mm.
Macro Section
The macro-section shall confirm complete bonding between the attachment and the pipe
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wall over the full cross section of the joint, with porosity or other defects < 3mm in maximum
dimension.
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Appendix C Requirements for AUT
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C.1 Introduction
This Appendix provides guidance on the issues to be addressed when automated ultrasonic
testing is being considered for inspecting the girth welds of new pipelines in construction.
The inspection is intended to show that the welds meet the design acceptance criteria in all
respects before the pipeline is put into service.
Construction and testing shall be carried out by competent contractors using a well-trained,
qualified, and experienced workforce, using reliable, modern, and well maintained
technology and the work must comply with safe and environmentally sound working
practices at all times. In particular non-destructive testing and inspection personnel shall be
properly trained and qualified to recognised industry standards by examination and/or by
individual test and be widely experienced in operations with the equipment.
Subject to COMPANY approval, AUT may be based on the requirements of DNV-OS-F101
as an alternative to this Appendix.
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C.2 System Requirements
C.2.1 General
a. The AUT system shall detect all flaws in the pipeline girth welds which might compromise
its structural strength and its physical integrity as a chemical barrier.
b. The system should be accepted by qualification to a rigorous specification (clause C 2.9)
or alternatively by a verification procedure, during which a previous qualification is verified
as being applicable for a new application, (clause C 2.10).
c. ‘Verification’ is not the ‘validation’ cited in other documents, but an option intended to
allow the maximum use of pre-existing knowledge to shorten project timescales and
preparation costs.
d. If the AUT system is to be used for inspecting repaired sections of weld, this shall be
demonstrated to be effective as part of either the qualification and/or the verification
process.
C.2.2 Agreed Items

Any AUT system and examination procedure proposed for use shall be approved by
COMPANY before any production weld examination is carried out. A range of items shall be
agreed with COMPANY. These shall include:
1. Any relaxation to the requirement to detect flaws that are oriented transverse to the
direction of the weld.
2. The system performance requirement, ECA based or otherwise; the types and minimum
sizes of flaws that are required to be detected shall be defined.
3. The need for a full qualification or the acceptance of verification.
4. The requirements of either qualification or verification. This includes the associated
probability of detection of the minimum sized flaws, with a defined target for the reliability
(90% and 95 % respectively).
5. The design of the calibration block(s) shall be approved by COMPANY before
manufacture.
6. The frequency of calibration scans, following the first 20 welds.
7. The maximum loss of signal (its diminution and extent along the weld) due to reduced
coupling, which can be tolerated. It is recommended that this does not exceed 6 dB.
8. Details of the means of sectioning the qualification flaws to define the actual dimensions
of the flaws.
9. The parameters of the AUT system used for its qualification and the qualification
programme. These shall be agreed as valid and appropriate for the production and
qualification weld testing, as defined in clause C 2.5, and shall additionally include:
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a. The method used to determine the height of flaws, with sufficient detail to allow
COMPANY inspectors to replicate any assessment.
b. Details of the method used to determine the length of flaws, including the treatment
of ‘intermittent’ flaws.
c. The treatment of flaws near the intersection of the seam and girth welds.
d. Flaw interaction rules, (e.g. BS 7910) or project-specific rules.
e. The number of qualification test repeats over the same test welds with the system
and guide band removed and replaced between scans.
f. The number of elevated temperature tests during the qualification.
10. The parameters of the system used for its verification, if applicable, similarly to points 9
above.
11. Weld scanning direction and weld numbering scheme.
12. The provision of hardware and software to allow the weld data to be retrieved and re-
interpreted by COMPANY in the same manner as the operator viewed it at the time of the
inspection.
13. Access to the sectioning images for qualification weld flaws, (if historical data is used as
part of the qualification/verification).
14. The necessity for a slave-monitor for COMPANY inspection personnel to oversee the
testing during production.
15. The use of pulse-echo zone heights above 3 mm (1/8 in), if applicable.
16. Whether weld repairs are also to be inspected by AUT.
C.2.3 Equipment Requirements

a. The ultrasonic system shall use both pulse-echo and time of flight diffraction (ToFD).
b. The system shall include probe sets specifically designed to detect the presence of any
flaws transverse to the line of the weld that may be present in either the internal or external
weld near-surface zones. The transverse flaw scanning unit does not require a
complimentary ToFD scan.
c. The ultrasonic probes should be within a frequency range of 2 to 6 MHz. However, it is
recognized as desirable that certain systems, such as ToFD, should employ higher
frequency probes. All probe frequencies shall be advised. Individual probes shall comply
with the requirements of DNV OS-F 101, Appendix C, Annex A, although phased array
probes require specific definition. In the case of phased array probes the purchasing
specification for the probes and the goods-inwards test records against this specification
will be made available for inspection.
d. The system shall have sufficient examination channels (both pulse echo and tandem
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channels) configured so that the complete through-wall thickness of the weld can be
examined, preferably in a single circumferential scan.
e. The volume of weld examined by each channel shall be divided into primary examination
zones of a height not exceeding 3 mm (1/8 in) unless specifically agreed by COMPANY (for
thicker walled applications). Each examination channel shall provide:
1. A linear A-scan presentation
2. Adjustable gain control with maximum 2 db steps over a range of at least 60 db.
3. One or more gates, each adjustable for start position and length.
4. Recording threshold between 5 and 100% of full screen height.
5. Signal outputs that record the signal amplitude and its time of arrival representing
the beam travel distance.
f. The system shall provide an overlap of the start and end of the scans of at least 50 mm (2
in).
g. The recording or marking system shall clearly indicate the location of flaws relative to the
12 o’clock position of the weld (the ‘zero datum’), with a +/–10 mm (3/8 in) accuracy. The
system resolution shall be such that each scan of recorded data from an individual
inspection channel does not represent more than 1 mm of circumferential weld distance.
h. The system shall have a fully automatic recording system to detect and display the
presence and location of flaws, by reference to distance markers on the recording at
intervals of 100 mm or less.
i. Transducers shall couple to the surface though a water layer. The system shall display
the integrity of the acoustic coupling. An environmentally safe agent may be used to help
wet the pipe surface or to prevent freezing, but it shall leave no residue after the liquid has
evaporated.
j. The ultrasonic examination equipment performance characteristics shall meet the
requirements of BS EN 12668 or ISO 12710. Instrument amplitude linearity shall be within
5% of the ideal and shall be assessed before qualification and production AUT commences.
Calibration certificates shall be made available to COMPANY.
k. The instrument shall provide a record of the ToFD image. This shall complement the AUT
system in confirming the presence, nature, and size of weld flaws. ToFD shall not be used
in place of pulse echo. The ultrasonic instrument shall meet the requirements detailed in BS
EN 12668 and BS EN ISO 16828.
l. Reference and calibration blocks: The AUT contractor shall supply the necessary
reference and calibration blocks for the system. The design of the block(s) shall be specific
to the geometry of the weld bevel to be used in the welding system and the pipe thickness
to be used on the project. COMPANY reserves the right to retain any or all reference and
calibration blocks on completion of any pipeline inspection.
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1. Separate calibration blocks shall not be required if differences in material, either from
different sources or differing wall thicknesses, are demonstrated to give beam angle
differences in the test materials of less than 1,5°, for the AUT beams in use.
2. Calibration blocks shall be identified with a hard stamped, unique, serial number that
provides traceability to the examination work and the material source of supply for
which the standard was manufactured.
3. Records of the serial number, wall thickness, bevel design, diameter, and ultrasound
velocity shall be kept and be available.
4. The machining tolerances for calibration reflectors shall be as tabulated below. All
reflectors shall be protected physically from degradation.
Hole diameters +/–0,2 mm (0,008 in)
Hole depth +/–0,2 mm (0,008 in)
Flatness of flat +/–0,1 mm (0,004 in)

bottomed holes
Position of centres of +/–0,1 mm (0,004 in)

holes
Notch depth +/–0,1 mm (0,004 in)
Notch length +/–0,5 mm (0,020 in)
Position of reflecting +/–0,1 mm (0,004 in)

face of notch
All pertinent angles +/–0,1°
5. A calibration block register shall be established.

a. The register shall include all calibration blocks to be used, identified with the unique
serial number and include the dimensional verification records, ultrasound velocity,
name of the plate/pipe manufacturer, and the heat number.
b. The register shall be available for review.
6. The inspection report for the calibration block(s), following manufacture, shall be
from an independent third party, who shall be approved by COMPANY beforehand.
m. If it is agreed that a slave monitor is required by COMPANY inspectors, to facilitate
viewing the inspection data as it is generated, this shall be provided.
n. Any software required to view the results shall be included on the data disc(s) that will be
provided as part of the final results.
o. Any software licenses shall be agreed before any of the production welds are examined.
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p. The software version used in the construction shall be clearly identified.

q. The equipment’s power supplies and regulators shall be required to accommodate the
possibility of significant variations in site supplies (particularly ship-borne supplies).
C.2.4 Inspection Procedure

General
a. The examination procedure to be used in production shall be documented and agreed
with COMPANY, for each wall thickness and joint geometry (including that of repairs).
b. This includes description of the proposed configuration of the system and how it is to be
used, particularly detailing its set-up and calibration.
C.2.5 System Configuration

a. The AUT contractor shall supply the necessary reference blocks for defining these
factors, and the procedure shall describe their use in the assessment of results.
b. The procedure document shall fully describe the intended system configuration.
c. This shall include a description of:
1. A functional description of the system and a detailed equipment description.
2. Any limitations of the system with regard to material or weld features such as sound
velocity variations, geometry, size, surface finish, or material composition.
3. Transducer numbers and configuration(s), characteristics, set-up and coverage.
4. Means of monitoring probe wear.
5. The number of examination zones and their heights.
6. Gate and threshold settings; the thresholds shall be set to meet the detection
required for the minimum sized flaw, with the required, defined, PoD (as in clause C
2.9).
7. Ultrasonic instrument, number of channels, and data acquisition system.
8. The processing and recording of signals.
9. Coupling method and coupling monitoring method. Positive confirmation of acoustic
coupling during the weld examination scan is required for each weld examination.
a) The un-inspected length and loss of signal amplitude associated with below-
adequate coupling shall be specified by the contractor and agreed with
COMPANY.
b) Such below-adequate acoustic coupling during a weld examination shall require
a complete re-examination of the weld.
10. Pipe preparations, such as seam weld removal (internal and external), coating
removal, and surface preparation.
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11. The temperature range for testing and any limitations.

12. Maximum scanning speed and direction.
a) The scanning speed (Vs) shall not exceed that defined in ASTM E1961,
repeated below, unless otherwise agreed.
Vs ≤ W * PRF/3
where W is the –6 dB beam-width at the target distance,
and PRF is the pulse repetition frequency to the transducers.
b) The weld scanning direction (clockwise or anti-clockwise relative to a fixed
datum) shall be agreed with COMPANY and shall be consistent for all production
girth weld examination.
c) Identification means for inspection starting point and scanning direction.
13. Reporting of indications and the documentation of sensitivity settings.
14. Full description of calibration equipment.
a) A detailed description of calibration block(s) including type, size, and location of
the calibration reflectors.
b) No preferred calibration reflectors are defined by COMPANY. The procedure
shall detail how the calibration reflectors for pulse-echo channels are suitable to
give full coverage of the through-weld thickness, with an acceptable uniformity of
response to flaws at the appropriate fusion face angle.
c) The spacing between targets along the scan length shall be adequate to ensure
that the response from one target reduces to grass level before any signal from the
next target is detected in the scan.
d) Calibration of transverse probes preferably use EDM notches.
e) Calibration targets for the system to detect transverse flaws, such as cracking,
should be made having regard to the non-linearity of the relationship between the
signal level and the depth of the notch/slot.
f) Calibration plates are in the same surface condition as that of the production
welds, with whatever surface treatment is used in the field before AUT scanning.
15. The configuration of the system for inspection of repaired sections of weld, if AUT is
agreed as the inspection means.
C.2.6 Mode of Use

The procedure document shall fully describe the way that the system shall be used. This
document shall include description of the following:
a. The recording of calibration files and inspection scan files, within the requirements of the
project QA/QC system.
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b. The method for alignment of the scanner and method for maintenance of this alignment.
c. The method of scanner location with regard to the weld centre-line and the accuracy of
location.
1. A scribe line should be applied to the pipe ends before welding.
2. The procedure shall also describe the means of establishing whether there will be
any weld shrinkage and the means of accommodating it should it occur.
e. Transducer checks and overall functional checks and the recording of such results in the
equipment log book.
f. The frequency of monitoring probe wear, to what specification and how it is done, and the
remedial action when wear is detected.
1. If carbide runners are used (or similar) then the grooves in the calibration block(s)
shall be periodically monitored.
2. If the groove becomes deeper than 0,5 mm (0,02 in) then the calibration block
should be renewed.
g. The instructions to operators for reporting, to include an example of the recorder chart
and the forms to be used.
h. A diagram showing the weld-scan zones for the weld preparation which is to be tested,
as an aid to interpretation.
i. The interpretation method, including specifically:
1. The method used to determine the height of flaws, with sufficient detail to allow a
COMPANY inspector to replicate an assessment.
2. Details of the method used to determine the length of flaws.
3. The flaw interaction rules to be applied, e.g. BS 7910 or project specific rules.
4. The treatment of flaws near or at the intersection of the seam and girth welds.
i. The operator shall keep a log book that conforms to the following:
1. Identifies the instruments and transducers and details their performance
characteristics.
2. Updated as changes are made or as more information is gathered.
3. Kept at the place of inspection and made available for review upon request.
j. Each weld shall be numbered in the sequence used in the pipe tracking system, as
specified in Section 3.6 (1.7) of the main text.
k. Welds joining pipes of different wall thickness shall only be examined by AUT if the
internal surfaces are in line, within normal offset (or hi/lo) tolerances (See main text).
1. This may require that the thicker material is counter-bored back from the weld face
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(to reduce it to that of the thinner section) by a sufficient length to avoid disruption of
the ultrasonic beams.
2. Transition tapers shall not be used.
l. If AUT is agreed as the inspection means for the inspection of repaired sections of weld,
the configuration and mode of use of the AUT system shall be fully defined for that
geometry. Manual UT should be used in support of such use.
m. The performance of the transverse flaw detection channels shall be such as to
guarantee detection of flaws of height greater than 10% of the nominal wall thickness (i.e.
an N10 slot) in either the inside or the outside surface of the pipe. Alternatively, an ECA
based figure may be employed.
C.2.7 Set-Up and Calibration

General
The procedure document shall fully describe the intended set-up and calibration methods.
This shall include a static calibration that is initially used to optimize the system, followed by
dynamic calibrations.
Statistic Calibration
a. A procedure describing the static calibration of the system shall be written. This shall
cover all aspects, including the following:
1. For each pulse-echo (including tandem) channel in turn, the signal from its
calibration target in the calibration block shall be maximized and adjusted to be 80% of
the height of the full screen. The gain level required to attain this level, the signal to
noise ratio, and the ultrasonic transducer stand-off distance from the weld shall all be
recorded.
2. The detection gates shall conform to the following:
a) Each shall be set, in turn, as each transducer is positioned to obtain the peak
signal response from its calibration target.
b) The gates shall start before the theoretical weld preparation and a suitable
allowance shall be included to allow for the width of the heat affected zone (HAZ),
so that complete coverage of the HAZ is achieved.
c) The gate shall end after the theoretical weld centre-line, including a suitable
allowance for offset of the actual weld centre-line after welding (e.g. from
shrinkage).
d) For mapping channels (also called ‘porosity’ or ‘volumetric’ or ‘stacked A-scan’
channels), the gates shall be set to encompass the full weld width at that depth in
the weld section.
e) The ToFD channel gate should start at least 1 μs before the time of arrival of the
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lateral wave and should extend beyond the arrival of the first back wall echo.
3. The sensitivity of the ToFD channel is not critical, but shall be clearly defined.
Dynamic Calibration
A procedure describing the dynamic calibration of the system shall be written. This shall
cover all aspects, including the following:
a. During dynamic calibrations the calibration standard shall be scanned at the same travel
speed as the speed for testing the production welds.
b. The positional accuracy of the recorded target reflectors relative to each other shall be
within ± 2 mm (0,08 in) and it shall be within ± 10 mm (0,4 in) with respect to the zero
datum over the full circumference.
c. Gate settings shall not deviate by more than 0,25 mm (0,01 in) from the reference
positions defined during the static calibration.
d. No coupling loss is acceptable during calibration.
e. Calibration signals for the pulse-echo channels shall be within the range 70% to 99% of
the FSH.
f. If, during the dynamic field calibration, the signal falls outside this range, one of the
following shall apply:
1. If a calibration signal falls below 70% FSH, welds inspected since the last successful
calibration scan shall be re-tested, unless otherwise agreed by COMPANY.
2. If a calibration signal; is over 99%FSH, then the results for all welds scanned since
the last successful calibration shall be reviewed.
Calibration Intervals
a. The system shall be calibrated by scanning the calibration block(s) at the start and end of
each work period and at any point if the nominal wall thickness is changed or if any system
changes or adjustments are made.
b. Calibration shall also be conducted before and after each repair is inspected.
c. A calibration scan shall be done before or after each of the first 20 welds inspected in
production and before and after every weld during qualification.
d. The proposed frequency of calibration scans following the initial 20 production welds
shall be agreed with COMPANY.
C.2.8 AUT Operators

a. Personnel engaged in AUT shall have successfully completed a period of formal training
by the AUT Company on the specific equipment to be used on the pipeline; a training
duration of at least two weeks is expected.
b. Additionally, AUT interpreters shall hold at least UT Level 2 certification (specific to
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welds) and shall have undergone a period of supervised AUT interpretation in the field
before assuming responsibility for weld interpretation.
c. AUT interpreters shall hold current UT certification, specific to weld testing, to any of the
following standards, as a minimum:
1. CSWIP (TWI, UK) level 2.
2. BGAS-CSWIP (TWI, UK) – full ultrasonic.
3. PCN (BINDT, UK) level 2.
4. ACCP (ASNT) level 2.
5. SNT-TC-1A (ASNT) level 2.
d. NDT personnel certificated to the requirements of a Written Practice under the rules of
SNT-TC-1A shall not be used, unless the written practice and the personnel certification
has been reviewed and accepted by COMPANY for the specific work.
e. Details of the AUT operators and interpreters, proposed for employment under the
contract, shall be submitted to COMPANY for review and approval before their starting any
pipeline weld examination. This includes documentary evidence of adequate training,
supervised experience, and ongoing practical experience.
f. Operators and interpreters of all types of AUT equipment shall be required to demonstrate
to the approval of COMPANY, their satisfactory application of the approved AUT
procedures under the contract. This should involve the correct interpretation of flaws in 10
previously collected AUT screen records.
g. Roles and responsibilities for each individual involved with the QC/AUT operations shall
be defined, with the chain of responsibility of the operators also defined.
h. Support shall be available to operators from a qualified level 3 individual, throughout the
conduct of the pipeline construction.
i. Operators shall not be changed without the prior approval of COMPANY.
C.2.9 System Qualification

Qualification Procedures
a. Before any system is used for the inspection of production welds on the pipeline it shall
be qualified to the agreed procedure to demonstrate, to the satisfaction of COMPANY, that
the system and operators can reliably achieve
the detection, location, characterization, and sizing capability needed to support the project
acceptance criteria.
b. The procedure for qualification should require a minimum of 50 flaws.
c. These flaws shall be in a number of test welds, sufficient to ensure that each flaw can be
individually identified, with at least three times the flawed length of weld having no flaws
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present or interacting therein.

d. This flaw set shall include a number of each class of flaw which is of importance to the
duty of the pipeline under construction.
e. Depending on the welding process these may include:
1. Lack of fusion (LoF), either in the root (LoRF) or/and in the side wall (LoSWF),
or/and at the cap.
2. Lack of penetration (LoP).
3. Porosity (cluster, scattered, and/or isolated).
4. Lack of inter-run fusion (LoIRF).
5. Lack of cross penetration (LCP).
6. Non-metallic inclusions, including slag inclusions.
7. Burn-through.
8. Centre line cracks.
9. Stacked flaws (particularly stop/start indications).
10. Others (e.g. hollow bead, concave root, etc.).
(see ISO/DIS 6520-1 and API 1104).
f. Flaws shall be made of varying lengths and at varying depths from the outer surface.
g. The welds shall be tested to confirm the presence of the defects and define their
locations.
1. The welds shall be radiographically tested. The RT interpretation shall be conducted
by two interpreters separately and their results combined to include all indications.
2. Any areas of uncertainty from the RT and a proportion of the unflawed weld length of
the welds shall be scanned by manual UT at a high sensitivity, to identify any sub-
critical defects.
h. The test welds shall be scanned with the AUT equipment to the method defined in the
procedure, without variation.
i. Following AUT interpretation, a report of all these results shall be presented to
COMPANY.
j. Sectioning of qualification flaws:
1. An agreed selection of the flaws shall be cut in section, in a defined manner to be
agreed (e.g. ‘Salami’ slices as in DNV OS-F 101, section H 802, or by maximum values
as described below) to define both the nature and size of the flaws (principally the
height).
2. The maximum sectioned flaw height may be correlated with the maximum AUT
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Page C-13
signal for each flaw, to give one sectional data point per flaw.
a) In this case the AUT scanner should be used to identify the best location for the
metallurgical section and the position marked on the weld cap in a positive manner
(e.g. punch mark).
b) Additional sections may be taken nearby to give the best maximum value of the
flaw height.
k. Statistical analysis of the data shall be required to demonstrate satisfactory performance,
both for the detection of flaws and for their size estimation.
1. Performance shall be considered to be satisfactory if the required minimum flaw size
is shown to be detectable at a probability level of 90%, this probability estimate being
95% reliable.
2. Appropriate characterization and an acceptable accuracy of sizing shall also be
demonstrated, i.e. within the bounds of project productivity.
l. The procedure requires that, for each flaw, the error figure is added to the AUT estimate
of the flaw height, before it is decided if it is to be accepted or rejected to the defined
acceptance criteria.
m. As an alternative to qualification, previous data may be used, if a qualification has been
completed for an earlier project with the same parameters.
n. Qualification of repair weld sections shall employ an agreed number of repaired sections
of weld, covering the range of variety of repair groove geometry anticipated in construction.
o. The qualification tests shall include repeat tests over the same test welds with the system
and guide band removed and replaced between scans. The number of repeats is to be
agreed between the parties.
p. The qualification tests may include repeat tests over the same test welds with the test
sample temperature elevated to that expected to apply, as a maximum, in field conditions.
The necessity for elevated temperature tests is to be agreed between the parties.
q. The COMPANY representative witnessing the qualification tests may select one or
several of the scans for independent interpretation.
r. A full report of the qualification tests and/or verification tests shall be prepared for
COMPANY and the interpretation outcomes detailed in terms of the system requirements.
C.2.10 Verification
a. This shall require an initial evaluation of the previous qualification data by COMPANY
representatives to confirm that the projects are similar in all the key factors, both in terms of
the AUT system and the project requirements.
b. Verification should still require a set of flaws (around 30 in number) to be made, tested
with the AUT system, their character and sizes identified by the analyst and these results
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Page C-14
compared with values from sectioning the flaws.

c. This should demonstrate detection of flaws near the detection threshold with sufficient
signal to support the required PoD.
d. The accuracy of sizing of the flaws should demonstrate that sufficient numbers of the
flaws are within the accuracy claimed by the Contractor to support the accuracy,
statistically.
C.2.11 Change to Qualification

a. If there are any changes to the ‘essential variables’ of the system (DNV OS-F 101, I 201),
the validity of the qualification of the modified system shall be demonstrated. This may be
done by verification in the manner described in C 2.10.
C.2.12 System Checks

a. Before the ultrasonic system is used for examination of production welds, the system
shall be tested.
b. For an acceptable test, three consecutive satisfactory scans and recalibrations are
required.
1. After calibration of the complete system, the first weld shall be scanned three times,
followed by re-calibrations, with the probe transport system removed and replaced
between each scan.
2. If any of the echo amplitudes from the reflectors of the calibration block deviate by
more than 2 dB from the initial calibration, the system shall not be used until acceptable
corrections have been made.
c. Transducer wear shall be monitored during the course of operations as described in the
procedure.
C.2.13 Documentation
a. A quality assurance system shall be used, covering all aspects of the development and
use of the automated ultrasonic inspection systems.
b. The principal products of the inspection shall be:
1. Hard copy output from each weld inspection and calibration scan should be provided
to COMPANY.
2. The output from each weld inspection and calibration scan, provided additionally in
electronic form.
3. The assessment of the weld to the defined criteria.
4. A full set of data for all repairs.
C.2.14 AUT Application
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Page C-15
General
The application of AUT within the overall project construction process shall be considered
at the planning stage.
Support to AUT Operations
Visual testing shall be done in accordance with ISO 17637.
It may sometimes be necessary to dress the weld cap where it is excessively proud or wide,
to allow unhindered passage of the AUT probes. This shall only be done after consultation
with the COMPANY welding engineer.
Welder Qualification Welds
Requirements regarding AUT of welder qualification test welds are given in Section 6 of the
main text.
If AUT is agreed for application to welder qualification welds, then the same AUT procedure
shall be used as that to be used in production.
NDT of Repaired Area
a. Defective welds that have been repaired shall be re-examined visually and by non-
destructive testing. If the repaired areas are examined using AUT in accordance with this
Appendix , the support inspection, carried out using manual ultrasonic methods, shall
require a separate procedure to be written, which shall be approved by COMPANY before
the work starts.
b. If the repair is conducted by fully removing the defective weld and re-welding, the new
weld may be examined using AUT to the agreed procedure.
Special Applications
The application of AUT to dissimilar metal welds is not permitted unless it can be
demonstrated to the satisfaction of COMPANY, that a cost effective and technically
successful procedure can be applied.
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Page C-16
Appendix D Requirements for Procurement, Storage and Control of

Welding
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Page D-1
D.1 Basic requirements

Welding consumables shall be purchased from manufacturers operating a quality system
based on ISO 9001 or EN 12074.
Unless specifically agreed otherwise by COMPANY, welding consumables shall be
manufactured to meet test requirements of the relevant ISO/EN consumable standards
(e.g., ISO 18274, ISO 2560, ISO 14171, ISO 18575, ISO 21952, ISO 14343, or ISO 18276),
the ASME SFA 5 series or the AWS A5 series.
Welding consumables shall be certified in accordance with EN 10204, 3.1.
Unless specifically agreed by COMPANY, welding consumables shall be supplied in
accordance with ISO 14344/ASME SFA 5.01/AWS A5.01 lot classification and ISO
14344/ASME SFA 5.01/AWS A5.01 lot certification as follows:
- Welding consumables shall be supplied with lot certification to ASME SFA 5.01/AWS
A5.01 Schedule H or ISO 14344 Schedule 3 as a minimum.
- For critical applications, lot certification shall also include, as a minimum, weld metal
tensile, impact toughness, and soundness (X-ray) test data. Additional project specific
testing may be required by the project specification/engineering design.
- “G” type welding consumables (e.g., SMAW EXXXX-G electrodes, FCAW EXXTGS
wires) shall be supplied with lot certification which includes, as a minimum, weld metal
chemistry, tensile, and impact toughness data.
- SMAW electrodes shall be supplied in accordance with requirements of lot classification
Class C3.
- For critical applications, in which mechanical property batch testing of SMAW
electrodes is specified electrode lot classifications of Class C4 or C5 shall be specified.
- Solid wires shall be supplied in accordance with requirements of lot classification Class
S3.
- Flux cored or metal cored wires shall be supplied in accordance with requirements of
classification Class T2.
- For critical applications, in which mechanical property batch testing of FCAW wires is
specified an electrode lot classification of Class T3 shall be specified.
- SAW flux shall be supplied in accordance with lot classification Class F2.
For carbon and ferritic steel SMAW, FCAW, and SAW welding consumables, certification
shall be available from the manufacturer stating the as deposited weld metal diffusible
hydrogen level determined in accordance with ISO 3690 or AWS A4.3.
SAW fluxes that add alloying elements to the weld deposit shall not be used (i.e., only
neutral submerged arc fluxes shall be employed). SAW fluxes for use with stainless steel
wires may contain small additions of Cr to prevent Cr depletion in the weld deposit.
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Page D-2
Welding consumables proposed for use on any given construction shall be qualified for use
in accordance with the applicable project fabrication specification and requirements of the
relevant design code.
Welding consumables used for fabrication of the following structures shall be traceable to
the relevant manufacturing lot certification:
- Structural steel: Primary structure, including attachments, for both offshore and onshore
construction.
- Pipelines and risers: Girth welds and any attachments to both offshore pipelines/risers
and onshore pipeline systems carrying hydrocarbons or other volatile or toxic
substances.
- Subsea production equipment (manifolds, production trees, jumpers, flow lines, etc.).
- Pipework and pressure vessels: Process pipework and pressure vessels categorised as
criticality CR1 and CR2.
- Storage facilities: Tankage used for storage or holding of hydrocarbons or other volatile
or toxic substances.
- Other components as dictated by regulatory authorities, construction codes, or project
specifications.
The number of different welding consumables to be used on a particular fabrication or in a
specific fabrication area shall be minimised. Additionally, consumables should be used on a
lot by lot basis, a new lot only being used after supply from the initial lot has been
exhausted.
Segregation of materials during fabrication.
- Different materials (including parent metal components or materials, as well as welding
consumables) shall be segregated during fabrication.
- Thus, specific areas should be established for the fabrication of carbon steels, low alloy
steels, stainless steels or nickel alloys.
- In certain instances, it may be necessary to further segregate specific grades of
material (e.g., normal grades and low temperature grades of carbon steel and austenitic
and duplex grades of stainless steels).
If the construction specification requires positive material identification to be used during
fabrication, deposited weld metals shall be included in the sampling routine agreed with
COMPANY.
Measuring devices and instruments required for implementation of the consumable storage
and control procedure shall be included in the list of equipment requiring regular calibration
under CONTRACTOR quality assurance procedures.
Where specified by COMPANY, batch testing of welding consumables shall be performed
in accordance with the requirements of the relevant EN/ISO or AWS specification for the
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Page D-3
consumable / parent material type.
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Page D-4
D.2 Procedure Checklist

A CONTRACTOR consumable control procedure shall be established to suit the specific
operations. However, consumable control procedures should as a minimum comply with the
checklist detailed below. This checklist covers the principal points that would be expected to
be found in a storage and control procedure acceptable to COMPANY and will form the
basis of any audit undertaken by COMPANY.
A flowchart for a typical consumable control procedure is shown in Figure D.1.
Welding consumables shall be supplied in clearly marked packaging. Each SMAW
electrode, straight wire length, consumable spool, or bag of submerged arc flux shall be
supplied individually marked and identified by the manufacturer.
Exceptionally and if specifically agreed by COMPANY responsible engineer, spooled solid
wire consumables may be cut into individual lengths for use with GTAW welding. In such
cases, the individual lengths of wire shall be clearly identified.
On receipt, welding consumables shall be held in a weather protected quarantine area until:
- Compliance with the purchase order has been verified.
- Full certification details (including supplier, manufacturer, brand name, lot number,
- quantity received, and delivery date) have been recorded.
- Certificates have been checked and filed.
Consumable deliveries shall be specifically examined for packaging damage. Any damage
that has resulted in the perforation of vacuum or hermetically sealed packaging or has
resulted in perforation or other damage to flux sacks shall be cause for rejection.
Storage.
- Following receipt and inspection, consumables should be promptly transferred to the
storage area.
- Storage area shall be dry and heated in accordance with manufacturer
recommendations.
- Typically, the storage area should be humidity controlled (not exceeding 60% RH and a
minimum temperature of 20°C (68°F) should be maintained.
- The temperature within the welding consumable store should not be lower than the
ambient temperature of the fabrication shop/site.
- Humidity and temperature shall be recorded regularly at a minimum frequency of twice
per day.
- CONTRACTOR shall adopt an appropriate stock rotation scheme.
Consumables shall be transferred to the workshop or other secondary storage areas only
as they are required for use as follows:
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Page D-5
- This transfer shall take place at the request of the CONTACTOR welding supervisory
staff, and full details of each transfer shall be recorded in both of the storage areas
concerned.
- For vacuum or hermetically sealed packaging, the packaging shall again be inspected
for damage on receipt at the workshop or secondary storage. Damaged seals shall be
cause for rejection, and the consumables shall be returned to the quarantine area.
- The temperature and humidity of secondary storage areas shall be monitored and
controlled.
If hydrogen controlled SMAW electrodes are to be used for fabrication, preference should
be given to use of vacuum packed consumables.
If vacuum packed hydrogen controlled SMAW consumables are used, the CONTRACTOR
welding engineer shall issue a procedure concerning storage and handling of the
consumables and the maximum time the consumables may be exposed to the atmosphere
once the vacuum seal is broken as follows:
- This procedure shall be based on manufacturer recommendations and shall require the
time of opening each packet to be recorded.
- Any consumables either exceeding the agreed exposure time or remaining at the end of
the work period shall be removed from the COMPANY work site, unless a specific re-
drying cycle has been agreed by the COMPANY.
If hydrogen controlled SMAW consumables requiring drying prior to use are used, the
CONTRACTOR welding engineer shall issue drying instructions based on manufacturer
recommendations. Electrodes shall not be redried, unless a specific redrying cycle has
been agreed by the COMPANY responsible engineer as follows:
- Drying and elevated temperature storage (holding) shall be performed in purpose built,
thermostatically controlled ovens located within the secondary storage area.
- These ovens shall be vented and have a temperature indicator and temperature
recorder.
- Ovens shall not be overloaded, and individual shelves shall contain no more than four
layers of electrodes. If oven shelves are loaded with electrodes more than two layers
deep, the control thermocouple shall be placed between the layers.
- Each type and size of consumable shall be clearly marked and segregated within the
drying and storage (holding) ovens.
- Contents of each oven shall be clearly marked on the outside of the door.
- Procedures for SMAW electrode baking and issue shall include the requirement to
record the time and temperature spent in the baking and holding ovens.
- SMAW electrodes should not be subject to more than two baking and holding cycles.
- The maximum time SMAW electrodes spend in the holding oven should not exceed 7
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Page D-6
days.
- If electrical power outages to the baking/holding oven exceed 2 hr, the electrodes shall
either be:
a) Scrapped, if this was the second baking cycle, or
b) Rebaked if it was the first baking cycle.
The CONTRACTOR welding engineer shall issue procedures for the control and use of
SAW fluxes, based on manufacturer recommendations, as follows:
- SAW flux shall only be recycled in accordance with manufacturer recommendations and
with the specific agreement of the COMPANY.
- The procedure shall clearly state the measures required to prevent deterioration of any
SAW flux held in welding machine hoppers when the welding equipment is not in use
(e.g., overnight and during weekends or longer term shutdowns).
- Crushed slag shall not be used as welding flux.
- Any flux recycling procedure shall include measures to remove fines from the flux and
maintain the grain size distribution of the flux.
- The procedure shall clearly state the measures and controls (storage ovens, flux
baking, heated hoppers, etc.) undertaken to minimise moisture pick up by the flux
during storage and use.
- SAW flux shall not be held in holding ovens for more than 7 days.
- If electrical power outages to the flux holding oven exceed 4 hr the flux shall be
scrapped.
A recording system shall be in place which records the welding consumables issued to
welders based on production of a requisition endorsed by the CONTRACTOR welding
supervisory staff on at least a daily basis. The recording system shall list full details of the
job, including application and joint number (if appropriate), consumable type, and quantity
required for the work period (i.e., one shift maximum), as follows:
- Non hydrogen controlled SMAW electrodes shall be issued in manufacturer packaging
or in a dry and appropriately labelled quiver.
- Vacuum packed SMAW hydrogen controlled electrodes shall be issued in manufacturer
packaging or in a dry and appropriately labelled quiver.
- CONTRACTOR dried SMAW hydrogen controlled electrodes shall be issued in quivers
heated to and subsequently maintained at 70°C to 100°C (158°F to 212°F). The quiver
shall be appropriately labelled.
- GTAW welding wire should be issued in either the manufacturer container or in an
appropriately labelled tubular plastic container.
- Spooled wire for GMAW, FCAW, SAW, or other semiautomatic or mechanised welding
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Page D-7
processes shall be issued in the manufacturer’s original packaging.

Consumables for one welding procedure shall only be issued to a welder or welding
operator at any given time, and a record of consumables issued shall be maintained at the
point of issue.
SMAW and manual GTAW consumables remaining at the end of a work period shall be
returned to the store and treated as follows:
- Returns shall be recorded and shelved.
- SMAW electrodes shall be placed in holding ovens or, if necessary, re-dried in
accordance with manufacturer recommendations prior to reissue. SMAW them from
new electrodes.
- Hydrogen controlled SMAW electrodes shall not be re-dried, unless a specific redrying
cycle has been agreed by the COMPANY. Hydrogen controlled SMAW electrodes shall
only be subjected to one re-drying cycle.
- Returned SMAW electrodes that have previously been subjected to two baking/drying
cycles shall be scrapped.
Spooled welding consumables shall be returned to the store upon completion of the job for
which they were issued. Unless directed otherwise by manufacturer recommendations,
consumables shall also be returned to the store if the welding equipment will stand idle for
more than 12 hr.
Any unidentified, contaminated, or otherwise damaged consumables, including those
suspected of being damp, that are found in any storage or fabrication area shall be
immediately destroyed under control of the CONTRACTOR welding supervisory staff.
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Page D-8
Receipt of Transfer Transfer Primary Transfer

Quarantine Secondary Storage
Materials Storage
Consumable
Verification of Release transfer
certification requests Drying Holding
Temperature
and humidity
records
Issue Return
Welding
Supervisory
Staff
Consumable Consumables
requisition
Consumable Welder
requisition
Local Storage,
e.g., Vac-pack
or quiver
Release
Quality Fabrication
Control Verification of
correct consumable
usage (certification Damaged or
or PMI) (Ref 03) unidentified
Paperwork route
consumable
s
Consumable
route
Remove from
Shop floor
Worksite
record
Self-contained controlled
storage, drying and issuing area
Figure D.1 Example Flowchart for Typical Consumable Control Procedure
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Page D-9

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Provision of FEED for PLD

Development Project, Block

SPECIFICATION FOR WELDING AND NDT OF

1.0 Introduction ....................................................................................................................... 9

2.0 Codes and Standards, regulations and Project Documents ........................................ 14

3.0 HSE and Quality Assurance / Quality Control ............................................................... 19

4.0 Specifications (API 1104:2016 Section 4) ...................................................................... 20

8384-2602-SQ-0720 | Rev B1 | June 2017

5.4 Essential Variables (API 1104:2016 Section 5.4) ................................................................... 29

6.0 Qualification of Welders (API 1104:2016 Section 6) ...................................................... 44

7.0 Design and Preparation of a Joint for Production Welding (7)..................................... 47

8384-2602-SQ-0720 | Rev B1 | June 2017

7.4.2 Field Bevel (API 1104:2016 Section 7.4.2) ........................................................................ 48

9.0 Acceptance Standards for NDT (API 1104:2016 Section 9) .......................................... 57

8384-2602-SQ-0720 | Rev B1 | June 2017

9.3 Ultrasonic Testing (API 1104:2016 Section 9.6) ..................................................................... 59

11.0 Procedures for Non-Destructive testing (NDT (11)........................................................ 64

8384-2602-SQ-0720 | Rev B1 | June 2017

12.5.1 General (API 1104:2016 Section 12.5.1) ........................................................................... 69

Appendix A CTOD Testing ..................................................................................................... A-1

Appendix C Requirements for AUT ....................................................................................... C-1

8384-2602-SQ-0720 | Rev B1 | June 2017

8384-2602-SQ-0720 | Rev B1 | June 2017

8384-2602-SQ-0720 | Rev B1 | June 2017

Figure 1.1 Phong Lan Dai Development

1.2 Scope and Purpose of this Document

This Specification details the minimum requirements welding processes, consumable

8384-2602-SQ-0720 | Rev B1 | June 2017

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASNT American Society of Non-destructive Testing

ASTM American Society for Testing and Materials

AUT Automated Ultrasonic Testing

AWS American Welding Society

CSWIP Certification Scheme for Welding and Inspection Personnel

CTOD Crack Tip Opening Displacement

CVN Charpy V-Notch

ECA Engineering Critical Assessment

EWE European Welding Engineer

FBW Flash Butt Welding

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding

HAZ Heat Affected Zone

8384-2602-SQ-0720 | Rev B1 | June 2017

HV10 Hardness Vickers with a 10 kg load

H2S Hydrogen Sulphide

IQI Image Quality Indicator

ISO International Standards Organisation

ITP Inspection and Test Plan

IWE International Welding Engineer

MPT Magnetic Particle Testing

MUT Manual Ultrasonic Testing

NDT Non Destructive Testing

pWPS Preliminary Weld Procedure Specification

RMS Root Mean Square

RTR Real-Time Radiography

SAW Submerged Arc Welding

SI International System of Units

SMAW Shielded Metal Arc Welding

SMTS Specified Minimum Tensile Strength

SMYS Specified Minimum Yield Strength

SWSI Single Wall Single Image

WPQR Welding Procedure Qualification Record

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