4749-440-666-004 Rev.0 (Welding & NDT Specification) (Sealine)

SPECIFICATION PAGE 2 OF 35
PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

REV REVISION D
DESCRIPTION
0 Issuued for Approoval

10000-Z-000-GE1-TMP-0002 (09/14)

PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

CONTEN
NTS
PAGE
E
1.0 SC
COPE 4
2.0 RE
EFERENC
CE DOCUM
MENTS 4
3.0 OR
RDER OF PRECEDE
ENCE 5
4.0 DE
EFINITION
NS 5
5.0 AB
BBREVIAT
TIONS 6
6.0 GE
ENERAL REQUIRE
R MENTS 6
7.0 W
WELDING MATERIA
M AL AND EQ
QUIPMEN
NT 7
8.0 W
WELDING PROCEDU
P URE QUAL
LIFICATIO
ON 8
9.0 QU
UALIFICA
ATION TESTS FOR WELDING
W G PROCED
DURE 11
10.0 DE
ESIGN OF
F JOINTS FOR
F PROD
DUCTION WELDING
G 14
11.0 IN
NSPECTIO ESTING OF PRODUC
ON AND TE CTION WELDS 19
12.0 AU
UTOMATIIC ULTRA
ASONIC TE
ESTING 25
13.0 RE
EPAIR AN
ND REMOV
VAL OF DE
EFECTS 27
14.0 W
WELD ACC
CEPTANCE
E 29
15.0 QU
UALIFICA
ATION OF
F WELDER
RS AND WELDING OPERATO
O ORS 31

RES
FIGUR
FIGURE 1. ISO TENSILE

T T
TEST SPEC
CIMEN 34
10000-Z-000-GE1-TMP-0002 (09/14)
FIGURE 2. ALL-W

WELD ME
ETAL TEN
NSILE TES
ST SPECIM
MEN 35

PETROBE
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WEELDING AND
A NDT
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1.0 SC
COPE
Thhis specificaation coverss the techniccal guidelinnes for the execution,

e q
qualification
n, inspectionn and
reppair for thee girth fieldd welding and
a Non-Destructive Testing T of Subsea Pippelines, withh due
considerations to the requuirements ofo DNV-OS-F101.
2.0 RE
EFERENC
CE DOCUM
MENTS
ow form an integral parrt of this Specification.

Thhe referencee documentss listed belo
2.1 LA
AWS & RE
EGULATIO
ONS.
Ammendments Sets out employmennt practicees and haas elements related to

“E
Egyptian Laww No. 9, Occupationnal Health aand Safety, including workplace
w e
environmenntal
20009” issues.
Eggyptian Law
w No.4, Law of the Environmeent and its Executive
E Regulations
R 338/1995 and
a
19994 amended byy decree Noo. 1741/20005, and decree No. 10955/2011
2.2 CO
ODES, STA
ANDARDS
S, RECOM
MMENDED PRACTIC
CES & GUIIDELINES
S
AS
STM E14177 Standard Practice for L Liquid Peneetrant Testinng
AS
STM E18155 Standard Test
T Methhod for Cllassification n of Film Systems for
Industrial Radiography
R y
AS
STM E3 Preparationn of Metalloographic Sppecimens
AS
STM E317 Standard Practice
P foor Evaluating Perform mance Chaaracteristics of
Ultrasonic Pulse-Echoo Testing Innstruments and System ms without the
Use of Elecctronic Meaasurement Innstruments
ASSTM E709 Standard Guide
G for Magnetic Partticle Testingg
BS
S 4105 Specificatioon for Liquuid Carbon Dioxide
D - Inndustrial
DIIN 54109 Image Quaalities of X--Ray and Gamma
G Rayy Radiograpphs on Metaallic
Materials
DN
NV-RP-F1118 Pipe Girthh Weld AU UT System Qualification and Prroject Speccific
Procedure Validation
V
DNNV-OS-F1001 Submarine Pipeline Syystems Offsshore Standard
ISO 11699-1 Non-Destru uctive Testting - Induustrial Radiiographic Film F - Partt 1:
Classificatiion of Film Systems foor Industrial Radiographhy
ISO 17636 Non-Destru uctive Tessting of Welds
W - Radiographi
R ic Testing of
Fusion-wellded Joints
ISO 17637 Non-Destru uctive Testiing of Weld
ds - Visual Testing
T of Fusion
F Wellded
10000-Z-000-GE1-TMP-0002 (09/14)
Joints
ISO 17638 Non-Destru uctive Testiing of Weld
ds - Magnetiic Particle Testing
T
ISO 17640 Non-Destru uctive Testting of Wellds - Ultrasonic Testiing of Wellded
Joints
ISO 17643 Non-Destru uctive Testiing of Weldds - Eddy Current
C Tessting of Weelds
by Compleex-plane Annalysis.
ISO 19232-1 Non-Destru uctive Testting - Imagge Quality of Radiogrraphs - Partt 1:
Image Quaality Indicaators (Wiree Type) - Determinattion of Im mage
Quality Vaalue
ISO 2566-1 Conversionn of Elongattion Valuess - Carbon anda Low Allloy Steels

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WEELDING AND
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ISO 5580 Non-Destru uctive Testting - Induustrial Raddiographic Illuminatorrs -

Minimum Requiremen
R nts
ISO 5817 Welding - Fusion Welded Joints In Steel, Nickel,
N Titannium and Thheir
Alloys (Beam Weldingg Excluded) - Quality Levels
L For Imperfectioons
ISO 6507-1 Metallic materials
m - Vickers
V Haardness Tesst - Part 1:: Test Methhod
Vickers Haardness Testt for Steel
ISO 6892 Metallic Materials
M -Teensile Testinng
SN
NT-TC-1A Recommennded Practtice for NDT N Persoonnel Quaalification and
Certificatioon
2.3 OT
THER DOCUMENTS
S
ISO 4063-111
1 Process forr Manual Metal Arc Weelding
ISO 4063-12 Process forr Submergedd Arc Weld ding
ISO 4063-1311 Process forr Metal Inertt Gas Welding
ISO 4063-1355 Process forr Metal Actiive Gas Welding
ISO 4063-1366 Process forr Tubular Cored Mettal Arc Weelding withh Active Gas G
Shield
ISO 4063-137
7 Process forr Flux-Corred Wire Metal-Arc
M W
Welding wiith Inert Gas
G
Shield
ISO 4063-1411 Process forr Tungsten Inert
I Gas Arrc Welding
ISO 4063-15 Process forr Plasma Arc Welding
Unnless otherw
wise stipullated, the applicable
a v
version of these docu uments, inccluding rellevant
appendices annd supplem
ments, is thee latest reviision published at the EFFECTIV VE DATE of o the
ONTRACT.
CO
Coodes & Stan

ndards equivvalent to those referencced herein shall
s not bee substitutedd without written
w
approval from
m the Custoomer.
3.0 OR
RDER OF PRECEDE
ENCE
In the event of
o conflicts among
a the referenced
r d
documents above, the order
o of preecedence shhall be
as follows:
a) The Laws and Regulaations.

b) The referennced Codess & Standardds.
W
Where this sppecification states no overriding
o r
requirement
ts, the referenced Codees and Stanndards
10000-Z-000-GE1-TMP-0002 (09/14)
shall apply in full.
Anny conflictss between thhis specificaation and otther applicabble Specificcation, Codees and Stanndards
or local appliccable laws shall
s be brought to the attention off the Custom mer for resolution.
4.0 DE
EFINITION
NS
CO
ONTRACTOR The Organnization whhich carries out the works deffined in th
his
specificatio
on and in thee related coontractual aggreement.

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CU
USTOMER
R The Organiization or peerson that reeceives a prroduct.
CU
USTOMERR The Organiization or Person
P dulyy appointed by the CUUSTOMER or
RE
EPRESENT
TATIVE COMPANY Y to act ass its represeentative(s) to
t supervise and contrrol
the job.
IN
NSPECTION
N The Confformity evvaluation by obserrvation annd judgmeent
accompanieed as approppriate by measurement
m t, testing or gauging.
IN
NSPECTOR
R The CUST TOMER or COMPANY Y representtative(s), (aas applicable),
or memberr(s) from ana Inspectioon Agency duly appoointed by the t
CUSTOME ER or COM MPANY to act as its representattive(s) for thet
purpose of the contractt.
MA
ANUFACT
TURER The party selected by b the CU USTOMER or the SU UPPLIER (as
(
applicable) as the Mannufacturer of the said materials.
m
5.0 AB
BBREVIAT
TIONS
ASSTM American Society

S for Testing
T andd Materials
AUUT Automated Ultrasonic Testing
AWWS American Welding
W Society
BSS British Stan
ndard
DIIN Deutsches Institut
I fur Normung
N
DNNV Det Norskee Veritas
DPPI Dye Penetrrant Inspectiion
FC
CAW Flux Coredd Arc Weldiing
GMMAW Gas Metal Arc
A Weldinng
GTTAW Gas Tungstten Arc Welding
HAAZ Heat Affectted Zone
ISO Internationaal Organizaation for Staandardizatioon
MP PI Magnetic Particle
P Insppection
NDDT Non-Destruuctive Testinng
SA
AW Submergedd Arc Weldiing
SM
MAW Shielded Metal
M Arc Welding
W
UTT Ultrasonic Testing
T
6.0 GENERA
AL REQUIREMENTS
S
Thhe Specificaation coverss all field welding

w on Submarine
S Pipelines foor all appliccable API and/or
a
DNNV Steel Grades, incluuding, but no ot limited too, pipe-to-pipe, pipe-too-bend, and pipe-to-fittiing.
10000-Z-000-GE1-TMP-0002 (09/14)
Thhe following
g Field Wellding Technniques (or thheir combinaations) are to
t be used:
‐ Shielded Metal
M Arc Welding,
W SM
MAW (Proceess ISO 406 63-111)
‐ Flux Coredd Arc Weldding with acttive gas shield, G-FCA AW (Process ISO 4063-136)
‐ Flux Coredd Arc Weldding with ineert gas shielld, G-FCAWW (Process ISO 4063-1137)
‐ Gas Metal Arc Weldinng with inerrt gas shieldd, GMAW (Process
( ISOO 4063-1311)
‐ Gas Metal Arc Weldinng with actiive gas shieeld, GMAW W (Process IS SO 4063-1335)
‐ Tungsten Inert
I Gas Arrc Welding,, GTAW (P Process ISO 4063-141)

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WEELDING AND
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‐ Submergedd Arc Weldding, SAW (Process

( ISO
O 4063-12)
‐ Plasma arcc welding, PAW
P (Proceess ISO 40663-15) may be used forr specific appplications.
It should be noted
n that where
w Flux Cored
C Arc W Welding and d/or automaatic weldingg process is used,
am manual wellding proceddure shall be
b qualifiedd as back-upp; and this requirement
r t may be waived
w
forr automatic welding onnly when Coontractor caan give eviddence of succcessful pastt experiencee.
Anny other tecchnique, equuipment andd procedurees proposed by the Conntractor shalll be field prroven
in the industryy and shall be
b submitteed to the Cuustomer for Review andd Approval.
Coontractor is bound to allow

a Custo
omer free acccess for inspection duuring weldinng, as far as it is
reaasonably poossible.
Thhe Customeer right to supervise

s thhe work caarried out byb the Con ntractor willl not, under any
cirrcumstancess, substitutee Contractorr inspectionn for his uniq
que responssibility for the
t quality of
o the
woork.
7.0 WELDIN
NG MATER
RIAL AND
D EQUIPM
MENT
7.1 W
WELDING
G CONSUM
MABLES
Alll welding consumable

c es shall connform to thhe requirem ments of DNNV-OS-F1001 (Appenddix C,
C1100 to C6000), and shalll be specifieed in the Coontractor Welding
W Proccedure Speccification (W
WPS),
inccluding the Manufacturrer’s name and brand.
W
Welding conssumables shhall be purcchased from m Manufactu urers who are
a currentlly acknowleedged
byy bodies whhich indepenndently andd annually test consum
mables, andd shall be seelected baseed on
theeir mechannical properrties, comppatibility with
w adjoiniing materiaal, and suiitability fo
or the
inttended servvice, so as to producee welds witth yield strrength at leeast equal to
t the miniimum
specified for the
t parent m material.
W
Welding conssumables ussed during production shall be frrom the sam
me manufaccturer, brandd and
AW
WS type as those used and approvved during welding
w procedure quallifications.
Coontractor sh
hall maintainn a traceability system
m, whereby the batch numbers/lot
n t numbers of
o the
weelding consuumables aree related to weld joint numbers,
n whhich they arre used.
Coontractor shhall submit the

t certificaates for eacch batch or container showing
s thee mechanicaal test
ressults and chhemical anallysis for Cu
ustomer Appproval.
10000-Z-000-GE1-TMP-0002 (09/14)
Cuustomer maay, at its diiscretion, teest the mecchanical and

d chemical characterisstics of the weld
meetals in accoordance witth the recognized standdards.
Thhe storage and

a handlingg of the wellding consuumables andd fluxes shaall be in accordance witth the
maanufacturer instructions.
Thhe coated electrodes annd SAW fluxx shall be sttored in the original containers tilll issued for use.
If low-Hydro ogen electroodes are seelected, the diffusible Hydrogen content shaall not exceeed 5
mll/100 g in thhe resulting deposited weld
w metal.

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WEELDING AND
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If Cellulose covered electrodes are selectted, then the t requireements of DNV-OS--F101

reqquirements (Appendix C, E108) shhall strictly apply.
Onnce an origiinal containner is openedd, the consuumable shalll be kept free from conntamination
n till it
is used up or its
i exposuree life is reacched.
Thhe maximuum exposurre time an nd maintennance of covered

c ellectrodes shall be ass per
Manufacturerr instructionns. Reconditioning of moisture
m coontaminatedd coated eleectrodes or SAW
fluux shall not be permitteed.
7.2 S
SHIELDIN
NG GASES
Alll gases and gas mixtures to be useed shall havve certificatees accepted by Custom
mer.
t gas quaality (purity, dryness, dew

Coontractor shhall be respoonsible for the d point. etc.)
e used fo
or the
quualified weldding proceddure.
Thhe purity annd dryness of

o the shieldding gases sshall be of values
v suitaable for the welding prrocess
annd the base material.
m
If Argon or Carbon Diooxide gasess are used,, the maxim

mum level of impuritiies shall at least
correspond too the requireements of BS
B 4105 (Tyype 1).
Thhe moisture content of any gas or gas

g mixturee shall correespond to a dew point of
o minus 300°C or
low
wer, and shall be defined in the relevant certifficates.
7.3 W
WELDING
G EQUIPM
MENT
Alll Welding Equipmentt, Line-Up Clamps, Beveling

B M
Machines, Cutting
C Torrches, and other
eqquipment, to
ools, and suppplies used
d in the weldding activitiies shall be always maaintained in good
woorking condditions.
Suufficient meeters shall bbe providedd to calibraate machinees, regulate voltage annd amperag
ges as
neecessary.
Thhe welding equipment

e u
used in prodduction wellding shall be
b the samee type and m
model of weelding
eqquipment defined in thee approved Welding
W Proocedure Qu ualifications.
8.0 WELDIN
NG PROCE
EDURE QU
UALIFICA
ATION
10000-Z-000-GE1-TMP-0002 (09/14)
Prior to startt of producction, Conttractor shall submit, for

f Custom mer review and approvval, a
deetailed Weldding Proceddure Qualiffication for each pipe grade, sizee, and wall thickness. Each
weelding proceedure shall consist of a Welding Procedure Specificatio on “WPS” and a Procedure
Quualification Record “PQQR”.
A new Weldin ng Proceduure shall neeed to be re-qqualified whhen any of the

t essentiaal variables listed
heerein after haave been chhanged.

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Coontractor Welders/Ope
W erators, as well
w as thee personnel performing g the destrructive and non-
deestructive teests shall haave to be prre-qualifiedd by the Cu
ustomer prio
or to the coommencemeent of
thee work.
Thhe requirem
ments for addopting the previously Qualified Welding
W Prrocedures shhall be baseed on
DNNV-OS-F10 01 (Appenddix C, D200).
8.1 W
WELDING
G PROCED
DURE SPEC
CIFICATIION (WPS))
In addition to
o the requireements set in DNV-OS S-F101 (App pendix C, D500
D & D7000), the Weelding
Procedure Specification shall cover the followinng:
‐ Welding eqquipment annd its relevaant descripttion.
‐ Process (ty ype, along with
w details of special machines).
m
‐ Consumab bles manufaccturer, tradee name, type and lot nuumber.
‐ Pipe material (steel grade, walll thickness, diameter, supplier, manufactur m ing processs and
specificatioon).
‐ Filler metaal and numbber of beadss (dimensionns, number//sequence of passes, typpe, classificcation
of electrodde/wire and relevant Maanufacturerr).
‐ Weld preparation and fit-up tolerrances.
‐ Electrode stick-out
s lenngth.
‐ Time betw ween end of root bead and start of hot h pass (second pass).
‐ Interpass teemperature (minimum and maxim mum).
‐ Electrical characterist
c ics (currentt, type of cuurrent and poolarity, volttage, heat innput, ..etc).
‐ Direction ofo welding (uphill/dow
( wnhill or mixxed).
‐ Type and removal
r off Line-Up Clamp
C (interrnal or exteernal, minim
mum percenntage of rooot and
hot pass welding
w or minimum
m nu
umber of passses before clamp remooval).
‐ Shielding flux
f (type, grain
g size, manufacture
m er).
‐ Travel speed (rate andd variation ranger for eaach pass).
‐ Pass widthh.
‐ Minimum number of ppasses to bee completedd before disccontinuing the t weld.
‐ Minimum number of w welders req quired for eaach pass.
‐ Minimum number of rruns before joint is alloowed to coool-down.
‐ Oscillationn width and frequency (for ( automaatic weldingg).
‐ Preheat tem mperature and
a method, taking intoo consideration the folloowing:
 Accepptable methhods shall bee Electric innduction, Ellectric resisttance, Oxy--fuel gas.
10000-Z-000-GE1-TMP-0002 (09/14)
 Use of o oxyacetyllene gas forr preheating is not perm mitted.

 Full encirclemen
e nt rings are preferred
p when oxy-fueel gas is useed for preheeating.
 In casse hand-helld torches are a approveed by Custoomer, a min nimum of tw wo oxy-fueel gas
torchees shall be used
u on pipee diameters greater thaan 6-inch.
 Oxyg gen cutting torches
t are not
n permitteed.
 All tiie-in weldss, fillet wellds, pipe too hot bend ds, and fittting-to-pipe welds shaall be
preheeated to 50°C minimum m above thaat required for f similar pipe-to-pipe
p e butt weldss, and
the in
nterpass tem mperature sh hall not exceeed 250°C.

PETROBE
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WEELDING AND
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Moreover, a Separate Welding Procedures shall be submitted to the Customer C and

a a
Quualification shall be perrformed forr the followiing:
‐ Main pipelline weldingg.
‐ Welding of short pre-ffabricated assemblies
a (
(spools).
p pieces, anchor flannges, isolatioon joint, etcc) and
‐ Welding of fittings (suuch as bendds, valves, pup
Weldolets..
‐ Repair wellding.
‐ Fillet weldds.
‐ Cap, partiaal penetratioon and full penetration
p repairs.
Pippes supplied
d from diffeerent Suppliiers shall reequire Separrate Proceduure Qualificcation.
Thhe number and positiion of welld beads shhall be deffined to giive the com
mpleted weld a
subbstantially uniform
u crooss-section.
In case that Post-Weld

P H
Heat Treatm
ment is requuired, it shaall be qualified duringg weld procedure
quualification, and a separrate dedicated procedurre shall be submitted
s foor Customerr approval.
Thhe Acceptabble methodds for Postt-Weld Heat Treatmeent shall be electricall resistancee and
eleectrical indu
uction.
8.2 P
PROCEDU
URE QUAL
LIFICATIO
ON RECOR
RD (PQR)
Evvery detail of the quualification tests shalll be witnessed and accepted

a byy the Custtomer
Reepresentativve.
Alll Welding Procedurees revised in accorddance with the actuaal performaance duringg the
quualification tests,
t and thhe qualificaation test daata, shall bee recorded inn a Proceduure Qualificcation
Reecord “PQR R” issued byy the Contraactor.
Thhe Final Reeports shall contain, inn addition to t the PQR

R, the compplete docum
mentation of
o test
conditions andd the resultss of the quaalification teests.
Coontractor shhall keep all

a original Test Repoorts and coopies of th
hese Test Reports
R shaall be
subbmitted to Customer
C foor Review and
a Approval.
Alll Test Couppons and Sppecimens ussed to qualify a proced

dure shall bee labeled, paacked in wo
ooden
booxes and subbmitted to Customer
C fo
or acceptancce of the useed procedurre.
10000-Z-000-GE1-TMP-0002 (09/14)
8.3 E
ESSENTIA
AL VARIAB
BLES
Thhe Welding Proceduress remains qualified

q as long as thee essential variables
v givven hereafteer are
keept within thhe limits sett by DNV-O
OS-F101 (A
Appendix C, Table C-2)):
‐ Welding Process.
P
‐ Welding Equipment.
E
‐ Pipe Base Material.
‐ Pipe Thickkness and Diameter.
D
‐ Filler metaal or diameter of electroode.

PETROBE
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WEELDING AND
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2 SUBSEEA PIPELIN
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‐ Consumab ble manufactturer and/orr trade namee, or AWS classificatioon to anotheer.

‐ Travel Speeed.
‐ Groove connfiguration.
‐ Heat Inputt.
‐ Shielding, backing annd Plasma gaases.
‐ Electrical characterist
c ics and pulssing data.
‐ Arc characcteristics.
‐ Number off root pass or
o hot pass welders.
w
‐ Direction of
o welding.
‐ Preheatingg and Interpaass Temperrature.
‐ Post weld heat
h Treatm ment.
In case of Semmi-Automattic or Autommatic Weldiing, the folllowing addiitional requiirements shhall be

considered as per DNV-O OS-F101 (A
Appendix C, D812):
‐ Any changge of control software.
‐ Any changge of pre-sett parameterss for autom
matic welding g.
‐ Any chang ge in prograammed paraameters andd their variaation, exceptt that necesssary variatiion in
oscillation width for welding off thinner/heaavier wall than
t used during
d qualiification shaall be
allowed foor mechanizeed GMAW and GTAW W.
‐ Any changge in limits for
f parametters that cann be adjustedd by the weelder.
9.0 QU
UALIFICA
ATION TESTS FOR WELDING
W G PROCED
DURE
9.1 GE
ENERAL
W
When a propposed Weldding Proced dure has beeen approveed by the Customer, Contractor shall
deemonstrate the
t suitabilitty of the prooposed proccedure, by means
m of a procedure
p q
qualification
n test.
Coontractor shhall inform the Custom mer of the date

d and plaace of the procedure
p q
qualification
n tests
wiith sufficien
nt notice to allow
a for Cuustomer atteendance.
Alll qualification test weelds shall bee made on thet intended d linepipe itself,
i and the
t base maaterial
sellected for thhe qualificaation testingg and shall be represeenting the upper
u range of the speccified
chhemical commposition for Carbon Stteels.
Thhe tests musst adequatelly simulate the on-site welding coonditions ussing the sam
me equipmeent as
thoose to be ussed during welding.
w
Thhe pipe nippples used to make-up th

he weld shalll be at leastt [1.5xpipe diameter] inn length.
10000-Z-000-GE1-TMP-0002 (09/14)
Thhe measureement of electric

e paraameters duuring the qualification
q n shall be carried ouut by
acccurately callibrated insttruments.
Thhe NDT opeerators’ equuipment mayy be requireed to demonnstrate to thee Customer the capabillity of
thee proceduree to detect defects,
d as well
w as the ability to properly
p perrform the teests and inteerpret
thee results.

PETROBE
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WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

9.2 VIISUAL INS

SPECTION
N AND NDT
Thhe Visual Exxamination and Non-D Destructive Tests

T shall be performed not earliier than 48-hhours
aftter the comppletion of thhe welding of each testt piece.
Thhe joints shhall be thorroughly cleeaned and bburnished by b means of

o mechaniical brushess and
buuffers and sppatter removved immediiately prior to weld insp
pection.
Alll retests shaall be perforrmed after Customer

C appproval.
Onnce the vissual inspecttion has beeen accepteed, the test weld shalll be subjeccted to ND
DT by
raddiography; in case of AAutomatic or Semi-Auutomatic weelding, the welds shalll be subjectted to
1000% UT, in addition to radiographiic tests to detect
d any laack of side wall
w fusion.
9.3 DE
ESTRUCT
TIVE TEST
TING
9.3.1 GENER
RAL
Haaving satisfa mpleted the visual and Non-Destruuctive inspeection, the test weld shall be
factorily com
subbjected to a mechanicaal test, using
g weld speccimens taken at the loccations definned in DNV
V-OS-
F1101 (Appenddix C, Fig. 2)
2 and from m areas free from defectts as much as
a possible.
Thhe minimum m number oof tests to be b carried outo shall be as per DN NV-OS-F1011 (Appendixx C -
Taable C-3), annd the tests shall be carrried out at laboratories accepted by
b the Custtomer on thee ISO
tesst specimen illustrated in Fig. 1.
Thhe acceptance criteria of

o the bendd testing shaall be accorrding to DN
NV-OS-F1001 (Appenddix C,
F3306).
Thhe acceptannce criteria of the tran nsverse weeld tensile is i generallyy “no fractture in the weld
meetal”, however and subbject to Weelding Conttractor capaabilities withh Companyy approval; weld
could still be accepted prrovided thatt the ultimaate tensile sttrength of thhe joint is proven
p by teesting
to be at least equal
e to thee specified minimum
m teensile strenggth of the baase metal.
Reetests (mechhanical/imppact) requirred for failled specimeens shall follow

f the requiremennts of
DNNV-OS-F10 01 (Appenddix C, F106 to F110) annd shall be so
s that at least two speccimens wouuld be
doone for everyy single failled specimeen.
9.3.2 MACR C INSPECTION

ROSCOPIC
10000-Z-000-GE1-TMP-0002 (09/14)
Thhe macrosco opic inspecttion shall beb prepared by grindin ng and polisshing and etching to cllearly
revveal the welld metal, heeat affected zone and baase material.
Thhe specimenns shall be taken

t at thee locations ggiven in DN
NV-OS-F1001 (Appendiix C, Fig. 2)
2 and
shall be prepaared in accoordance withh ASTM E33.
Thhe macro-seections (at least threee times thee width off the weld)) shall be documenteed by
maacrographs and shall shhow a soundd weld mergging smoothhly into thee base materrial withoutt weld
deefects accorrding to thee visual ex
xamination and NDT acceptance criteria inn DNV-OS--F101
(A
Appendix D)).

PETROBE
EL 7479-440-6666-004
WEELDING AND
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FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

Thhe acceptan
nce criteria for macro-eexaminationn shall be in
i accordan
nce with IS
SO 5817 (qu
uality
levvel C).
Thhe specimenns shall be carefully examined

e u
under the microscope,
m with a magnification of at
leaast 25 timess.
Magnificationn for docum

mented macrrograph shall be minim
mum “5X”.
9.3.3 HARD
DNESS TES
ST
Thhe prepared d macro-secction test shhall be carriied out in accordance

a with ISO 6507-1 (Viickers
haardness) usin ng a laboraatory type machine
m conntrolled andd using a diamond
d pyrramid peneetrator
sett at 2.37 rad
d (136°) witth a load of 10 kg.
Inddentations are
a to be maade along trraverses appproximately
y 1 mm beloow the surfa
face at either side
off the weld.
A minimum of 6 indenttations equaally spacedd along the traverses are

a to be made
m in the weld
meetal.
In the HAZ, indentationns are to bee made alonng the traveerses approximately eaach 0.5 mm
m into
unnaffected maaterial, and starting as close
c as posssible to thee fusion linee.
n exceed the limits defined inn DNV-OS-F101 (Apppendix C F312,

Haardness vallues shall not F
“T
Testing of Butt Weld”).
In case of a single readinng slightly higher

h than the specifieed limit, furrther indenttations shou
uld be
maade to checkk if the highh value was an isolatedd case.
9.3.4 CHARP
PY V NOT
TCH IMPA
ACT TEST
Thhe impact test

t temperrature shalll be the pipeline min
nimum dessign temperrature whenn the
folllowing connditions appply:
‐ The minim mum design temperaturee is -10°C (or ( lower)
‐ The wall thhickness is less than orr equal to 255 mm.
‐ The materiial SMYS iss less than or 5 N/mm2 (80 ksi).
o equal to 555
In all cases, thhe impact teest temperatture shall noot be higherr than minuss 10°C.
Thhe specimenns shall be taken

t at the locations given
g in DN
NV-OS-F101 (Appendiix C, Fig. 2)), and
10000-Z-000-GE1-TMP-0002 (09/14)
wiithdrawn as per DNV-O OS-F101 (A Appendix B,, Fig. 3).
Thhree test speecimens shaall be takenn from eachh sample andd they shalll be cut andd worked soo that
theeir length is transversaal and perppendicular to
t the weldd bead, withh the notchh position as a per
DNNV-OS-F10 01 (Appenddix B, Fig. 10c); the nottch shall be perpendicuular to the roolled surfacce.
Thhe test piecees shall be immersed in

i a thermoostatic bath and maintaained at the test temperrature
forr at least 15
5 minutes, and
a then be placed in thhe testing machine
m and broken witthin 5 seconnds of
theeir removal from the baath.

PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

Thhe impact ennergy with full size sppecimen (100 x 10 mm) shall be as DNV-OS-F
F101 (Sectiion 7,
a the evaaluation of the test results shall be as per DNV-OS-F
Taable 7-5), and F101 (Section 7,
B4400).
9.3.5 ALL-W
WELD MET
TAL TENS
SILE TEST
TING
Thhe dimensioons of the test specim men shall be

b as given 2 with the largest possible
n in Fig. 2,
diaameter so as
a to providee adequate distance beetween the specimen
s gaauge sectionn and the fuusion.
Neevertheless, in case thee specimen dimensions
d set in Fig. 2 are not poossible, redduced dimennsions
shall be agreeed upon withh the Custom
mer Repressentative.
Alll-weld mettal tensile teesting shalll be carriedd out in acccordance wiith the requuirements of
o this
Sppecification and ISO 68892.
Geenerally, thee ultimate tensile

t strenngth and yieeld strengthh shall be eqqual to or higher
h than those
off the base meetal.
Thhe elongatio
on shall be equal to orr higher thaan the minim
mum speciffied elongattion for thee base
maaterial.
Coorrection for differencees in specim

men dimenssions shall eventually
e b made in accordancee with
be
ISO 2566-1.
Shhould any teest specimenn fail to meet the accepptance criterria, two mo ore specimenns from a siimilar
areea of the teest joint shaall be testeed if possible; if not, two
t specim
mens from another
a test joint
weelded with the
t same proocedure as the t first joinnt shall be tested.
If more specimmens fail, thhe particulaar circumstaances shall be

b closely reviewed
r annd discussedd with
Cuustomer beffore makingg any furtherr decision.
10.0 DESIGN OF JOINT

TS FOR PR
RODUCTIO
ON WELD
DING
10.1 G
GENERAL
L
Coontractor sh hall supply all weldinng system, equipment

e and apparaatus requireed for clam
mping,
weelding, cuttting, beveliing…etc, along
a with valid recoords of callibration, too the Custtomer
sattisfaction.
Thhe equipmeent mentionned above shall havve the chaaracteristics necessaryy to satisfyy the
reqquirements indicated in
i the quallified weldiing proceduure specificcation, and shall guarrantee
10000-Z-000-GE1-TMP-0002 (09/14)
continuous opperation andd the safety of personneel.
Thhe Automattic and Sem mi-Automatic Weldingg System shhall be equuipped withh instrumentts for
meeasuring thee current annd arc voltagge during welding.
w
10.2 A
ALIGNME
ENT
Alll joints shaall be aligneed with an internal linee-up clamp, except for tie-ins or uunder excepttional
conditions app proved by Customer,
C f which exxternal line--up clamp may
for m be usedd.

PETROBE
EL 7479-440-6666-004
WEELDING AND
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R 0

Thhe root gap shall be acccurately cheecked and shhall conform

m to the quaalified weldding procedu
ure.
Foor pipes havving the saame outsidee diameter and the sam me nominaal wall thickkness, the offset
o
beetween surfaaces shall noot exceed 1.5 mm. Anyy greater offfset, caused
d by dimenssional variaations,
shall be equallly distributed around the
t circumfeerence of thhe pipe.
Foor pipes havving the sam

me outside diameter
d annd different wall thicknness, the diffference bettween
thee wall thick
knesses shall not exceedd 1.5 mm.
Hoowever, in case the diffference in wall thicknnesses exceeds 1.5 mmm, the Contrractor may carry
ouut the follow
wing subjectt to Customer approvall:
‐ Internally taper the thicker
t pippe end by machining its inside surface to give the abovea
mentioned alignment with a taperr not steepeer than 1 to 4.
4
‐ If feasible and appliccable accordding to the available pipes,
p a trannsition piecce of approp
priate
thickness and
a length shall
s be usedd.
W
When lining-uup longituddinally weld
ded pipe, thee pipe shalll be positionned so that the seam will
w be
beetween the 9 o’clock and
a 3 o’cloock locationns, with a minimum offset o of 200 mm bettween
adj
djacent longiitudinal wellds.
Thhe misalignnment toleraance (the taangent of the

t angle fo ormed by two
t successsive pipes) shall
neever exceed 1/100, whicch correspoonds to an anngle of 0.57
7°.
When external clamp is used, fouur segments of weld shall be executed

W e for the first pass;
seggments shalll be groundd flushed too feather edgge to ensuree continuityy of the welld bead andd shall
alsso be equidiistant from each other and
a long ennough to covver at least 60%
6 of the circumferennce.
Alll equipmen
nt used for aligning
a pipees must nott damage thee pipe ends.
10.3 B
BEVEL
If the Contracctor elects to weld thee pipes usinng a joint design

d differrent from thhe one suppplied,
theen re-beveliing shall be carried outt by adequatte mechaniccal bevelingg devices.
In this case, dimension

d shall be in accordance
a w the appproved weldding proceddure and thee new
with
beevel shall bee examined by MPI or DPI.
D
In case of therrmal cuttingg of a pipe, material shhall be remo

oved by macchining intoo base materrial in
ordder to remove the oxiddized part.
10000-Z-000-GE1-TMP-0002 (09/14)
Affter cut-out of the origiinal pipe ennds, the new

w ends shall be subjecteed to UT exxamination (of ( 50
mmm bandwidtth from edgge) accordin ng to materiial specificaation for dettection of laamination defect.
d
In addition, thhe new beveel shall be examined
e byy MPI or DP PI.
Prior to weldiing, the bevveled surfacces and the adjacent material

m (inteernally and externally) for a
disstance of at least 50 mm
m of each end,
e shall bee free from scale, rust, paint, greaase, moisturre and
othher foreign matter that may adverssely affect the
t weld quaality.

PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

10.4 W
WEATHER
R CONDIT
TIONS
If the weathher conditiions (windd, rain, saand,…etc.) may, in the opinion of Custtomer
Reepresentativve, affect thhe weld quaality, then tthe weldingg operationss may be suspended
s u
unless
appropriate measures
m aree taken and approved byy the Custoomer Repressentative.
Coontractor shhall providde the neceessary windd breaks and

a platform
ms when the
t bad weeather
conditions waarrant their use.
u
10.5 W
WELDING
G
Thhe first passs shall be carried

c out byb a minim mum of twoo welders, working
w sim
multaneously
y, in
ordder to produuce minimuum distortioon of the linne pipe. Oncce the depossit of the firrst pass hass been
staarted, it musst be compleeted as rapiidly as possiible, reducinng interrupttions to the minimum.
Beefore startin
ng the second pass, th
he first passs shall be cleaned
c witth rotating brushes,
b annd the
rem
moval of deposit
d maaterial by grinding
g shhall be lim
mited to casses where it is absollutely
maandatory.
Affter a stop or delay longl enouggh to causee the weld to cool beelow the specified
s prreheat
tem
mperature in n the weldiing betweenn passes, a preheating as specifieed in the weelding procedure
specification shall be carrried out uppon restartinng. Subsequuent passes up
u to weld completionn shall
bee well shieldded in case of
o any adveerse meteoroological con nditions.
Anny grinding
g done to immprove the weld cap coontour shall be under the superviision of an AWS
Ceertified Wellding Inspecctor; repair by
b insert paatching or welding
w is noot allowed.
W
Weld joint fitt-up (high-llow) shall be
b within thhe tolerancees providedd in the quaalified WPS
S, and
shall not, in anny way, excceed 2.4 mm
m at any loccation arounnd the insidee circumference.
Inddividual pippe joints may

m be pree-sorted acccording to their insidde diameterr as neededd and
sellected so that the maxim
mum high-llow is not exceeded.
e
Precautions shhall be takeen during welding

w to ensure
e that no arcing occurs
o betw
ween the weelding
maachine grouund leads annd the pipe or
o fitting at any point.
Alll Arc-burnss on the pippe shall be removed

r byy cutting ouut the pipe pup
p containning the arcc burn
annd replacing with soundd pipe.
Thhe suspected areas on the pipe nextn to the weld shalll be tested for arc buurn using a 20%
10000-Z-000-GE1-TMP-0002 (09/14)
Ammmonium persulfate
p solution; if Ammonium
A m solution reveals
r a daark blackishh spot indiccating
thaat the pipe has
h been arcc burned, thhe section off pipe shall be removed
d as a cylindder.
Thhe arc burn removal

r shaall, as a minnimum, clossely mind th
he followingg:
‐ The arc buurn or arc strrike shall bee contour grround smoooth using a power
p grindder.
‐ The grindiing shall be performed in a manneer that no heath affectedd zone deveelops on thee pipe
or fitting su
urface.

PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
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EGYPT REV.
R 0

‐ The grounnd area shalll first be chhecked by wet

w magnetic particle inspection
i t ensure thhat no
to
surface crracking is present.
p Thhe area shaall then bee examined d with a 20% Ammoonium
persulfate solution.
‐ Appearancce of a blackk stain will indicate thaat additionall grinding iss required.
‐ The grounnd area willl then be checked ussing a calibbrated ultraasonic thickkness meassuring
device to ensure
e that the
t requiredd design thicckness remaains.
Thhe completeed weld shaall be carefuully brushedd and cleaned and shalll appear freee from spaatters,
scaales, …etc.
10.6 P
PRE-HEAT
TING AND
D INTERPA
ASS TEMP
PERATUR
RE
Thhe Weldingg Procedurre Specification shalll specify the t necessaary preheaat and inteerpass
tem
mperature taking
t mateerials and weather
w connditions intoo considerattion. The loocations off such
tem
mperatures measuremeents shall be
b as specified in DN NV-OS-F101 (Appendiix C, G2088 and
G2211).
Thhe necessaryy preheat teemperature shall be seelected baseed on weldding proceddure qualificcation
tessts and prevvious experiience on sim
milar materials.
Preheating shhall not dam mage the piipeline prottective coatiing, and sh
hall be appllied by elecctrical
meethods, gas fired mufffles or otheer methods accepted by b Customeer, so as too heat the entire
e
cirrcumferencee of the joinnt in a unifoorm manner and avoid overheating
o g.
Thhe minimumm preheat teemperature shall be maaintained an nd measuredd over a disstance of att least
500 mm or 5 tiimes wall thhickness wh
hichever is greater
g on each side of the joint.
Thhe maximum a specified in the weldding proceddure specificcation

m interpass temperaturee shall be as
(noormally nott exceedingg 250°C). The
T minimuum interpass temperatuure shall noot fall below w the
specified minimum preheeat temperaature.
Thhe preheat and

a interpass temperatu
ures shall bee closely mo
onitored at all
a times.
Teemperature shall be measured

m b means of
by o contact Pyrometer or Infra-rred methodds, no
inddicating craayons are alllowed.
10.7 T
TACK WE
ELDS
Unnder normall circumstannces, tack welds

w are noot permittedd; however,, it may be allowed in some
exxceptional caases only iff qualified during
d WPQ Q and backeed-up by dettailed proceedures developed
10000-Z-000-GE1-TMP-0002 (09/14)
byy Contractorr for Custommer approvaal.
If permitted, Tack
T welds shall be performed by qualified personnel
p inn accordancee with DNV
V-OS-
F1101 (Appenddix C, B2000).
Taack welds shhall be weldded verticall-up and shaall be minim mum 50 mm m long. Succh welds shall be
carrried out wiith the samee weld procedure speciification and d welder as the root runn. Where prreheat
is required forr the root ruun, it shall be
b applied prior
p to tackk welding annd maintainned until thee joint
is completed.

PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
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2 SUBSEEA PIPELIN
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EGYPT REV.
R 0

Taack welds incorporatedd into the final

f weld shall
s be groound to a feather
f edgee at each end
e to
ennsure adequaate fusion on
o the root pass.
p
Taack welds shhall not be permitted

p w
when a clampp is used.
10.8 B
BACKING
G
Peermanent baacking is noot permittedd, while temmporary baacking is onnly permitteed provided
d it is
specified in a qualified welding
w proccedure speccification.
10.9 IINTERPAS
SS CLEAN
NING/GRIN
NDING OF
F WELDS
Eaach weld paass shall be cleaned byy experienceed helper/wwelder usingg power toools to removve all
weelding slag and
a foreignn matter prioor to weldinng the succeessive pass in
i accordingg to the WP
PS.
W
Where accesssible, all welds to valvees, flanges and
a fittings shall be groound back smooth
s interrnally
priior to proceeeding with radiographyy or ultrasonnic examinaation.
10.10 G
GOLDEN WELDS
W
Goolden Welds (i.e. not-hhydrotested welds) shalll be subjectted to 100%

% radiographhy (using AGFA
A
D44 film, or eqquivalent), 100%
1 UT annd 100% MPI.
M
10.11 P
PARTIALL
LY COMPL
LETED JO
OINTS
Thhe welds shaall not be leeft partially completed overnight.
W
When producction condittions are suuch that pippe joints haave to be leeft partiallyy completedd, the
folllowing shaall apply:
‐ A minimum m of 4 runs shall be completed;
‐ upon discoontinuation of weldingg, the joint shall
s be wrapped in drry, insulatinng, heat resisting
material with
w a waterpproof backin ng, and shalll be alloweed to cool-down slowlyy and uniforrmly;
Prior to weld
ding restartinng, the joinnt shall be examined
e u
using magneetic particlee inspectionn, and
preeheated witthin the speccified interppass temperature range.
10.12 W
WELD MA
ARKING
t welders according to
Alll welds shaall be markeed with painnt stick by the t their assiigned numbbers at
thee time of th
heir qualificaations. Shouuld any wellder leave thhe job, his number shaall be voided and
10000-Z-000-GE1-TMP-0002 (09/14)
noot duplicatedd on the prooject. No puunch or steell stamping shall

s be perrmitted.
Prior to radiography of thhe circumfeerential weldd, Contractoor shall painnt the weld location nuumber
onn the coverinng of the pipe adjacentt to the weldd at a point where it shhall remain visible
v afterr field
coating. These numbers shall be useed for locatting and reccording the weld. The numbers
n shall be
applied with a spray cann or a brush h and water--proof paint of a contrrasting color to pipe ouutside
coating.

PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

10.13 D
DE-MAGN
NETISM
Coontractor shhall providde onsite de-magnetizi

d ing system
m for use when
w the pipe
p ends show
maagnetism noot suitable for
f welding.
10.14 E
END PROT
TECTION
Thhe open end

d of pipe striings shall bee securely closed
c at thee end of eacch day (or shhift) by adeequate
deesigned coveers, placed over
o the pip
pe ends to prevent ingreess of waterr, dirt, and small
s objectts.
Thhese covers shall not bee removed until

u the woork is to be resumed.
r
Metal covers shall not bee tack-weldeed to the pippe.
10.15 R
REMOVAL
L OF LINE
E-UP CLAM
MPS
Intternal line-u
up clamps may
m be remo oved only after
a the rooot pass is 1000% compleeted and whhen no
subbsequent piipe movemeents are foreeseen.
Exxternal line--up clamps can

c be remooved when the root passs is at leastt 50% compplete and eqqually
spaced aroundd the pipe circumferencce, and wheen no subseqquent pipe movements
m are foreseeen.
11.0 INSPECT
TION AND
D TESTING
G OF PROD
DUCTION
N WELDS
11.1 G
GENERAL
L
Thhe joints shhall be thorroughly cleeaned and bburnished by b means of

o mechaniical brushess and
buuffers and sppatter removved immediiately prior to weld insp
pection.
Thhe welds shhall be visuaally inspectted during welding

w andd after weld completioon; and oncce the
vissual inspecttion has passed satisfacctorily, the weld
w shall be
b subjectedd to NDT.
Alll required weld

w parameeters recordding shall bee done at leaast 3 times per
p each woorking day.
Alll welds shaall be subjeected to 1000% radiogrraphy; and for pipe wall w thickneesses > 9.5 mm,
ulttrasonic testting shall bee required inn the follow
wing cases:
‐ On the firsst 20 welds ffor each shiift at start of productionn
‐ When in thhe opinion of Customeer ultrasoniic testing iss required to o confirm or
o clarify deefects
indicated by
b radiograpphy.
‐ When pipee end are cut, c as suppplied, then new end sh hall be ultrrasonically inspected for
f an
10000-Z-000-GE1-TMP-0002 (09/14)
additional cut length uup to 20 mm m to assure that

t no lamiinations exiist.
‐ When weld ds are repaired.
Cuustomer mayy require otther NDT tyype(s) to be carried outt (Magnetic particle or Dye Penetrrant).
Thhe NDT inteerpretation shall be carrried out by the Contraactor in conjjunction witth Inspectorr, and
in case of anyy dispute ovver weld accceptance, Customer
C shhall retain the
t final calll and couldd cut-
ouut for examin
nation at ann independeent laboratorry to confirm
m the weld acceptabilitty.

SPECIFICATION PAGE 20
2 OF 35
PETROBE
EL 7479-440-6666-004
WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

ND
DT personnnel qualificaations (incluuding NDT supervisorss) shall meeet the requirrements of DNV-
D
OS
S-F101 (Apppendix D, A500).
A
Alll NDT techhnicians shaall be qualiified to SNT-TC-1A LevelL II or III, and all weld inspeectors
shall be qualiffied to CSW
WIP 3.1 certtified (equivvalent to Ceertified Welding Inspecctor “CWI”)).
Thhe following
g informatioon, as a min
nimum, shalll be given to
t Customerr at the startt of each daay:
‐ A copy of generated N NDT reportss.
‐ A copy of weld inspecction reportts.
‐ A copy of production monitoringg sheets (weelding param meters recorrdings).
‐ A copy of field joint inspection reeports.
‐ A copy of the pipe traacking reporrts.
‐ Status of thhe producedd weld.
11.2 R
RADIOGR
RAPHY
11.2.11 GENE
ERAL
Coontractor sh
hall developp the radioographic teesting proceedures, covvering, as a minimum
m, the
reqquirements of DNV-OS S-F101 (Ap ppendix D, B203).
B
Thhe radiograp phic testingg shall be 100%

1 on alll welds, byy X-rays onnly. The usse of gamm
ma ray
souurce shall only
o take place
p in excceptional caases, upon Customer authorizatio
a on, providedd that
Isootope Iridiuum 192 is ussed.
Beefore work start, Conntractor shaall present a specification for the

t radiographic procedure
quualification in accordaance with DNV-OS-F
D 101 (Appenndix D, B2200), coverring at leasst the
folllowing:
‐ Heat shield which, iff used, must be compposed of materials
m whhich do nott produce weave
w
patterns orr other imagges on the radiograph
r which may y interfere with
w interpreetation, musst not
hold the fiilm more thhan 7 mm fromf the weld, must not
n place a sheet of metal betweeen the
weld and film and thhe Penetram meter “IQI” must be placed betweeen the heaat shield annd the
pipe.
‐ Film densiity.
‐ Temperatuure of the joint to be insspected.
‐ Film coverrage.
Thhe radiograpphic proceddure qualifiication test shall be reepeated at the t discretioon of Contrractor
10000-Z-000-GE1-TMP-0002 (09/14)
whhenever a change
c is made
m to thee operating techniques, or wheneever producction films differ
appreciably frrom the sennsitivity, conntrast or dennsity of the qualificatio
on radiograpphs.
Thhe quality of radiogrraphs obtaiined on sitte shall bee the samee as that obtained during
d
quualification of
o the proceedure.
Ass a minimum
m, the identtification off the radiogrraphic film shall includde the follow
wing:
‐ Material deesignation;
‐ Material Grade;
G

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‐ Size and Wall

W Thicknness;
‐ Weld Num mber;
‐ Item Referrence;
‐ Date;
‐ Radiograph hy Positionn;
‐ The zero datum.
d
Foor weld repaair, the film shall coverr 100 mm onn either sidee of the areaa of repair.
Coontractor shhall be well organized with

w sufficiient personnnel, instrum
ments and eqquipment, soo that
raddiography can
c be carrieed out withoout delays.
Coontractor shhall supply all instrumments, equiipment andd material necessary ffor radiogrraphic
tessting. The equipment/in
e nstruments shall, as a minimum, meet the reequirementss of the quaalified
insspection pro
ocedure, whhilst not com
mpromising the safety of
o the invollved personnnel.
Coontractor shhall also enssure the opeerational effficiency annd maintenaance of the instrumentss, and
shall immediaately substittute any item
m, which Cuustomer connsiders unsu uitable.
Moreover, Coontractor shhall be in possession

p o the requiired permits, issued byy state or public
of p
boodies, relevaant to the poossession, use
u and transsport of danngerous radiiation sourcces.
Alll instruments and eqquipment necessary

n f carryinng out radiiography shall
for s satisfyy the
reqquirements establishedd by the public bodies or
o institutionns regulatin
ng “work saffety”. Contrractor
shall assume full responnsibility of his own peersonnel, annd for otherr personnell involved in i the
woorking area while radioographic insspections aree being carrried out.
Coontractor, subject
s to Customer approval, may proppose an alternative
a to conventtional
raddiography by
b real time radiographhy (RTR).
11.2.22 EXPO
OSURE GEOMETRY
Y
Whenever poossible, pipeeline welds will be insspected by placing

W p the radiation source
s insid
de the
pippe, on the pipeline axxis, with a radiation of
o 6.28 rad.. The positiioning of the center of
o the
raddiation beam
m shall be within
w 5° froom the weldd.
If it is not possible to plaace the radiiation sourcce inside thee pipe, the weld
w will be
b inspectedd with
thee source on the outsidee (i.e. doublee wall technnique DWE E/SWV).
10000-Z-000-GE1-TMP-0002 (09/14)
Ovverlap of att least 40 mm

m shall bee required too ensure that the first and last loccation increement
nuumbers are common too successivve film andd to establish that no point of a weld has been
ommitted.
11.2.33 PENETRAMETE
ERS
Thhe radiograpphic sensitivvity shall bee measured with the wiire image qu
uality indicaator “IQI”.

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IQ
QI sensitivityy shall be better
b than 1.6% on eaach side off the weld for
f single wall
w single imagei
raddiographs, while
w on double wall single imagge radiograaphs the IQQI sensitivityy shall be better
b
thaan 1.8% forr sources sidde and betteer than 1.6%
% for film siide.
Thhe Penetram
meters shalll be selecteed accordinng to DIN 54109
5 typee, and IQI’s shall meeet the
reqquirements of ISO 192232-1
Thhe image qu uality indicaator “IQI” shall be used for the qualification
q n of the weelding procedure
annd during noormal line production.
Foor radiograp phs made with

w the souurce on the outside, a Penetrometter shall bee placed onn both
ennds of the film
fi with thhe smaller wire
w of the Penetrametter turned towards
t thee end of thee film
itself; a third Penetramete
P er shall also
o be positionned in the middle
m of thhe film.
11.2.44 PROD
DUCITON RADIOGR
R RAPHY
Coontractor shhall have files

f concerning radioographers containing
c informationn related too the
proocedures byy which theyy were quallified, the naame of peopple qualifiedd and, finally the date.
Thhe qualificattion is validd for three years.

y m be re-qqualified if there is dou
Radiographers may ubt as
to their abilityy, or at the beginning
b o a new jobb.
of
IQ
QI shall, whenever posssible, be plaaced on the source sidee during exxposure. If the
t IQI's muust be
plaaced on thee film side production
p radiography
r y, this shouuld be indicaated by proojecting the letter
“F
F” onto the film.
f
Thhe sensitivitty of the film

m side IQI from the prrocedure quualification shall be useed as accep
ptance
criiteria.
Thhe Evaluatioon of radioggraphs shalll be perforrmed in acccordance wiith the requuirements off ISO
55580, radiogrraphs from the
t radiograaphic proceddure qualification shalll be availablle as referen
nce at
thee place wheere evaluatioon of produuction radioggraphy is peerformed.
11.2.55 IMAG
GES IDENT
TIFICATIO
ON
Thhe identificaation codes and marks (Numbers and Letters made of Lead) L shall be
b clearly shhown
onn each radiograph, and beside
b the welded
w jointt, the other data to be shown
s are as
a follows:
‐ Pipeline onn which the weld was made; m
‐ Number off weld; the nnumbering system adoppted shall be b the one acccepted by Customer;
10000-Z-000-GE1-TMP-0002 (09/14)
‐ Any other necessary informationn, such as: radiographh of repaired d weld, raddiograph of weld
replacing one
o that hass been cut, repeat
r expossure…etc.
‐ A graduateed tape witth centimeteer divisionss in lead sh hall normally be placeed alongsidee and
parallel to the weld soo that the distance of anny defect caan be read off
o on the film from thee zero
datum whiich shall be on top of thhe pipe at thhe start of thhe weld.
‐ The divisioons shall ruun clockwisse in ascendding order viewedv in the
t directionn of the runnning
production n.

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11.2.66 FILM STORAGE

E
Thhe film storrage shall bbe such thatt the films maintain thheir quality for a miniimum of 5 years
wiithout deteriioration, if film
f storagee time in exxcess of 5 yeears is required, the raddiographs sh
hould
bee adequatelyy digitized and
a stored inn electronic media.
Thhe radiograpphs relevantt to each joiint includingg those of rejected

r wellds, repair and
a re-takess shall
bee stored seqquentially inn boxes provided for thhis purposee, accordingg to the secttions of thee pipe
rouute and the sequential numbering
n of welds.
b used to store radioographs in multiples

Booxes shall be m of 25, 50, oro 100 weldds, and the weld
nuumbers of thhe stored raddiographs inn each box shall
s be cleaarly visible.
Att the end of the work, thhe films shaall be deliveered to Custtomer.
11.2.77 FILM DENSITY

Y
Fillm density shall be bettween 2.0 and

a 3.0; in cases whenn viewing box
b has stroong light, deensity
upp to 3.2 mayy be accepteed.
Thhe density shall be meaasured in reelation to the radiograpphic image of

o the weld and as speccified
in the radiographic proceedure descriiption.
11.2.88 TYPE OF FILM

M AND SCR
REENS
Thhe type of film

f used for
fo weld exaamination shall
s be ISOO 11699 1 Class T2 oro ASTM E1815 E
Cllass I, e.g. Agfa
A Structuurix “D5” or
o “D4” (proovided that special quaalification prrocess is doone to
ennsure the ressulting denssity and sen
nsitivity vallues remainn according to the requuirements ofo this
Sppecification)), or Kodak Industrex T200,
T or finner grain (slo
ower) film.
If the exposurre time wouuld exceed 2 minutes uusing X ray equipmentt with this film,
f then thhe use
off ISO 11699 9 1 Class T3
T or ASTM M E1815 Class
C II may
y be permittted at Custtomer discretion.
Leead intensifyying screenss shall be ussed.
11.2.99 IMAG
GE PROCE
ESSING
Foor the deveelopment annd fixing processes,

p w
which may be automaatic or mannual, approppriate
chhemicals and
d adequate treatment
t tiimes shall be
b adopted in
i order to obtain
o the best
b radiogrraphic
quuality.
10000-Z-000-GE1-TMP-0002 (09/14)
Thhe processinng shall incllude a dryin

ng stage andd all radiogrraphs shall be
b viewed dry.
d
Tyype, temperrature, timess and chem

mical produccts for the processing
p of
o films shaall be definned in
thee radiographhic proceduure.
Alll radiograpphs shall bee processedd to give minimum

m sto
orage life of
o five yeaars after con
ntract
completion.

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Byy the use off residual Thiosulfate

T t
tests and otther special test methods, it shall be demonsttrated
thaat the type of process used will allow storeed films to be free off any deterioration afteer the
miinimum speecified storaage life.
Thhiosulphate tests shall be taken att the end of o each shifft, and in caase of test failure the films
deeveloped durring the shift shall be re-fixed
r in a new fix so
olution.
11.3 U
ULTRASO
ONIC
Thhe Equipmeent and matterial shall conform too the requirrements of ASTM E317, and shaall be
callibrated twiice a day whhen in operaation.
Thhe Ultrasoniic examination shall bee required foor the follow

wing cases:
‐ After re-beeveling duee to pipe cu utting, pipe damage an nd/or cut ouuts (not initial pipe en
nd re-
beveling foor automaticc GMAW welding).
w
‐ On a zone 100 mm wiide around planned
p cutt-outs for noozzles, bran
nches, ..etc.
‐ To verify minimum
m w thicknesss after grinnding.
wall
‐ At the initiial testing of
o automaticc welds.
Uppon the commmencemennt of weldin ng with an approved

a auutomatic proocess (otherr than SAW W), all
weelds shall bee tested 1000% by ultrasonic exam
mination untiil Customerr is satisfiedd that the prrocess
is under compplete controol (e.g minim
mum of 50 welds).
w
Thhe level off UT exam mination maay then be reduced su ubject to Customer
C ap
approval whhen a
sattisfactory leevel of conffidence in thhe automaticc process annd weld quaality has beeen reached.
11.4 M
MAGNETIIC PARTIC
CLE
W
Where Magneetic Particlee Inspection n (MPI) is applied
a on parent
p mateerial (e.g. foollowing pippe re-
beeveling), no cracks or crrack-like deefects shall be permitteed.
Anny indicatioons revealed by MPI shall be innvestigated and removed by grindding or pippe re-
cuutting, as neccessary.
MPPI shall be required

r forr the follow
wing cases:
‐ Re-bevelinng due to pippe cutting, pipe
p damagge and/or cuut outs.
‐ Repair exccavations.
‐ On removaal of arc striikes.
10000-Z-000-GE1-TMP-0002 (09/14)
Thhe MPI shaall be basedd on ASTM M E709 orr equivalentt, as approoved by Cuustomer, an nd the
callibration bloocks and appproved maggnetic flux indicators shall
s be avaiilable on sitte at all timees.
Thhe electromaagnetic yokke and/or adj

djacent cablee techniquess shall be ussed.
Cuustomer reseerves the rigght to test th

he Contracttor proposed
d MPI proceedure prior to use.

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11.5 D
DESTRUCTIVE TES
STING
Thhe Customer shall retaiin the right to order thee cutting off a number of productiion welds fo
or the
puurpose of deestructive teesting. Morreover, weldds already cut out forr defect reasson may also be
subbjected to destructive
d t
testing.
Thhe destructiive testing for produuction weldds shall foollow the same requiirements of
o the
Quualification Tests for Welding
W Procedure defined above.
In case of deestructive Testing

T failuure, it shalll be broughht immediaately to the attention of
o the
Cuustomer forr review in order to en nsure that the
t approprriate correcctive actionss are perforrmed,
meeanwhile thhe Customerr shall retain
n the right too suspend all
a welding operations
o i necessaryy.
if
12.0 AUTOMA
ATIC ULT
TRASONIC
C TESTING
G
Thhe Automateed UT “AU UT” shall gennerally folloow the requuirements off DNV-OS--F101 (Appendix
E), in additioon to the primary
p reqquirement that
t its perrformance is
i documennted in term
ms of
addequate dettection andd sizing, or
o rejectionn abilities, in relatioon to speccified/determ
mined
accceptable defects .
Thhe AUT accceptance critteria shall be

b as per DN
NV-OS-F1001 (Appendiix E, Sectioon E400).
Thhe AUT shall be qualified accordding to DN NV-RP-F118 to be fit for purposse, based on o the
reqquired perfoormance as identified by the requuirements for f Probabillity of Deteection (PoD
D) and
sizzing ability;; or, alternattively a requuirement to defect rejection.
Onnce AUT system

s quaalification have
h been performed, only a lim mited validdation would be
reqquired for any
a future jobs if the system
s is within
w the quualified rannge of validdity, accordiing to
Seection 9.0 off DNV-RP-F118.
Thhe qualificattion processs is regardeed as an AUUT specific system

s and shall remaiin valid when all
Esssential Varriables remmain unchan nged; such Essential Variables
V s
specific forr the AUT shall
incclude the foollowing:
‐ Root and cap c channelss transducerr set-up.
‐ Transducerr set-up.
‐ Reference reflectors.
‐ Focal law design proccedure (for phased
p arrayy probes onnly).
‐ System andd data acquuisition/handdling.
10000-Z-000-GE1-TMP-0002 (09/14)
‐ Software version
v (exccept changess affecting viewing
v or display
d only
y).
‐ AUT Operrator/Interprreter traininng and qualification.
Thhe qualificaation testingg shall be performed

p u
using test welds
w contaaining intenntionally indduced
deefects typicaal to those expected
e in the welds produced with
w the involved welding methodd. The
indduced defeccts shall bee vary in leength, heigght and locaation, avoidding too close spacingg and
staacking, and shall address the followwing:
‐ Repeatabillity of AUT T system undder variablee examinatioon conditionns.
‐ Sensitivityy of AUT syystem to thee temperaturre of tested objects.

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‐ Ability of AUT
A systemm to detect defects of relevant
r typees and sizess in relevantt locations.
‐ The detecttion ability shall be deeemed sufficcient if the probability
p of detectinng a defect ofo the
smallest alllowable heeight determmined by ann Engineeriing Criticall Assessmennt “ECA” or o by
other consiiderations iss 90% show
wn at a 95%% confidencee level (i.e. a 90%-95% % PoD).
‐ Accuracy ini sizing annd locating defects.
d
Thhe ultrasonicc system maay use Pulse Echo, Tanndem, Timee-Of-Flight Diffractionn “TOFD” and/or
a
thrrough transmmission tecchniques em
mploying eitther fixed or
o phased arrrays, and shall have a fully
auutomatic reccording sysstem to inddicate the location of defects annd the integgrity of acooustic
coupling.
Thhe ultrasonicc instrumennt shall provvide an adeqquate numbber of inspecction channnels to ensurre the
exxamination of
o the compplete weld (iincluding HAZ)
H in one circumfereential scan (if possible).
Thhe recordingg or markinng system shall clearlyy indicate thhe location of imperfecctions relatiive to
thee 12 o’clock
k position of
o the weld with
w a +1% accuracy or o 10 mm, whichever
w iss greater.
Thhe system resolution

r s
shall be such that eacch segment of recordeed data from an indivvidual
insspection chaannel does not
n represennt more thann 2 mm of circumferen
c ntial weld diistance.
Thhe informatiion provideed by all AUTA channeel types shaall be activeely used inn order to ensure
e
addequate defeect detectionn and sizing
g.
Duue to the wide

w variatioon in repair weld groovve shapes that
t may lim
mit the deteection efficiiency,
maanual UT (or semi-auttomatic UT T) shall suppport the AU
UT on weldd repairs unnless the grroove
shape is contrrolled to be within giveen tolerancees.
AU UT shall haave a dedicaated constan nt power suupply, and provisions

p for
f alternativve power suupply
shall be availed in case of o failure inn the main power
p supp
ply; there shhall be no looss of inspeection
daata as a resullt of a possiible power failure.
f
W
Whenever it is likely thhat the weeld process,, parent maaterial, application andd environm mental
condition mayy increase the t risk for transverse flaws,
f then the ultrason
nic system shall incorpporate
faccilities for detection
d off such defectts.
Coontractor shhall ensure that variatiions in thee inspected pipe wall thickness shall
s not reequire
addditional vallidations or qualificatio
on to providde evidencee of 100% coverage of the fusion
n face
annd root area.
10000-Z-000-GE1-TMP-0002 (09/14)
Coontractor sh hall establish a qualitty assurancce system covering thhe AUT syystem, softtware,
quualification of
o personneel and operaation, and heence docum menting the following,
f a a minimu
as um:
‐ System perrformance.
‐ System com mponents and
a calibratiion blocks.
‐ Verificatio on of deliverred system componentss and calibrration blockks.
‐ Control an nd verificatioon of software developpment/changges.
‐ Design of AUTA systemm set-up forr specific fieeld operatio
on conditionns/requirem
ments.
‐ Operator trraining and qualificatioon.

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Thhe calibratioon blocks shhall be used

d to set AU
UT system sensitivity, and
a to veriffy the system
m for
fieeld inspectioon, and to m
monitor the ongoing
o sysstem perform
mance.
Thhe wall thicckness of thhe pipe useed for calibbration bloccks shall prreferably coorrespond to
t the
noominal wall thickness of
o the pipes used.
Thhe details off the specifiic weld bevvel geometriies (includinng relevant dimensionss and toleraances)
shall be provvided in ordder to determine the particulars and a number of the required calibrration
bloocks.
Prior to weldiing, a refereence line shhall be scribed on the pipe surface at a fixed distance
d fromm the
cennterline of the
t weld preeparation onn the inspecction band side;
s this reference linee shall be ussed to
ennsure that thhe band is adjusted
a to the same distance
d from
m the weldd centerline as to that ofo the
callibration bloock.
Thhe tolerancee for band positioning is

i ± 1 mm relative to thhe weld cennterline, andd the band can
c be
poositioned eitther wholly on the baree pipe or on the corrosioon coating.
Foor that purpoose, the corrrosion coatting shall neeed to be suufficiently flat
f and rem main hard en
nough
at designated preheat/weelding temperatures to avoid that the band su upports slip or penetratte the
coating. Posittioning of thhe band parttly on bare pipe and paartly on the corrosion coating
c shouuld be
avvoided.
Thhe cut-back of the corrrosion coatting to baree pipe shall be wide enough to accommodat
a te the
foootprint of alll transducers at the reqquired standd-off distancce + minimu
um 20 mm.
Thhe cut-back of any weiight coating g shall alloww placing thhe band whholly on thee bare pipe or on
thee corrosion coating, ass applicable, and sufficcient to avoiid interferen
nce betweenn weight cooating
annd scanner.
W
Welds shall be
b re-examinned whenev ver any of thhe followingg occur:
‐ Welds exam mined at seensitivity ou
utside ± 2 dBB from the Primary
P Reference Levvel “PRL”.
‐ Welds exhhibiting a looss of acoustic couplinng over a circumferent
c tial distancee which exceeds
the minimuum allowabble defect length for thee affected ch hannel.
‐ Coupling loss in twoo adjacent zones at the t same position
p req
quires re-exxamination,, also
wherever the
t minimum m allowablee defect height is smalller than the zone heighht for the afffected
channel, thhe weld shalll be re-exammined.
‐ If a verification scan shows
s that the
t system is i in anywayy “out of caalibration”.
10000-Z-000-GE1-TMP-0002 (09/14)
13.0 REPAIR AND REM

MOVAL OF
F DEFECT
TS
13.1 G
GENERAL
L
Geenerally, alll weld defeects not sattisfying the acceptancee criteria deefined hereein after shaall be
recctified by onne of the foollowing meethods:
‐ Grinding.
‐ Repair wellding, after removal off the defect (only( permiitted after Customer
C auuthorization)).
‐ Cut-out off the weld (ppipe to be cu ut at least 25 mm awayy from the weld
w toe).

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Thhe weld repaairs shall bee carried ouut with low hydrogen content
c weldding processses, and shall be
quualified by developingg a repair procedure test weldd in accorddance with DNV-OS--F101
(A
Appendix C, C Table C--4), with th he same accceptance criteria
c as for the weelding procedure
quualification.
Beefore repair welding, thhe defect shall be comppletely remooved by grinnding, machhining or thermal
gaauging (wheen thermal gauging
g is used,
u the gaauged area shall
s finallyy be prepareed by grindiing to
briight metal); and defects spaced wiith less thann 50 mm shaall be treated as one continuous deefect.
It is the Conttractor respoonsibility, before

b requesting authoorization foor repairing crater or star or
hoot cracks, too first invesstigate the cause of thhe defect annd provide a remediall action to avoid
reppetition of this
t defect.
Coontractor sh
hall cut nonn-repairable defects froom the pipeeline as cyliinders and replace witth the
cuut section with
w new pippe. The length of cylinnder to be cut c shall bee at least 1.5 times thee pipe
diaameter, and
d in no case shall be less than 15 cm
m.
hall be donee if the totaal length of excavated areas is mo

Noo repairs sh ore than 30%
% of the ouutside
cirrcumferencee.
Onnly one reppair attemppt is permiitted; shoulld the repaair weld faail to meett the accep
ptance
reqquirements, the weld shhall be cut-oout, edges re-beveled
r a re-welded.
and
W
Weld repairs to
t the pipe body
b or to the
t body off fittings or bevels
b are not
n permitteed.
Sinngle pass reepairs are not

n permitteed, and repaair to the weeld root by welding frrom the insiide of
thee pipe shall not be perm
mitted.
Coontractor shhall preparee, for Cusstomer apprroval, detaiiled repair procedure covering, as a
miinimum, thee following::
‐ Method off defect remmoval;
‐ Preparationn of the grooove;
‐ Welding process and welding
w connsumables;
‐ Final prepaaration and method forr inspection of the excaavated area;
‐ The minim mum and maaximum length of the section to bee repaired;
‐ Maximum root openinng.
Quualification of a through thicknesss repair prrocedure shhall normallly also quallify for a partial
p
10000-Z-000-GE1-TMP-0002 (09/14)
thrrough thickkness repaiir procedurre providedd that idenntical WPS S’s are appplied exceppt for
exxcavation deepth and num
mber of fill layers.
W
Weld repairs for flaws shall
s be madde accordinng to a repaair procedurre prepared and qualifiied in
acccordance off DNV-OS--F101 (Appendix C, G3300).
Thhe preheatinng temperatuure for repaair welding shall be off at least 100
0°C or 50°C
C above th
he one
eleected for thhe qualifiedd welding procedure,
p w
whichever is higher, and
a the preeheating shaall be
exxtended to cover
c a miinimum of 50 mm (orr 5 times the t pipe wall thicknesss, whichevver is
greeater) on eaach side of the
t weld at the
t repair arrea.

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WEELDING AND
A NDT
FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

Thhe repaired weld sectioons shall bee 100% re-eexamined and

a the acceeptance critteria shall be
b the
sam
me as the orriginal weldd.
13.2 C
CRACKS
Reepairs of cracks shall not

n be authorized exceept for shalllow crater cracks
c or sttar cracks or
o hot
craacks.
W
Weld containning longituudinal or traansverse craacks shall not
n be repaiired, but cuut-out for fuurther
exxamination.
Coontractor shhall prepare a detailed procedure

p f Customeer approval covering thhe repair off weld
for
craacks basedd on the ppremises thaat repair welding
w is only perm mitted undeer the follo owing
conditions in accordancee with DNV V-OS-F101 (Appendix
( C,
C G300):
‐ The cause of crackingg must be established
e a not a sysstematic weelding error;; this impliees the
as
need for a technical evvaluation off the cause of
o cracking.
‐ Repair weelding shall be perform med according to quallified repairr welding pprocedures; each
repair shall be perform
med with a minimum
m o two passees over a lenngth not lesss than 50 mm.
of m
‐ The total leength of weeld repair inn any single pipe shall not
n exceed 5% 5 of the weld
w length.
‐ Weld defeccts separateed by less thhan 100 mm m shall be reepaired as a single contiinuous repaair.
‐ Re-inspecttion of repaair welds sh hall be 100%% visual exxamination and
a 100% uultrasonic and/or
a
100% radioographic tessting as required for thhe original weld.
w
13.3 R
REPAIR RECORD
R
Coontractor shhall maintaiin a full reccord of all completed repairs, coovering, as a minimum
m, the
folllowing:
‐ Weld numb ber;
‐ Type and size
s of defecct;
‐ Circumfereential locatiion (definedd to an approved systemm);
‐ Estimate ofo the depth (assessed byb ultrasonicc test wheree possible);
‐ Name of th he welder who
w produceed the defecct;
‐ Repair wellding proceddure numbeer;
‐ Name of reepair welder;
‐ Copy of thhe inspectionn report for the repair;
‐ Date of rep pair.
10000-Z-000-GE1-TMP-0002 (09/14)
14.0 WELD ACCEPTAN

A NCE
14.1 G
GENERAL
L
Thhe weld accceptance staandard shalll apply for welding prrocedure quualification tests, Weldder or
W
Welding Operrator qualifi
fication testss and produuction weldss.
Thhe weld acceptance shaall be basedd upon the relevant

r requuirements of
o DNV-OS
S-F101, and
d shall
alsso comply with
w the reqquirements given
g in Secction 14.2.

3 OF 35
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WEELDING AND
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FOR 26”
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NE
EGYPT REV.
R 0

Thhe following
g Standards shall apply
y for NDT methods
m accceptance:
‐ ISO 176377 for visual inspection.
‐ ISO 176366 for radiogrraphy.
‐ ISO 176400 for ultrasoonic (absolutely requireed to detect transverse flaws).
f
‐ ISO 176388 for Magneetic Particle.
‐ ISO 176433 for Eddy Current.
C
‐ ASTM E14417 for Liqquid Penetraant.
14.2 G
GENERAL
L CRITERIIA
14.2.11 WELD PREPARA

ATION
In areass of weld preparation

p such as pippe ends, bevvel faces annd branches, planar deefects
shall noot be acceptaable whatevver their sizees.
14.2.22 EXTER
RNAL PRO
OFILE
The weld reinforceement shall be uniformm, not less th

han 1.0 mm
m and no more than 3.0 0 mm
in heighht, and shall merge sm moothly with the pareent metal annd shall exttend beyonnd the
originall weld prepaaration by no
n more thann 2.5 mm.
14.2.33 INTER
RNAL PRO
OFILE
The welld shall fusee the pipe at

a the root without
w prottruding exceessively into the bore of
o the
pipe, annd the maxim
mum permissible weld eccentricityy at the roott shall be 2 mm.
14.2.44 CAP UNDERCUT

T
Undercu ut exceedinng 0.5 mm in depth shhall not be accepted an nd shall bee blended out by
light griinding priorr to radiograaphy; grindding shall noot reduce th
he pipe wall thickness below
b
the speccified minimmum.
14.2.55 ROOT UNDERCU

UT
Depth shall
s not excceed 0.4 mm
m, and the length shall not exceed
d 25 mm inn any continnuous
weld lenngth of 300 mm.
14.2.66 ROOT CONCAV

VITY
10000-Z-000-GE1-TMP-0002 (09/14)
Root cooncavity shaall be permiitted up to 1.2 mm in depth if theere is no lacck of root fusion
f
and if thhe thicknesss of the welld (includinng cap reinfo
forcement) is
i not less thhan the speccified
wall pippe thicknesss
14.2.77 POROS
SITY (OTH
HER THAN
N ELONGA
ATED POR
ROSITY IN
N ROOT RUN)
R
Porositiies shall nott exceed a total

t area of 2% of anyy 600 mm2 of projecteed weld area. An
isolated
d pore greateer than 20%% of the pippe thickness or 3 mm, whichever
w i smaller, in
is n any
directionn, shall not be accepted
d. Worm hooles shall noot be accepttable.

3 OF 35
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WEELDING AND
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R 0

14.2.88 CRACK
KS
Welds with
w cracks or suspecteed cracks shhall be cut-out. Repairs could be applied soleely to
shallow
w cracks, starr cracks or hot
h cracks.
14.2.99 ARC ST
TRIKES
Arc strik
kes are not permitted.
14.3 A
ACCEPTA
ANCE CRIT OR GIRTH WELD DE
TERIA FO EFECTS
Thhe acceptannce criteria for NDT foor welds likkely to be exposed

e to design straain level < 0.4%
shall be accoording to DNV-OS-F1
D 01 (Appenndix D, Tab ble D-4 forr visual insppection, D--5 for
raddiography and
a D-6 forr manual UT). U For weelds likely to
t be expossed to desiggn strain leevel ≥
0.44% and Auutomatic UT U is used,, the accepptance criteeria shall be b establishhed by an ECA
(E
Engineering Critical A Assessment)) accordingg to DNV V-OS-F101 (Appendixx A), with h the
folllowing proovisions takeen into conssideration:
‐ The uncerttainty data for AUT obbtained from
m the relev
vant qualificcation testinng in accorddance
with DNV-OS-F101 (Appendix
( E
E).
‐ If an embeedded defecct is locatedd close to a surface, succh that the ligament heeight is lesss than
half the defect height, the ligamennt height beetween the defect
d and the
t surface shall
s be included
in the defect height.
‐ Sizing of indication
i h
height and length by manual
m or automated
a ultrasonic
u t
testing will have
inherent innaccuracies,, and hencee the allow wable defectt sizes derivved from an a ECA muust be
corrected accordingly
a for the ultrrasonic testing uncertainties (sizingg error) as follows:
f
a) If the ECA
E gives the allowabble defect size,
s the sizzing error shall be subbtracted from
m the
calculatted allowabble defect height
h and length for establishingg the accepptance criterria of
NDT.
b) If the ECA
E gives the materiaal propertiees and stresses/strains allowed to tolerate a given
defect size,
s the siziing error shhall be addedd to the deffect height and
a length used
u as inpu
ut into
the ECAA for establlishing the acceptance
a c
criteria of NDT.
N
15.0 QUALIFIICATION OF WELD

DERS AND
D WELDIN
NG OPERA
ATORS
15.1 G
GENERAL
L
Beefore startinng productiion welding

g, the Conttractor shalll provide Customer
C w
with a list of
o the
10000-Z-000-GE1-TMP-0002 (09/14)
weelders.
Alll Welder annd Welding Operators shall be quaalified in acccordance to

o DNV-OS--F101 (Appendix
C, B200).
Thhe Qualificaation Test shhall be carrried out sim

mulating as far
f as possiible the prodduction wellding,
using the sam
me equipmennt to be used d during connstruction.
Coontractor annd Customeer shall botth agree onn the date and
a place of
o the Weldder and Weelding
Opperator Quaalification T
Tests.

3 OF 35
PETROBE
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WEELDING AND
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FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

Eaach Welder or Weldingg Operator shall

s make a complete test weld (sstringer beadd, hot pass, filler
annd cap weldss) regardless the assignned weld typpe.
A Welder orr Welding OperatorO w has succcessfully completed

who c t weld quualification tests
the
(buutt-weld tesst and full-ssize branch connection test) shall be b qualifiedd to weld inn all position
ns, on
alll wall thicknnesses, jointt design, fitttings and onn all pipe diiameters.
Eaach Welder or Weldingg Operator shall be asssigned a unnique identiffication num

mber whichh shall
bee marked in paint against all welds produced by
b him.
A list of quallified personnnel with photographs

p s shall be keept up to daate by Conttractor and made
avvailable to thhe Customer.
Thhe Welder or
o Welding Operator
O muust be comppletely re-qu ualified in the
t followinng cases:
‐ A change ini electrodee or filler wiire, classificcation and diameter.
d
‐ A change ini the joint design.
d
15.2 W
WELDER ACCEPTA
A ABILITY
Thhe appearannce of the tesst weld shalll give imprression of go

ood welder workmanshhip.
Thhe presencee of semi-aautomatic welding

w bitss of wire in
i the weldd bead maay be enouggh to
dissqualify thee welder.
Thhe test weldd shall be reejected if itt has surfacce defects (not in accoordance withh the accep
ptance
criiteria given in this Speccification), cracks, inaddequate pennetration or burn througgh.
Moreover, un ndercutting adjacent to the final beead on the pipe outsid de shall not be > 1/32” deep
or 12.5% of wall thicknness, in adddition theree shall not be more th han 2” unddercutting inn any
continuous 12 2-inch lengtth of weld. In all thesee cases, Cusstomer shall decide whhether a rep
peated
tesst may be peerformed orr not.
Foollowing viisual inspecction, all welds

w for welder quualification shall be 100%
1 testeed by
raddiography.
In case of Au utomatic or Semi-Autoomatic weldding, the weelds shall bee subjected to 100% UT,
U in
adddition to raddiographic tests
t to deteect any lackk of side walll fusion.
In particular cases,
c Custoomer may additionally
a require desstructive tessts consistinng of 2 bendd tests
forr a Welder or
o Welding Operator.
10000-Z-000-GE1-TMP-0002 (09/14)
Thhe Welder or o Weldingg Operator shalls not bee qualified if any of teest welds fa
fail to satisffy the
esttablished accceptance crriteria givenn in this Speecification.
If a test weld fails to meeet the speciified requireements, the Welder or Welding Operator
O cann redo
thee test on a new
n test welld. Welderss who fail too meet the requirements after two attempts sh
hall be
dissqualified.

3 OF 35
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WEELDING AND
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R 0

15.3 R
RECORD
Alll details off a Welder or

o Welding Operator qualification
q n test shall be
b certified and accepted by
Cuustomer.
Alll documenttation relateed to Weldeer or Weldiing Operatoor Qualificaations shall be recordedd in a

“W
Welder Quallification Reecord” whicch shall be made
m availaable to Custtomer for reeview.
15.4 V
VALIDITY
Y
Unnless otherwwise agreedd upon withh Customerr, the Weldder or Weldding Operattor Qualificcation
shall remain valid
v for a period of 12
1 months, however shhall lapse after
a a periood of six months
m
wiithout produuction weldiing experiennce.
Thhe qualificattion may bee withdrawn n by unobjeectionable decision

d of Customer if
i the produuction
weelds executeed by the weelder are reppeatedly deefective.
10000-Z-000-GE1-TMP-0002 (09/14)

3 OF 35
PETROBE
EL 7479-440-6666-004
WEELDING AND
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FOR 26”
2 SUBSEEA PIPELIN
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EGYPT REV.
R 0

FIGURE
E 1. I
ISO TENSIILE TEST SPECIME
EN
10000-Z-000-GE1-TMP-0002 (09/14)

3 OF 35
PETROBE
EL 7479-440-6666-004
WEELDING AND
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FOR 26”
2 SUBSEEA PIPELIN
NE
EGYPT REV.
R 0

FIGUR
RE 2. ALL-WEL
LD META
AL TENSIL
LE TEST SP
PECIMEN
N
10000-Z-000-GE1-TMP-0002 (09/14)

4749-440-666-004 Rev.0 (Welding & NDT Specification) (Sealine)

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SPECIFICATION PAGE 2 OF 35

0 Issuued for Approoval

FIGURE 1. ISO TENSILE

FIGURE 2. ALL-W

Thhis specificaation coverss the techniccal guidelinnes for the execution,

ow form an integral parrt of this Specification.

Ammendments Sets out employmennt practicees and haas elements related to

ISO 5580 Non-Destru uctive Testting - Induustrial Raddiographic Illuminatorrs -

Coodes & Stan

a) The Laws and Regulaations.

shall apply in full.

ASSTM American Society

Thhe Specificaation coverss all field welding

‐ Submergedd Arc Weldding, SAW (Process

Coontractor is bound to allow

Thhe Customeer right to supervise

Alll welding consumable

Coontractor shhall submit the

Cuustomer maay, at its diiscretion, teest the mecchanical and

Thhe storage and

If Cellulose covered electrodes are selectted, then the t requireements of DNV-OS--F101

Thhe maximuum exposurre time an nd maintennance of covered

t gas quaality (purity, dryness, dew

Thhe purity annd dryness of

If Argon or Carbon Diooxide gasess are used,, the maxim

Thhe moisture content of any gas or gas

Alll Welding Equipmentt, Line-Up Clamps, Beveling

Thhe welding equipment

Prior to startt of producction, Conttractor shall submit, for

A new Weldin ng Proceduure shall neeed to be re-qqualified whhen any of the

 Use of o oxyacetyllene gas forr preheating is not perm mitted.

Moreover, a Separate Welding Procedures shall be submitted to the Customer C and

In case that Post-Weld

Evvery detail of the quualification tests shalll be witnessed and accepted

Thhe Final Reeports shall contain, inn addition to t the PQR

Coontractor shhall keep all

Alll Test Couppons and Sppecimens ussed to qualify a proced

Thhe Welding Proceduress remains qualified

‐ Consumab ble manufactturer and/orr trade namee, or AWS classificatioon to anotheer.

In case of Semmi-Automattic or Autommatic Weldiing, the folllowing addiitional requiirements shhall be

Coontractor shhall inform the Custom mer of the date

Thhe pipe nippples used to make-up th

Thhe measureement of electric

9.2 VIISUAL INS

Thhe Visual Exxamination and Non-D Destructive Tests

Thhe joints shhall be thorroughly cleeaned and bburnished by b means of

Alll retests shaall be perforrmed after Customer

Thhe acceptance criteria of

Reetests (mechhanical/imppact) requirred for failled specimeens shall follow

9.3.2 MACR C INSPECTION

Thhe specimenns shall be taken

Thhe specimenns shall be carefully examined

Magnificationn for docum

Thhe prepared d macro-secction test shhall be carriied out in accordance

A minimum of 6 indenttations equaally spacedd along the traverses are

n exceed the limits defined inn DNV-OS-F101 (Apppendix C F312,

In case of a single readinng slightly higher

Thhe impact test

Thhe specimenns shall be taken

wiithdrawn as per DNV-O OS-F101 (A Appendix B,, Fig. 3).

Thhe test piecees shall be immersed in

Thhe dimensioons of the test specim men shall be