Copyright 1994 Shell U.K. Limited. All rights reserved.

Additional registered or controlled copies can be obtained from Central Engineering Library.

Shell U.K. Exploration and Production

SHELL

ENGINEERING REFERENCE DOCUMENT

STANDARD WELDING AND INSPECTION OF PROCESS AND UTILITY PIPEWORK
Document Number : ES/124 Part 1 Rev : 2

UEOE/28

is the appointed Custodian of this document and should always be consulted for advice on validity and currency by a user.

ES/124 Part 1 Rev 2 1994

CONTENTS
Para 1 1.1 1.2 1.3 2 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.7 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.8 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5 5 5.1 INTRODUCTION Use Ruling Specification Modifications SCOPE REFERENCE DOCUMENTS General Requirements Shell Documents British Standards Other National Standards Certification Schemes for Inspection Personnel FERRITIC STEELS Materials Welding Processes Welding Consumables Selection Limitations Consumable Handling Welding Procedures Approval Essential Variables Welding Procedure Qualification Test Repair Welding Procedures Welder Qualification General Pre-Qualification Documentation Time Limitations Welding - General Requirements Shop/Site Conditions Equipment Preparation for Welding Weld Execution Post-Weld Heat Treatment Inspection General Requirements Visual Inspection Magnetic Particle Inspection Radiographic Examination Ultrasonic Examination Inspection Personnel Extent of Inspection of Production Welding Acceptance Standards Reporting Repairs General Defect Removal Root Repairs Rewelding Non-Destructive Testing STAINLESS STEELS, NICKEL ALLOYS, COPPER-NICKEL AND TITANIUM Materials Page 13 13 13 13 15 17 17 17 17 17 18 19 19 19 20 20 20 20 21 21 22 23 26 26 26 26 26 27 27 27 27 27 29 31 33 33 33 34 34 35 35 35 35 36 36 36 36 36 36 37 39 39

Page 3 of 90

ES/124 Part 1 Rev 2 1994 5.2 5.2.1 5.3 5.3.1 5.3.2 5.3.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7 5.7.8 5.7.9 5.8 5.8.1 5.8.2 5.8.3 5.8.4 5.8.5 Welding Processes Welding Heat Input Limitations Welding Consumables Selection Limitations Consumable Handling Welding Procedures Approval Essential Variables Welding Procedure Qualification Test Repair Welding Procedures Welder Qualification General Pre-Qualification Documentation Time Limitations Welding - General Requirements Shop/Site Conditions Equipment Preparation for Welding Weld Execution Post-Weld Heat Treatment Inspection General Requirements Visual Inspection Dye Penetrant Inspection Radiographic Examination Ultrasonic Examination Inspection Personnel Extent of Inspection of Production Welding Acceptance Standards Reporting Repairs General Defect Removal Root Repairs Rewelding Non-Destructive Testing 39 39 40 40 40 41 42 42 42 44 47 48 48 48 48 49 49 49 49 50 51 54 54 54 54 55 55 56 56 56 56 57 57 57 57 57 57 57

TABLES
Table 1 2 3 4 5 6 7 8 9 Thickness Limits for Application in the As-Welded Condition Procedure Qualification - Qualified Positions Welding Procedure Testing Requirements Charpy Impact Testing Temperatures and Acceptance Criteria IQI Wire Sensitivity For Pipework Using X and Gamma Radiography Inspection Classes Extent of Inspection Visual Acceptance Criteria Radiographic Acceptance Criteria Page 67 68 69 70 71 72 73 74 75

Page 4 of 90

ES/124 Part 1 Rev 2 1994

FIGURES
Fig 1 2 3 4 Position of Test Specimens Position of Hardness Traverses Location of Impact Specimens Weld Profile - Weldolets Page 60 61 62 63

APPENDICES
App A B C D Reporting Requirements for Welding Procedure Qualification Minimum NDT Reporting Requirements Recommended Practice for Determining Volume Fraction of Ferrite in Duplex Stainless Steel Weldments by Systematic Point Count Recommended Practice for Pitting Corrosion Testing of Duplex Stainless Steel Weldments by the Use of Ferric Chloride Solution Page 79 81 83 87

Page 5 of 90

ES/124 Part 1 Rev 2 1994

Page 6 of 90

ES/124 Part 1 Rev 2 1994

PREFACE
Shell Expro Standard ES/124 details the requirements for fabrication and installation of process and utility pipework. This document forms Part 1 of the Standard and covers the welding and inspection of process and utility pipework for new offshore oil and gas installations in the UK North Sea, together with related onshore facilities. Included in the scope of this Standard are the fabrication of pipework, both onshore and offshore, the onshore installation of pipework in modules and integrated decks and installation during offshore hook-up. ES/124 Part 1 was extensively revised in 1993 at Rev 1 and incorporated the requirements of the various draft supplements covering 3% Ni steel, duplex, super duplex and 6% Mo stainless materials. These supplements had been prepared at the time of the first use of the materials by Shell Expro and had been subject to a number of amendments based on accumulated knowledge and experience during the period of their application. A small number of persistent queries have arisen since the issue of this Standard, Rev 1, which were not identified in the pre-publication review cycle. It was decided that these comments merited consideration and have been included in this Rev 2 issue to ensure consistent interpretation as well as eliminating repetitive queries.

Page 7 of 90

ES/124 Part 1 Rev 2 1994

Page 8 of 90

ES/124 Part 1 Rev 2 1994

GLOSSARY
Within the context of this Standard the following words shall have the meanings stated: must/shall should may SIPM Shell Shell Expro Purchaser Vendor Manufacturer Contractor Sub-contractor indicates a mandatory requirement indicates a preferred course of action indicates one acceptable course of action Shell Internationale Petroleum Maatschappij B.V. Shell U.K. Ltd. Shell U.K. Exploration and Production OR its Authorised Representative. The organisation responsible who carry out the purchasing function, e.g. Shell Expro or a Shell Expro appointed Contractor, Consultant or Agent. The supplier of materials for the manufacture - not necessarily the Manufacturer. The company responsible for the manufacture - not necessarily the Vendor. The Shell appointed main Contractor for a defined piece of work. A company awarded a contract by a Contractor to do part of the work awarded to the Contractor by Shell Expro. The work of the Sub-contractor is carried out under the direction and control of the Contractor. Under its model contracts Shell Expro has the right to review all proposed Sub-contractors, and sub-contracts. A term having a special legal meaning applicable to the unusual case where the terms and conditions of the contract between Shell Expro and the Contractor provide that special terms and conditions apply to any Sub-contractor that is nominated by Shell Expro. Shell Expro model contracts avoid use of the term 'nominated'. A company awarded a contract by Shell Expro for the company to advise or give guidance on specific subjects. The Scope of Work may include instructions to act as an Agent for Shell Expro (see Agent). The legal status of any person or company authorised by Shell Expro to act on Shell Expro's behalf on the matters specified in the agency agreement or contract. Third parties can usually rely on the Agent as acting on behalf of and with the authority of Shell Expro, provided that the Agent acts within the scope of his apparent authority from Shell Expro. ES/124, Part 1.

Nominated Sub-contractor

Consultant

Agent

This Standard

Page 9 of 90

ES/124 Part 1 Rev 2 1994

Page 10 of 90

ES/124 Part 1 Rev 2 1994

ABBREVIATIONS
AFC ASME ANSI ASTM AWS BS C CMn CSWIP DPI DWDI DWSI FCAW GMAW GTAW HAZ ID MPI NDT OD PCN PWHT SAW SNT SMAW Approved for Construction American Society of Mechanical Engineers American National Standards Institute American Society for Testing and Materials American Welding Society British Standard Carbon Carbon Manganese Certification Scheme for Weld Inspection Personnel Dye penetrant inspection Double Wall, Double Image Double Wall, Single Image Flux cored arc welding Gas metal arc welding Gas tungsten arc welding Heat affected zone Internal Diameter Magnetic particle inspection Non-destructive testing Outside Diameter Personal Certification Number Post weld heat treatment Submerged arc welding Society for Non-Destructive Testing Shielded metal arc welding (manual metal arc)

Page 11 of 90

ES/124 Part 1 Rev 2 1994 SWSI WPS WPQR Single Wall, Single Image Welding Procedure Specification Welding Procedure Qualification Record

SYMBOLS
e t B Thickness at the weld centre line Nominal pipe wall thickness Maximum nominal pipe wall thickness for as-weld application

Page 12 of 90

ES/124 Part 1 Rev 2 1994 1 1.1 INTRODUCTION Use This Standard is intended for use by the engineering divisions of Shell Expro, their engineering contractors and where applicable manufacturers of pipework components. 1.2 Ruling Specification Process and utility pipework is to be welded in accordance with ANSI B31.3 unless stated otherwise in this Standard. This Standard must be read in conjunction with ASME IX. Unless modified by this Standard the requirements of ASME IX apply. 1.3 Modifications This Standard must not be modified except by issue of revisions or addenda by Shell Expro or through the ruling deviation request procedure. The general provisions of this Standard also apply if materials other than those listed are specified. Particular requirements for the welding of these materials will be issued as addenda to this Standard if found necessary.

Page 13 of 90

ES/124 Part 1 Rev 2 1994

Page 14 of 90

ES/124 Part 1 Rev 2 1994 2 SCOPE This Standard covers the welding and inspection of process and utility pipework for onshore and offshore installations. The following are not included: (1) (2) (3) Risers, pipelines, and associated topsides pipework coming under the scope of the Department of Energy Submarine Pipelines Guidance Notes (refer to ES/106) Large bore low pressure ducting; Domestic pipework that is not installed by welding.

For ease of use in the field, the technical requirements have been compiled in two sections covering: Section 4 - Ferritic steels, including 3% Nickel. Section 5 - Stainless steels, Nickel alloys, Copper-Nickel and Titanium. To enable each section to be used as a stand alone document common elements have been reproduced as necessary in each section. ES/124 Part 2 covers the general fabrication and installation requirements for the same scope as above.

Page 15 of 90

ES/124 Part 1 Rev 2 1994

Page 16 of 90

ES/124 Part 1 Rev 2 1994 3 3.1 REFERENCE DOCUMENTS General Requirements The documents listed below are referred to in this Standard. The Contractor shall ensure all these documents are available to the personnel engaged on the project. The editions listed are those current at the time of publication. Amendments published prior to the date of publication of this Standard shall also apply. Subsequent editions should only be used with the approval of Shell Expro. 3.2 Shell Documents ES/106 1989 ES/124 Part 2 1989 DEP 30.10.02.31 GEN 1987 3.3 British Standards BS 427 Part 1 1990 BS 638 (all parts - latest editions) BS 891 1989 BS 2910 1986 BS 5135 1984 BS 6503 1984 BS 6693 Part 3 1988 BS EN 10045-1 1990 3.4 Other National Standards American Society of Mechanical Engineers (ASME) ANSI/ASME B16.25 1986 ASME B31.3 1990 Section V 1992 Section VIII 1992 Section IX 1992 Butt Welding Ends Chemical Plant and Petroleum Refinery Piping Non Destruction Examination Pressure Vessels, Division 1 Welding and Brazing Qualifications Methods for Vickers Hardness Test and for Verification of Vickers Hardness Testing Machines Arc Welding Power Sources, Equipment and Accessories Methods for Hardness Test (Rockwell method) and for Verification of Hardness Testing Machines (Rockwell method) Methods for Radiographic Examination of Fusion Welded Circumferential Butt Joints in Steel Pipe Process of Arc Welding of Carbon and Carbon Manganese Steels Hand Held Blowpipes, Mixers and Nozzles, using Fuel Gas and Oxygen for Gas Welding, Cutting and Related Processes Primary Method for the Determination of Diffusible Hydrogen in Manual Metal Arc Ferritic Steel Weld Metal Charpy Impact Test on Metallic Materials; Test Method (V- and U- notches) Shell Expro Standard - Welding of Steel Pipelines on Land and Offshore Shell Expro Standard - Piping Fabrication and Installation Royal Dutch/Shell Technical Specification - Requirements for Prevention of Brittle Fracture in Low Temperature Service

ASME Boiler and Pressure Vessel Code:

American Society of Testing Materials (ASTM) ASTM A370 1990 ASTM E562 1989 Standard Test Methods and Definitions for Mechanical Testing of Steel Products Practice for Determining Volume Fraction by Systematic point Counting

Page 17 of 90

ES/124 Part 1 Rev 2 1994 DIN Standards DIN 54109 Pt 1 1987 3.5 Non Destructive Testing; Image Quality of Radiographs

Certification Schemes for Inspection Personnel CSWIP-WI-6-80 PCN\GEN\92 PCN\GEN\92 PCN\GEN\92 Requirements for the Certification of Welding Inspectors and Senior Welding Inspectors General Requirements for Certification of Personnel Engaged in Non-Destructive Testing Appendix C - Welding Sector Specific Appendix E - Multi Sectorial

Page 18 of 90

ES/124 Part 1 Rev 2 1994 4 4.1 FERRITIC STEELS Materials The following ferritic steels are covered by this Section. Carbon-Manganese Steels Non-impact tested ASTM A106B, A105, A234-WPB API 5L GrB.

Impact tested ASTM A333 Gr6, A350 LF2, A420 Gr WPL6 API 5L X52, X60, X65

3% Nickel Steels ASTM A333 Gr3, A350 LF3, A420 Gr WPL3 Low Alloy Steels AISI 4130 4.2 Welding Processes All welding of ferritic steels shall be performed with one of the following processes within the restrictions of this Standard unless an alternative is approved by Shell Expro. Shielded Metal Arc Welding Gas Tungsten Arc Welding Submerged Arc Welding Flux Cored Arc Welding - Self shielded and Gas shielded

The heat input shall not exceed 3 kJ/mm unless otherwise approved by Shell Expro. Gas Metal Arc Welding may be allowed if the Contractor can demonstrate to Shell Expro's satisfaction, his experience and control over the process and the competence of his welders. Only GTAW and SMAW shall be used for welding 3% Nickel steels. Unless otherwise approved by Shell Expro, the root and second pass of all welds shall be made using GTAW. Gas shielded processes (GTAW, GSFCAW and GMAW) shall only be used on site with adequate weather shielding approved by Shell Expro. Only fully mechanised SAW systems are permitted.

Page 19 of 90

ES/124 Part 1 Rev 2 1994 4.3 4.3.1 Welding Consumables Selection All consumables offered for use shall be supplied by a manufacturer accredited to ISO 9002 or an equivalent quality standard approved by Shell Expro, be suitable for the application in question and be capable of meeting the requirements of this Standard. The limitations stated in Clause 4.3.2 represent Shell Expro's minimum technical requirements. Where alternative consumables are required for particular applications, (e.g. enhanced corrosion resistance), these will be specified by Shell Expro prior to procedure qualification. All consumable selections shall be submitted for approval by Shell Expro prior to procedure qualification and be supported by manufacturers or other certified performance data. 4.3.2 Limitations Carbon-Manganese and Low Alloy Steels Only AWS Class EXX16 and EXX18 SMAW electrodes shall be used for C and CMn steels unless otherwise agreed with Shell Expro. Consumables producing weld metal Ni contents of 0.6-1.0% shall be used for the first two passes adjacent to the internal surface of all pipework. Consumables (for all welding processes) producing Carbon-Manganese weld metal without alloy additions shall not be used for any pass where an impact testing temperature below -30C has been specified. In this case, consumables producing a weld metal Ni content of between 0.6-1.0% shall be used for all passes, unless otherwise agreed by Shell Expro. 3% Nickel Steels SMAW consumables shall comply with class 7016C2L, 7018C2L, 8016C2 or 8018C2. The GTAW root pass of welds completed using SMAW fill shall use wires complying with AWS A5.28, ER 80S-Ni 2. For welds to be completed using the GTAW process a Nickel wire complying with AWS A5.14, ER NiCr-3 shall be used. 4.3.3 Consumable Handling All consumables shall be supplied in moisture resistant sealed containers. Consumables in unidentified or damaged containers shall be rejected. All consumables in storage shall be clearly identified with brand name, classification and batch number. Records of consumables shall be maintained during pre-treatment, issue to operators and return to stores so that the identity can be verified at any stage. Consumables that cannot be identified to the satisfaction of Shell Expro shall be removed from the work site and any welds made with such consumables shall be cut out and rewelded. All consumables shall be controlled by a procedure approved by Shell Expro. Storage and handling shall be in accordance with the manufacturers' recommendations for the consumable type and packaging adopted. Low hydrogen electrodes supplied to the welder shall be in a condition capable of achieving weld metal hydrogen contents less than 5ml/100g (test method as in BS 6693 Part 1).

Page 20 of 90

ES/124 Part 1 Rev 2 1994 Vacuum packed electrodes may be used subject to the acceptance by Shell Expro of Manufacturers evidence that the claimed weld metal hydrogen levels can be consistently achieved. If adopted, the Contractor shall institute controls and checks that demonstrate, to the satisfaction of Shell Expro, that the claimed hydrogen levels are met at the point of application. Vacuum packed electrodes unused at the end of the period recommended by the manufacturer shall be discarded unless the Contractor obtains Shell Expro approval for rebaking and recycling. Baking and holding ovens and electrode quivers, when used, shall be maintained in good working order and subject to regular calibration checks. Electrodes in quivers shall be maintained at a temperature that is too hot to handle by bare hands. Baking, usage, rebaking and recycling controls shall be appropriate to the electrodes adopted and clearly specified in the consumable handling procedure. Electrodes which are bent, have damaged coatings, have been contaminated or have lost their identity shall be discarded. SAW fluxes shall not be left in the machine hoppers for extended periods when welding is not being carried out, e.g. overnight or during non productive shifts. Recycling of flux shall only be allowed if the procedure is endorsed by the consumable manufacturer and by Shell Expro. GTAW filler wires shall be cleaned with a solvent immediately prior to use. Bare wire for automatic or semi-automatic welding, remaining from a partly used coil or spool, may be reused as new wire if it is promptly repackaged after use in new sealed containers and stored as a new consumable. Bare filler wire in coils or spools that has not been kept in sealed containers after use or has been contaminated with rust, grease or other debris, shall not be re-used without cleaning in accordance with the wire manufacturer's advice. All wire that cannot be cleaned without damage to the surface, change in size or other damage that would adversely affect its use, shall be discarded. 4.4 4.4.1 Welding Procedures Approval Welding procedures shall be qualified for all welded joints in accordance with ASME IX, plus the additional requirements of this Standard. The Contractor shall submit to Shell Expro a list of all welded joint types to be encountered in terms of size, material and position, and the welding procedures by which they shall be made. Prior to the start of welding all procedures shall be approved by Shell Expro. Except when sour service is identified, fillet welds shall be qualified by groove welds per ASME IX, although separate WPSs shall be submitted. Where sour service requirements apply, separate welding procedure qualification tests shall be made (see Table 2). Approval of welding procedures by Shell Expro is subject to acceptable performance in subsequent production. Approval may be withdrawn where excessive repair rates are encountered that cannot be attributed to bad workmanship. 4.4.1.1 Previously Qualified Procedures

Welding procedures previously qualified by the Contractor may be submitted for approval as long as they meet the requirements of this Standard. The Contractor must be able to furnish evidence of the successful application of the procedures on previous work. 4.4.1.2 Procedures to be Qualified

The Contractor shall prepare, for Shell Expro approval, a preliminary WPS for each welding procedure proposed, or a welder instruction card containing standard parameters for the nominated process and consumable combination; if acceptable it shall be approved for qualification only. Procedure qualification shall then be performed according to these instructions.

Page 21 of 90

ES/124 Part 1 Rev 2 1994 Procedure documentation, including the final WPS, (which may be modified from the original submission according to the parameters actually used during qualification), and welder instruction card (if adopted), shall be submitted to Shell Expro for final approval. The WPS and WPQR documentation shall include the information specified in Appendix A. 4.4.2 Essential Variables Any change to the welding procedure outside the allowances of the essential variables in ASME IX, or the limitations below, shall require re-qualification. 4.4.2.1 Thickness

As-welded procedures shall only qualify up to and including 19mm, or B mm for impact tested steel, as defined in Table 1, unless specifically advised on the AFC drawings or by Shell Expro that PWHT is not required. Welding procedure tests conducted on impact tested materials less than 5mm thick need not be impact tested. However, such procedure tests shall not qualify for thicknesses greater than 5mm. 4.4.2.2 Position

The positions qualified by testing are shown in Table 2. Butt weld procedures for site erection and offshore hook-up shall be qualified in either the 6G or 2G and 5G position as allowed in Table 2. Vertical up and vertical down welding require separate qualification. 4.4.2.3 Material

For non-sour service, qualification on any steel designated P1 Group 1 or 2 by ASME IX, shall also qualify any other P1 Group 1 or 2 steel. For sour service, if the Carbon Equivalent of the production material (according to the formula specified in BS 5135) exceeds 0.38%, it shall not be more than 0.03% greater than that of the qualification test material. When Charpy impact testing below -30C is specified, for both sour and non-sour applications, a new procedure qualification shall be required if the impact test temperature specified is lower than that already tested or if the energy requirement is greater than the values recorded in the existing procedure. Qualifications carried out on 3% Nickel steels shall only qualify that material. For welding 3% Nickel steels to other material where impact properties are required, specific procedures shall be qualified using the particular combination of dissimilar materials. 4.4.2.4 Preheat

Preheat temperatures used for qualification tests may be changed within the following limits provided the requirements of Clause 4.6.4.3 in Section 4 of this Standard are satisfied. Carbon-Manganese and Low Alloy steel 3% Nickel Steel 4.4.2.5 Joint Preparation +50C, -0C +25C, -0C

Joint bevel angle shall not be decreased by more than 5 degrees.

Page 22 of 90

ES/124 Part 1 Rev 2 1994 Single sided and double sided preparations require separate qualification. Single bevels and double bevel (K) preparations qualify single vee's and double vee (X) respectively but not vice versa. Otherwise all preparation shapes require separate qualification. However, for SMAW only, changes between single and compound angle V-preparations without re-qualification may be permitted if approved by Shell Expro. Removable backing strips or inserts (if permitted) require separate qualification. 4.4.2.6 Welding Process

The welding process, combination of processes or order of welding processes shall not be changed. 4.4.2.7 Welding Consumables

For welding pressure containing parts where Charpy impact testing below -30C is specified, the brand name of the consumable shall not be changed. For all other items any consumable manufactured to the same classification shall be acceptable (subject to 4.3.1 above). For impact tested material, electrode or filler wire size shall not be changed at any stage of welding. The amount of the minor constituent of the shielding or backing gas in a gas mixture shall not be changed by more than 10%. 4.4.2.8 Welding Conditions

The polarity, or electrical characteristics (ac/dc), shall not be changed for any weld pass. The welding current for SAW, GMAW, FCAW or GTAW shall not be changed by more than +10%. The calculated heat input shall not be increased by more than 20% for any service or decreased by more than 10% for sour service. The stick-out length for FCAW, GMAW and SAW shall not be changed beyond the range specified in the WPS or approved standard parameters. 4.4.2.9 Post Weld Heat Treatment

Post weld heat treated welding procedures require separate qualification. 4.4.3 Welding Procedure Qualification Test All material to be used for qualification shall be agreed with Shell Expro prior to testing. Material to be used for qualification testing shall be positively identified and be traceable to chemical analysis and mechanical properties that confirm it is technically consistent with the materials to be welded in production and the requirements of this Standard. Weld procedure tests shall not commence without the presence of a representative of Shell Expro unless permission has been given to the contrary. The Contractor shall supply all current meters, temperature measurement devices, and other instruments necessary to record the information required by the WPQR (Appendix A). All instruments shall have a current certificate of calibration. The Contractor shall record all the information required by Appendix A. The Weld Procedure Qualification Record shall be signed as witnessed by the Contractor and submitted to Shell Expro.

Page 23 of 90

ES/124 Part 1 Rev 2 1994 PWHT if specified, shall be carried out in accordance with Clause 4.6.5 of this Standard Prior to the final NDT. The welding procedure test piece shall be submitted to the inspection and testing programme detailed below. The required number and type of tests are shown in Table 3. For butt welds, the positions from which specimens are to be taken are shown in Figure 1. For fillet weld test pieces, macro sections shall be removed in accordance with ASME IX, the section nearest to the weld start being taken for hardness survey. 4.4.3.1 Non-Destructive Testing

The following NDT shall be performed in accordance with Section 4.7 of this Standard. Butt Welds Visual MPI Radiography Ultrasonic (as directed by Table 7) Fillet Welds Visual MPI Visual examination of the completed weld shall be conducted by both the Contractor and Shell Expro. No cutting of the test piece for mechanical testing shall take place until it has been examined by a representative of Shell Expro. Should, however, the test piece diameter be too small to allow proper examination of the weld root, the test piece shall be cut longitudinally to facilitate examination. Radiographic examination shall be by X-radiography. 4.4.3.2 Macro Examination

Macro sections shall be prepared so that the whole cross section of the weld, HAZ, and adjacent parent material may be finished and etched to reveal the weld structure including the individual passes and the full extent of the HAZ. The section shall be examined at a magnification of x5. A macro-photograph of the section shall be included in the procedure documentation. The hardness survey indentations (see Clause 4.4.3.3) shall be visible on the macro-photograph. The macrophotograph shall be marked with its magnification. Only original photographs shall be accepted as part of the weld procedure qualification documentation. The prepared surface shall not exhibit cracks, lack of fusion (root, sidewall or inter-run) or volumetric defects (slag, porosity, etc) outside the limits set by Section 4.7 (these may be investigated by grinding and/or re-sectioning to define their extent). Fillet welds shall meet the following, additional requirements: Fillet welds must show full fusion to the root of the fillet. The length of each leg shall be equal to or greater than the specified weld size and there shall be no more than 3mm difference between the two. The throat thickness shall be at least 0.7 x the specified leg length. Convexity or concavity shall be no greater than 1.5mm.

Page 24 of 90

ES/124 Part 1 Rev 2 1994 4.4.3.3 Hardness

Hardness surveys shall be carried out using Vickers hardness at 10Kg load on a macro section prepared as above. Testing shall be in accordance with BS 427 Part 1. The location of the traverses, for both butt and fillet welds, shall be as shown in Figure 2. For pipe butt welds where the wall thickness is 9.5 mm or over, an additional traverse shall be made midway between the two shown. The spacing of indentations in the visible HAZ shall be 0.75mm between centres. The centre of the first impression in the HAZ shall be 0.5mm from the fusion line. The spacing in the weld and parent metal shall be 2mm. The maximum acceptable hardness values shall be: Non-sour service Weld, HAZ, Parent material Sour service (single sided welds) Wall thickness < 9.5mm Weld, HAZ, Parent material Wall thicknesses 9.5mm Weld, HAZ, Parent material (Root) Weld, HAZ, Parent material (Cap) 250 HV10 275 HV10 250 HV10 325 HV10

For welds made from two sides the root hardness requirements shall apply to the weld cap on the ID of the pipe. 4.4.3.4 Charpy Impact Testing

Charpy impact testing shall only be required if the service application requires impact tested material. Charpy V-notch specimens shall be prepared and tested in accordance with BS EN 10045 Part 1. For welds made with a maximum heat input of 2kJ/mm, a set of three Charpy impact specimens shall be taken with notches at the weld centre line, fusion line and fusion line + 2mm as shown in Figure 3. Where heat inputs greater than 2kJ/mm have been used an additional set of three specimens is to be taken at fusion line + 5mm. For single sided welds, the specimens shall be taken with the lower surface no more than 2mm above the inner pipe surface. Additionally, for material thicknesses of greater than 20mm, a set of three specimens shall be taken with their notches at the weld centre line and with their upper surfaces within 2mm of the outer surface of the pipe. Each specimen shall be etched prior to notching and the location of the notch relative to the fusion or weld centre line individually marked. The notch shall be placed in the square face of single bevel welds. The notch positions for 2 sided welds shall be agreed with Shell Expro. Full size (10mm x 10mm) impact test specimens shall be used wherever possible; where this is not possible, the larger of three quarter size (7.5mm x 10mm) or half size (5mm x 10mm) specimens shall be used. The test temperature and acceptance criteria shall be in accordance with Table 4. No result shall be less than the specified minimum individual value and not more than one result shall be less than the minimum average value specified.

Page 25 of 90

ES/124 Part 1 Rev 2 1994 If the above requirements are not met, 3 further specimens shall be tested. The average of the 6 specimens shall be not less than the minimum specified average; only 2 values may be below the specified minimum average value and only one of those may be below the specified minimum individual value. 4.4.4 Repair Welding Procedures Repair welding shall normally be carried out to the same procedure as the original welding. In these circumstances repair welding procedure qualification shall not be required but a separate WPS shall be required. The Contractor shall submit to Shell Expro for approval a general repair procedure detailing: method of defect excavation; shape and size of excavation prior to re-welding; inspection prior to re-welding; weld procedure to be used (if different from original weld).

Where a different welding procedure is to be used for repair welding, (e.g. SMAW for the repair of SAW welds) a procedure shall be qualified in accordance with this standard. Qualification shall require the reproduction of a typical production repair. For part wall excavations the remaining ligament adopted shall be the smallest allowed in production. Full penetration excavations shall be qualified separately. The test repair welds shall be subject to hardness survey and transverse tensile testing. In addition, where impact testing had been specified for the original weld, impact testing of the repair weld metal and the adjacent HAZs, both in the parent material and the original weld metal, shall be carried out at the testing temperature of the original weld. 4.5 4.5.1 Welder Qualification General All welders and welding operators shall be qualified in accordance with ASME IX. Fillet welds may be qualified by groove weld performance tests. For site erection and offshore hook-up qualification testing shall be in the 6G position. 4.5.2 Pre-Qualification Welders qualified on work other than for Shell Expro shall be accepted provided: qualification has been carried out to ASME IX and the requirements of this Standard have been met. qualification testing has been witnessed by a Certifying Authority or independent third party acceptable to Shell Expro, and the certificate of qualification is endorsed as acceptable by the Authority; the Contractor can give proof that the welder has been continuously employed by him for the previous six months and has been welding with reasonable continuity during that time, to the same, or similar, procedures with satisfactory results.

4.5.3

Documentation Prior to commencement of work, the Contractor shall submit:

Page 26 of 90

ES/124 Part 1 Rev 2 1994 4.5.4 a register of the welders to be used on the work, giving the procedures, positions and thickness ranges in which they are qualified, together with the identity number for each welder; all weld performance qualification certificates, including relevant back-up documentation, such as NDT and mechanical test certificates.

Time Limitations Welder and Operator performance qualification shall be for a six month period from the date of approval. Qualification certificates may be re-approved for further periods of six months by Shell Expro provided the welder has been employed with reasonable continuity on welding covered by the performance certificate. The essential variables in ASME IX applicable to performance qualification apply to these criteria. Shell Expro may demand the re-qualification of any welder, at any time, if there are reasonable grounds to question that welder's ability to weld to the specified procedure.

4.6 4.6.1

Welding - General Requirements Shop/Site Conditions The Contractor shall ensure that welding is adequately screened from draughts and inclement weather. Particular care shall be taken where gas shielded methods are employed; should, in the opinion of Shell Expro, inadequate protection be provided, work shall be halted until the situation has been rectified to the satisfaction of Shell Expro.

4.6.2

Equipment All equipment shall be in good condition and properly maintained. 4.6.2.1 Gas Cutting Equipment

All gas cutting equipment shall comply with BS 6503. 4.6.2.2 Welding Equipment

All welding equipment shall be in accordance with the relevant section of BS 638. Ammeters and voltmeters shall be fitted to equipment for GMAW, FCAW and SAW. In addition, separate voltmeters and ammeters ('tong tester' or Hall effect type) shall be provided for all welding processes. All meters shall be calibrated immediately prior to the commencement of production welding and thereafter at regular intervals according to the Contractor's calibration procedure. This procedure shall be agreed with Shell Expro before the start of production. 4.6.3 Preparation for Welding 4.6.3.1 Permitted Weld Detail

All pipe joint welds shall be full penetration butt welds unless otherwise specified. Permanent backing strips shall not be used. Fusible inserts or removable backing strips may only be used with the approval of Shell Expro. Where fillet welds are used, the requirements of ANSI B31.3 shall be applied. Socket welded fittings shall not be permitted unless approved by Shell Expro.

Page 27 of 90

ES/124 Part 1 Rev 2 1994 4.6.3.2 Weld Preparation

Weld preparations shall be in general accordance with ANSI B16.25. Square butt ends are permissible below 2mm wall thickness. Weld preparations and a distance 25mm either side shall be free from rust, scale and other contaminants. Deep gouges and dents on the preparation surface shall be cause for rejection. Weld repair of such defects shall only be permitted by approval of Shell Expro. Laminations identified on the bevel surface by visual examination shall be investigated by MPI prior to removal. Where weldolets or similar fittings of greater than 50mm branch size are to be attached, the run pipe at that point shall be examined by compression wave UT in accordance with ASME V, Article 5, requirements for welds. Indications over reference level shall be reported to Shell Expro prior to cutting the opening in the run pipe. Wooden or plastic covers shall be provided to protect weld bevels from mechanical damage and prevent ingress of foreign material into the pipe. 4.6.3.3 Cutting and Bevelling

Pipes may be cut mechanically or by oxy-fuel gas cutting. Weld bevels are to be prepared by machining or by mechanically guided flame cutting. Bevelling with hand-held cutting torches is not permitted except when specifically approved by Shell Expro. Flame cut bevel surfaces shall be ground to bright metal unless the welding procedure was qualified with unground surfaces. 4.6.3.4 Alignment

The permitted maximum misalignment of butt welds shall be: Internal Pipe Diameter 100mm >100mm External Pipe Diameter 12mm > 12mm Misalignment pipe thickness/4 3mm Misalignment 1.0mm 1.6mm

Misalignments greater than these limits may be corrected by grinding or machining to a taper of 1:4 provided the wall thickness is not reduced below the minimum tolerance. Reforming of the pipe, either hot or cold, shall not be attempted without the approval of Shell Expro. 4.6.3.5 Spacing

Longitudinal seams on adjacent pipes shall be separated by at least 45 degrees of rotation or 150mm, whichever is the less. Circumferential welds shall be separated by at least 4 times the nominal pipe wall thickness (toe to toe). Attachments shall be at least 2 times the nominal pipe thickness or 40mm (toe to toe) from any weld, whichever is the smaller.

Page 28 of 90

ES/124 Part 1 Rev 2 1994 4.6.3.6 Tack Welding and Clamping

If line-up clamps are used without tack welding they shall not be removed until after the root pass has been completed. The preferred method of tack welding for single sided welds shall be by the temporary welding of a short length of round bar along the bevel faces of the preparation. The bar material shall be specified by the Contractor and approved by Shell Expro. Tack welds intended to be an integral part of the root weld shall be ground to a taper edge to facilitate weld pick-up. Tack welds shall be at least 25mm in length and shall be equally spaced around the circumference in sufficient number to support the pipe or fitting. They shall be welded in accordance with the root parameters of the weld procedure specified for the joint. Cracked or badly profiled tack welds are to be completely removed prior to welding. All tack welding is to be carried out according to a qualified weld procedure and performed by qualified welders. 4.6.4 Weld Execution 4.6.4.1 Identification

Welds are to be uniquely identified (see Clause 4.7.1). The Contractor shall demonstrate to the satisfaction of Shell Expro that individual welds can be positively identified at all stages of construction, with particular attention being given to maintaining identification during grit-blasting and painting. The identification number shall be marked adjacent to the weld by crayon, paintstick or similar marker prior to welding. Similarly, welders shall mark their numbers adjacent to the weld they are about to make. 4.6.4.2 Backpurging

A back purge with high purity Argon shall be required for GTAW of 3% Nickel steels unless otherwise approved by Shell Expro. The method of application of backpurging shall be detailed, either in the relevant WPS or in a separate document referred to by the WPS and shall be submitted to Shell Expro for approval prior to weld procedure qualification. The oxygen content shall not exceed 1.0% immediately prior to welding. This shall be demonstrated during weld procedure qualification and production by means of a suitable oxygen meter. Where internal dams are to be used on site, the procedure shall include precautions for ensuring their removal after welding. Soluble dams are to be approved by Shell Expro and used in accordance with the Manufacturer's recommendations. 4.6.4.3 Preheat Temperature Requirements

The Contractor shall submit for approval by Shell Expro a schedule of preheats complying with this clause for the ranges of thickness and configurations to be used in construction. This may be included in the welder's instruction cards if adopted. For Carbon-Manganese and low alloy steels, the minimum preheat shall be as calculated in accordance with BS 5135 using the maximum Carbon equivalent allowed for the material to be welded and the weld metal hydrogen level guaranteed by the approved consumable control procedure. The arc energy used in the calculation shall be the lowest single pass value, by that welding process, encountered in any of the qualification test welds of the weld procedures to be used in production.

Page 29 of 90

ES/124 Part 1 Rev 2 1994 If higher preheats are found to be necessary to meet the hardness values required by this Standard, particularly for sour service conditions, the temperature margin above the minimum required by BS 5135 shall be preserved for all thicknesses to be welded. Where Sweepolets are to be welded, the minimum preheat is to be 50C above that indicated by BS 5135. When preheat is not explicitly required by this Standard, sufficient preheat shall be applied to ensure the work is dry and warm to touch if the ambient temperature is below zero or if condensation or other moisture is apparent on the work. For 3% Nickel steels, a minimum preheat of 100C shall be used for welding all thicknesses. 4.6.4.4 Preheat Application

For up to and including 19 mm, preheating shall be by gas torch or electrical resistance heaters. Above 19 mm, electric resistance heating mats shall be used except when it is agreed with Shell Expro that access or location makes it impractical. Electric resistance elements shall be controlled by thermocouples attached on or adjacent to the weld preparation unless an alternative proposal is accepted by Shell Expro. Preheating with oxy/fuel gas shall only be by soft flame burners designed for the purpose. Hand held oxy/fuel gas burners shall only be used for welds on pipes less than 150mm OD or attachment welds less than 300mm long. Preheat temperature may be measured using contact pyrometers, temperature indicating crayons or thermocouples. Thermocouple devices shall be regularly calibrated according to a procedure agreed with Shell Expro. Where access permits, preheat temperature shall be measured on the opposite surface of the work being heated. Temperature shall be measured at a location displaced from the source of heat by a minimum of 25mm in a direction parallel to the pipe axis. Contact pyrometers and temperature indicating crayons must be offered to the work after application of heat and after removal of the flame. If access is not possible to the opposite surface temperature measurement shall be delayed for a period not less than 2 seconds per mm of thickness after removal of the heat source. Temperature indicating crayons shall be certified free of lead and sulphur. Residue from crayons shall be removed from the weld surface before proceeding with the weld. 4.6.4.5 Interpass Temperature

The maximum interpass temperature, unless otherwise established by procedure qualification, shall be 300C for non-impact tested CMn steels, 250C for impact tested CMn and low alloy steels, and 150C for 3% Nickel steel. The minimum interpass is to be the minimum preheat temperature. 4.6.4.6 Interruption of Welding

Unless otherwise approved by Shell Expro, a minimum of 25% of the joint thickness or, where greater, the root and second pass is to be completed before welding is interrupted and the joint allowed to cool. Slow cooling is to be insured by wrapping the joint in insulation. 4.6.4.7 Arc Strikes

Arc strikes shall be removed by grinding and the area shall be subject to MPI.

Page 30 of 90

ES/124 Part 1 Rev 2 1994 The thickness of material remaining after the removal of such defects shall be measured ultrasonically. Materials below the minimum required thickness shall be replaced. Weld repair of such areas shall not be permitted. 4.6.4.8 Weld Finish

All welds must be finished with a smooth profile, without overlap, abrupt ridges or valleys, and blend smoothly with the base material. Toe profile grinding or cosmetic grinding is only to be carried out if directed by the AFC drawings or approved by Shell Expro. If fillet welds are concave or not equal, the minimum throat size shall not be less than 0.7 x the specified leg length. The profile of the root bead on weldolets shall be as specified for butt welds. The contour of the completed weld shall be as shown in Figure 4, unless Shell Expro advise that the design requirement can be met with a smaller weld. Visual imperfections shall comply with Clause 4.7.8 of this Standard. 4.6.5 Post-Weld Heat Treatment Welds in NON IMPACT tested pipes and fittings shall be PWHT if the wall thickness exceeds 19mm unless advised otherwise on the AFC drawings or by Shell Expro. For branch connections in non impact tested steels the wall thickness, t, shall be taken as the 'governing thickness' as defined in ANSI B31.3 Section 331.1.3. Welds in IMPACT tested pipes and fittings shall be PWHT if the wall thickness exceeds the thickness B defined in Table 1. All welds in AISI 4130 material shall be PWHT. For branch connections in impact tested steel, PWHT is required where the wall thickness of the fitting exceeds thickness B, as defined in Table 1, or where, for 'O'-let fittings, the maximum thickness of the fitting exceeds 4B, or the weld thickness exceeds 38 mm (refer to Figure 4). 4.6.5.1 Procedures

All PWHT shall be carried out in accordance with a procedure approved by Shell Expro prior to commencement. As a minimum the procedure shall include the following information: name of (sub) contractor; ruling specification; material and item type; method of heating; fuel gas and method of atmosphere control (if gas-fired furnace); size and type of electrical element (if electrical resistance); type, location and number of thermocouples; method of thermocouple attachment;

Page 31 of 90

ES/124 Part 1 Rev 2 1994 details of loading and supporting arrangements to avoid distortion; provisions to avoid flame impingement (if flame heated) holding time and temperature; heating and cooling rates; type of recording equipment including number of channels; chart speed. Conditions

4.6.5.2

Holding temperature CMn steels 3% Nickel steel CrMo steel (AISI 4130) 580C - 620C 590C - 630C 660C - 700C

In the case of quench and tempered steels the actual holding temperature shall be at least 25C below the finishing temperature recorded on the material certificate. Holding time t 25 t > 25mm Maximum heating rate above 300C Maximum cooling rate above 300C t 25mm t > 25mm t 25mm t > 25mm 1 hour t/25 hours 220C/hour 220 x 25/tC/hour 275C/hour 275 x 25/tC/hour

(Cooling in still air is permitted below 300C.) 4.6.5.3 Furnace PWHT

Wherever possible PWHT shall be performed in a fully enclosing furnace. Combustion heated furnaces shall be controlled to avoid an oxidising furnace atmosphere. There shall be no direct flame impingement on the items being heat treated. During heating and cooling the temperature shall not vary by more than 150C in any 4500mm length. The soak temperature shall within the range given above in Clause 4.6.5.2. The number of thermocouples shall be sufficient to ensure that the temperature and thermal gradients of the whole of the work are within the required range. One thermocouple shall be attached directly to each spool at the point of greatest wall thickness. If a large number of small spools are to be treated in one batch, thermocouples may be attached to a representative number (no less than one in four) of the spools.

Page 32 of 90

ES/124 Part 1 Rev 2 1994 4.6.5.4 Local PWHT

Local PWHT shall be allowed where size or installation restrictions prevent furnace treatment. Heating shall normally be by electrical resistance heating elements. Other heating methods shall only be approved by Shell Expro after demonstration that the required temperature controls are systematically achievable. The soak temperature shall be achieved and maintained in a band 2.5 x weld thickness (e) either side of the weld centre line. The width of the thermal insulation shall be 7.5e either side of the weld centre line. Circulation of air in the bore of the pipework shall be prevented. The minimum number and position of thermocouples shall be as follows: External Pipe Dia. mm 100 >100 300 > 300 No. of Thermocouples per Weld. 1 2 4 'Clock' Position 12 6, 12 3, 6, 9, 12

Thermocouples shall be located on the weld centre line and shall either be held in intimate contact with the surface of the weld mechanically or be attached by capacitance discharge welding. The attachment points of capacitance discharge welded thermocouples shall be dressed by grinding after removal. 4.6.5.5 Recording and Reporting

The temperature measured by each thermocouple shall be recorded graphically throughout the whole heat treatment cycle by means of a multi-channel chart recorder. The chart shall be submitted to Shell Expro, together with a heat treatment report. The chart shall be marked with the date of the PWHT, the weld or spool number(s), channel identification and signature of (sub)contractor. The heat treatment report shall reference the procedure and technique sheet, if relevant, and contain sufficient information to ensure traceability to the item(s) under treatment and confirm compliance with the approved procedure. It shall also contain an authorised signature of the (sub)contractor. 4.7 4.7.1 Inspection General Requirements Inspection, as detailed below, shall be carried out by the Contractor. The Contractor shall establish, and submit to Shell Expro for approval, a system, uniquely identifying each weld, for the control and recording of inspection. It is recommended that isometric drawings, marked with the individual weld numbers, be maintained for this purpose. The Contractor shall submit to Shell Expro for approval detailed NDT procedures. These shall, unless otherwise permitted by Shell Expro, be demonstrated on a representative test piece to meet the requirements of this Standard. Where PWHT is required, final non-destructive testing shall not take place until this has been completed. 4.7.2 Visual Inspection Visual inspection shall be carried out by the Contractor on all:

Page 33 of 90

ES/124 Part 1 Rev 2 1994 prepared joints prior to welding; completed welds.

Pre-weld checks shall include compliance with Clause 4.6.3.4 and the tolerances of the WPS. Examination is to include the internal surface of the weld wherever possible. The visual acceptance of each weld shall be recorded by the Contractor. 4.7.3 Magnetic Particle Inspection Magnetic particle inspection shall be carried out in accordance with ASME V, Article 7. Surface irregularities, such as weld spatter, shall be removed from the weld area prior to testing. Magnetisation shall normally be by electromagnetic yoke using alternating current. Coil or parallel conductor methods shall only be used if approved by Shell Expro. Only the wet method shall be employed, using either black ink on white background or ultra-violet fluorescent ink. The thickness of background paint shall not exceed 10m. The sensitivity of the method employed shall be demonstrated, prior to acceptance of the MPI procedure by means of a calibrated Burmah-Castrol strip, Type 1, and/or suitable sample welds. It shall also be periodically checked during production at the request of Shell Expro and also in accordance with the Contractor's own QA procedures. 4.7.4 Radiographic Examination Radiography shall be in accordance with BS 2910, with the following additional requirements and modifications: the source/thickness limitations tabulated below shall apply except when approved by Shell Expro as indicated in the notes to the table. Thickness mm 12 > 12 Shop Fabrication X-ray (1) Gamma Site & Offshore Gamma Gamma Isotope Ytterbium 169 OR Iridium 192 (2) Iridium 192 (3)

Notes to the above Table (1) (2) Unless it can be demonstrated that the sensitivity requirements of Table 5 can be achieved by specific gamma ray procedures. Ytterbium offers benefits in both radiographic quality and a reduction in health and safety hazards which allows less disruption to surrounding work. Its use is therefore encouraged. Iridium 192 may be used at thicknesses below 12mm, provided the required sensitivity can be obtained. Thicknesses greater than 12mm may be attempted using Ytterbium 169 provided it can be demonstrated that the required sensitivity can be obtained. for general radiography, only lead intensifying screens shall be used. Fluoro-metallic screens may be used in particular cases, if approved by Shell Expro, where the purpose is to extend the practicable range of radiography. sensitivity shall be assessed by DIN 54109 type image quality indicators. for the DWSI and DWDI technique the required sensitivity (and wire number) is shown in Table 5. For the SWSI technique, the values specified by BS 2910 shall be required.

(3)

Page 34 of 90

ES/124 Part 1 Rev 2 1994 the radiographs shall be positively located relative to a marked datum point on the weld. For radiographs other than those taken with the DWDI technique this shall be affected by means of a number tape with lead numbers at a maximum of 100mm spacing. For DWDI radiographs the three radiographs shall be identified as 'A', 'B' and 'C' by means of lead letters. The centre line of these three exposures shall be marked on the weld.

4.7.5

Ultrasonic Examination Ultrasonic examination of welds shall be carried out in accordance with ASME V, Article 5. On branches, O-lets and similar geometry's, scanning from the internal surface shall be carried out if practicable.

4.7.6

Inspection Personnel The inspection personnel to be used by the Contractor are to be individually approved by Shell Expro. Shell Expro reserve the option to interview operatives and, when necessary, to require a practical skill test. The minimum qualification requirements are as follows: Visual MPI Radiography Interpretation only Ultrasonic CSWIP WI-60-80, 3.1 (Welding Inspector) PCN/GEN/92 Appendix E1.1, Level 2 PCN/GEN/92 Appendix C2.1, Level 1 or level 2 PCN/GEN/92 Appendix C2.1, Level 2 OR Radiographic Interpreter PCN/GEN/92 Appendix C1.1, Level 2 Group 3.2

Alternative qualifications (e.g. SNT) will be accepted only by specific approval of Shell Expro. Approval will be subject to satisfactory demonstration of independence and control of the qualification standards. 4.7.7 Extent of Inspection of Production Welding Table 6 provides guidance on inspection classes in terms of service and pressure rating but specific inspection classification will be advised on the AFC drawings or pipework schedules. The required extent of inspection for each class is listed in Table 7. For wall thicknesses over 19mm, radiography of individual welds, in place of ultrasonic examination, shall be carried out when specified by Shell Expro. Percentage radiography refers to the number of whole welds to be fully radiographed. The welds shall be selected so that the maximum number of welders are evaluated. Should an Inspection Class 1 or 2 weld contain unacceptable defects two further welds made by that welder shall be radiographed. If either of these prove unacceptable, all welds produced by that welder shall be considered unacceptable unless proved otherwise to the satisfaction of Shell Expro. All welds found to be unacceptable shall be removed or repaired. 4.7.8 Acceptance Standards Visual Examination Prior to welding Finished welds MPI In accordance with Clause 4.6.3 of this Standard. In accordance with Table 8 of this Standard. ASME VIII, Appendix 6-4

Page 35 of 90

ES/124 Part 1 Rev 2 1994 Radiography Ultrasonic Examination 4.7.9 Reporting All inspection reports shall be signed by the approved operative who did the inspection and contain sufficient information to ensure traceability to the weld inspected and the procedure used. It shall record all equipment identification and settings to enable the inspection to be repeated to the same procedure. All defects shall be identified and located relative to a clear reference. Details of the minimum information to be recorded are included in Appendix B. 4.8 4.8.1 Repairs General Repairs and remedial grinding shall not commence before informing Shell Expro. Second attempts at repairing the same weld area shall only be made by permission of Shell Expro. Where permission for a second repair is not given the whole weld is to be removed. Welds containing repairs that were made after PWHT shall be re-heat treated in accordance with this Standard, unless approved otherwise by Shell Expro. 4.8.2 Defect Removal Surface profile defects or surface porosity on the cap, or root if accessible, may be removed by disc grinding or burr grinding to a smooth profile subject to the minimum material thickness being maintained. Unacceptable defects shall be excavated by mechanical means or Carbon arc gouging followed by grinding. Carbon arc gouging operatives shall be approved by Shell Expro. The excavation shall be controlled by gauges and MPI to ensure the minimum amount of material necessary is excavated to completely remove the defect. The excavation shall be ground to a smooth boat shape with no sharp edges and have sufficient slope on the sides to permit proper access for welding. 4.8.3 Root Repairs Where access permits and if approved by Shell Expro, weld repairs to the root of a single sided weld may be permitted from the inside subject to the availability of a suitably qualified procedure. Where access does not permit internal rectification, special attention shall be necessary to locate the defect prior to excavation from the outside and to controlling the root gap of the excavation. If the component remains under external loading during the excavation, the permitted size of the excavation shall be agreed with Shell Expro. Specific provision may be necessary to support the assembly in some circumstances. 4.8.4 Rewelding Repair welding shall be in accordance with Clause 4.4.4 of this Standard. If, after excavation, the root gap geometry is outside the allowable tolerances of the relevant procedure, a new repair welding procedure shall be qualified unless alternative proposals are accepted by Shell Expro. In accordance with Table 9 of this Standard ASME VIII, Appendix 12-3

Page 36 of 90

ES/124 Part 1 Rev 2 1994 4.8.5 Non-Destructive Testing All repair welds are to be 100% re-inspected by the methods specified for the original weld.

Page 37 of 90

ES/124 Part 1 Rev 2 1994

Page 38 of 90

ES/124 Part 1 Rev 2 1994 5 5.1 STAINLESS STEELS, NICKEL ALLOYS, COPPER-NICKEL AND TITANIUM Materials The following materials are covered by this section. Austenitic Stainless Steels AISI 300 Series, Grades 304L, 304, 316L, 316, 321, 347 6 Mo Stainless Steels UNS S31254, UNS N08367, UNS N08925, UNS N08926 Duplex Stainless Steel UNS S31803, (22% Cr) UNS S3255O, UNS S32750, UNS S32760 (25% Cr) Nickel Alloys UNS N08825 (825), UNS N06625 (625) Copper - Nickel UNS N04400 (Monel), BS 2870/2871/2875 grade CN102 DIN 17664 No. 2.0872 CU NI 10 FE Titanium ASTM B337 Gr2 (Pipe) ASTM B363 Gr.WPT2 (Fittings) ASTM B381 Gr.F2 (Flanges) 5.2 Welding Processes All welding shall be performed by the GTAW process except as noted below. A filler wire shall always be used for welding 6 Mo stainless steel and all duplex stainless steels. The SMAW or SAW process may be used for the fill passes (pass 3 onwards) of welds in austenitic, 6 Mo and duplex stainless steels. All GTAW equipment shall be fitted with a high frequency starting unit and a crater-eliminating slope out control. If these are not permitted by legislative bodies, alternative proposals shall be submitted to Shell Expro for approval. For welding Titanium, GTAW torches shall be fitted with gas lenses. 5.2.1 Welding Heat Input Limitations Welding heat inputs shall not exceed the following limits:

Page 39 of 90

ES/124 Part 1 Rev 2 1994 Material Austenitic stainless steels 6 Mo stainless steel 22% Cr Duplex 25% Cr Duplex Root Passes 2 and 3 Remainder Nickel Alloys Copper-Nickel Titanium 5.3 5.3.1 Welding Consumables Selection All consumables offered for use shall be supplied by a manufacturer accredited to ISO 9002 or an equivalent quality standard approved by Shell Expro; be suitable for the application in question and be capable of meeting the requirements of this Standard. The limitations stated in Clause 5.3.2 represent Shell Expro's minimum technical requirements. Where alternative consumables are required for particular applications, (e.g. enhanced corrosion resistance), these will be specified by Shell Expro prior to procedure qualification. All consumable selections shall be submitted for approval by Shell Expro prior to procedure qualification and be supported by manufacturers or other certified performance data. 5.3.2 Limitations SAW and SMAW consumables shall not be used where the principal alloy additions are added through the flux. However, final alloy compositions may be achieved through supplementary additions in the flux to compensate for element losses during welding or to trim an appropriate alloy core wire analysis to that required. The shielding gas shall be high purity Argon, except as noted below, unless other mixtures are approved by Shell Expro. The root and second pass of single-sided welds in duplex stainless steel shall be deposited with an Argon shielding gas containing 2-3% Nitrogen unless otherwise approved by Shell Expro. High purity Helium or Argon/Helium mixtures are also acceptable shielding gases for welding Titanium. Consumables shall be selected from one of the following classifications: Austenitic Stainless Steels 304, 304L 321, 347 316, 316L ER308L, ER347 (GTAW), E308, E347 (SMAW) ER347 (GTAW), E347 (SMAW) ER316L (GTAW), E316L (SMAW) 1.0 - 1.5 kJ/mm 0.5 - 1.2 kJ/mm 0.5 - 1.75 kJ/mm Unrestricted Unrestricted Unrestricted Heat Input Unrestricted 1 kJ/mm max 0.5 - 1.75 kJ/mm

When required by the application, or advisd by Shell Expro, Nickel consumables as defined below shall be used.

Page 40 of 90

ES/124 Part 1 Rev 2 1994 SMAW GTAW 6 Mo Stainless Steels UNS S31254, UNS N08367, UNS N08925 and UNS N08926 Duplex Stainless Steels Consumables shall comply with a chemical composition accepted as suitable by the material supplier. Only consumables that can be shown to meet the acceptance criteria for the mechanical and corrosion testing required by this Standard shall be proposed. The Nickel content shall also overmatch the parent material analysis unless the finished fabrication is to be solution annealed. Nickel Alloys UNS N08825 UNS N06625 UNS N0440 (Monel) Copper-Nickel Grade CN102 (90/10) Titanium Filler materials shall have the same nominal composition as the base material. Where it is proposed to weld any of the above materials to other materials (e.g. CMn steels) and this considered to be feasible, consumables shall be selected with regard to the effects of dilution and submitted to Shell Expro for approval. 5.3.3 Consumable Handling All consumables shall be supplied in moisture resistant sealed containers. Consumables in unidentified or damaged containers shall be rejected. All consumables in storage shall be clearly identified with brand name, classification and batch number. Records of consumables shall be maintained during pre-treatment, issue to operators and return to stores so that the identity can be verified at any stage. Consumables that cannot be identified to the satisfaction of Shell Expro shall be removed from the work site and any weld made with such consumables shall be cut out and rewelded. All consumables shall be controlled by a procedure approved by Shell Expro. Storage and handling shall be in accordance with the manufacturer's recommendations for the consumable type and packaging adopted. TAW AWS 5.7 ERCuNi or BS 2901 Pt 3, C18 SMAW GTAW SMAW GTAW GTAW AWS 5.11 ENiCr-3 or AWS 5.11 ENiCrMo-3 AWS 5.14 ERNiCr-3 or AWS 5.14 ERNiCrMo-3 AWS 5.11 ENiCrMo-3 AWS 5.14 ERNiCrMo-3 AWS 5.14 ERNiCu-7 or AWS 5.14 ERNiCrMo-3 AWS 5.14 ERNiCrMo-3 (GTAW) AWS 5.11 ENiCrMo-3 (SMAW) AWS 5.11 ENiCrMo-3 AWS 5.14 ERNiCrMo-3

Page 41 of 90

ES/124 Part 1 Rev 2 1994 Electrodes that are bent, have damaged coatings, have been contaminated or have lost their identity shall be discarded. SAW fluxes shall not be left in the machine hoppers for extended periods when welding is not being carried out, e.g. overnight or during non-productive shifts. Recycling of flux shall only be allowed if the procedure is endorsed by the consumable manufacturer and by Shell Expro. GTAW filler wires shall be cleaned with a solvent immediately prior to use. Bare wire for mechanised or semi-automatic welding, remaining from a partly used coil or spool, may be reused as new wire if it is promptly repackaged after use in new sealed containers and stored as a new consumable. Bare filler wire in coils or spools that has not been kept in sealed containers after use or has been contaminated with rust, grease or other debris, shall not be re-used without cleaning in accordance with the wire manufacturer's advice. All wire that cannot be cleaned without damage to the surface, change in size or other damage that would adversely affect its use, shall be discarded. 5.4 5.4.1 Welding Procedures Approval Welding procedures shall be qualified for all welded joints in accordance with ASME IX, plus the additional requirements of this Standard. The Contractor shall submit to Shell Expro a list of all welded joint types to be encountered in terms of size, material and position, and the welding procedures by which they shall be made. Prior to the start of welding all procedures shall be approved by Shell Expro. Except for 6 Mo and duplex stainless steels and when sour service is identified, fillet welds shall be qualified by groove welds in accordance with ASME IX, although separate WPSs shall be submitted. For 6 Mo and duplex stainless steels and where sour service requirements apply, separate welding procedure qualification tests shall be made (see Table 2). Approval of weld procedures by Shell Expro is subject to acceptable performance in subsequent production. Approval may be withdrawn where excessive repair rates are encountered that cannot be attributed to bad workmanship. 5.4.1.1 Previously Qualified Procedures

Welding procedures previously qualified by the Contractor may be submitted for approval as long as they meet the requirements of this Standard. The Contractor must be able to furnish evidence of the successful application of the procedures on previous work. 5.4.1.2 Procedures to be Qualified

The Contractor shall prepare, for Shell Expro approval, a preliminary WPS for each welding procedure proposed, or a welder instruction card containing standard parameters for the nominated process and consumable combination; if acceptable it shall be approved for qualification only. Procedure qualification shall then be performed according to these instructions. Procedure documentation, including the final WPS, (which may be modified from the original submission according to the parameters actually used during qualification), and welder instruction card (if adopted), shall be submitted to Shell Expro for final approval. The WPS and WPQR documentation shall include the information specified in Appendix A. 5.4.2 Essential Variables Any change to the welding procedure outside the allowances of the essential variables in ASME IX, or the limitations below, shall require re-qualification.

Page 42 of 90

ES/124 Part 1 Rev 2 1994 5.4.2.1 Thickness

25% Cr duplex stainless steels The thickness ranges qualified shall be as follows: Thickness tested (t) < 5 mm 5 mm Thickness Qualified t - 1.5t 0.75t (but not < 5mm ) - 1.5t

Weld procedure tests conducted on material less than 5mm thick need not be impact tested. However, such procedure tests shall not qualify for thicknesses greater than 5mm. Titanium The thickness tested is the maximum qualified. 5.4.2.2 Position

The positions qualified by testing are shown in Table 2. In addition, butt weld procedures for site erection and offshore hook-up of 6 Mo and duplex stainless steels shall be qualified in the 2G and 5G position. Vertical up and vertical down welding require separate qualification. 5.4.2.3 Material

Qualification on type 316 stainless steel shall qualify for type 316L but not vice versa. Qualification on type 304 stainless steel shall qualify for type 304L but not vice versa. A new procedure qualification shall be required for duplex and 6 Mo stainless steels if the UNS number is changed. Also for duplex stainless steels, a new procedure qualification shall be required if the parent material Nitrogen content is changed by more than 15% of that qualified. 5.4.2.4 Joint Preparation

Joint bevel angle shall not be reduced by more than 5 degrees. In addition it shall not be increased by more than 10 degrees for 6 Mo and duplex stainless steels. For welding 6 Mo and duplex stainless steels and Titanium, the root gap tolerance shall be -0 +2mm Single sided and double sided preparations require separate qualification. Single bevels and double bevel (K) preparations qualify single vee's and double vee (X) respectively but not vice versa. Otherwise all preparation shapes require separate qualification. Removable backing strips or inserts (if permitted) require separate qualification. 5.4.2.5 Welding Process

The welding process, combination of processes or order of welding processes shall not be changed.

Page 43 of 90

ES/124 Part 1 Rev 2 1994 5.4.2.6 Welding Consumables

The electrode or filler wire size shall not be changed at any stage of welding. The composition of the minor constituent of the shielding or backing gas in a gas mixture shall not be changed by more than 10%. The brand name or country of origin of consumables for welding duplex stainless steels shall not be changed. The PREN of consumables used for duplex stainless steels shall not be reduced by more than 0.5. 5.4.2.7 Welding Conditions

The polarity, or electrical characteristics (ac/dc), shall not be changed for any weld pass. The welding current for GTAW shall not be changed by more than +10% nor shall the characteristics change from normal to pulsed current or vice versa. For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by Shell Expro. The calculated heat input shall not be changed by more than 10%. The stick-out length for SAW shall not be changed beyond the range specified in the WPS or approved standard parameters. 5.4.3 Welding Procedure Qualification Test All material to be used for qualification shall be agreed with Shell Expro prior to testing. Material to be used for qualification testing shall be positively identified and be traceable to chemical analysis and mechanical properties that confirm it is technically consistent with the materials to be welded in production and the requirements of this Standard. Weld procedure tests shall not commence without the presence of a representative of Shell Expro unless permission has been given to the contrary. The Contractor shall supply all current meters, temperature measurement devices, and other instruments necessary to record the information required by the WPQR (Appendix A). All instruments shall have a current certificate of calibration. The Contractor shall record all the information required by Appendix A. The Weld Procedure Qualification Record shall be signed as witnessed by the Contractor and submitted to Shell Expro. The weld procedure test piece shall be submitted to the inspection and testing programme detailed below. The required number and type of tests are shown in Table 3. For butt welds, the positions from which specimens are to be taken are shown in Figure 1. For fillet weld test pieces, macro sections shall be removed in accordance with ASME IX, the section nearest to the weld start being taken for hardness survey. 5.4.3.1 Non-Destructive Testing

The following NDT shall be performed in accordance with Section 5.7 of this Standard.

Page 44 of 90

ES/124 Part 1 Rev 2 1994 Butt Welds Visual DPI Radiography Ultrasonic (only if directed or approved by Shell Expro) Fillet Welds Visual DPI Visual examination of the completed weld shall be conducted by both the Contractor and Shell Expro. No cutting of the test piece for mechanical testing shall take place until it has been examined by a representative of Shell Expro; should, however, the test piece diameter be too small to allow proper examination of the weld root, the test piece shall be cut longitudinally to facilitate examination. Radiographic examination shall be by X-radiography unless otherwise approved. 5.4.3.2 Macro Examination

Macro sections shall be prepared so that the whole cross section of the weld, HAZ, and adjacent parent material may be finished and etched to reveal the weld structure including the individual passes and the full extent of the HAZ. The section is to be examined at a magnification of x5. A macro-photograph of the section shall be included in the procedure documentation. The hardness survey indentations (if required, see Clause 5.4.3.5) shall be visible on the macro-photograph. The macro-photograph shall be marked with its magnification. Only original photographs shall be accepted as part of the weld procedure qualification documentation. The prepared surface shall not exhibit cracks, lack of fusion (root, sidewall or inter-run) or volumetric defects (slag, porosity, etc) outside the limits set by Section 5.7 (these may be investigated by grinding and/or re-sectioning to define their extent). Fillet welds shall meet the following, additional requirements: Fillet welds must show full fusion to the root of the fillet. The length of each leg shall be equal to or greater than the specified weld size and there shall be no more than 3mm difference between the two. The throat thickness shall be at least 0.7 x the specified leg length. Convexity or concavity shall be no greater than 1.5mm. Metallurgical Examination

5.4.3.3

Austenitic Stainless Steels The microsections of the weld shall be polished to 1 micron finish and etched to reveal the weld microstructure. A measurement of weld metal ferrite content shall be made in the root, centre and cap of the weld, using a metallographic method as specified in ASTM E562. The ferrite content of the weld metal shall be 4 - 10%.

Page 45 of 90

ES/124 Part 1 Rev 2 1994 6 Mo Stainless Steel The microsections shall be prepared to a procedure approved by Shell Expro and the microstructure of the weldment shall be assessed by a qualified metallurgist at a magnification of at least x 400, and reported in the PQR. The microstructure shall be free of any fissuring and any feature considered deleterious or unusual shall be reported. Original copies of photomicrographs, taken at a magnification of x 250, of the HAZ at the fusion line and the weld metal shall be included in the PQR package. Duplex Stainless Steels The ferrite/austenite phase balance shall be determined using the procedure in Appendix C. The ferrite content shall be measured 1mm from both root and cap surfaces for base metal, HAZ and weld metal. The ferrite level shall be in the range 40 - 60% for the base material and 30 - 70% for HAZ and weld metal. In addition the microstructure of the weldment shall be assessed by a qualified metallurgist at a magnification of at least x 400, and reported in the PQR. The microstructure shall exhibit a phase distribution consistent with the material manufacturer's recommendations and be free from microphases considered deleterious to mechanical or corrosion resisting properties. Original copies of photomicrographs, taken at a magnification of x 250, of the HAZ at the fusion line and the weld metal shall be included in the PQR package. 5.4.3.4 Weld Metal Chemical Analysis

A weld metal analysis shall be taken from material sampling the root area for 6 Mo and duplex stainless steel welding procedures. The method of sample extraction shall be agreed with Shell Expro. The analysis shall include all deliberately added elements with the following elements as a minimum: 6 Mo: Duplex: C, Si, Mn, S, P, Cr, Fe, Mo, Ni, Cu, Nb, and N C, Si, Mn, S, P, Cr, Ni, Mo, Cu, Al, (W) and N

The chemical analysis shall be reported. 5.4.3.5 Hardness

Hardness surveys shall be required as follows: Material AISI 300 Series SS 6 Mo SS 25% Cr Duplex SS. 22% Cr Duplex SS Nickel Alloys Copper-Nickel Titanium NR - not required Vickers hardness measurements shall be in accordance with BS 427. Rockwell hardnesses shall be in accordance with BS 891. (Note: The use of Vickers hardness measurements shall not be substituted for Rockwell measurements unless the basis of the correlation is substantiated.) Duty Sour only Sour only Sour only Sour only Sour only All All Test Method Rockwell Rockwell Rockwell Rockwell Rockwell NR Vickers Scale C C C C C 5kg Acceptance Criteria 22 35 32 28 35 200

Page 46 of 90

ES/124 Part 1 Rev 2 1994 The location of the traverses, for both butt and fillet welds, shall be as shown in Figure 2. The spacing of indentations in the visible HAZ shall be 0.75mm between centres. The centre of the first impression in the HAZ shall be 0.5mm from the fusion line. The spacing in the weld and parent metal shall be 2mm. 5.4.3.6 Charpy Impact Testing

Charpy impact testing is only required for duplex stainless steels. Charpy V-notch specimens shall be prepared and tested in accordance with BS EN 10045 Part 1 or ASTM A370. A set of three Charpy impact specimens shall be taken with notches at weld centre line, fusion line, fusion line + 2mm and fusion line +5mm, as shown in Figure 3. For single sided welds, the specimens shall be taken with the lower surface no more than 2mm above the inner pipe surface. Additionally, for material thicknesses of greater than 20mm, sets of three specimens shall be taken at the same locations but with the upper surfaces within 2mm of the outer surface of the pipe. Each specimen shall be etched prior to notching and the location of the notch relative to the fusion or weld centre line individually marked. The notch shall be placed in the square face of single bevel welds. The notch positions for two-sided welds shall be agreed with Shell Expro. Full size (10mm x 10mm) impact test specimens shall be used wherever possible. Where this is not possible, the largest of either the three quarter size (7.5mm x 10mm) or half size (5mm x 10mm) specimens shall be used. The test temperatures and acceptance criteria shall be in accordance with Table 4. No result shall be less than the specified minimum individual value and not more than one result shall be less than the minimum average value specified. If the above requirements are not met, 3 further specimens shall be tested. The average of the 6 specimens shall be not less than the minimum specified average; only 2 values may be below the specified minimum average value and only one of those may be below the specified minimum individual value. 5.4.3.7 Corrosion Testing

Ferric chloride testing in accordance with the procedure in Appendix D shall be carried out for welding procedures for 6 Mo and all duplex stainless steels. Any deviation to this due to the specimen size or configuration shall be approved by Shell Expro. The test temperature shall be as follows: 6 Mo: 22% Cr Duplex: 25% Cr Duplex: 30C 22C 35C

If a test specimen fails to comply with the requirements specified in Appendix D.8 (x), guidance shall be sought from Shell Expro regarding repeat or alternative testing. 5.4.4 Repair Welding Procedures Repair welding shall normally be carried out to the same procedure as the original welding. In these circumstances, with the exception of 6 Mo and duplex stainless steel, (see below) repair welding procedure qualification shall not be required but a separate WPS shall be prepared. The Contractor shall submit to Shell Expro for approval a general repair procedure detailing:

Page 47 of 90

ES/124 Part 1 Rev 2 1994 method of defect excavation; shape and size of excavation prior to re-welding; inspection prior to re-welding; weld procedure to be used (if different from original weld).

Where a different welding procedure is to be used for repair welding, and for all repairs to 6 Mo and duplex stainless steels, a procedure shall be qualified in accordance with this standard. Qualification shall require the reproduction of a typical production repair. For part wall excavations the remaining ligament adopted for the test weld shall be the smallest allowed in production. Full penetration excavations shall be qualified separately. Repair welds shall be tested in accordance with the requirement for the original weld except as noted below for 6 Mo and duplex stainless steels. Where impact testing had been specified for the original weld, impact testing of the repair weld metal and the adjacent HAZs, both in the parent material and the original weld metal, shall be carried out at the testing temperature of the original weld. Where repair welding in 6 Mo and duplex stainless steel is performed using the same procedure as the original weld, the test weld only requires the macro examinations, hardness tests, micro examinations, ferrite determinations and the ferric chloride tests specified for the root of the original welding procedure (see Table 3). 5.5 5.5.1 Welder Qualification General All welders and welding operators shall be qualified in accordance with ASME IX. Fillet welds may be qualified by groove weld performance tests. For site erection and offshore hook-up qualification testing shall be in the 6G position. 5.5.2 Pre-Qualification Welders qualified on work other than for Shell Expro shall be accepted provided: qualification has been carried out to ASME IX and the requirements of this Standard have been met; qualification testing has been witnessed by a Certifying Authority or independent third party acceptable to Shell Expro, and the certificate of qualification is endorsed as acceptable by the Authority; the Contractor can give proof that the welder has been in continuous employment with the Contractor for the previous six months and has been welding with reasonable continuity during that time, to the same, or similar, procedures.

5.5.3

Documentation Prior to commencement of work, the Contractor shall submit: a register of the welders to be used on the work, giving the procedures, positions and thickness ranges in which they are qualified, together with the identity number for each welder; all weld performance qualification certificates, including relevant back-up documentation, such as NDT and mechanical test certificates.

Page 48 of 90

ES/124 Part 1 Rev 2 1994 5.5.4 Time Limitations Welder and Operator performance qualification shall be for a six month period from the date of approval. Qualification certificates may be re-approved for further periods of six months by Shell Expro provided the welder has been employed with reasonable continuity on the welding process covered by the performance certificate. Shell Expro may demand the re-qualification of any welder, at any time, if there are reasonable grounds to question that welder's ability to weld to the specified procedure. 5.6 5.6.1 Welding - General Requirements Shop/Site Conditions The shop fabrication of stainless steel and non-ferrous pipework shall be carried out in a separate area (preferably a separate shop) from that of Carbon-Manganese and low alloy steels. Titanium welding shall be carried out in a fully enclosed quarantined area dedicated to Titanium fabrication. Periodic checks for iron contamination shall be made by a chemical method (e.g. Ferroxyl) on surfaces to be welded. Prior to welding the Contractor shall submit, for approval by Shell Expro, a procedure for the segregation of all materials in the workscope and control of the tools to be used with them. The Contractor shall ensure that welding is adequately screened from draughts and inclement weather. Particular care shall be taken where gas shielded methods are employed; should, in the opinion of Shell Expro, inadequate protection be provided, work shall be halted until the situation has been rectified to the satisfaction of Shell Expro. 5.6.2 Equipment All equipment shall be in good condition and properly maintained. 5.6.2.1 Welding Equipment

All welding equipment shall comply with the relevant section of BS 638. Ammeters and voltmeters shall be fitted to equipment for SAW welding. In addition separate voltmeters and ammeters ('tong tester' or Hall effect type) shall be provided for all welding processes. All meters shall be calibrated immediately prior to the commencement of production welding and thereafter at regular intervals according to the Contractor's calibration procedure. This procedure shall be agreed with Shell Expro before the start of production. 5.6.2.2 Grinding and Cleaning Equipment

Only stainless steel wire brushes shall be used. Wire brushes and grinding discs shall be dedicated to one material type and not have been used on any other material before. Precautions shall be established to ensure that grinding wheels, files, wire brushes and similar tools that have been used on Carbon-Manganese and low alloy steels are not used on other materials.

Page 49 of 90

ES/124 Part 1 Rev 2 1994 5.6.3 Preparation for Welding 5.6.3.1 Permitted Weld Detail

All pipe joint welds shall be full penetration butt welds unless otherwise specified. Permanent backing strips shall not be used. Fusible inserts or removable backing strips may only be used with the approval of Shell Expro. Where fillet welds are used, the requirements of ANSI B31.3 shall be applied. Socket welded fittings shall not be permitted unless approved by Shell Expro. 5.6.3.2 Weld Preparation

Weld preparations shall be in general accordance with ANSI B16.25. Square butt ends are permissible below 2mm wall thickness. The root gap for 6 Mo and duplex stainless steels shall not be less than 2mm. Deep gouges and dents on the preparation surface shall be cause for rejection. Weld repair of such defects shall only be permitted by approval of Shell Expro. Laminations identified on the bevel surface by visual examination shall be investigated by DPI prior to removal. Wooden or plastic covers shall be provided to protect weld bevels from mechanical damage and prevent ingress of foreign material into the pipe. 5.6.3.3 Cutting and Bevelling

Austenitic, 6 Mo and duplex stainless steels and Copper-Nickel may be cut mechanically or by plasma arc cutting. All plasma spatter and other debris shall be removed from the pipe surface by disc grinder or emery disc. Thermal methods shall not be used on Titanium. All weld bevels are to be prepared by machining or grinding. 5.6.3.4 Alignment

The permitted maximum misalignment of butt welds shall be: Internal Pipe Diameter 100 mm >100 mm External Pipe Diameter 12 mm > 12 mm Misalignment pipe thickness/4 3 mm Misalignment 1.0 mm 1.6 mm

Page 50 of 90

ES/124 Part 1 Rev 2 1994 Misalignments greater than these limits may be corrected by grinding or machining to a taper of 1:4 provided the wall thickness is not reduced below the minimum tolerance. Reforming of the pipe, either hot or cold, shall not be attempted without the approval of Shell Expro. 5.6.3.5 Spacing

Longitudinal seams on adjacent pipes shall be separated by at least 45 degrees of rotation or 150mm, whichever is the less. Circumferential welds shall be separated by at least 4 times the nominal pipe thickness (toe to toe). Attachments shall be at least 2 times the nominal pipe thickness or 40mm (toe to toe) from any other weld, whichever is the smaller. 5.6.3.6 Tack Welding and Clamping

If line-up clamps are used without tack welding they shall not be removed until after the root pass has been completed. The preferred method of tack welding for single sided welds shall be by the temporary welding of a short length of round bar, compatible with that being welded, across the bevel faces of the preparation. The bar material shall be specified by the Contractor and approved by Shell Expro. Tack welds intended to be an integral part of the root weld shall be ground to a taper edge to facilitate weld pick-up. Tack welds shall be at least 25mm in length and shall be equally spaced around the circumference in sufficient number to support the pipe or fitting. They shall be welded in accordance with the root parameters of the weld procedure specified for the joint. Cracked or badly profiled tack welds are to be completely removed prior to welding. All tack welding is to be carried out according to a qualified weld procedure and performed by qualified welders. 5.6.4 Weld Execution 5.6.4.1 Identification

Welds are to be uniquely identified (see Clause 5.7.1). The Contractor shall demonstrate to the satisfaction of Shell Expro that individual welds can be positively identified at all stages of construction, with particular attention being given to maintaining identification during grit-blasting and painting. The identification number shall be marked adjacent to the weld by crayon, paintstick or similar marker prior to welding. Similarly, welders shall mark their numbers adjacent to the weld they are about to make. 5.6.4.2 Cleaning

Weld preparations and a distance 50mm either side shall be free from rust, scale, oil, grease and other contaminants. Specifically for Copper-Nickel and Titanium, immediately prior to welding the weld preparation and an area 50mm on each side shall be abraded with a stainless steel brush or stainless wire wool and degreased with a non-toxic, non-inflammable solvent on both external and internal surfaces. Filler wires shall be cleaned with stainless steel wool and solvent. Cleaned filler wires shall only be handled by welders using clean gloves that have been used for handling only one material type. Any interrun tarnishing observed in Titanium welds shall be removed by wire brushing. POn completion of fabrication the Contractor shall clean the inside and outside of all fabricated assemblies of all loose material, scale, slag and weld spatter.

Page 51 of 90

ES/124 Part 1 Rev 2 1994 5.6.4.3 Backpurging

The internal surfaces of pipework adjacent to welds are to be maintained free from scale and excessive oxidation (slight bluing is permitted). Backpurging with high purity Argon, or other gas or gas mixture as agreed with Shell Expro, shall be used for all welds in austenitic, 6 Mo stainless steels, Nickel alloys and Copper-Nickel. The backpurge is to be maintained for a minimum of the root and second pass for welding austenitic stainless steels, Nickel alloys and Copper-Nickel and the first 3 passes for 6 Mo stainless steels. Duplex stainless steel welds shall use a backpurge of high purity Argon containing 2-3% Nitrogen unless otherwise approved by Shell Expro. The purge shall be maintained for a minimum of the first three passes. Titanium welds shall use a backpurge of high purity Argon, Helium or Argon/Helium mix, as qualified by the procedure test piece. The purge shall be maintained until the metal temperature drops below 500C after the completion of welding. The method of application of backpurging shall be detailed, either in the relevant WPS or in a separate document referred to by the WPS and shall be submitted to Shell Expro for approval prior to weld procedure qualification. For austenitic stainless steels, Nickel alloys and Copper-Nickel welds, the oxygen content of the backpurge gas shall not exceed 1.0% immediately prior to welding. For all other materials the oxygen content shall not exceed 0.5% immediately prior to welding. This shall be demonstrated during weld procedure qualification and production by means of a suitable oxygen meter. Where internal dams are to be used on site, the procedure shall include precautions for ensuring their removal after welding. Soluble dams are to be approved by Shell Expro and used in accordance with the manufacturer's recommendations. 5.6.4.4 Calibration

The (sub)contractor's calibration procedures for all temperature measurements as well as recording equipment shall be submitted to Shell Expro for approval. Temperature recorders shall be calibrated every three months and a re standardisation check carried out each week using a dedicated millivolt source. Thermocouples (other than those attached by capacitance discharge welding) are to be calibrated before use and be subject to re-calibration per the (sub)contractor's approved procedures. 5.6.4.5 Preheat Temperature Requirements

Preheat is not normally required for welding these materials. However, heating above the ambient temperature to remove surface moisture is to be carried out on site and offshore. Where these steels are to be welded to C-Mn steels the preheat level and application requirements appropriate for the C-Mn steel in Section 4 of this Standard shall apply. 5.6.4.6 Preheat Application

If pre-heat is required the following shall apply.

Page 52 of 90

ES/124 Part 1 Rev 2 1994 Electric resistance heating mats shall be used except when it is agreed with Shell Expro that access or location makes it impractical. In the case of Titanium welds an alternative method will only be approved if it can be demonstrated that it does not carry any risk of contaminating the weld area with any impurity. Electric resistance elements shall be controlled by thermocouples attached on or adjacent to the weld preparation unless an alternative proposal is accepted by Shell Expro. Preheating with oxy/fuel gas shall only be by soft flame burners designed for the purpose. Hand held oxy/fuel gas burners shall only be used for welds on pipes less than 150mm OD or attachment welds less than 300mm long. Preheat temperature may be measured using contact pyrometers, temperature indicating crayons or thermocouples. Where access permits, preheat temperature shall be measured on the opposite surface of the work being heated. Temperature shall be measured at a location displaced from the source of heat by a minimum of 25mm in a direction parallel to pipe axis. Contact pyrometers and temperature indicating crayons must be offered to the work after application of heat. If access is not possible to the opposite surface, temperature measurement shall be delayed for a period not less than 2 seconds per mm of thickness after removal of the heat source. Temperature indicating crayons shall be certified free of lead and sulphur. Residue from crayons shall be removed from the weld surface before proceeding with the weld. 5.6.4.7 Interpass Temperature

The maximum interpass temperatures shall not exceed the following temperatures, unless it can be rigorously demonstrated that mechanical and corrosion properties can be consistently maintained using higher temperatures. Material Austenitic stainless steels 6 Mo stainless steel Duplex stainless steels Nickel Alloys Ni-Cr Ni-Cu Copper-Nickel Titanium Maximum Temp. C 175 100 150 200 175 175 175

The minimum interpass temperature is to be the minimum preheat temperature. 5.6.4.8 Secondary Shielding (Titanium welding only)

A secondary inert gas shield shall be established over the solidified and cooling weld metal and HAZ and maintained until the metal temperature falls below 500C.

Page 53 of 90

ES/124 Part 1 Rev 2 1994 5.6.4.9 Interruption of Welding

Unless otherwise approved by Shell Expro, a minimum of 25% of the joint thickness or, where greater, the root and second pass is to be completed before welding is interrupted and the joint allowed to cool. 5.6.4.10 Arc Strikes The arc shall be struck on weld metal or the preparation surface. Any accidental arc strikes shall be removed by grinding and the area shall be subject to DPI. The thickness of material remaining after the removal of such defects shall be measured ultrasonically. Materials below the minimum required thickness shall be replaced. Weld repair of such areas shall not be permitted. 5.6.4.11 Weld Finish All welds must be finished with a smooth profile, without overlap, abrupt ridges or valleys, and blend smoothly with the base material. Toe profile grinding or cosmetic grinding is only to be carried out if directed by the AFC drawings or approved by Shell Expro. If fillet welds are concave or not equal, the minimum throat size shall not be less than 0.7 x the specified leg length. The profile of the root bead on weldolets shall be as specified for butt welds. The contour of the completed weld shall be as shown in Figure 4, unless Shell Expro advise that the design requirement can be met with a smaller weld. Visual defects shall comply with Clause 5.7.8 of this Standard. 5.6.5 Post-Weld Heat Treatment PWHT is not normally required for any of these materials and shall not be carried out unless approved by Shell Expro. If approval is granted or if directed by Shell Expro, e.g. where austenitic steel is to be welded to C-Mn steel above 19mm in thickness, PWHT shall be carried out generally in accordance with Clause 4.6.5 of this Standard. Additional restrictions as deemed necessary for the materials involved will be advised by Shell Expro. 5.7 5.7.1 Inspection General Requirements Inspection, as detailed below, shall be carried out by the Contractor. The Contractor shall establish, and submit to Shell Expro for approval, a system, uniquely identifying each weld, for the control and recording of inspection. It is recommended that isometric drawings, marked with the individual weld numbers, be maintained for this purpose. The Contractor shall submit to Shell Expro for approval detailed NDT procedures. These shall, unless otherwise permitted by Shell Expro, be demonstrated on a representative test piece to meet the requirements of this Standard. 5.7.2 Visual Inspection Visual inspection shall be carried out by the Contractor on all:

Page 54 of 90

ES/124 Part 1 Rev 2 1994 prepared joints prior to welding; completed welds.

The pre welding checks shall include compliance with Clause 5.6.3.4 and the tolerances of the WPS. Examination is to include the internal surface of the weld wherever possible. The visual acceptance of each weld shall be recorded by the Contractor. 5.7.3 Dye Penetrant Inspection DPI shall be carried out in accordance with ASME V, Article 6. Colour contrast, solvent removable penetrant shall normally be used. 5.7.4 Radiographic Examination Radiography shall be in accordance with BS 2910, with the following additional requirements and modifications: the source/thickness limitations tabulated below shall apply except when approved by Shell Expro as indicated in the notes to the table. Thickness mm 12 > 12 Shop Fabrication X-ray (1) Gamma Site & Offshore Gamma Gamma Isotope Ytterbium 169 OR Iridium 192 (2) Iridium 192 (3)

Notes to the above Table (1) (2) Unless it can be demonstrated that the sensitivity requirements of Table 5 can be achieved by specific gamma ray procedures. Ytterbium offers benefits in both radiographic quality and a reduction in health and safety hazards that allows less disruption to surrounding work. Its use is therefore encouraged. Iridium 192 may be used at thicknesses below 12mm, provided the required sensitivity can be obtained. Thicknesses greater than 12mm may be attempted using Ytterbium 169 provided it can be demonstrated that the required sensitivity can be obtained.

(3)

for general radiography, only lead intensifying screens shall be used. Fluoro-metallic screens may be used in particular cases, if approved by Shell Expro, where the purpose is to extend the practicable range of radiography. sensitivity shall be assessed by DIN 54109 type image quality indicators. for the DWSI and DWDI technique the required sensitivity (and wire number) is shown in Table 5. For the SWSI technique, the values specified by BS 2910 shall be required. The radiographs shall be positively located relative to a marked datum point on the weld. For radiographs other than those taken with the DWDI technique this shall be affected by means of a number tape with lead numbers at a maximum of 100mm spacing. For DWDI radiographs the three radiographs shall be identified as 'A', 'B' and 'C' by means of lead letters. The centre line of these three exposures shall be marked on the weld.

Page 55 of 90

ES/124 Part 1 Rev 2 1994 5.7.5 Ultrasonic Examination Ultrasonic examination of welds is not normally required for these materials but may be necessary in specific circumstances. It shall only be carried out if approved or directed by Shell Expro. 5.7.6 Inspection Personnel The inspection personnel to be used by the Contractor are to be individually approved by Shell Expro. Shell Expro reserve the option to interview operatives and, when necessary, to require a practical skill test. The minimum qualification requirements are as follows: Visual DPI Radiography RT Interpretation Ultrasonic (if approved) CSWIP WI-6-80, 3.1 (Welding Inspector) PCN/GEN/92 Appendix E2.1, Level 2 PCN/GEN/92 Appendix C2.1, Level 1 or level 2 PCN/GEN/92 Appendix C2.1, Level 2 OR Radiographic Interpreter PCN/GEN/92 Appendix C1.1, Level 2 Group 3.2

Alternative qualifications (e.g. SNT) will be accepted only by specific approval of Shell Expro. Approval will be subject to satisfactory demonstration of independence and control of the qualification standards. 5.7.7 Extent of Inspection of Production Welding Table 6 provides guidance on inspection classes in terms of service and pressure rating but specific inspection classification will be advised on the AFC drawings or pipework schedules. The required extent of inspection for each class is listed in Table 7. Percentage radiography refers to the number of whole welds to be fully radiographed. The welds shall be selected so that the maximum number of welders are evaluated. Should an Inspection Class 1 or 2 weld contain unacceptable defects two further welds made by that welder shall be radiographed. If either of these prove unacceptable, all welds produced by that welder shall be considered unacceptable unless proved otherwise to the satisfaction of Shell Expro. All welds found to be unacceptable shall be removed or repaired. 5.7.8 Acceptance Standards Visual Examination - Prior to welding - Finished welds DPI Radiography Ultrasonic Examination In accordance with Clause 5.6.3 of this Standard In accordance with Table 8 of this Standard ASME VIII, Appendix 6-4 In accordance with Table 9 of this Standard As agreed with Shell Expro.

Page 56 of 90

ES/124 Part 1 Rev 2 1994 5.7.9 Reporting All inspection reports shall be signed by the approved operative who did the inspection and contain sufficient information to ensure traceability to the weld inspected and the procedure used. It shall record all equipment identification and settings to enable the inspection to be repeated to the same procedure. All defects shall be identified and located relative to a clear reference. Details of the minimum information to be recorded are included in Appendix B. 5.8 5.8.1 Repairs General Repairs and remedial grinding shall not commence before informing Shell Expro. Second attempts at repairing the same weld area shall only be made by permission of Shell Expro. Where permission for a second repair is not given the whole weld is to be removed. 5.8.2 Defect Removal Surface profile defects or surface porosity on the cap, or root if accessible, may be removed by disc grinding or burr grinding to a smooth profile subject to the minimum material thickness being maintained. Unacceptable defects shall be excavated by mechanical means only. The excavation shall be controlled by gauges and DPI to ensure the minimum amount of material necessary is excavated to completely remove the defect. The excavation shall be ground to a smooth boat shape with no sharp edges and have sufficient slope on the sides to permit proper access for welding. 5.8.3 Root Repairs Where access permits and if approved by Shell Expro, weld repairs to the root of a single sided weld may be permitted from the inside subject to the availability of a suitably qualified procedure. Where access does not permit internal rectification, special attention shall be necessary to locate the defect prior to excavation from the outside and to controlling the root gap of the excavation. If the component remains under external loading during the excavation, the permitted size of the excavation shall be agreed with Shell Expro. Specific provision may be necessary to support the assembly in some circumstances. 5.8.4 Rewelding Repair welding shall be in accordance with Clause 5.4.4 of this Standard. If, after excavation, the root gap geometry is outside the allowable tolerances of the relevant procedure, a new repair welding procedure shall be qualified unless alternative proposals are accepted by Shell Expro. The backpurge shall be re-established if the repair excavation encroaches closer than 5mm to the inside surface of the pipe. 5.8.5 Non-Destructive Testing All repair welds are to be 100% re-inspected by the methods specified for the original weld.

Page 57 of 90

ES/124 Part 1 Rev 2 1994

Page 58 of 90

ES/124 Part 1 Rev 2 1994

FIGURES

Figure 1 Figure 2 Figure 3 Figure 4

Position of Test Specimens Position of Hardness Traverses Location of Impact Specimens Weld Profile - Weldolets

Page 59 of 90

ES/124 Part 1 Rev 2 1994

Ferric chloride test/ Macro and Hardness/ First series Micro and Ferrite determination/ of samples Chemical analysis

Tensile

Bend

Bend

Charpy

Charpy

Bend

Bend

Tensile

Second series of samples for 6Mo and Duplex S/S

Ferric chloride test/ Micro and Ferrite determination/ Macro and Hardness
(illu5580477)

Figure 1

Position of Test Specimens

Page 60 of 90

ES/124 Part 1 Rev 2 1994

1.5mm

1.5mm

Butt Welds

1.5mm

1.5mm

1.5mm

1.5mm

Fillet Welds

1.5mm

1.5mm

1.5mm

1.5mm

(illu5580478)

Tee Butt Welds

Figure 2 Position of Hardness Traverses

Page 61 of 90

ES/124 Part 1 Rev 2 1994

(1) Notch at centreline of weld

2mm

(2) Notch at fusion line

2mm

(3) Notch at 2mm from fusion line (and at 5mm for heat inputs of over 2kJ/mm).
2mm 2mm 2 or 5mm

(4) Notch at centreline of weld

2mm

(5) Notch at fusion line

2mm

(6) Notch at 2mm from fusion line (and at 5mm for heat inputs of over 2kJ/mm).
2 or 5mm

NOTE: (1), (2) and (3) - All welds (4) - Additional for ferritic steels with wall thicknesses over 20mm. (4), (5) and (6) - Additional for duplex stainless steels with wall thickness over 20mm.
(illu5580479)

Figure 3

Location of Impact Specimens

Page 62 of 90

ES/124 Part 1 Rev 2 1994

PWHT if t 4B t 38mm

Section 'A-A'
Figure 4

Section 'B-B'
(illu5580480)

Weld Profile - Weldolets

Page 63 of 90

ES/124 Part 1 Rev 2 1994

Page 64 of 90

ES/124 Part 1 Rev 2 1994

TABLES

Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9

Thickness Limits for Application in the As-Welded Condition Procedure Qualification - Qualified Positions Welding Procedure Testing Requirements Charpy Impact Testing Temperatures and Acceptance Criteria IQI Wire Sensitivity For Pipework Using X and Gamma Radiography Inspection Classes Extent of Inspection Visual Acceptance Criteria Radiographic Acceptance Criteria

67 68 69 70 71 72 73 74 75

Page 65 of 90

ES/124 Part 1 Rev 2 1994

Page 66 of 90

ES/124 Part 1 Rev 2 1994 Table 1 Thickness Limits for Application in the As-Welded Condition (Reference DEP.30.10.02.31-Gen Graph 1) Max. thickness for as-welded application, B (mm) for Min. Service Temp. -50C A333 Gr A420 Gr WPL6 A 350 LF2 A333 Gr3 A350 LF3 A420 WPL3 NOTES: (1) The thicknesses listed above are based on the requirements of Graph 1 in DEP.30.10.02.31-GEN and should be adopted unless otherwise advised in the relevant Shell Expro Piping Class or Approved Drawing. For service temperatures not listed the thicknesses may be interpolated. Reference should be made to the DEP for any other conditions. All thicknesses assume Charpy impact toughness in compliance with Table 4. The maximum thickness for as-welded applications at a service temperature of -80C is 12.5 mm. For service below -80C all thicknesses shall be PWHT. LT80 Refer note (3) LT50 19 17 14 LT30 14 -55C 12 -60C 9

Material

Designation

(2) (3)

Page 67 of 90

ES/124 Part 1 Rev 2 1994 Table 2 MATERIAL C-Mn steel (non-sour), Austenitic steels, Nickel alloys Copper-Nickel and Titanium Procedure Qualification - Qualified Positions PROCEDURE TEST WELD POSITION 1G 2G 5G 6G or 2G+5G C-Mn steel (sour), 6 Mo and duplex stainless steels 1G 2G 5G 2G+5G All Materials 1F 2F+3F 2F+3F+4F NOTE: POSITION QUALIFIED BUTT WELD 1G 1G+2G 1G+5G All 1G 1G+2G 1G+5G All 1F 1F,2F,3F All Butt welds do not qualify FILLET WELD All per ASME IX

For site erection and offshore hook-up qualification in 6G or 2G and 5G, as appropriate, will normally be required

Page 68 of 90

ES/124 Part 1 Rev 2 1994 Table 3 Welding Procedure Testing Requirements

Fillet Welds TYPE OF TEST Macro Section Hardness Survey Butt Welds TYPE OF TEST Tensile Test Bend Test t 10mm Face bend t < 10mm Root bend t > 10mm Side bend CMn/Alloy (Section 4) Chemical analysis - weld metal root Micro examination and Ferrite count Macro Section and Hardness Survey (1) Pitting Corrosion (Appendix D) Charpy Impact t 20mm Weld heat input 2kJ/mm Weld heat input > 2kJ/mm t > 20mm Weld heat input 2kJ/mm Weld heat input > 2kJ/mm NOTES: (1) (2) For non-ferritic and non-ferrous requirements, refer to Section 5, Clause 5.4.3.5. Duplex stainless steels only. 4 (sets of 3) 5 (sets of 3) 8 (sets of 3) (2) 3 (sets of 3) 4 (sets of 3) 4 (sets of 3) (2) 1 1 Austenitic (Section 5) 1 1 1 1 2 2 4 6 Mo/Duplex (Section 5) 1 2 2 2 2 2 Ni/Ti/Cu-Ni (Section 5) 1 1 NUMBER OF TESTS All Materials 2 NUMBER OF TESTS 4 1

Page 69 of 90

ES/124 Part 1 Rev 2 1994 Table 4 Material LT30 A333 Gr 6, A350 LF2 & A420 WPL6 LT50 A333 Gr 6 A350 LF2 & A420 WPL6 UNS S31803 UNS S32550 UNS S32750 UNS S32760 LT80 A333 Gr 3, A350 LF3, A420 WPL3 NOTES: (1) The acceptance criteria for subsize specimens shall be reduced to: 7.5mm x 10mm 5mm x 10mm (2) 0.83 x full size values 0.67 x full size values -80 (2) 27 19 -50 -50 -50 -50 -50 -50 27 27 27 41 41 41 19 19 19 27 27 27 -46 20 16 Charpy Impact Testing Temperatures and Acceptance Criteria Charpy Energy J (1) Average Individual

Charpy Test Temp. C

If the design temperature is lower than -80C, the test temperature shall be the same as the minimum design temperature

Page 70 of 90

ES/124 Part 1 Rev 2 1994 Table 5 PIPE NB

1 1.5 2 3 4 6 8 10 12 14 16 18 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5 10/16 5

IQI Wire Sensitivity For Pipework Using X and Gamma Radiography SCHEDULE

10S

20

30

40
10/16 5 10/16 5 10/16 5 10/16 5 10/16 4 10/16 4 10/16 4 10/16 3 10/16 2 10/16 2 10/16 2 10/16 2

80
10/16 5 10/16 5 10/16 5 10/16 4 10/16 4 10/16 2 10/16 2 10/16 2 6/12 5 6/12 5 6/12 4 6/12 4 6/12 4

12

160
10/16 4 10/16 4 10/16 4 10/16 2 10/16 2 6/12 5 6/12 4 6/12 4 6/12 3 6/12 3 6/12 3

XXS
10/16 4 10/16 2 10/16 2 6/12 5 6/12 5 1/2"

OTHER

10/16 4 10/16 4 10/16 4 10/16 4 10/16 4 10/16 4 10/16 4

10/16 4 10/16 4 10/16 4 10/16 4 10/16 4 10/16 2 10/16 2

10/16 2 10/16 2 6/12 5 6/12 4 6/12 4 6/12 4 6/12 3 6/12 3 6/12 3

5/8"

10/16 2

6/12 5

20

1/7 6

5/8" 6/12 5

15/16" 6/12 4

1" 6/12 4 11/16" 6/12 4

22

24

10/16 4

10/16 4

10/16 2

6/12 3

1/7 6

1/7 6

1/2" 10/16 2

5/8" 6/12 5

11/16" 6/12 4

11/2" 6/12 3 15/8" 6/12 3 15/8" 6/12 3 15/16" 6/12 3

NOTES: 1. 2. Double wall single image technique assumed, i.e. sensitivity is based on single wall thickness and includes an allowance for weld reinforcement. Chart shows minimum number of IQI wires to be visible through the weld for acceptance of radiographs. IQIs to DIN 54109 TYPE FE.

Page 71 of 90

ES/124 Part 1 Rev 2 1994

Table 6 SERVICE Utility

Inspection Classes INSPECTION CLASS 1 2 3 2 3

ANSI CLASS 150 300 >300

Fire Fighting

150 >150

Process Low temperature service All other services All 150 >150 3 2 3

Page 72 of 90

ES/124 Part 1 Rev 2 1994 Table 7 INSPECTION CLASS 1 Visual Radiography 2 Visual MPI/DPI. Radiography 3 Visual MPI/DPI METHOD 100% 5% 100% NR 10% 100% t 19mm - NR t > 19mm - 100% Radiography t 19mm - 100% t > 19mm - 100% (2) Ultrasonic Testing (1) NR = Not required NOTES: (1) C-Mn and low alloy steels only unless directed or approved by Shell Expro. For wall thicknesses over 19mm, radiography of individual welds, in place of ultrasonic examination, shall be carried out when specified by Shell Expro. (2) All materials covered by Section 5 when so directed by Shell Expro. t > 19mm - 100% t 10mm - 100% Extent of Inspection EXTENT OF TESTING BUTT WELDS BRANCH WELDS 100% 5% (where possible) 100% 10% 10% (where possible) 100% 100% 100% NR

Page 73 of 90

ES/124 Part 1 Rev 2 1994 Table 8 TYPE OF DEFECT/FEATURE Cap Reinforcement (mm) Visual Acceptance Criteria PERMITTED MAXIMUM t < 6.4 6.4 t 12.7 12.7 < t 25.4 t > 25.4 Root Penetration (mm) (where visible) Pipe Dia 200 mm Pipe Dia > 200 mm Root Concavity (mm) (where visible) Undercut (mm) Surface Breaking Porosity and Slag Inclusions Cracks NOTE: Depth 1.5mm Depth 0.5mm Not Permitted Not Permitted In the case of different thicknesses, the lower will be taken as t. 1.6 3.2 4.0 4.8 1.5 3.0

Page 74 of 90

ES/124 Part 1 Rev 2 1994 Table 9 DEFECT TYPE Planar Defects Cracks and lamellar tears Lack of root fusion Lack of side fusion Lack of inter-run fusion Lack of root penetration Cavities Isolated pores (or individual pores in a group) Uniformly distributed or localised porosity Wormholes, crater pipes Linear Porosity Maximum dimension t/3 and no greater than 3mm 2% by area (area to be considered should be the length of weld containing the porosity multiplied by the width of the image of the weld) Length 6 mm Width 1.5 mm Shall be investigated in case this indicates lack of fusion that is not permitted. Otherwise as for individual pores in a group. Length t/3 Width t/3 and no greater than 2.4 mm Inclusions shall be separated by a minimum distance of t/3 and shall not exceed a total length of t in any weld length of 12t Tungsten Inclusions (1) Isolated (2) Grouped Copper Inclusions Profile Defects Root Concavity As isolated pores As localised porosity Not permitted Radiographic density of indication is not to exceed that of parent material Not Permitted Radiographic Acceptance Criteria PERMITTED MAXIMUM

Solid Inclusions

Slag Inclusions

NOTE:

In the case of different wall thicknesses, the lower will be taken as t.

Page 75 of 90

ES/124 Part 1 Rev 2 1994

Page 76 of 90

ES/124 Part 1 Rev 2 1994

APPENDICES

App A B C D Reporting Requirements for Welding Procedure Qualification Minimum NDT Reporting Requirements Recommended Practice for Determining Volume Fraction of Ferrite in Duplex Stainless Steel Weldments by Systematic Point Count Recommended Practice for Pitting Corrosion Testing of Duplex Stainless Steel Weldments by the Use of Ferric Chloride Solution

Page 79 81 83 87

Page 77 of 90

ES/124 Part 1 Rev 2 1994

Page 78 of 90

ES/124 Part 1 Rev 2 1994

APPENDIX A REPORTING REQUIREMENTS FOR WELDING PROCEDURE QUALIFICATION

A1 Welding Procedure Documentation

The following documentation is to be presented for approval for each welding procedure qualified: A1.1 Weld Procedure Specification (final version); Weld Procedure Qualification Record; parent material certification; consumable batch certification; NDT reports on test weld (including visual examination); post-weld heat treatment record charts (if applicable); mechanical test reports: Weld Procedure Specification

The Weld Procedure specification shall be on a clean and clear format and shall include the following information. Alternatively the required information may be submitted clearly and concisely on a welder instruction card: a unique procedure number; the applicable welding standard; the welding process(es); the parent material(s) specification(s); the thickness and diameter range qualified; the weld preparation or preparations (including sketch with dimensions and tolerances); method of clamping or tack welding; weld position, and direction if vertical; minimum preheat level; the maximum interpass temperature; welding consumables (AWS classification and trade name); electrode size for each pass or group of passes (e.g. for root, second pass, fill and cap); the electrical conditions, i.e.; polarity (or if ac), current and voltage ranges for each weld pass or group of passes; travel speed (SAW, GMAW, FCAW and GTAW) or run out length (for SMAW) range for each pass or group of passes; shielding and backing gases, type and flow rate; electrode stick-out for SAW GMAW and FCAW; electrode material and size for GTAW; gas shroud diameter for GMAW, FCAW (gas shielded) and GTAW; post-weld heat treatment, including heating rate, soak time and temperature, and cooling rate;

Page 79 of 90

ES/124 Part 1 Rev 2 1994 A1.2 Weld Procedure Qualification Record

The weld procedure qualification record shall include the following information: weld procedure number and test weld number; date and time of test; parent material(s) (including dimensions), specification(s) and certification number(s); welding consumables, AWS classification, trade names, batch numbers; welders' names and identification number(s); welding positions(s); drawing showing actual weld preparation; drawing showing actual run location; method of alignment/tacking; method of preheating and preheat temperature at start of welding; reference to PWHT procedures and record charts if applicable; welding machine(s), type and make.

In addition, the following information shall be recorded for each, individual weld run: electrode size and type; polarity (or if ac); current; voltage; average run out length of electrodes (for SMAW); welding speed (for SAW, FCAW, GMAW and GTAW); calculated heat input; interpass temperature immediately prior to commencement of run; electrode stick-out length (FCAW, GMAW or SAW).

The weld procedure qualification record shall be endorsed by the Contractor and by the witnessing inspector(s) as a true record of the weld.

Page 80 of 90

ES/124 Part 1 Rev 2 1994

APPENDIX B MINIMUM NDT REPORTING REQUIREMENTS

B1 All Methods. work location; description and identity of weld tested; date of test; stage of test (e.g. before or after PWHT repair etc); NDT procedure used; statement of compliance or non-compliance with the acceptance criteria; name of NDT company; name and signature of the person performing the tests.

The position and description of all reportable indications shall be recorded. The position of such indications shall be uniquely defined, with if necessary, a drawing. Any deviation from the approved NDT procedure due to access, surface condition or other factors shall be reported. In addition to the above general information, each report shall contain the information specific to the process, as detailed below. B1.1 B1.2 MPI method of surface preparation and resulting surface condition method of inducing magnetic field current and waveform details pole spacing or coil/conductor arrangement type of field strength indicator used and frequency of calibration thickness of background paint, (where used) method and frequency of mixing magnetic inks. DPI surface condition dye used developer used development time

Page 81 of 90

ES/124 Part 1 Rev 2 1994 B1.3 B1.4 Radiography source type; size, strength and type of isotope (if used); type of x-ray equipment and focal spot size (if used); source to film distance; exposure details; for gamma radiography - source strength and exposure time; for x-radiography - tube current, voltage and exposure time; IQI type, location and sensitivity; film density over weld. Ultrasonic Examination surface condition; instrument used (including serial number); probe angles and frequencies used; primary reference level sensitivity; sensitivity level for examination; surface correction factor; response level of reportable defects as percentage of the DAC curve.

Page 82 of 90

ES/124 Part 1 Rev 2 1994

APPENDIX C RECOMMENDED PRACTICE FOR DETERMINING VOLUME FRACTION OF FERRITE IN DUPLEX STAINLESS STEEL WELDMENTS BY SYSTEMATIC POINT COUNT
C.1 Scope

This procedure describes a method for estimating the volume fraction of delta ferrite in duplex stainless steel by systematic point counting on transverse metallographic sections. C.2 Basis of Method

The method involves the superimposition of a test grid over an image, produced by an optical light microscope, of the appropriate microstructural area. The number of grid points falling within delta ferrite are counted and divided by the total number of grid points, to yield a point fraction which represents an estimate of the volume fraction of delta ferrite present within the field of view. The average point fraction taken over a number of appropriately selected fields gives an estimate of the volume fraction within the region sampled. C.3 (i) (ii) (iii) C.4 C.4.1 Planar sections shall be taken through parent material or the weldment, transverse to the welding direction and perpendicular to the material surface. Each sample shall section the whole of the weldment and HAZ and an area of parent material on either side of the weld. Preparation of these specimens shall be in accordance with standard metallographic techniques, such as described in Reference 1. It is recommended that the last grinding stage should be with 600 grit, or finer, abrasive and the final polish should be with 1 m, orfiner, abrasive (e.g. diamond paste). C.4.2 The specimen shall be etched electrolytically in 40% KOH solution (i.e. 400g KOH in 1000 ml of solution made with distilled water). Etching shall be carried out in a container of sufficient size to allow immersion of the specimen in the etch at a distance of 100mm from the platinum cathode. Electrical contact between the specimen and power source may be made by means of a suitably shaped conducting probe. Acceptable contrast can generally be obtained at an anode/cathode voltage of 7-8V for 2-5 seconds, but trials may be necessary to determine the most appropriate conditions for a particular specimen. It may be noted that the contrast between the delta ferrite and austenite phases will probably vary through the weldment. Terminology Point count - the number of grid points which lie within areas of a specific phase (in this case delta ferrite). Point fraction (Pp) - the point count divided by the total number of points in the test grid. Volume fraction (Vv) - the volume of a specific phase per unit volume, expressed as a fraction. Sample Preparation

Page 83 of 90

ES/124 Part 1 Rev 2 1994 C.5 Area Selection

The areas in which measurements have been made shall be as specified in Section 5, Clause 5.4.3.3. The weld pass shall be stated (e.g. root, cap, fill - preferably with a number) as shall the area which has been measured (i.e. weld metal, HAZ or parent material). Where possible it should be indicated whether the area has been re-heated or is as-deposited. Any uncertainty shall be noted. The location of measurements shall be recorded on a sketch or photograph of the section. C.6 C.6.1 An optical light microscope that projects an image of the magnified micro-structure onto a viewing screen shall be used, preferably with graduated x and y translation controls. The magnification shall be selected such that the ferrite particles have an average dimension approximately one half of the grid point spacing. This should be judged visually in more than one field of view, before measurements are made. For many weldment microstructures, particularly in re-heated areas, a magnification in the range x500 - x1000 is suitable, and is preferred. C.6.2 The test grid shall be marked on a transparent sheet that shall be superimposed on the magnified image of the microstructure. The grid shall consist of a square array of equally spaced points, produced by the intersection of fine parallel lines (maximum width 0.3mm), and shall have 16 or 25 points. It is recommended that the spacing of the points should be 10mm along both directions parallel to the edges of the square grid, e.g. as in Figure C.6.2. At a magnification of 1000x this corresponds to a point spacing on the actual microstructure of 10 m. C.7 C.7.1 Superimpose the test grid on the magnified image of the microstructure in the chosen area of the parent material or weldment. C.7.2 Count the number of points that lie within the delta ferrite phase; any points that cannot be assigned positively to either phase shall be counted as one half. Delta ferrite is the phase that is stained dark by the etch, although its colour may vary significantly throughout the weldment. The austenite phase remains light coloured in all areas after etching. C.7.3 The specimen shall then be moved by a small amount in x and/or y so that another field is chosen. A second point count shall be performed in the new field, provided that this field of view still falls within the specified region of the parent material or weldment. If the field of view falls outside the area of interest the specimen must be moved back, without rotating, to an appropriate position within the specified area. Where possible the specimen should be moved without looking at the micro-structure in order to avoid bias in the choice of fields. It is recommended that the use of overlapping fields be avoided. This process shall be continued until a minimum of 400 points have been counted. C.7.4 When measurements are being made within the coarse grained HAZ, the operator must first assess whether the test grid can be superimposed over an area that is entirely within the coarse grained HAZ. This can be done simply by attempting to fit the grid within a single coarse grain. If the grid size is less than the grain size, then the technique described in C.7.1 - C.7.3 shall be used. If the whole grid is too large, a smaller area of the grid shall be used, by ignoring one or more whole rows of grid points. The Procedure Apparatus

Page 84 of 90

ES/124 Part 1 Rev 2 1994 area chosen may be either square or rectangular. If a rectangular grid is used, the specimen shall be rotated so that the long axis of the rectangle is kept parallel to the fusion boundary. Measurements in the coarse grained HAZ shall be made within approximately two grain diameters of the fusion line. C.7.5 The volume fraction of delta ferrite shall be estimated by taking an average of the point fractions counted in each of the n fields as follows:

where i is the field number. C.7.6 The 95% confidence interval (CI) shall be calculated as follows:

where

The accuracy of the technique shall comply with the allowable errors specified in Table C.7.6. C.8 Reporting

The following details shall be included in the point counting report. (i) (ii) (iii) (iv) (v) (vi) (vii) The number of sections taken from the weld. The locations of sections taken along the weld. The polishing procedure and etching conditions. The magnification used. The number of points and shape of the grid. Whether the fields were chosen randomly or at regular intervals. If regular intervals were employed, report the spacings used. The location of the areas in which measurements were made, preferably on sketch or photograph and in words, specifying parent metal or the weld pass, the region of the weld pass (i.e. weld metal or HAZ) and, where practical, whether the area was re-heated or not. Any uncertainty should be indicated. A list of the point fractions of delta ferrite in each field. An estimate of the volume fraction of delta ferrite, calculated as the average of the point fractions. The calculated value of the 95% CI. Stage of manufacture, i.e. procedure qualification, production test, etc.

(viii) (ix) (x) (xi)

Page 85 of 90

ES/124 Part 1 Rev 2 1994 (xii) (xiii) Location of sample and cast number. Statement of conformance with specified ferrite content.

(xiv) Signature of operator responsible for ferrite determination. C.9 Acceptance Criteria

In the event that the ferrite determinations do not conform with the specified requirement (see Clause 5.4.3.3), then the product represented by the sample shall be rejected at the discretion of Shell Expro. C.10 Safety

This recommended practice involves materials, equipment and procedures that may represent a health hazard. This document does not attempt to address the safety issues associated with the described practice. It is the responsibility of the testing establishment to ensure that the appropriate health and safety precautions are taken. C.11 (1) (2) References ASTM E3-80 (Reapproved 1986) 'Methods of Preparation of Metallographic Specimens'. Gladman T and Woodhead JH: 'The Accuracy of Point Counting in Metallographic Investigations', JISI 1960, 194, 189-193.

(illu5580481)

Figure C.6.2

Two Grid Types Suitable for Systematic Manual Point Counting of Delta Ferrite in Duplex Stainless Steel. Table C.7.6 Allowable Error in Ferritic/Austenite Determination Volume % 45-50 40-45 35-40 0-35 Error 10% 11% 12% 14%

Page 86 of 90

ES/124 Part 1 Rev 2 1994

APPENDIX D RECOMMENDED PRACTICE FOR PITTING CORROSION TESTING OF DUPLEX STAINLESS STEEL WELDMENTS BY THE USE OF FERRIC CHLORIDE SOLUTION
D.1 Scope

This procedure describes a simple accelerated test technique for assessing the pitting corrosion resistance of duplex stainless steel in chloride containing environments. D.2 Basis of Method

The test involves total immersion of a test specimen in an aqueous solution of ferric chloride at a constant temperature for 24 hour period and assesses whether the specimen has passed or failed on the basis of weight loss. The temperature of exposure shall be specified. D.3 Terminology

Figure D.3 indicates the nomenclature to be used to describe various aspects of the test piece. (i) (ii) (iii) (iv) (v) (vi) (vii) The face including the area of weld to be tested shall be called the 'test face'. If there are two 'test faces' these should be unambiguously named, e.g. the 'root test face' and 'cap test face'. If there is only one 'test face', the face opposite shall be called the 'reverse face'. The smallest faces, lying parallel to the weld direction, shall be named the 'ends'. The remaining faces shall be called the 'sides'. The line of intersection of two faces shall be referred to as an 'edge'. The point of intersection of three faces shall be referred to as a 'corner'. The larger dimension of the test face (i.e. perpendicular to the weld direction) shall be called the 'length' and the shorter dimension the 'width', while the remaining dimension, perpendicular to the test face, shall be termed the 'thickness'. Sample Preparation

D.4 D.4.1

The weld shall be 'as prepared for service'. No additional preparation of the weld surface shall be allowed. D.4.2 At least two samples shall be prepared from the weld under test. D.4.3 An approximately cuboidal specimen (i.e. with six nominally rectangular faces) shall be used, with a test face size of 50 x 25mm. There is no specific limit on thickness but it is most convenient to test specimens of 5-10mm thickness. The weld direction shall be approximately parallel to the shorter edge of the test face, and the weld shall be positioned equidistant from the two ends of the specimen.

Page 87 of 90

ES/124 Part 1 Rev 2 1994 If a weld width exceeds one third of the specimen length, the length shall be increased to a value equal to at least three times the weld width. When comparisons are made between a series of specimens, they shall all be of the same size. It should be noted that the need to weigh the specimen to 1mg requires its weight to be within the range of a balance with the required accuracy (Clause D.6). Consequently, it is recommended that the specimen weight should be no more than 200g. This may require that the specimen thickness be reduced to less than 20mm, particularly for specimens with a non-standard test face size. Dimensions within 10% of those stated shall be considered acceptable. All corners of the test face should be 90 10. All cutting and machining operations must be carried out avoiding undue contamination of the test face, and with no overheating or 'bluing' of the sample. Specimens from pipe material shall be removed by cutting either radially or along appropriate parallel chords. D.4.4 The sides and ends of the specimen shall be ground to remove machining marks, using a suitable range of grit sizes, to produce a 1200 grit finish by standard metallographic procedures (1). If the reverse face requires machining to achieve the desired specimen thickness, it shall also be ground to a 1200 grit finish; otherwise the reverse face may be left as-welded, although it should be noted that attack may occur on this face also. If 1200 grit abrasive is not available, 1000 grit, or any finer abrasive, may be used. All corners and edges shall be rounded off and have any burrs removed during the grinding process. D.4.5 Specimens shall not be marked either by stamping or with ink/paint; light stamping is allowed for identification purposes but only in parent material outside of the test face and well away from the fusion zone and HAZ, i.e. on the ends or sides of the specimen. However, corrosion or pitting at these locations may render the test void. Alternatively, each specimen may be kept in a clearly labelled envelope prior to exposure and, after cleaning and drying, at the completion of the test. D.5 Test Solution

The test solution shall be made up from 100g of Analar grade ferric chloride hexahydrate (FeCl3 .6H20) and 20g of disodium ethylenediamine tetra-acetate di-hydrate (Na2 EDTA.2H20) per 900ml of distilled water, or other water meeting ASTM standard D1193 type IV (2). D.6 (i) Apparatus The solution and specimen shall be contained in a tall-form glass beaker or a wide neck, Erlenmeyer flask. A capacity of 1000ml should be sufficient for standard specimens, but larger capacity, e.g. 2000ml may be necessary for non-standard specimens. Each specimen shall be placed in a separate container. Each specimen shall sit at approximately 45 on a cradle designed to allow easy passage in and out of the container and ensure minimum contact with the specimen, so as to reduce the likelihood of crevice corrosion. The containers shall be held within a constant temperature water bath, capable of maintaining a specified temperature to within 0.5C. The temperature of the bath shall be monitored throughout the test with a thermometer or a calibrated thermocouple. Specimens shall be weighed before and after testing using a balance capable of 1mg accuracy.

(ii)

(iii)

(iv)

Page 88 of 90

ES/124 Part 1 Rev 2 1994 D.7 (i) Procedure The specimen shall be decontaminated with clean acetone or methanol and air dried, then weighed to the nearest 1mg, immediately prior to testing. If the specimen is to be stored, it shall be kept in a desiccator, and then weighed prior to testing. A minimum of 20ml of test solution per 100mm of total specimen surface area shall be placed in the test container. The specimen shall be placed on a cradle and immersed in the test solution in the container, which shall be covered with a watchglass. (iii) (iv) The container and solution shall then be covered with a watchglass and placed in a water bath pre-heated to within 0.5C of the specified test temperature. The temperature of the solution shall be monitored. When it has reached 0.5C of the test temperature, the specimen shall be placed on a cradle and immersed in the test solution. The specimen shall be oriented with its test face uppermost at an angle of approximately 45 to the vertical. The test temperature must be maintained within 0.5C of the required value throughout the exposure period. The specimen shall be removed from the test solution after 24 hours, rinsed and scrubbed with a nylon bristle brush under running water and finally immersed in acetone or methanol and dried thoroughly. The scrubbing process should remove any loose corrosion product and staining from the specimen surface. When dry, the specimen shall be re-weighed to 1mg or better. After weighing, the specimen shall be observed under a binocular microscope in order to identify the location of any pitting and/or general corrosion. A steel pin may be used to probe the surface of the specimen in an attempt to open up covered pits. Reporting

(ii)

(v)

(vi) (vii)

D.8

The following shall be included in the test report. (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) A description of the weld condition, i.e. details of all post-weld heat treatments and surface preparation. The specimen dimensions. A sketch of the test specimen, prior to testing, showing the general shape of the weld and any notable features, in particular any which might be mistaken for pits after exposure. The volume of test solution to the nearest 50ml. The actual test temperature, including any variation noted during the test exposure. The weight of the specimen immediately prior to testing. The weight of the specimen after cleaning and drying at the completion of the test. The weight change during testing. The location of any pits discovered shall be recorded on a sketch of the specimen. If no pits are observed, this shall be stated. The use of probling shall be reported, with the observed results. Whether the specimen has passed or failed the test, or whether a re-test is to be performed. If the specimen has gained weight or lost 20mg it shall be considered to have passed the test.

Page 89 of 90

ES/124 Part 1 Rev 2 1994 If the weight loss is >20mg, the specimen shall be considered to have failed the test, unless pitting can be positively identified only on areas outside of the test face, in which case a re-test on a duplicate specimen will be allowed. Under no circumstances shall the same specimen be re-tested. If a test weld has been cleaned after welding, e.g. by pickling, as part of its preparation for service, the specimen shall be considered to have failed if any pitting is visible on the test face, regardless of weight loss. If the fill passes of the test weld are deposited with a consumable having lower pitting resistance than that used for the root, pitting in the weld metal on the specimen sides is acceptable. In such cases the pass/fail assessment must be performed visually if the weight is >20mg. The specimen will be considered to have failed if pitting is visible on the test face. D.9 Safety

This recommended practice involves materials, equipment and procedures that may represent a health hazard. This document does not attempt to address the safety issues associated with the described practice. It is the responsibility of the testing establishment to ensure that appropriate health and safety precautions are taken. D.10 (1) (2) References ASTM: E3-80 (Reapproved 1986) 'Methods of Preparation of Metallographic Specimens'. ASTM: D1193-77 (Reapproved 1983) 'Standard Specification for Reagent Water'.

Edge Test Face Corner Side Thickness

End Width

Length

(illu5580482)

Figure D.3

General Layout of Test Specimen Showing the Test Face Uppermost. The underside may be either a second test face or simply ground flat and referred to as the reverse side.

Page 90 of 90