PHEONWJ-W-PRC-0005~2 (Guidance for Pipeline Welding)

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PT. PHE ONWJ Guidance for Pipeline Welding

PHEONWJ-W-PRC-0005 Rev.2 Page 2 of 49

Revision Log Register

Document Number : PHEONWJ-W-PRC-0005

Document Title : Guidance for Pipeline Welding

Revision : 2

Page Date Revision

PHE ONWJ

Reviewer

All 29-Sep-11 Change document title:

Jimmi Beng/

Soeryono

Nano

Old: STP for Pipeline Welding

New: Guidance for Pipeline Welding

All 29-Sep-11 Replace PHE ONWJ Ltd. with PT. PHE ONWJ

Jimmi Beng/

Soeryono

Nano

All 29-Sep-11 Replace text STP with guidance

All 29-Sep-11 Replace GP 18 02 with PHEONWJ-W-SPE-0008

All 29-Sep-11 Replace GP 43 34 with API 1104

1 of 53 29-Sep-11 Replace Revision Log Register page with new standard.

2 of 53 29-Sep-11 Delete Foreword page

52 of 53 29-Sep-11 Delete Bibliography page




Table of Contents

Page

Table of Contents ............................................................................................................................................3

Introduction .....................................................................................................................................................6

1 General ..................................................................................................................................................7

1.1 Scope ........................................................................................................................................7

1.2 Welding Process Restrictions ....................................................................................................7

1.3 HSSE for Pipeline Welding Operations ......................................................................................7

1.4 Pre-Production Consultation ......................................................................................................8

1.5 General Duties of the Contractor ...............................................................................................8

1.6 Quality Assurance......................................................................................................................8

1.7 Records .....................................................................................................................................8

1.8 Contractors Personnel ..............................................................................................................8

1.9 Abbreviations and Acronyms ...................................................................................................10

2 Referenced Publications ......................................................................................................................11

3 Definitions of Terms ............................................................................................................................13

3.2 Definitions ...............................................................................................................................13

4 Specifications ......................................................................................................................................13

4.1 Equipment ...............................................................................................................................13

4.2 Materials..................................................................................................................................14

4.3 Minimum design temperature (MDT) ......................................................................................16

5 Qualification of Welding Procedures for Welds Containing Filler-Metal Additives................................16

5.1 Procedure qualification ............................................................................................................16

5.2 Record .....................................................................................................................................16

5.3 Procedure Specification ...........................................................................................................17

5.4 Essential Variables ...................................................................................................................20

5.5 Welding of Test JointButt Weld ...........................................................................................22

5.6 Testing of Welded JointsButt Welds....................................................................................22

5.7 Welding of Test JointsFillet Welds.......................................................................................29

5.8 Testing of Welded JointsFillet Welds...................................................................................29

6 Qualification of Welders ......................................................................................................................30

6.1 General ....................................................................................................................................30

6.2 Single Qualification ..................................................................................................................31

6.3 Multiple Qualifications .............................................................................................................31

6.4 Visual examination...................................................................................................................31

6.6 Radiographybutt welds only .................................................................................................31

7 Design and Preparation of a Joint for Production Welding................................................................... 31

7.1 General ....................................................................................................................................31

7.2 Alignment ................................................................................................................................32

7.3 Use of Line-Up Clamp for Butt Welds......................................................................................32

7.4 Bevel .......................................................................................................................................33

7.5 Weather Conditions .................................................................................................................34




7.6 Clearance.................................................................................................................................34

7.7 Cleaning between Beads.........................................................................................................34

7.10 Identification of Welds.............................................................................................................34

7.11 Pre-and Post-Heat Treatment ..................................................................................................34

7.12 Weld Interruption.....................................................................................................................35

7.13 Branches .................................................................................................................................36

7.14 Fillet Weld Attachments ..........................................................................................................36

8 Inspection and Testing of Production Welds........................................................................................37

8.1 Rights of Inspection.................................................................................................................37

8.2 Methods of Inspection.............................................................................................................37

8.3 Qualification of Inspection Personnel ......................................................................................37

8.4 Certification of Non-Destructive Testing Personnel .................................................................37

9 Acceptance Standards for Non-Destructive Testing ............................................................................38

9.1 General ....................................................................................................................................38

9.3 Radiographic Testing ...............................................................................................................38

9.7 Visual Acceptance Standards for Undercutting ........................................................................39

9.8 Suspect Welds ........................................................................................................................39

10 Repair and Removal of Defects ...........................................................................................................39

10.1 Authorisation for Repair...........................................................................................................39

10.2 Repair Procedure .....................................................................................................................40

10.6 Arc Burns.................................................................................................................................41

11 Procedures for Non-Destructive Testing..............................................................................................42

11.1 Radiographic Test Methods.....................................................................................................42

11.2 Magnetic Particle Test Method................................................................................................44

11.4 Ultrasonic Test Methods .........................................................................................................44

12 Mechanised Welding with Filler Metal Additions.................................................................................44

12.2 Procedure Qualification............................................................................................................45

12.3 Record .....................................................................................................................................45

12.4 Procedure Specification ...........................................................................................................45

12.5 Essential Variables ...................................................................................................................45

12.6 Qualification of Welding Equipment and Operators .................................................................45

13 Automatic Welding without Filler-Metal Additions...............................................................................46

Appendix AAlternative acceptance standards for girth welds.....................................................................46

Appendix B In-service welding....................................................................................................................46

B.1 General ....................................................................................................................................46

Appendix C Additional requirements for pipelines subject to high strain levels...........................................46

C.1 Introduction .............................................................................................................................46

C.2 General ....................................................................................................................................46

C.3 Weld procedure qualification testing .......................................................................................47

C.4 Production welding ..................................................................................................................48

Appendix DCTOD testing ...........................................................................................................................48

Appendix EPin brazing and aluminothermic welding of anode leads ..........................................................49

E.1 Joining technique ....................................................................................................................49

E.2 Specification and approval of procedure ..................................................................................49




List of Tables

Table A - Grade and thickness limits for cellulosic electrodes........................................................................14

Table B - Diameter and test pipe thickness range of approval .......................................................................17

Table C - Minimum preheat levels for SMAW (cellulosic) welds....................................................................19

Table D - Specified minimum delay time before NDT for WPQT welds .........................................................23

Table 2 - Type and number of test specimens (a) for procedure qualification test .........................................25

Table E - Charpy impact test requirements ....................................................................................................27

Table F - Maximum permissible weld and HAZ hardness values (HV10)........................................................29

Table G - Type and number of test specimens for repair weld procedure qualification test........................... 41

Table H - IQI sensitivity levels........................................................................................................................43

List of Figures

Figure 3 - Location of test pieces from a butt weld in pipe ............................................................................24

Figure A - Charpy V notch locations ...............................................................................................................26

Figure B - Locations for hardness indents......................................................................................................28

Figure C - Fillet weld hardness indent locations.............................................................................................30




Introduction

a. This guidance for pipeline welding is based on API STD 1104.

b. Guidance statements of this document are modifications to API 1104, Welding of

Pipelines and Related Facilities, Twentieth Edition, November 2005.

c. Modifications to API 1104 are identified as Add, Modify to Read, or Delete.

d. Paragraph numbers in this specification correspond to API 1104.

e. Paragraphs of API 1104 that are not revised remain applicable.

f. If any statement is contradictory to API 1104, the requirements of this guidance shall take

precedence.

g. The technical integrity of all aspects of design, construction, and operation of pipelines is

of the highest importance to PT. PHE ONWJ and compliance with PT. PHE ONWJ policy

shall remain paramount.

The normative text of API 1104 and this guidance is primarily applicable to the main line, double

joint, and tie-in welding operations for the construction of C-Mn steel and low alloy steel

pipelines.

This guidance has been written primarily for pipelines up to X80 grade. However, it also allows

for construction of pipelines in higher strength steels up to Grade X120 (which are not yet

included in the base API 1104 standard and for which some parameters such as mechanical

properties and defect acceptance criteria will need to be specified individually).




1 General

1.1 Scope

The scope includes the off-line fabrication of items such as welding nipples to valve bodies or

other fittings and the fabrication welding of branches. The following items are outside the

scope of this guidance:

- Corrosion resistant alloy (CRA) clad linepipe

- Solid CRA linepipe

- The welding of process piping in terminals, pump or compressor stations, or in refineries

- Hyperbaric welding

- Wet welding

- Overlay welding

- Steel catenary risers (SCRs)

Additional requirements for high strain pipelines are given in Appendix C.

Requirements for pin brazing and aluminothermic welding of anode leads are given in

Appendix E

1.2 Welding Process Restrictions

Mechanised and automatic welding processes are preferred and should be used whenever

possible for pipeline girth welding. Main line welding should be by mechanised or automatic

gas metal arc welding (GMAW) which may include single, multi-torch, or tandem-arc variants of

the process and the use of cored wires. If the use of mechanised or automated GMAW

processes is impracticable, alternative processes may be used. In such instances, welding may

be performed by shielded metal arc welding (SMAW), manual or automated gas tungsten arc

welding (GTAW), semi-automatic GMAW processes using solid or cored wires, or a

combination of these processes.

For double or multiple jointing, girth welds should be made using submerged arc welding

(SAW) whenever possible. If SAW cannot be used, the alternative mainline processes listed

above may be utilised either alone or in combination with SAW.

The welding of pipelines by the oxy-acetylene process or by the flash butt welding process

(FBW) or by any other process not defined above is not permitted.

1 .3 HSSE for Pipeline Welding Operations

Welding, cutting, NDT, and associated operations shall be undertaken in a safe manner and

with due regard to individual health and safety and the minimisation of environmental impact.

Welding, cutting, NDT, activities and associated operations shall feature in the operational

safety planning and in the safety audit schedule.

During welding operations, adequate ventilation shall be provided and the quality of breathing

air shall be controlled.

Detail of good practice related to safety during welding, cutting, and associated

operations can be found in AWS Z49.1.

Radiography operations shall conform to local regulations regarding the dangers of ionizing

radiation.

Environmental guidance shall be taken from EN 14717 when undertaking welding and its

associated processes.




1.4 Pre-Production Consultation

Pre-production meetings shall be held with PT. PHE ONWJ, the Contractor and any third-party

inspection personnel in order to ensure that all parties fully understand the specified

requirements. These meetings shall be held before welding procedure qualification testing and

before commencement of fabrication.

The PT. PHE ONWJ Welding Engineer shall, as a minimum, be consulted at the following

stages:

a. During bid evaluation to review the basic welding and NDT methods proposed and to

advise on acceptability.

b. Before weld procedure qualification for approval of the proposed welding procedures.

c. Before production welding for final WPS approval.

1 .5 General Duties of the Contractor

Be responsible for quality assurance.

Be responsible for the compliance of sub-contractors with this guidance.

Unless advised otherwise by PT. PHE ONWJ, supply necessary welding and associated

equipment including, but not limited to: heating equipment, fluxes, gases, filler metals,

mechanical handling, and testing equipment.

If NDT is conducted by the contractor, appropriate NDT equipment including consumables and

handling equipment shall be provided.

If NDT services and equipment are provided by sub-contractors, ensure that the equipment

provided is suitable, well maintained, and, if necessary, is calibrated.

1.6 Quality Assurance

The quality assurance system shall comply with either ISO TS 29001 (API Q1 ) or ISO 9001.

A Quality Plan for the systematic control of construction, inspection, and testing shall be

prepared and implemented. The Quality Plan shall define inspections and tests, the sequence

in which they are to be performed during fabrication, and the level of involvement for the

contractors quality control/inspection personnel, third-party inspection personnel, and PT.

PHE ONWJ.

The Quality Plan shall be submitted to PT. PHE ONWJ and approval obtained before

commencement of fabrication.

1 .7 Records

Documentation shall be collated, indexed, stored safely, and presented to PT. PHE ONWJ. A

log identifying, by number, each pipe or fitting and identifying the weld numbers joining them

to other items, shall be compiled. Each circumferential weld (whether a field joint or shop-made

weld) shall be allocated a unique number, which shall be used for reference to the weld in

reports, radiographs, and test documents.

1 .8 Contractors Personnel

1.8.1 Welding Engineer

A competent and suitably qualified Welding Engineer shall be employed. The Welding Engineer

shall be responsible for the technical aspects of welding operations including the following:

a. Selection of welding processes, equipment, and consumables

b. Preparation and qualification of welding procedures

c. Qualification of welders




d. Providing technical oversight of the production welding

e. Liaison with PT. PHE ONWJ and the NDT sub-contractors

The minimum experience and qualification level for the Welding Engineer should be:

- In USA: Professional Engineer (PE) holding as a minimum a degree in engineering,

metallurgy or materials science and having specialised training in welding technology.

Membership of American Welding Society (AWS) is desirable and a minimum of 5 years

relevant experience in the pipeline welding or fabrication industry is essential.

- In Europe/Rest of the World: Chartered Engineer (CEng/ Dipl Ing) holding, as a minimum, a

degree in engineering, metallurgy or materials science and having specialised training in

welding technology. The requirements of 5.2.2, EN 719 should be met as demonstrated

by the European Welding Engineer (EWE) or International Welding Engineer (IWE)

qualification. Professional Membership of The Welding Institute (UK) is desirable and a

minimum of 5 years relevant experience in the pipeline welding or fabrication industry is

essential.

1 .8.2 Welding Inspectors

Competent and certificated welding inspection personnel shall be employed in sufficient

numbers to ensure that welding related activities are adequately inspected.

Welding Inspectors shall have a sound knowledge of welding processes and their application to

pipeline welding, and possess the knowledge and skills to carry out the tasks given in the

approved Quality Plan, including those necessary for the following:

- Conduct of routine inspections and checks on site or at suppliers in a systematic manner

- Production of accurate records and reports

Welding Inspectors shall hold current certification to any of the following standards as a

minimum:

- CSWIP (TWI, UK) Welding Inspector

- BGAS-CSWIP (TWI, UK) Welding Inspector

- PCN (BINDT, UK) Weld Inspection Level 2

- AWS QC1 (1996 or later edition) Certified Welding Inspector (CWI)

- MIGAS Welding Inspector

Alternative Welding Inspector certification is unacceptable unless approved by PT. PHE ONWJ.

A Senior Welding Inspector shall be employed to coordinate and supervise the work of the

welding inspectors. The role of Senior Welding Inspector requires at least 10 years relevant

experience and sound knowledge of welding processes and their application. Formal

engineering training through apprenticeship and technical college education are required.

Senior Welding Inspectors shall hold current certification to any of the following standards as a

minimum:

- CSWIP (TWI, UK) Senior Welding Inspector

- BGAS-CSWIP (TWI, UK) Senior Welding Inspector (SWI) or Senior Pipeline Inspector (SPI)

- PCN (BINDT, UK) Weld Inspection Level 3

- AWS QC1 (1996 or later edition) Senior Certified Welding Inspector (SCWI)

- MIGAS Welding Inspector

1.8.3 NDT Personnel

NDT personnel shall hold current Level 2 certification (or equivalent), specific to weld testing,

for the appropriate NDT methods to any of the following standards as a minimum:




- CSWIP (TWI, UK)

- BGAS-CSWIP (TWI, UK)

- PCN (BINDT, UK)

- ACCP (ASNT)

- SNT-TC--1A (ASNT)

NDT personnel certificated to the requirements of a Written Practice under the rules of

SNT-TC-1A shall not be used, unless the Written Practice and the personnel certification has

been reviewed and accepted by PT. PHE ONWJ for the specific work.

1.9 Abbreviations and Acronyms

The following abbreviations and acronyms are used in this guidance:

ACCP ASNT Central Certification Program

AUT Automatic Ultrasonic Testing

BAM Federal Institute for Materials Research and Testing (Germany)

BGAS-CSWIP British Gas Approval Scheme Certification Scheme for Welding and

Inspection Personnel

BINDT British Institute of Non-Destructive Testing

CE

IIW

Carbon equivalent (IIW formula)

C Eng Chartered Engineer (UK)

CP Cathodic protection

CRA Corrosion resistant alloy

CSWIP Certification Scheme for Welding and Inspection Personnel

CTOD Crack tip opening displacement

CVN Charpy V-notch

Dipl Ing Diploma Ingenieur (Europe)

ECA Engineering Critical Assessment

FCAW Flux-cored arc welding

GMAW Gas-metal arc welding

GS-FCAW Gas-shielded flux-cored arc welding

GTAW Gas tungsten arc welding

HAZ Heat affected zone

HV Vickers hardness

ID Internal diameter

IIW International Institute of Welding

IQI Image Quality Indicator

MDT Minimum design temperature

MT Magnetic testing

MUT Manual ultrasonic testing

NDT Non-destructive testing

NIST National Institute of Standards and Technology (USA)




OD Outside diameter

P

CM

Cracking parameter (Ito-Bessyo formula)

PCN Personnel certification in non-destructive testing

P-GMAW Pulsed gas metal arc welding

PQR Procedure Qualification Record

PT Penetrant testing

pWPS Preliminary welding procedure specification

RMS Root mean squared

RT Radiographic testing

SAW Submerged arc welding

SCR Steel catenary riser

SMAW Shielded metal arc welding

SMYS Specified minimum yield strength

SS-FCAW Self-shielded flux-cored arc welding

SWE Single wall examination

SWV Single wall viewing

TWI The Welding Institute (UK)

UT Ultrasonic testing

VT Visual testing

WPQT Welding Procedure Qualification Test

WPS Welding procedure specification

2 Referenced Publications

The following standards contain requirements that, through reference in this text, constitute

requirements of this guidance. For references below that are dated, subsequent amendments

to, or revisions of, any of these publications do not apply, although parties to agreements based

on this guidance are encouraged to investigate the possibility of applying the most recent

editions of the standards indicated below. For references below that are undated, the latest

edition of the referenced standards applies.

API

Q1 Specification for Quality Programs for the Petroleum, Petrochemical and

Natural Gas Industry

ASTM

A370 Standard Test Methods and Definitions for Mechanical Testing of Steel

Products

E23 Standard Test Methods for Notched Bar Impact Testing of Metallic Materials

E92 Standard Test Methods for Vickers Hardness of Metallic Materials

E1815 Standard Test Method for Classification of Film Systems for Industrial

Radiography




AWS

D1.1/D1.1M Steel Structural Welding Code

A4.3 Determination of Hydrogen Content Produced by Arc Welding

C5.3 Recommended Practices for Air Carbon Arc Gouging and Cutting

A5.32 Specification for Welding Shielding Gases

BSI

BS 4515-1 Specification for Welding of Steel Pipelines on Land and Offshore Part 1 :

Carbon and Carbon Manganese Steel Pipelines

BS 7448-1 Fracture mechanics toughness tests. Part 1. Method for the determination

of K

IC

, critical CTOD and critical J values of metallic materials

BS 7910 Guide on methods for assessing the acceptability of flaws in metallic

structures

Canadian Standards Association (CSA)

CSA Z245.1 Steel Line Pipe

CSA Z662 Oil and Gas Pipeline Systems

European Standard (EN)

EN 439 Welding consumables Shielding gases for arc welding and cutting

EN 719 Welding coordination. Tasks and responsibilities

EN 875 Destructive tests on welds in metallic materials - Impact tests - Test

specimen location, notch orientation and examination

EN 1011-2 Welding recommendations for welding of metallic materials Part 2: Arc

welding of ferritic steels

EN 10045-1 Charpy impact test on metallic materials - Part 1 : Test method (V- and

U-notches)

EN 10204 Metallic products - Types of inspection documents

EN 10208-1 Steel pipes for pipelines for combustible fluids. Technical delivery conditions.

Pipes of requirement class A

EN 10208-2 Steel pipes for pipelines for combustible fluids. Technical delivery conditions.

Pipes of requirement class B

EN 14717 Welding and allied processes Environmental check list

International Organisation for Standardisation (ISO)

ISO 148 Steel - Charpy impact test (V-notch)

ISO 2504 Radiography of welds and viewing conditions for films - Utilization of

recommended patterns of image quality indicators (I.Q.I.)

ISO 3183 Petroleum and natural gas industries Steel pipe for pipeline transportation

systems

ISO 3690 Welding and allied processes - Determination of hydrogen content in ferritic

steel arc weld metal

ISO 5580 Non-destructive testing - Industrial radiographic illuminators - Minimum

requirements

ISO 6507-1 Metallic materials Vickers hardness test Part 1: Test method

ISO 9001 Quality management systems - Requirements

ISO 10005 Quality management Guidelines for quality plans

ISO 11699-1 Non-destructive testing - Industrial radiographic films Part 1: Classification

of film systems for industrial radiography




ISO 17636 Non-destructive testing of welds Radiographic testing of fusion-welded

joints

ISO 17638 Non-destructive testing of welds Magnetic particle testing

ISO 17640 Non-destructive testing of welds Ultrasonic testing of welded joints

ISO TS 29001 Petroleum, petrochemical and natural gas industries - Sector-specific quality

management systems requirements for product and service supply

organizations

3 Definitions of Terms

3.2 Definitions

3.2.3 Company

PT. PHE ONWJ or its authorized representative

3.2.4 Contractor

A contractor responsible to PT. PHE ONWJ for construction (including welding) of the pipeline

3.2.21 Arc Energy

The unfactored energy input calculated from the current, voltage and travel speed.

Note: Heat input requires an efficiency factor dependent on the welding process.

3.2.22 PT. PHE ONWJ

PT. PHE ONWJ, an associate or subsidiary of PT. PHE ONWJ, or other organization as defined

in the Conditions of Contract on a project.

3.2.23 Lot

A single heat of filler wire, a single blend of flux, or for covered electrodes or cored wire, the

combination of a single heat of cored wire with a single dry blend of flux cover or core.

3.2.24 Quality Plan

Document specifying which procedures and associated resources shall be applied by whom

and when to a specific project, product, process or contract.

Note: Guidance for the production of Quality Plans is given in ISO 10005.

4 Specifications

4.1 Equipment

Welding power supply voltage and amperage meters shall be calibrated. Independent calibrated

instrumentation shall be provided to measure relevant parameters during production. NDT

equipment shall also be calibrated. Certificates showing that equipment calibration is valid for

the period of use shall be available.

The manufacturer, model and type of equipment shall be identified in the Procedure

Qualification Record (PQR).

SMAW electrode holders shall be fully insulated.

Welding return cables connections shall be of sufficient cross-sectional area to prevent

concentration of current and shall be securely attached to prevent arc burns.




4.2 Materials

4.2.1 Pipe and Fittings

c. ISO 3183

d. EN 10208

e. CSA Z245.1

The requirements given apply to materials that comply with any of the standard specifications

listed in a & b (in API 1104) and c to e above. Note that API 5L is supplemented by PHEONWJ-

W-SPE-0005 and that PHE ONWJ supplementary requirements may be applied to any of the

above specifications. Other material specifications may be used if required by statutory

regulations of the countries in which the pipeline will operate.

4.2.2 Filler metal

4.2.2.1 Type and size

In principle, the yield strength of the weld metal should be selected to ensure that the yield

strength of the deposited pipeline girth welds overmatches the actual yield strength of the

parent pipe material. Additional guidance will be provided by the pipeline designer. The

deposited weld metal shall also meet the specified ductility, toughness, and limiting hardness

criteria in accordance with the pipeline design and with this guidance.

4.2.2.1 .1 Limitations of use for cellulosic electrodes

Cellulosic coated electrodes shall not be used for:

- Pipe grades and thicknesses beyond those shown in Table A

- Pipelines subject to high strain (e.g. reeled pipelines)

- Strain based design pipelines

- The welding of fittings, flanges and valves

- Fillet welding (e.g. for anode doubler plate attachment)

In applications in which cellulosic SMAW consumables are being evaluated for use, the

possibility of employing low hydrogen vertical down electrodes shall be considered.

Cellulosic electrodes shall neither be baked nor dried and shall be used straight from the

original packaging.

Table A - Grade and thickness limits for cellulosic electrodes

Pipe Grade

(API 5L)

Pipe Grade

(ISO 3183)

(EN 10208)

(CSA Z.245)

Maximum Wall Thickness

(a,b)

< X65 < L450 3/4 (approx 19 mm)

X70 L485 5/8 (approx 16 mm) with E8010 fill passes

3/8 (approx 10 mm) with E9010 fill passes

X80 L555 Root & hot pass only

> X80 > L555 Not permitted

a. E6010 or E6011 electrodes may be used for root pass welding provided sufficient overall weld

strength and toughness is obtained.

b. Preheat shall be applied to cellulosic welds (see 5.3.2.13 and 7.11 .1 ).




4.2.2.1 .2 Consumable selection for root welding

In some instances it may be necessary to select a root welding consumable having a specific

chemical analysis in order to provide resistance to preferential weld metal corrosion. The

pipeline designer will provide advice on any such requirement. If a weld metal composition is

specified, then one root weld metal chemical analysis shall be conducted for each WPS and

each weld repair procedure to check that the required composition has been achieved.

4.2.2.2 Storage and handling of filler metals and fluxes

The storage and handling of welding consumables shall be in accordance with PHEONWJ-W-

SPE-0008. A detailed consumable storage and handling plan shall be submitted for PT. PHE

ONWJ review and approval.

4.2.2.3 Consumable lot testing by supplier*

*Note: Some standards, project specifications and/or consumable

suppliers may refer to Consumable Batch Testing.

Each lot of welding consumables shall have a consumable manufacturers certificate

conforming to the relevant ISO, AWS or EN filler metal specification. The testing of each lot

shall include actual deposited weld metal chemical composition, tensile and Charpy impact

tests; refer to PHEONWJ-W-SPE-0008.

For low hydrogen SMAW consumables, manufacturers certificates shall include average-

diffusible-hydrogen level as determined and reported in accordance with ISO 3690 or

ANSI/AWS A4.3.

Certificates shall comply with PHEONWJ-W-SPE-0008 and EN 10204 type 3.1 .b.

SAW wire shall be tested in combination with the same brand and classification of flux as that

to be used during production welding.

The consumable certificates shall be examined to verify that the same weld properties can be

expected for the production welds as those obtained during weld procedure testing.

4.2.2.4 Additional lot testing

Only the lots of consumables mechanically tested during qualification of the weld procedure

shall be used for production welding of the following pipeline types:

- If the NDT acceptance criterion has been established by an ECA

- For pipe grades of X65 and above

- If consumables with an AWS G designation are used, e.g. E8010-G or ER70S-G

Testing may be conducted to gain approval for additional lots of consumables. Testing shall be

undertaken on a weld made in accordance with the production WPS and shall include:

- 2 all-weld tensile tests

- 2 sets of weld metal Charpy impact tests

- 1 macro-section and hardness survey sampled from the 3 oclock position

- 1 set of weld metal CTOD tests

The testing shall be in accordance with 5.6. The results shall meet the levels required for the

relevant weld procedure(s) and, if applicable, the ECA.

4.2.3 Shielding gases

4.2.3.3 Compliance

Shielding gases shall meet BS EN 439 or AWS A5.32. They shall be pre-mixed and bottled by

the supplier and shall have certificates of compliance. The certificates shall show the

composition and dew point. Subject to PT. PHE ONWJ approval, Ar/CO

2

gases may be mixed at

site.




4.3 Minimum design temperature (MDT)

Unless otherwise specified in the contract, the MDT shall be 0C (32F).

5 Qualification of Welding Procedures for Welds Containing Filler-

Metal Additives

5.1 Procedure qualification

5.1 .1 General

Preliminary Welding Procedure Specifications (pWPSs) shall be submitted for PT. PHE ONWJ

agreement before commencement of the Welding Procedure Qualification Tests (WPQTs).

Welding procedures, including fillet welds and repair procedures, shall be qualified by visual

examination, NDT, and mechanical testing as specified in this guidance.

Welding, NDT and mechanical testing of the WPQT welds shall be witnessed by PT. PHE

ONWJ or an approved third party. The witnessing of mechanical tests shall include the

positioning of the notches for Charpy and CTOD tests.

A WPS written with more than one supporting Procedure Qualification Record (PQR) shall not

permit optional processes, but shall uniquely specify the process for each pass.

5.1 .2 Welding Procedure Parameters

During weld procedure qualification, relevant procedure data, irrespective of whether the item

is a listed essential variable, shall be captured and recorded. Sufficient information shall be

recorded to allow full replication of the procedure qualification welds. A record of the data shall

be kept for the purpose of aiding production and to assist with the diagnosis of problems, but

need not be formally entered on to the PQR, e.g. GMAW machine slope-in settings.

The methods of measuring the welding parameters and the records to be kept shall be agreed

with the PT. PHE ONWJ Welding Engineer.

Following qualification, the pWPS shall be revised to reflect the parameters recorded during

qualification. The revised WPS values for current, voltage, and travel speed for each pass shall

be either:

(i) Within the range recorded during WPQT. Transient or anomalous values shall not be used

to establish the range, or

(ii) The mean value +/10%.

The arc energy shall be calculated using the recorded values of current, voltage, and travel

speed without the addition of a percentage.

The final WPS shall state parameters for each pass. However, if fill passes (i.e. passes other

than root, hot pass, and cap) have similar values, the parameters may be combined on the

WPS.

If a welding consumable or group of consumables is qualified to weld several different

components or pipe sizes, every effort should be made to ensure that the parameters specified

on the individual WPSs are common across the group of WPSs.

5.2 Record

The details of each procedure shall be recorded

Forms used to record WPS and WPQT details shall contain the relevant information. The format

shall be subject to approval by PT. PHE ONWJ.




The PQR documentation package for each WPS shall comprise:

a. As-run records

b. NDT results

c. Mechanical test results and macrographs

d. Consumable certification

e. Parent material certification

The following data shall also be available if requested by the PT. PHE ONWJ Welding Engineer:

f. Calibration certificates for equipment and measuring devices

g. SNT (ASNT) Written Practice (if applicable)

h. Welding Inspector and NDT personnel certification

i. NDT procedure qualification records

j. Testhouse approval certification

The approved WPSs and PQR packages shall also be available in a good quality electronic

format.

5.3 Procedure Specification

5.3.1 General

The relevant PT. PHE ONWJ approved WPSs shall be displayed at each work location and shall

be readily available to each welder.

5.3.2 Specification Information

5.3.2.2. Pipe and fitting materials

Pipe, valves, flanges, and fittings from different manufacturers, or manufactured from materials

supplied from different sources or in different supply conditions, shall require separate

procedure qualification as detailed in 5.4.2.2, unless a material grouping is approved by PT. PHE

ONWJ. The manufacturer(s) shall be noted on the WPS.

5.3.2.3 Diameters and wall thicknesses

The ranges of pipe diameters and wall thicknesses over which the procedure is approved are

identified in Table B unless alternative ranges are agreed by PT. PHE ONWJ.

Table B - Diameter and test pipe thickness range of approval

5.3.2.4 Joint design

The use of permanent or consumable backing rings is not permitted. An exception is the outer

pipe welds in a pipe-in-pipe system. Non-consumable temporary backing as an integral

permanent feature on an internal clamp will be permitted subject to satisfactory demonstration

of the process.

Test Pipe Diameter Range of Approval

(in) (mm) (in) (mm)

D < 2.375 D < 60.3 < 2.375 < 60.3

2.375 < D < 12.75 60.3 < D < 323.9 2.375 to 12.75 60.3 to 323.9

12.75 < D < 24.0 323.9 < D < 610 12.75 to 24.0 323.9 to 610

D > 24.0 D > 610 > 24.0 > 610

Test pipe thickness = t 0.75t to 1 .5t




5.3.2.5 Filler metal and number of beads

The brand name, electrode or wire name, designation and ISO/AWS/EN welding consumable

classification shall be stated in the PQR.

5.3.2.6 Electrical characteristics

The following parameters shall be specified on WPSs:

a. Welding current (including pulse rate, pulse shape or dwell time, and max/min current for

pulsed welding procedures)

b. Diameter of electrodes or welding wires

c. Wire-feed speed (and pulse rate or frequency for pulsed wire procedures)

d. Arc energy for each pass. For multiple (electrically isolated) tandem electrode welding

processes, e.g. SAW or P-GMAW, the effective arc energy per pass shall be calculated as

the sum of the individual arc energies for each electrode. For pulsed procedures, the

effective arc energy shall be calculated on the basis of RMS values. Voltage and current

shall be determined with calibrated meters and recorded for each pass during WPQT

welding using suitable PT. PHE ONWJ approved data monitoring equipment.

If applicable, the following parameters shall be specified in the WPS:

e. Type, diameter and angle of tip for GTAW tungsten electrodes

f. Hot wire diameter, feed speed, current, and voltage

g. Head angle, electrode spacing from top-dead centre and direction of rotation for 1G-

rotated welding

h. Contact tip to workpiece distance

i. Electrode spacing and individual angles relative to pipe surface (for welding with multiple

electrodes)

j. Torch separation and angle for multiple torch welding

k. Torch oscillation frequency for mechanised (automatic) welding

l Shroud (gas-cup) diameter

The welding unit, power supply type, manufacturer, model number, and software version

number shall be stated for automatic, mechanised, or semi-automatic welding procedures.

5.3.2.8 Position

The welding position shall be stated on the WPS and PQR documents.

5.3.2.10 Time between passes

The time between completion of the root bead and commencement of deposition of the hot-

pass shall be not greater than that qualified in the WPQT and should not be greater than

10 minutes.

If cellulosic welding is used, the second run (hot-pass) shall be deposited immediately after

completion of the root bead.

5.3.2.11 Type and removal of line-up clamp

For pipe-to-pipe joints over 150 mm (6 in) diameter, an internal line-up clamp should be used. If

it is agreed by PT. PHE ONWJ that this is impracticable, e.g. for tie-ins, an external line-up

clamp shall be used.

If an internal line-up clamp is used, the root run shall be 100% complete before the clamp is

removed. If an external line-up clamp is used, the root run shall be at least 50% complete

before the clamp is removed. In either case, the pipes on both side of the joint shall not be

raised, lowered or otherwise moved until both the root and the second weld pass (hot pass)




have been completed, unless it can be demonstrated to the satisfaction of PT. PHE ONWJ that

the root run alone is adequate to resist the deformation. For SMAW welding using cellulosic

coated electrodes, the hot pass shall always be completed before the pipe is moved.

5.3.2.13 Pre- and post-heat treatment

As a minimum, a preheat temperature shall be selected to ensure that:

a. The pipe is dry before welding

b. The metal temperature is greater than 30C (86F)

c. The metal temperature is greater than 50C (122F) if moisture is present on the pipe

and/or if ambient temperatures are below 5C (41C)

d. The hardness requirements of 5.6.8.3 are met for the weld metal and HAZ

e. The weld metal is not at risk of hydrogen cracking (for cellulosic welds see Table C for

guidance on minimum preheat levels)

f. Sufficient heat is present to prevent cold (hydrogen) cracking in the HAZ

Note: Guidance for the avoidance of HAZ cracking is given in EN 1011-2,

AWS D1.1/D1.1M Annex XI, and BS 4515-1 Annex E.

Table C - Minimum preheat levels for SMAW (cellulosic) welds

The preheat temperature shall not be lower than that recorded during WPQT welding.

The interpass temperature shall not be less than the preheat temperature and shall not exceed

the highest value recorded during WPQT. In no case shall the interpass temperature exceed

300C (572F).

The preheat and interpass temperatures shall be measured in accordance with 7.11 .1 .

If any form of post-weld heat treatment or delayed cooling of the weld is to be used, it shall be

specified in the WPS.

If the weld is to be cooled rapidly to allow immediate AUT, then this shall be simulated during

WPQT. Assisted cooling shall not commence until the weld temperature has cooled without

interference to below 400C (750F).

5.3.2.14 Shielding gases and flow rate

Shielding gas type, composition, and flow rate (for each torch in multi-torch systems) shall be

specified in the WPS.

5.3.2.17 Bead map

A sketch of the weld cross-section showing the bead sequence shall be made for each WPS.

If bead deposition is by a weaving technique, this shall be designated on the WPS.

Filler Grade

(AWS Designation)

Wall Thickness Minimum Preheat

Temperature

(in) (mm) (F) (C)

E6010

< 0.4 < 10 122 50

0.4 < 0.6 10 < 15 167 75

> 0.6 < 0.8 > 15 < 20 212 100

E7010

&

E8010

< 0.4 < 10 176 80

0.4 < 0.6 10 < 15 212 100

> 0.6 < 0.8 > 15 < 20 248 120

E9010 < 0.4 < 10 212 100




Low hydrogen SMAW electrodes shall not be weaved by more than 3 times the nominal

electrode core wire diameter.

5.3.2.18 Period of validity for welding procedures

For new pipeline construction projects, new WPSs shall be prepared and qualified.

For the purposes of undertaking further work to an existing pipeline, a WPS may remain valid

indefinitely. The PT. PHE ONWJ Welding Engineer shall be consulted before re-using the WPS.

5.4 Essential Variables

5.4.1 General

An approval of a WPS obtained by a contractor is valid in workshops or sites of that contractor

under identical or equivalent technical and quality control. The validity shall be subject to the

approval of the PT. PHE ONWJ Welding Engineer. Welding procedures shall not be transferred

from one contractor or sub-contractor to another without requalification.

5.4.2 Changes Requiring Requalification

5.4.2.1 Welding process or method of application

Any change from a single torch per motorised head to multiple torches, or vice-versa, shall

constitute an essential variable.

Any change of wire delivery system for SAW or mechanised (automatic) GMAW/ GTAW,

including from single to double or multiple wires and/or from cold to hot-wire systems, or vice

versa, shall constitute an essential variable.

5.4.2.1 .1 Line-up clamp

A change from internal to external line up clamp, or vice-versa; or, from internal clamp without

an internal welder to an internal clamp incorporating an internal welder, shall constitute an

essential variable.

Removal of a line-up clamp at an earlier stage than qualified in the WPQT constitutes an

essential variable.

5.4.2.1 .2 Weld or joint backing

Use or removal of copper backing rings or shoes, or combination of these, shall be considered

an essential variable.

5.4.2.1 .3 Number of welders or welding operators

The number of welders shall be at least as many as during welding of the test piece and shall

be considered as an essential variable for each pass.

5.4.2.1 .4 Interpass cleaning

The method of interpass cleaning shall be considered an essential variable.

5.4.2.2 Base material

Base material grouping by strength shall only be allowed for materials with an SMYS less than

or equal to 42,000 psi (290 MPa); but, for all grades of material, the following shall constitute

essential variables:

a. Change of manufacturing facility for strip, billet, plate, pipe or forging

b. Change of steel making, plate rolling, forging or pipe manufacturing process

c. For grades up to and including X80, a change of composition resulting in a change of

greater than 0.03CE

IIW

or greater than 0.02P

cm

value. For sour service pipelines, a




change in composition resulting in greater than +0.01 or 0.03CE

IIW

or greater than +0.01

or 0.02P

cm

value.

1556

CuNiVMoCrMn

CCE

IIW

+

+

++

++=

B

VMoNiCrCuMnSi

CP

cm

5

1015602030

++++

++

++=

d. For grades above X80, composition limits will be advised on a project by project basis.

5.4.2.3 Joint design

For narrow gap welding, e.g. mechanised (automatic) GMAW, any change in bevel angle

beyond 1, root face beyond 50% or root gap +0.5 mm (0.02 in) constitutes an essential

variable. Any weld preparation with an included angle of less than 20 shall be considered to be

narrow gap welding.

For other welding, any changes in bevel angle by more than 5, or variation in root gap/root

face by more than 50%, constitutes an essential variable.

Note: For pipe grades above X80 (L555), it may be necessary to impose more

stringent limits on the joint design for mechanised (automatic) welding

than those quoted above as minor changes can result in significant

differences in mechanical properties of the girth welds.

5.4.2.4 Position

A change of welding position shall constitute an essential variable. Welding positions 5G and

2G shall be qualified separately. 6G qualification shall be required if the angle of the pipe is

between 25 and 65 to the horizontal.

5.4.2.5 Wall thickness

Any change outwith the grouping ranges of pipe by diameter and wall thickness designated in

5.3.2.3, shall constitute an essential variable.

5.4.2.6 Filler metal

The following changes in filler metal constitute essential variables:

a. Any change in filler metal designation, filler metal manufacturer, manufacturing location or

brand name

b. Any change in welding consumable or size

c. Lot testing as per 4.2.2.3 is required

The compatibility of the base material and the filler metal should be considered from the

standpoint of mechanical properties.

5.4.2.7 Electrical characteristics

Any change in the following shall be considered essential variables:

a. The welding current, arc voltage and travel speed outside that recorded on the WPS

b. For pulsed current welding the pulse rate, pulse shape, and max/min current recorded on

the WPS

c. For GMAW, cored wire welding and hot wire GTAW any change of wire feed speed

outwith the range qualified

d. Arc energy for each pass outside of the range recorded on the WPS

e. Head angle, electrode spacing from top dead centre and direction of rotation for 1G-

Rotated welding

f. Electrode spacing for welding procedures utilising multiple electrodes, e.g. tandem-wire

SAW, or mechanised (automatic) tandem wire or twin torch processes




g. Diameter of electrodes or welding wires

h. For semi-automatic and mechanised (automatic) welding, the welding unit, power supply

type, manufacturer, model number and software version number

5.4.2.8 Time between passes

If using cellulosic electrodes, the time lapse between the start of the root bead and the start of

the second bead shall not exceed the time lapse recorded during welding of the test piece.

5.4.2.10 Shielding gas and flow rate

Any change of shielding gas flow rate greater than 15% of that qualified shall constitute an

essential variable.

5.4.2.11 Shielding flux

For pipeline grades greater than X52, any change of shielding flux manufacturer, manufacturing

location, brand or type constitutes an essential variable. Any change of flux for pipeline grades

X52 and below shall be subject to the agreement of the PT. PHE ONWJ Welding Engineer.

5.4.2.12 Speed of travel

A change in speed of travel beyond the range on the qualified WPS constitutes an essential

variable.

5.4.2.13 Preheat

Any change in the preheat application method shall constitute an essential variable.

5.4.2.15 Arc energy per pass

Any change in arc energy outside of the range in the approved WPS shall constitute an

essential variable.

5.4.2.16 Interpass temperature

An increase in the specified interpass temperature shall constitute an essential variable. The

use of rapid cooling of welds constitutes an essential variable unless simulated in the WPQT.

5.5 Welding of Test JointButt Weld

5.5.1 Test Pipe for WPQT

The WPQT shall simulate the production welding of the pipelines and shall be undertaken as far

as practicable, under site ambient conditions. For land pipelines, lifting and lowering off shall be

simulated using full pipe lengths.

If an internal line-up clamp will be used in production welding, the length of the nipples used in

the WPQT shall be sufficient to accommodate the full length of the clamp. The minimum

length of any nipple piece used during qualification should be 1 m (3.3 ft) or 1 .5 pipe diameters

whichever is the greater.

The minimum length of test rings for the WPQT of fittings and flanges shall be subject to

agreement with PT. PHE ONWJ .

5.6 Testing of Welded JointsButt Welds

5.6.1 Preparation

Reference Figure 3 and Table 2, in accordance with this guidance

The blanks from which the mechanical test pieces are machined may be cut from the

qualification weld using oxy-fuel gas cutting, but its dimensions shall be sufficient to allow the




material of the final machined test piece to remain unaffected by the heat from the cutting

operation.

Test specimens shall not be subjected to any elevated temperature degassing treatment.

5.6.1 .1 Non-destructive testing of WPQT welds

WPQT welds shall be visually examined (VT) as soon as possible after completion of welding

with 100% coverage of weld surfaces. WPQT welds shall meet the same requirements for

weld profiles and VT as those specified for production welds.

The full circumference of WPQT welds shall be examined by radiographic testing (RT),

ultrasonic testing (AUT or MUT), and magnetic particle testing (MT). For WPQT welds, there

shall be a minimum delay time as specified in Table D between completions of welding and

non-destructive testing of the welds.

Table D - Specified minimum delay time before NDT for WPQT welds

Acceptance by PT. PHE ONWJ shall be required before sectioning of WPQT welds for

mechanical testing.

The NDT procedures for WPQT welds shall be qualified and subject to approval by PT.

PHE ONWJ.

5.6.1 .2 Mechanical testing

Mechanical testing shall be performed by a certified testing laboratory approved by PT. PHE

ONWJ.

Test specimens shall be taken from pipeline WPQT butt welds as shown in Figure 3. Repair

weld mechanical testing locations and specimen types/ numbers shall be in accordance with

Table H. Test specimens not shown in Figure 3, e.g. CTOD test pieces, may be taken from any

position around the weld where spare material is available, but the exact locations should be

agreed in each instance with the PT. PHE ONWJ Welding Engineer. More than one weld may

be required to provide sufficient material for testing. Table 2 shows the type and number of

test specimens required.

5.6.1 .3 Test temperature

Destructive testing shall be performed at ambient temperature, except for impact testing (see

5.6.6.3) or CTOD testing (see 5.6.10).

For design service temperatures above 100C (212F), elevated temperature transverse and

weld tensile testing shall be undertaken. The test temperature, extent of testing and required

strengths shall be specified on a project specific basis.

5.6.1 .4 Repair of WPQT welds

Weld repairs to WPQT welds are not permitted, except if the purpose is to qualify a repair

procedure.

5.6.2 Tensile-Strength Test

5.6.2.1 Preparation

Preparation of the tensile test piece shall be as per Figure 4, except that internal and external

weld reinforcement shall be removed before testing.

WPQT Welds in API/ISO Pipe Grades Welding Process Minimum Delay Before NDT

< API X70 / ISO L485 Any process except cellulosic SMAW 24 hours

< API X70 / ISO L485 Cellulosic SMAW

a

48 hours

> API X70 / ISO L485 Any welding process 72 hours

a

Welds made with cellulosic root/hot pass only may be inspected after 24 hours.




The position of failure shall be recorded, i.e. weld metal, HAZ or base metal.

Figure 3 - Location of test pieces from a butt weld in pipe

> 114.2mm (4.500)

but < 323.9mm (12.750)

3

1

3

4

4

2

2

6

1

5

5

6

5

3

1

3

4

4

2

2

6

1

5

5

6

5

1

1

1

1

3

22

3

3

3

2

4

4

4

4

2

5

5

5

6

6

1

1

1

1

3

22

3

3

3

2

4

4

4

4

2

5

5

5

6

6

Key:

1) Face or side bend

2) Transverse tensile

3) Root or side bend

4) Nick-break

5) Macrosection

6) Charpy V-Notch

Greater than 323.9mm (12.75)

NOTE: Test specimens not shown in Figure-3, e.g. CTOD test pieces, may be taken from any position around the

weld where spare material is available. More than one weld may be required to provide sufficient material for

testing.

< 60.3mm (2.375)

4

3

2

2

6

5

5

5

> 60.3mm (2.375) but

< to 114.3mm (4.500)

Also, < 114.3mm (4.500) when

wall thickness > 12.7mm (0.500)

2

3

3

4

4

2

5

6

5

5

2

3

3

4

4

2

5

6

5

5




Table 2 - Type and number of test specimens (a) for procedure qualification test

Number of Specimens for Wall Thickness 12.7 mm (0.500 in)

OD of Pipe

mm (in)

Tensile

Strength

(Cross

Weld

Tensile)

All-Weld

Metal

Tensile

(c)

Nick

Break

(d)

Root

Bend

Face

Bend

Side

Bend

Charpy

Impact

Tests

(set of 3)

(e)

Macro/

HV10

CTOD

(set of 3 )

(f & g)

323.9 (>12.750) 4 1 4 4 4 0 4 3 3

Number of Specimens for Wall Thickness > 12.7 mm (0.500 in)

OD of Pipe

mm (in)

Tensile

Strength

(Cross

Weld

Tensile)

All-Weld

Metal

Tensile

(c)

Nick

Break

(d)

Root

Bend

Face

Bend

Side

Bend

Charpy

Impact

Tests

(set of 3)

(e)

Macro/

HV10

CTOD

(set of 3)

(f & g)

114.3-323.9

(>4.500-12.750)

2 1 2 0 0 4 4 3 3

>323.9 (>12.750) 4 1 4 0 0 8 4 3 3

NOTES:

a Specimen locations shall be in accordance with 5.6 and Figure 3.

b One nick-break and one root-bend specimen shall be taken from each of two test welds, or for pipe less than or

equal to 34 mm (1 .315 in) diameter, two full section tensile strength specimens shall be taken.

c If an ECA is to be used for defect acceptance levels, three all-weld metal tensile specimens shall be taken.

d. Nick breaks are not required for mechanised (automatic) welding.

e Charpy impact tests shall comprise weld metal and fusion line specimens machined from the pipe outside diameter.

Pipes with wall thickness > 20 mm shall have additional specimens machined from the ID .Additional sets of Charpy

Impact specimens may be required by the PT. PHE ONWJ welding engineer, e.g. if very thick pipe is to be utilised

or the combination of processes or consumables have not been adequately sampled by the specified locations.

f CTOD tests shall comprise a minimum of one set of weld metal and two sets of HAZ samples (see paragraph D.4 of

Appendix D).

g CTOD tests are only required for pipelines with ECA based acceptance criteria or if required by the pipeline designer.

5.6.2.3 Requirements

The results of transverse weld tensile tests shall meet or exceed the specified requirements

for the pipe (base metal) with respect to specified tensile strength. Transverse weld tensile

specimens shall fail at a location within the HAZ or base metal.

If base metals of different strength levels are used, then acceptance criteria shall be based on

the lower strength base metal.

5.6.6 Charpy V Notch Testing

5.6.6.1 Scope

WPQT butt welds shall be subjected to Charpy V notch impact testing.




5.6.6.2 Preparation

The test pieces shall be prepared and tested in accordance with ISO 148, EN 10045-1 and

EN 875 or ASTM A370 and E23.

A set of Charpy impacts shall comprise three specimens. Sets of Charpy specimens shall be

taken from the locations shown in Figure 3.

Specimens shall be notched with the axis of the notch perpendicular to the pipe surface. The

position of the notch for each set shall be as depicted in Figure A.

Full size specimens shall be used if possible.

5.6.6.3 Method

The impact test temperature shall be the minimum design temperature when the following

conditions apply:

- The minimum design temperature is minus 10C (14F) or higher

- The wall thickness is 25 mm (1 in) or lower

- The material SMYS is 555 N/mm

2

(80 ksi) or lower

In addition to the above, for gas pipelines the impact test temperature shall be no higher than

minus 10C (14F).

Test temperatures for welds outside of the above conditions shall be advised by

PT. PHE ONWJ.

Figure A - Charpy V notch locations


The Charpy impact values shall meet or exceed the values given in Table E.

NOTES:

1 Specimens shall be positioned between 1 2 mm from the pipe outer surface. Additional specimens for

thicknesses greater than 20 mm shall be positioned within 1 2 mm from the inner surface.

2 Fusion line Charpy specimens shall sample 50% weld metal and 50% HAZ.

A(i) Weld Centreline

A(ii) Fusion Line




Table E - Charpy impact test requirements

For specimens below 10 mm in thickness, the energy requirement shall be reduced pro rata,

e.g. a 7.5 mm specimen shall achieve 75% of the required full size value.

The ductile shear area shall exceed 50%.

Individual samples may be replaced if there is evidence of a weld defect on the fracture

surface. Re-testing may be allowed following discussion with the PT. PHE ONWJ Welding

Engineer.

Test results, including percentage ductile shear area, shall be recorded.

5.6.7 Macro-Section

5.6.7.1 Method

Macro-sections shall be extracted from procedure qualification test welds at three locations

approximately 90 apart. For welds containing any pass made in the 5G position, macro-

sections shall be extracted as close as practicable to the 12 oclock, 3 oclock and 6 oclock

positions.

When girth welding seam-welded linepipe, an additional macro-section shall be extracted from

the girth-weld at the T-intersection region between the girth weld and seam weld.

Macro-sections shall be polished to a metallographic (1 m) finish and etched in a 2-10% Nital

solution, or other suitable PT. PHE ONWJ approved etchant. The etched specimens shall be

thoroughly examined at 10 times magnification.

Original photo-macrographs of macro-sections at approximately 3 to 5 times magnification shall

be included in the PQR documentation.

5.6.7.2 Acceptance criteria

When examined at 10 times magnification, the macro-section shall reveal:

a. No cracks

b. Complete fusion between adjacent layers of weld metal and between weld metal and

base metal

c. Complete fusion at the root

d. No lack of cross penetration

e. No undercut (unless weld surfaces are to be ground smooth). If weld surfaces are to be

ground smooth, minor undercut may be removed by the surface grinding operation. If the

undercut is of such depth that its removal would result in encroachment of the minimum

specified thickness of the pipe, it shall be deemed unacceptable.

f. No excess cap reinforcement exceeding 1.6 mm (1/16 in) above the base metal surfaces

for weld surfaces not specified to be ground smooth

g. Weld reinforcement shall blend smoothly into the adjacent base metal

h. No penetration of the root bead into the bore exceeding 3 mm (1/8 in). For pipe diameters

less than 60 mm (2-3/8 in) this penetration shall not exceed 1.5 mm (1/16 in).

i. At no point shall the weld surface, ID or OD, lie below the adjacent base metal

Any observed defects shall be within the limits given in Section 9.

Grade Minimum Average Energy Minimum Individual Energy

ft lbs J ft lbs J

< X80 < L555 37 50 30 40

X80 L555 44 60 33 45

> X80 > L555 To be advised




5.6.8 Hardness test

5.6.8.1 Preparation

The hardness testing technique shall be the Vickers method with an applied load of 10 kg in

accordance with ISO 6507-1 or ASTM E92.

The hardness surveys shall be undertaken on each of the macro-section specimens specified in

5.6.7. For non-sour pipelines, surveys on the 12 oclock and 6 oclock macro-sections may be

omitted.

5.6.8.2 Method

Each survey shall consist of three rows of indents. One traverse shall be located below the cap,

one above the root (or internal surface) and one at mid-thickness. The positions are shown in

Figure B. The mid-thickness traverse may be waived for single sided welds below 12.7 mm.

The PT. PHE ONWJ Welding Engineer may require additional hardness indent positions, e.g. if

a consumable type has not been sampled by the specified three traverses.

Figure B - Locations for hardness indents

t/2

1 - 2mm

1 - 2mm

t/2

1 - 2mm

1 - 2mm

The macrophotographs shall show the position of each hardness indent and shall be included in

the PQR along with a tabulation or diagram showing the result and location of each indent. The

maximum and minimum values shall be identified.


The individual hardness values shall not exceed the values given in Table F.

The parent material hardness values shall not exceed the values permitted in the relevant

material specification.

NOTES:

1. Parent material indentations shall be at least 20 mm from the fusion line.

2. The first HAZ indentation shall be placed as close to the fusion line as possible. Further indentations into the

HAZ shall be separated by approximately 0.5 mm, however the minimum centre-to-centre separation

requirement of 2.5 or 3 times the mean diagonal of the nearest indentation shall be maintained (ref.

ISO 6507-1 and ASTM E92).

3. The same survey pattern shall be applied to double-sided welds.




Table F - Maximum permissible weld and HAZ hardness values (HV10)

5.6.9 Weld Metal Tensile Test (All-Weld Metal Tensile Test)

Weld metal tensile test specimens shall be in accordance with ASTM A370. For narrow gap

welds in which the width of the weld bead is insufficient to permit a conventional all-weld

metal tensile test piece to be prepared, the geometry of the test piece shall be agreed

with PT. PHE ONWJ. The longitudinal axis of the tensile test specimen shall coincide with the

procedure qualification test-weld axis. The tensile specimen shall be prepared by machining,

and its size and location shall be such that the gauge length consists only of weld metal.

The weld metal yield strength shall not be less than the SMYS of the pipe. Weld metal

overmatching of the typical pipe yield strength is considered desirable. The weld metal

strength, in relation to the actual pipe yield strengths, shall be considered if an ECA is used or

the pipeline design requires this.

5.6.10 CTOD Testing

Requirements concerning CTOD testing can be found in Appendix D.

5.7 Welding of Test JointsFillet Welds

The tests specified in 5.8 do not provide comprehensive information on the mechanical

properties of the joint. If mechanical properties are relevant to the application, then an

additional qualification shall be made, e.g. a butt weld.

5.8 Testing of Welded JointsFillet Welds

5.8.1 Preparation

Two macro-sections shall be taken from the test weld at locations agreed with the PT. PHE

ONWJ Welding Engineer. The specimens shall be prepared and examined in accordance with

5.6.7.

5.8.2 Method

One of the macro-sections shall be subject to hardness testing. The test method shall be

Vickers with an applied load of 10 kg in accordance with ISO 6507-1 or ASTM E92. The survey

shall consist of two traverses with indentations as shown in Figure C.

Grade Location Sour

Non-Sour

SMAW Cellulosic

a

Other Processes

< X80 < L555 Inside Surface &

Mid-Thickness

Weld 248 275 275

HAZ 248 275 275

Outside Surface Weld 275 275 275

b

HAZ 275 325 350

> X80 > L555 To be advised

NOTES:

a Use of cellulosic electrodes is limited to the applications shown in 4.2.2.1 .1

b For grade X80 (L555), outside surface weld metal hardness levels up to 300HV10 are permitted




Figure C - Fillet weld hardness indent locations

1 2 mm1 2 mm

A macrophotograph shall show the position of each hardness indent and shall be included in

the PQR along with a tabulation or diagram showing the result and location of each indent. The

maximum and minimum values shall be identified.

5.8.3 Requirements

If the fillet weld is on the outside of the pipe wall and, therefore, not in contact with the

process fluids, then the criteria given in Table F for outside surface shall apply.

6 Qualification of Welders

6.1 General

Welder qualification tests shall be carried out on full diameter project pipe nipples. Test welds

shall be visually sealed at each end until at least the root bead and hot pass have been

completed around the full circumference. Testing shall be witnessed by a PT. PHE ONWJ

representative or a PT. PHE ONWJ approved third party inspector.

Welders shall be qualified for each welding process that they will use in production. Welders

shall complete at least 50% of the circumference for the passes they are being qualified for.

For automatic, mechanised or semi-automatic welding, each welder shall be qualified for each

type, manufacturer, and model number of the welding unit(s) and power supply to be used in

production welding or for weld repair.

Welders shall be qualified before welding on the pipeline.

A welder who has satisfactorily completed a procedure qualification test is automatically

qualified for that procedure.

Previous welder qualifications tests may be accepted by PT. PHE ONWJ provided they are fully

documented, supported by production records demonstrating satisfactory welder performance,

and is less than 6 months old. These tests shall have been conducted utilizing a WPS

substantially the same as that for the current work and, for automatic, mechanised or semi-

automatic welding procedures, utilizing the same type, manufacturer, and model number of

welding unit and power supply. Additionally, these tests shall have been conducted by the

same fabrication contractor and witnessed by PT. PHE ONWJ or have been conducted by a PT.

PHE ONWJ approved independent testing laboratory.

In addition to the practical welding test and before the commencement of production welding,

welders shall be required to attend a briefing session arranged jointly with the PT. PHE ONWJ

Welding Engineer. This briefing shall detail the elements of good welding practice and the

specification requirements applicable to production welding. These requirements shall be

further emphasized during regular tool-box sessions and each welder shall be issued a card or

booklet summarising these requirements. This card or booklet shall be available for reference at

all times when welding.

NOTE: Notes 1 and 2 from Figure B are applicable.




Any welder who, in the opinion of PT. PHE ONWJ, is either consistently ignoring good welding

practice or specification requirements or is responsible for a high level of repairs during

production shall be removed from the work, and shall undergo a re-training programme

approved by PT. PHE ONWJ before a retest may be considered.

6.2 Single Qualification

6.2.1 General

Qualification welds shall be assessed by VT and shall also be subject to RT. The agreed NDT

regime shall reflect production NDT and shall examine the full weld circumference.

Qualification of welders using GMAW (solid or cored wire) shall be by VT, RT, MUT, and

mechanical testing to include face and root bends or side bends. In the case of manual welds,

nick break tests are also required.

If the application of AUT for the inspection of production girth welds has been agreed

by PT. PHE ONWJ, it may be used for assessment of the welder qualification welds in place of

RT. However, the acceptance criterion used shall be Section 9 rather than an ECA based

criterion.

The position of the pipe used in the test shall determine the extent of qualification as follows:

a. Horizontal pipes shall be used to qualify for welds between pipes positioned within 25 of

the horizontal.

b. Vertical pipes shall be used to qualify for welds between pipes positioned within 25 of

the vertical.

c. Pipes at 45 to the horizontal shall be used to qualify for welds between pipes positioned

at intermediate angles between 25 and 65 to the horizontal.

6.2.2 Scope

For SMAW, a change of electrode manufacturer and brand name

6.3 Multiple Qualifications

Multiple qualification of the welder shall not be permitted.

6.4 Visual examination

Filler wire protruding into the pipe bore shall not be permitted.

6.6 Radiographybutt welds only

6.6.1 General

RT (or AUT: see 6.2.1 above) shall be performed on the qualification welds using the same RT

(AUT) procedure as to be used in production.

Testing procedures and acceptance criteria shall be subject to approval by PT. PHE ONWJ.

7 Design and Preparation of a Joint for Production Welding

7.1 General

Any protective coating on the end bevel shall be removed before welding by a PT. PHE ONWJ

approved method.

Before welding, the pipe end shall be cleaned inside and out using power driven wire brushes,

grinders or other method approved by PT. PHE ONWJ, for a minimum distance of 40 mm

(1 in) from the edge of the weld bevel.

If AUT is to be used, a reference line at a specified distance from the root face shall be scribed

onto the pipe surface to allow the AUT equipment to identify the exact location of the root

bead.




Arc burns outside of the weld groove shall not be permitted. Remedial action on arc burns shall

be in accordance with 10.6.

Attachment of welding return cables by welding shall not be permitted. Arc burns caused by a

faulty attachment shall be removed in accordance with 10.6.

Repair of the pipe body by welding shall not be permitted.

7.1 .1 Weld Proximity

The distance between pipeline girth welds shall not be less than twice the outside diameter of

the pipe.

The distance between pipeline girth and branch/attachment welds shall not be less than one

pipe diameter.

The distance between branch/attachment welds on the pipeline shall not be less than one pipe

diameter.

7.2 Alignment

Pipe ends shall be aligned by rotating pipes, avoiding pipe end bevel damage, thereby achieving

accurate fit up for welding.

The misalignment between the internal surfaces shall not exceed the lesser of 3.0 mm (1/8 in.)

or 1% of the pipe internal diameter at any point.

The longitudinal (or spiral) weld ends shall be separated, at the circumferential weld, by 90 or a

circumferential distance of 250 mm (10 in), whichever is the smaller.

Longitudinal welds shall lie within the top half of the pipe circumference.

If abutting pipes have the same outside diameter with different nominal bores, the smaller bore

shall be machined, ground or filed, to produce an internal taper no steeper than 1 in 4;

alternatively, a transition piece may be inserted. Internal tapering shall be subject to PT. PHE

ONWJ approval if the taper will interfere with ultrasonic inspection. Internal tapering may not

be used with AUT.

Any misalignment in pipe to fitting girth weld set-ups, which exceeds 3.0 mm (1/8 in.) at any

point on the internal surface, shall be subject to corrective action agreed with PT. PHE ONWJ .

Slight misal

Documents

PHEONWJ-W-PRC-0005~2 (Guidance for Pipeline Welding)