Wheatstone Project LNG Plant

Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

2 1 0 A
REV IP Security

27-Jan-2011 31-Aug-2010 21-Dec-2009 09-Jul-2009

DATE

Issued for Design Issued for FEED Issued for FEED Issued for Review
DESCRIPTION

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Total number of Pages (including Cover sheet):

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Contractor Rev.

For Contractor Documents COMPANY DOCUMENT CONTROL NO.

Contractor Document No

CW645766
Project Area Discipline

25504-100-3PS-NWP0-F0003
Type Originator Package Sequence-Sht

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Revision

WS1

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MAW

SPC

BEC

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00101-000

Chevron Australia Pty Ltd

Wheatstone Project LNG Plant

Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Bechtel Confidential Bechtel Oil, Gas and Chemicals, Inc. 2011. All rights reserved. This document contains information that is confidential and proprietary to Bechtel Oil, Gas and Chemicals, Inc.

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27 Jan-2011 31-Aug-2010 21-Dec-2009 09-Jul-2009 Date

Issued for Design Re-Issued for FEED Issued for FEED Issued for Review Revision Description CHEVRON DOCUMENT NO.

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BF BF BF BF Check REV. 2 REV. 000

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BECHTEL OG&C

WS1-0000-MAW-SPC-BEC-000-00101-000 BECHTEL DOCUMENT NO. 25504-100-3PS-NWP0-F0003

Chevron Australia Pty Ltd

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Bechtel Confidential 2010 Bechtel Oil, Gas and Chemicals, Inc. (Bechtel). Contains information confidential and/or proprietary to Bechtel and its affiliated companies that is not to be used, disclosed, or reproduced in any form by any non-Bechtel party without Bechtels prior written permission. All rights reserved.

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

TABLE OF CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 SCOPE ........................................................................................................................................4 REFERENCES ............................................................................................................................4 SUBMITTAL OF PROCEDURES.................................................................................................4 WELDING PROCESS LIMITATIONS ..........................................................................................6 WELDING FILLER MATERIALS..................................................................................................7 GENERAL WELDING REQUIREMENTS ....................................................................................8 PREHEAT AND INTERPASS TEMPERATURES........................................................................9 POSTWELD HEAT TREATMENT (PWHT)................................................................................10 WORKMANSHIP AND INSPECTION ........................................................................................11 CLOSURE WELDS....................................................................................................................12 RECORDS.................................................................................................................................14

Attachment and Appendix List

Attachment 1: Form 167 (Example)......................................................................................................15 Appendix A: Performance of Ultrasonic Examination in Lieu of Radiographic Examination For ASME Welds ...............................................................................................................................16

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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

1.0

SCOPE

This Specification establishes the welding, nondestructive examination (NDE), and heat treating requirements for Supplier-fabricated piping.

2.0

REFERENCES

This Specification is in addition to other Project requirements such as Codes, technical specifications, request for bids and the purchase order. Conflicts shall be referred to the Buyer for resolution. This Specification is based on, is supplementary to, but is not restricted to the latest editions of the following publications:
Doc. No. ASME B31.3 ASME B31.8 ASME Section I ASME V ASME Section IX API RP582 WS1-0000-TEC-SPCBEC-00106-000 Process Piping Gas Transmission and Distribution Piping Systems Rules for Construction of Power Boilers Nondestructive Examination Qualification Standard for Welding & Brazing Procedures, Welders, Brazers, & Welding and Brazing Operators Welding Guidelines for Chemical, Oil, and Gas Industries Specification for Positive Material Identification Document Title

3.0

SUBMITTAL OF PROCEDURES
1. Procedures for welding, control and storage of filler material, hardness testing, NDE and Post Weld Heat Treatment (PWHT) shall be submitted to the Buyer for review and approval both against Code requirements and for suitability for each intended application. A review status of "Work May Proceed" shall be obtained prior to use. Early submittal is necessary to allow time for possible revision. 2. Applications of the welding procedure specifications shall be described adequately on the Form 167 to allow verification of qualification range and suitability for use. Application of a procedure to its joint(s) may be supplemented by means of typical pipe spool drawings. These documents shall be submitted at the same time as the procedures required in 3.1 above. (Note: A blank sample Form 167 is attached to this Specification, to illustrate the format that will be used). The Form 167 will identify piping classes, pipe diameters, wall thicknesses, applicable fabrication Codes, NDE, and other technical requirements. The Supplier will complete the Form 167 with their proposed welding procedure specifications. The Suppliers PMI, PWHT, weld consumable control and related procedures shall be listed on page one of the Form 167. The Form 167 is
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

intended to identify all the Suppliers procedures applicable to the pipe fabrication order, but is not a design document and does not relieve the Supplier of following the requirements which are part of the Purchase Order. Form 167 takes precedence over other documents for percent NDE. 3. Welding procedure specifications shall be qualified in accordance with the requirements of the applicable Code of Construction and additional requirements defined on the Form 167. The Procedure Qualification Record (PQRs) shall be submitted along with the Welding Procedure Specifications (WPSs) and the completed Form 167 (see 3.2). WPSs will NOT be reviewed, without a corresponding review of the Form 167, showing procedures application(s). Individual welder qualifications will be verified at the Suppliers works and should not be submitted through the Buyers Document Control System. 4. It is not the Buyer's intent to require revisions to the Supplier's standard qualified WPS's, in order to meet the requirements of this Specification. However, the requirements of this Specification shall be clearly acknowledged and the instructions employed by the welders on the shop floor. To accommodate this, Suppliers may formally revise their WPS's, or issue project specific amendments or addenda to standard WPS's. Amendments or addenda shall become part of the WPS for the purchase order and shall be issued to the welders employed in the work. 5. For repair of a weld, either the original WPS or one originally submitted as a designated repair WPS shall be used. 6. Weld repair plans and procedures shall be submitted for review. Repair plans shall include the following: a. The method of defining the type and the extent of the defect b. Methods used for removing the defect, and the NDE conducted to ensure that the defect has been removed c. Welding procedure employed and NDE methods used to inspect the completed repair. 7. PWHT procedures describing cleaning requirements, heating and cooling rates, thermocouple locations, type of heating equipment, etc. shall be submitted to the Buyer for review and permission to proceed. 8. NDE procedures shall be submitted to Buyer for review and permission to proceed. NDE procedures shall meet the requirements of ASME Section V and the acceptance/rejection criteria of the applicable Construction Code. NDE procedures shall meet the requirements of the latest edition of the relevant Code, and shall state the acceptance criteria to be used for the work. The acceptance criteria shall be stated in the Suppliers procedures, and shall not just reference to criteria listed in another standard or code.
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

4.0

WELDING PROCESS LIMITATIONS

1. Root Pass of Single Side Butt Welds Without Backing Subject to the limitations listed, only the following welding processes shall be used: 1) Shielded Metal Arc Welding (SMAW) a. E6010 or E6011 electrodes for P-No. 1, materials. b. Maximum electrode diameter 2.5 mm of (3/32 inch) for less than DN 65 (NPS 2-). c. EXX10/11 are limited to impact test temperatures not colder than -29C (20F). 2) Gas Tungsten Arc Welding (GTAW) & Plasma Arc Welding (PAW) a. Back purge 2 layers minimum for alloy content higher than 2 Cr - 1 Mo. b. GTAW or PAW is required for all lubrication, hydraulic and instrument piping (lines). c. Filler material is required, except for thin wall expansion bellows and titanium. 3) Gas Metal Arc Welding (GMAW) a. Short circuiting transfer i. Lincoln Surface Tension Transfer (STT) b. Globular transfer c. Pulsed spray transfer Not permitted. d. For nominal pipe sizes less than DN 150 (NPS 6), all welding shall be performed in the 1G-rotated position. The Lincoln STT process may be used in all positions. e. Back purge two layers, minimum, for alloy content higher than 2- Cr - 1 Mo. Back-purging may be omitted when the Lincoln SST process is used. f. Not permitted for pipe sizes less than DN 50 (NPS 2) g. Not permitted for weldolets and other attachments. 2. Other Than Open Butt Root Passes (Fill and cap passes, sockets, fillets) Subject to the limitations listed, only the following welding processes shall be used: 1) Shielded Metal Arc Welding (SMAW) Filler metal F Nos.: F1 & F2 Not permitted on pressure retaining welds. F3 Not permitted for welding on castings and is limited to use on the root and hot pass for joints in other product forms. F3 electrodes may be used for P-No. 1 with 0.30% max. carbon or 485 MPa (70 ksi) max. ultimate tensile strength.
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

F3 electrodes are not permitted for use when the base material requires impact testing at temperatures below -29C (-20F). F4 Maximum electrode diameter 2.5 mm (3/32 inch) for less than DN 65 (NPS 2-).

2) Gas Tungsten Arc Welding (GTAW) or Plasma Arc Welding (PAW) a. Groove welds in DN 40 (NPS 1-) and smaller shall be welded with GTAW/PAW; b. Filler metal is required. 3) Gas Metal Arc Welding (GMAW) GMAW-P Pulsed spray transfer No limitations. GMAW-S Short circuiting or globular transfer* - maximum base metal thickness 9.5 mm (3/8 inch). i. Lincoln STT process is permitted for hot pass welding for thickness up to 10 mm (3/8 inch), uphill progression only. Spray Transfer No limitations. For nominal pipe sizes less than DN 150 (NPS 6), all welding shall be performed in the 1G-rotated position. The Lincoln STT process may be used in all positions for hot pass applications.

4) Flux Cored Wire Arc Welding (FCAW) a. Shielding gas is required for pressure retaining welds. b. For nominal pipe sizes < DN 150 (NPS 6), all welding shall be performed in the 1G-rotated position. c. Low-hydrogen consumables are required (H8 or lower). d. Wire diameter not to exceed 3.0 mm. e. Vertical downhill welding not permitted. f. Changes in brand name shall require requalification. 5) Submerged Arc Welding (SAW) a. DN 150 (NPS 6) minimum. b. Active fluxes are prohibited c. Run on/run off tabs shall be used where possible. d. Changes in brand name shall require requalification.

5.0

WELDING FILLER MATERIALS

1. Except where specified otherwise, welding materials shall be selected so that the deposited weld metal is similar in chemical composition and not significantly harder or stronger than the base material.

* Globular transfer for thicknesses over 9.5 mm (3/8 inch) requires special qualification and acceptance on a shop-by-shop
basis. Globular transfer is defined as the range between short circuiting and spray transfer. Normal parameters are 22 to 28 volts and 150 to 220 amps with 100% CO2 or Argon-CO2 mixtures. Security Level 2
Electronic documents, once printed, are uncontrolled and may become outdated. Refer to electronic documents in the EDMS for current versions. Bechtel Confidential 2011 Bechtel Oil, Gas and Chemicals, Inc. (Bechtel). Contains information confidential and/or proprietary to Bechtel and its affiliated companies that is not to be used, disclosed, or reproduced in any form by any non-Bechtel party without Bechtel's prior written permission. All rights reserved

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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

2. Austenitic stainless steel (A-No. 8) welding consumables for pressure boundary and load bearing welds shall conform to Section 6.3 in API 582. Ferrite content of all non-cryogenic weld joints shall be determined by a magnetic instrument according to AWS A 4.2. 3. Austenitic stainless steels to be used at temperatures colder than -101C (-150F) shall be toughness tested and shall be certified based on actual testing of each heat/lot (reported on the MTR). Test temperature shall be at or below the minimum design metal temperature. Acceptable impact values determine acceptable ferrite content. Use of E316L is acceptable for welding TP 304L base metals in cryogenic service. 4. Carbon or low-alloy welding materials required for use at temperatures colder than -29C (-20F) shall be toughness tested and certified based on actual CVN testing of each heat/lot (reported on the MTR). Test temperature shall be at or below the minimum design metal temperature. 5. E6013 electrodes may be used for joints in cement lined pipe, with prior permission from the Buyer. 6. For service temperatures above 454C low-carbon SS filler metal is not permitted. 7. For dissimilar welds, such as carbon or low-alloy steels to austenitic stainless steels or nickel-based alloys, selection of the filler materials shall subscribe to API 582 section 6.2, shall be specifically accepted by the Buyer, and be specified on the Form 167. When PWHT of these joints is required, the carbon or low-alloy steel member shall be "buttered with the selected stainless steel or nickel alloy consumable, and then receive PWHT. The joint shall be welded to the austenitic stainless steel component without further PWHT. 8. The storage, baking and drying of all welding consumables (i.e., covered electrodes, flux cored electrodes and fluxes) shall be as recommended by the manufacturer of weld consumables. Segregation of carbon steel consumables, impact tested carbon steel consumables, low-alloy steel consumables, and high-alloy consumables are required during storage, baking, holding, and handling (including portable ovens). 9. Only low-hydrogen consumables (H-8 designation or lower) shall be used for metals with tensile strength greater than 480 MPa or thickness greater than 50 mm.

6.0

GENERAL WELDING REQUIREMENTS

1. Welding shall be protected from wind, rain and other harmful weather conditions which may affect weld quality. 2. To-be-welded surfaces shall be dry, free of mill scale, oil, grease, dirt, paint, galvanizing, and other contaminants. The welding of austenitic stainless steels or nickel alloys to components that have been galvanized or coated with zinc containing paint (even if the coating has been removed) is prohibited.
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

3. Weld bevel preparations for P-No. 4 and higher alloys shall be machined or ground back to bright metal if they have been flame, arc, plasma, or laser cut. 4. Permanently installed backing rings or straps shall not be used. backing requires Buyer acceptance prior to use. Temporary

5. The individual weld layer thickness for all processes shall not exceed 9.5 mm (3/8 inch) for materials less than 32 mm (1-1/4 inch) thick, or 13 mm (1/2 inch) for thicker material thicknesses. 6. Pressure retaining weld joints shall have a minimum of two weld deposit passes, including socket welds 7. Where joints are welded from both sides, the first pass shall be back-chipped, ground or arc-gouged to sound metal before welding the second side. This requirement shall be stated on the WPS. 8. Preening shall not be used. The use of pneumatic tools or steel shot for slag removal is not considered peening. 9. Welding sequences in which a layer is not completed before the next layer is started (block welding) shall require written pre-acceptance by the Buyer, for each application. 10. Except for root passes, vertical welding shall be vertical-up unless approved otherwise by Buyer for each specific application. 11. Shielding and purging gases shall be welding grade, with a dew point of less than or equal to -40C (-40F). 12. Gas mixture combinations for weld shielding and purging shall be documented and approved, as part of the WPS. Changes in gas mixture require revision of the WPS and may require requalification in accordance with governing code. 13. Welding of stainless steel and nickel-based materials shall be physically separated from carbon steel welding and fabrication, to ensure contamination by tools, grinding dust, etc., does not occur. 14. Socket welds joining P-No. 8 materials and ferritic steels (P-1 thru P-5) are prohibited for piping design temperatures greater than 121C (250F). Socket welds between P-No. 1 material and P-3, P-4, P-5A, & P-5B components is prohibited.

7.0

PREHEAT AND INTERPASS TEMPERATURES

1. Preheat temperature shall be in accordance with the applicable Codes and Form 167. Code-recommended minimum preheat temperatures shall be mandatory. For P-1 materials, the minimum preheat temperature shall be 10C (50F) up to 30 mm (1.2 in.) thickness. For thickness above 30 mm (1.2 in.), 93C (200F) is the required preheat. Preheat requirements shall apply to all welding, including tack welding and welding of temporary attachments. Preheat requirements also
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

apply to thermal gouging and cutting operations (except for P-No. 1 steels). For GTAW root pass welding only, reduced preheat levels as permitted by the applicable Code may be used. Preheat shall be maintained a minimum of 75 mm (3 inches) on either side of the joint. 2. The interpass temperature for austenitic stainless steels, nickel-base alloys and 6000 series aluminum shall not exceed 177C (350F). 3. Preheat shall be determined by temperature indicating crayons, contact pyrometers or other equally suitable means. Temperature indicating crayons used on austenitic stainless steels and nickel base alloys shall not cause corrosion or other harmful effects. It is the Supplier's responsibility to determine suitable brands that may be used. This information shall be made available to the Buyer's representative on request. Measurement means shall be available at the work site at all times and shall be used often enough to insure adequate preheat is maintained. 4. If oxy-fuel torches are used for preheating, the torch tip shall be appropriate for the work (i.e., a rosebud, not a cutting or welding tip).

8.0

POSTWELD HEAT TREATMENT (PWHT)

1. PWHT requirements for piping shall be in accordance with the applicable Code and Project Specifications. The heat treatment temperature range and time at temperature shall be as specified in the Form 167. a. For P-No. 6 materials, the post weld heat treatment temperature used shall not exceed 746C (1375F). b. The PWHT temperature for piping in Amine Service shall be 635C 14C (1175F 25F), held for a minimum of one (1) hour. Pressure retaining welds and welds to pressure containing parts, shall be completed prior to PWHT. 2. PWHT performed in a furnace environment is preferred. For local PWHT, only resistance, induction, furnace or quartz lamp heating methods are permitted. Exothermic heat treatment is prohibited. Direct impingement by furnace burner flames is not permitted. 3. PWHT cycles shall be recorded on print out charts. Thermocouples shall be independently recorded and their locations on the equipment noted on the chart. 4. For local PWHT, each weld shall have at least one thermocouple attached for temperature monitoring purposes. Attachment areas on material requiring PWHT for their service conditions, including areas from which attachments have been removed, shall also receive PWHT. 5. Thermocouple attachment areas, on material requiring PWHT for service conditions, shall be ground flush and smooth after thermocouple removal. The
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

areas shall receive a Dye Penetrant (PT) or Magnetic Particle (MT) examination. The examination results shall be documented and submitted as part of the final data package.

9.0

WORKMANSHIP AND INSPECTION

1. Each layer of welding shall be smooth, free of slag inclusions, porosity, excessive undercut, cracks, and lack of fusion prior to beginning the next layer. In addition, the final weld layer shall be sufficiently free of coarse ripples, non-uniform bead patterns, high crown, and deep ridges, or other surface morphologies that would impede the performance required inspections. Arc strikes, starts, and stops shall be confined to the welding groove, or shall be removed by grinding. Welds containing defects shall be locally repaired. 2. Temporary attachments shall be removed, and ground smooth and flush. Areas shall receive PWHT (when required) and be inspected using the same NDE methods required for fillet welds. 3. Marking materials and liquid penetrant materials used on austenitic stainless steels and nickel-base alloys shall not cause corrosion or other harmful effects. 4. Socket welds shall have a gap of 1.5 mm (1/16 inch) minimum to 3 mm (1/8 inch) maximum between the bottom of the socket and the end of the pipe prior to welding. Socket connections require two pass welds. 5. Misalignment (high-low) in butt joints shall not exceed applicable Code requirements. 6. Deposited weld metal shall meet the hardness requirements identified on the Form 167 and/or as defined by Project-specific requirements. Testing shall be performed after PWHT. Hardness readings shall be taken with suitable testing equipment in accordance with ASTM or other pre-accepted Standards. 1) Hardness measurements taken as part of a weld procedure qualification shall be taken on weld transverse cross sections as prescribed in API 582, section 12. 2) Hardness measurements taken on production welds shall be taken as close to the HAZ as possible. The hardness testing shall be performed on the weldment exposed to the process fluid. When not accessible, the opposite side shall be tested. 3) If a hardness test fails to meet the acceptance criteria it shall be subsequent retested in an adjacent area. Should the retest results exceed the specified hardness limit, then the weld joint shall be removed and rewelded. For welds subjected to PWHT, a reheat treatment and retest may be performed). 7. When welding aluminum, each weld bead and the adjacent base material shall be cleaned to remove surface oxides. This requirement shall be noted in the Suppliers WPS or WPS addendum.
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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

WS1-0000-MAW-SPC-BEC-000-00101-000 2 27-Jan-2011

8. When welding titanium, each bead and the adjacent metal shall be cleaned to remove all surface discoloration prior to deposition of the next bead. This requirement shall be noted in the Suppliers WPS or WPS addendum. The final weld surface may have intermittent iridescent, straw-colored oxides. 9. Each weld shall be stamped with the welder's unique symbol or number identification using low stress stamps. Where thin wall materials are used or where specifications do not permit stamping, the proposed alternate method shall be submitted for Buyer review and acceptance, prior to implementation. 10. Sulfur and Lead containing substances, such as oil, grease, thread lubricants, and paint shall be removed from surfaces prior to PWHT. 11. As a minimum, NDE personnel shall be qualified to ASNT-SNT-TC-1A Level II or national/international equivalent. Records shall be available for review by the buyer. For UT in lieu of RT see Appendix A. 12. Radiographic examinations shall be made in accordance with the code of construction, and the acceptance standard shall be in accordance with the code of construction. 13. Surfaces of carbon steel where temporary attachments have been removed shall receive a magnet particle examination after grinding. 14. Liquid penetrant examinations shall be made in accordance to the articles and appendices associated with the code of construction.

10.0 CLOSURE WELDS

1. A closure weld is the final weld connecting piping systems or components that have been successfully leak tested in accordance with the provisions of the code. Closure Welds are not designated to be leak tested. 2. Closure Welds shall be determined prior to fabrication. The designation of a given weld as a Closure Weld, after start of welding for that joint, will not be allowed. 3. The Pipeline Design Engineering function is responsible for: Selection of the Closure Weld(s) Minimizing the number of Closure Welds Designation of the Closure Welds on Project drawings and documents so that the fabrication sequence and required examinations can be planned in advance

4. The pipeline installation contractor is responsible for transfer of Closure Weld information to Field Work Plans, and sequencing of welding and NDE, including submission of the pipeline Closure Weld Documentation to the Project Construction Welding Supervisor

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25504-100-3PS-NWP0-F0003-000

Wheatstone Project LNG Plant Specification for General Welding & NDE Requirements for Supplier Fabricated Piping

Document No: Revision: Revision Date:

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5. During fit-up of the closure joint, verify internal cleanliness, inside diameter alignment (centerline offset and hi-lo), root gap (12:00, 3:00, 6:00 & 9:00), and outside diameter mismatch. 6. Perform Visual examination of all weld passes. 7. Perform magnetic particle testing (MT) or liquid penetrant testing (PT) after completion of root pass, hot pass, each additional 6mm (1/4) of fill passes, and the weld cap passes. Note: The reported weld cap pass MT examination shall be performed no sooner than 24 hours after completion of the weld and cooling to ambient temperature. 8. At a minimum, each Closure Weld shall be subject to (and pass) a 100% radiographic or a 100% ultrasonic examination, in accordance with API 1104 and AS 2885-2. 9. Complete documentation of the designation, location, welding, and NDE of piping closure welds in accordance with ASME B31.3 and this Specification is required. 10. A document package shall be prepared for each closure weld as soon as practical after it has been selected and designated as a Closure Weld, and prior to beginning any welding. Associated documents shall be added to each package as soon as available. All reports and records associated with Closure Weld activity, including any repairs and associated NDE, shall be included in the document package. Each package shall include, as a minimum: An isometric drawing showing the Closure Weld, its location, and its weld number; Statement of justification for use of the Closure Weld designation, rather than the required Leak Test A summary of the analysis and results for any specific design review required (such as a stress analysis) A weld map or weld description sheet showing the welding procedure(s) and welder used for the Closure Weld Weld Procedures and Procedure Qualification Reports Reports documenting joint fit-up, clearance, alignment, and cleanliness Record showing verification of consumable mill cert. and WPS/PQR review prior to initiating the weld. Completed and signed leak test records for the adjoining piping; Individual NDE records for completed NDE The Closure Weld inspection record. This document should be the original, be kept with the rest of the package, and be updated as the required examinations are completed.

11. Root and hot passes shall be welded using the GTAW process. Use of Lincoln STT process for root pass and hot pass applications is permissible on a case-bySecurity Level 2
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case basis with written pre-approval by the Companys project quality assurance manager 12. Shielded metal arc welding (SMAW), Gas shielded Flux Core Arc Welding (FCAW(g), and Gas Metal Arc Welding (GMAW) (spray arc mode only) may be used for fill passes and cap welding for pipe with wall thickness 10mm (3/8) and greater. 13. Welds shall be completed with a minimum of 3 passes (root, hot fill/cap). 14. Weld Bevel dimension shall be checked/recorded and visually examined for cleanliness prior to joint fit-up. 15. RT procedures shall use fine grain, high contrast, and high-definition film. Exposed film shall meet a film density range of 2.0 to 3.5 (3.0 preferred) as verified by a calibrated densitometer. Film developing and processing techniques shall be of the highest quality for film viewing and evaluation

11.0 RECORDS
1. Records pertaining to base materials, filler materials, fabrication, and inspection shall be accessible for the Buyer's examination. 2. Examination and inspection reports, whether in-process or final, including radiographic film, shall be available to the Buyers representative.

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Attachment 1: Form 167 (Example)

Piping Classes: 1AE01, 3AE01, 6AE01
Design Code: Pipe Class(es): Non-NFPA 59A Service Codes ASME B31.3 & NFPA 59A Line Services NFPA 59A Service Codes HC, RE, RM, RP HC, RE, RM HC, RM Category: Normal Design Pressure (Bar g) 18.96 18.61 34.8 34.8 99.3 97.9 P Number: 25/23
(Note 2)

Design Temperature @ @ @ @ @ @ (C) -212 66 -212 66 -212 66 NA

Notes VT 100 100 100 100 100 100 1 IPVT

1AE01 3AE01 6AE01

----------------------

Piping Material Type: CVN Requirements:

Pipe Class or Weld Description

5083 Al (O temper) / 5083 O / 6061-T6

NA
Pipe Size
(NPS mm)

Hardness Requirements: NA

PMI Requirements:
Heat Treatment Max W.T.
(mm)

Ferrite Requirements:
Welding Procedure Specification(s) RT or UT 100 NDE (%) MT PT

Joint Type BW SW BR

PRE/IP( C) 10/177 10/177 10/177 10/177

POST (C) NA NA NA NA

Butt Weld Socket Weld All Branch Welds Attachment Welds

All 40

35

Notes: 1. In Process Visual Examination (IPVE) includes verification of: Joint preparation & cleanliness, Joint fit-up, Joint clearance, Internal alignment, Filler metal verification, Welding position per the WPS, Preheat per the WPS, Root pass & subsequent passes, & Final weld appearance per design and fabrication code. 2 Grade 5083 has a P number of 25. Grade 6061 has a P number of 23

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APPENDIX A: PERFORMANCE OF ULTRASONIC EXAMINATION IN LIEU OF RADIOGRAPHIC EXAMINATION FOR ASME WELDS
A1.0 SCOPE
This appendix establishes Project requirements for UT examination of welds when it is utilized in lieu of radiographic examination of welds in components fabricated in accordance with ASME B&PV Case 2235-9 and B31 Case 181. These requirements apply only to welds of P-1/3/4/5, and in specific cases, P-8 materials. Use of UT for acceptance of welds is subject to compliance with design code requirements, written acceptance from the Buyer, and this appendix. This appendix does not address the performance of UT for examination of welds fabricated in accordance with AWS or API requirements. These situations must be addressed on a case-by-case basis.

A2.0 REFERENCES
A2.1 A2.2 A2.3 A2.4 A3.0 A3.1 A3.2 References shall be the latest Edition and Addenda published at the time of the Purchase Order, unless otherwise specified in the purchase documentation. ASME B&PV Case 2235-9, UT in Lieu of RT B31 Case 181, UT in Lieu of RT ASME Section V, Article 4, Appendix VI, E-scan & S-scan Linear Scanning Techniques (approved, but not published as of 06 August 2008) DEFINITION OF TERMS The definitions of ASME Section V, Article 1, Appendix I, I-130 shall apply as applicable. The definitions of ASME Section V, Article 5, Appendix III, -540 shall apply as applicable. UT Techniques Techniques of ultrasonic testing performed with equipment and search units that are carriage mounted, remotely operated, mechanically guided, and motor-controlled (driven). The equipment used to perform the examinations shall be capable of recording the ultrasonic response data including the scanning positions, by means of an integral encoding device, such that the imaging of the acquired data can be performed.

A3.3

A3.3.1 AUT (Automated Ultrasonic Testing):

A3.3.2 Semi-Automatic Ultrasonic Testing (SAUT):

Techniques for ultrasonic testing performed with transducers that are mounted to a mechanical carriage, mechanically guided, and manually assisted. The equipment used to perform the examinations shall be capable of recording the ultrasonic response data including the scanning positions, by means of an integral encoding device, such that location of the acquired data/images is possible.
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Note: Scanning where probe and encoder displacement is controlled by hand without mechanized scanning apparatus, does not constitute SAUT techniques.
A3.3.3 Manual Ultrasonic Examination (or Encoded Manual Ultrasonic Examination):

Ultrasonic testing techniques performed with transducers that are manipulated by hand. Note: Manual techniques may be encoder equipped, but do not constitute Semi-Automatic Ultrasonic Testing (SAUT) or Automatic Ultrasonic Testing (AUT) techniques since the entire examination process is controlled by hand.
A3.3.4 Mechanized Scanning: Automatic or Semi-Automatic scanning apparatus by which a

rigid probe carriage apparatus, mounted with rollers or wheels, provides for linear scanning motion with motor-controlled or manually assisted displacement. A3.4 A3.5 A3.6 Calibration: The process of establishing a standardized system setup for a particular weld joint configuration in accordance with Code and procedure requirements. Calibration Block: The block designed, fabricated, and verified to provide a consistent approach to UT system standardization (calibration). Demonstration: The process of performing an examination on the appropriate flawed block specified by the applicable Code and / or Code case(s). Flaws in the block shall be oriented to simulate flaws parallel to the fusion line of the production weld. Flaw: An imperfection or discontinuity that may be detectable by Non Destructive Examination (NDE) and is not necessarily rejectable. Full-Volume Coverage: Two-directional beam coverage through the weld, Heat Affected Zone (HAZ), and base material as specified by the referencing code (or code case). Complete two-directional weld volume coverage shall impinge the weld HAZ (on each side) at an angle as close to normal to the weld as practical. Complete weld volume coverage may be obtained by scanning from both sides of the weld, or by using an extended sound path from one side of the weld. Where possible, scans shall be performed from both sides of the weld. Alternatively, complete weld volume coverage may be accepted from one side of the weld, where it can be demonstrated that flaw detection obtained is at least comparable to that obtained when scanning from both sides of the weld. Procedure: A written set of instructions that establishes minimum requirements for performing NDE in accordance with this Specification. AUT procedures for compliance with this Specification must meet the requirements of ASME Section V, Article 4, T-421 and applicable Code case(s).

A3.7 A3.8

A3.9

A3.10 Qualification: The process of documenting the proven adequacy of the UT procedure, system, and calibration.

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A3.11 Qualification/Demonstration Block: A block which provides a depiction of the production weld with regard to material, thickness, weld joint configuration, weld geometry, and contains real flaws of a specified type and location. A A3.12 Scan Plan: The documented examination strategy for AUT or SAUT scans that provides a standardized and repeatable methodology for weld acceptance. The scan plan shall contain sufficient information to show complete coverage and include: material specification and product form or equivalent P-Number weld thickness cross-section geometry extent of clad (if present) weld joint preparation configuration and dimensions extent of the HAZ and additional coverage weld crown width and profile beam plots for all refracted angles used extent of coverage calibration reflectors probe index spacing (from weld centerline), zone coverage overlap.

A3.13 Simulated Flaw: A machined side-drilled hole or notch that depicts the ultrasonic reflectance of a real flaw. Machined notches used to simulate flaws must be parallel to the representative production welds fusion line.

A4.0 GENERAL REQUIREMENTS

A4.1 Ultrasonic examination will be performed in accordance with an approved examination procedure. Procedures and techniques shall be in accordance with ASME Section V, Article 4, T-421 (latest edition). Examination procedures shall be submitted to the Buyer sufficiently in advance of production for technical review and approval. The procedure shall have been demonstrated to perform acceptably on the applicable calibration block and a qualification block with embedded flaws. Procedure qualification is required. The qualification of the Mechanized UT system shall be demonstrated and documented. The documentation shall be relevant for the material and weld geometry to be tested. Phased-Array, Pulse-Echo, Time of Flight Diffraction (ToFD), or combinations of these techniques may be utilized. Unless otherwise authorized in writing by the Buyer, ToFD techniques shall not be used independently. As a minimum, ToFD techniques must be augmented with a pulse-echo or phased-array technique. Where ToFD is utilized, the provisions of ASME Section V, Article 4, and Appendix III to Article 4 shall be considered mandatory. UT scans must produce a permanent record with each data point encoded and traceable to a length, width, and depth point of the weld.
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A4.2

A4.3

A4.4

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A4.5 A4.6

The requirements contained in this specification addendum may be applied only to P-1, P-3, P-4, and P-5 materials. Examination of high alloy steel welds, stainless steel, high nickel alloy welds, dissimilar metal welds, or other coarse-grained and/or directionally-oriented weld structures may be approved on a case-by-case basis pending successful demonstration on a weld mock-up depicting the production examination joint configuration containing known reflectors. The AUT or SAUT system accuracy must be demonstrated and validated. Scanning must be performed by automated mechanized equipment capable of recording the echo data and scanning position. The scanning system shall utilize a rigid apparatus capable of maintaining precise alignment through the full circumference (or length) of the weld. The use of semi-automated scanning techniques is subject to review and acceptance by the Buyer. Manually displaced probes with an integral encoding device are not acceptable for use, other than for supplemental scans. Straight beam scans for reflectors that could interfere with the angle beam examination shall be performed. The straight beam scans may be performed (1) manually, (2) documented as part of a previous manufacturing process, or (3) during the automatic UT examination, provided detection of these reflectors is demonstrated. Scans for defects oriented transverse to the weld shall be performed. A pulse-echo or phased array may be used.

A4.7

A4.8

A4.9

A4.10 A documented examination strategy or scan plan shall be provided showing transducer placement, movement, and component coverage. The scan plan must provide for a standardized and repeatable methodology for weld acceptance. Complete scan-plan documentation for each weld configuration shall be made available to the Buyer upon request. Configuration parameters are those as stipulated in ASME Section V, Article 4, T-421. The scan plan shall address the ultrasonic beam angle(s) used, beam directions with respect to weld center-line, number of probes and location, beam spread, beam frequency, material, joint type / configuration, and weld volume examined for each weld. A4.11 Complete weld volume coverage shall be obtained.
A4.11.1 Where complete weld volume coverage cannot be obtained, RT shall be performed. A4.11.2 Complete two-directional weld volume coverage shall impinge the weld HAZ (on

each side) at an angle as close to normal to the weld as practical.

A4.11.3 Complete weld volume coverage may be obtained by scanning from both sides of the

weld, or by using an extended sound path from one side of the weld. Where possible, scans shall be performed from both sides of the weld. Alternatively, complete weld volume coverage may be accepted from one side of the weld, where it can be demonstrated that flaw detection obtained is at least comparable to that obtained when scanning from both sides of the weld. Buyer shall be notified of plans
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for single-side examination. Buyer acceptance is required, prior to performance of the examinations from one side only.
A4.11.4 For single-sided scans, a scan plan shall be submitted for review and acceptance

showing full-volume coverage from the side of the weld from which scanning will be performed.
A4.11.5 Where single-sided scanning is used to obtain coverage, the weld crown shall be

contoured such that scanning can be performed and include the entire weld metal volume. Weld crown contouring may be waived with written Buyer acceptance only if it can be clearly demonstrated (and documented in the scan plan) that full-volume coverage can be obtained without weld crown contouring.
A4.11.6 Inaccessible welds, restricted access zones, or other areas where partial coverage is

obtained shall be documented. Where full-volume coverage cannot be obtained, either (1) radiography shall be performed, or (2) the condition shall be communicated to the Buyer for input, via a Supplier Deviation Disposition Request (SDDR). A4.12 To maintain accuracy and resolution of the UT system and equipment, the maximum temperature differential allowed between the search units, the calibration block and the production item being inspected shall be established. The written examination procedure shall indicate the temperature range over which the UT system will operate.

A5.0 PERSONNEL QUALIFICATION AND CERTIFICATION REQUIREMENTS

A5.1 UT personnel shall be certified in accordance with ANSI / ASNT-CP-189 or ASNT SNT-TC-1A as Level I, II, or III. Personnel certification programs written for compliance to other systems shall be submitted to the Buyer for acceptance, prior to implementation of the program or examinations. The NDE organization may be required to provide detailed evidence of equivalence to the ASNT requirements and program. Personnel who will be performing analysis of the data shall have received additional specific training in the data analysis techniques to be used in the procedure qualification. Personnel who will be performing analysis of the data shall participate in the successful completion of the procedure qualification. Personnel collecting UT data (acquisition) shall have demonstrated their ability to perform an acceptable examination and evaluation in accordance with the performance and acceptance criteria requirements using demonstration blocks which meet the applicable fabrication requirements. Personnel who acquire AUT data shall be trained in the use of the AUT equipment and participate in the performance demonstration. Personnel analysing UT data (analysis) shall have demonstrated their ability to perform an acceptable examination and evaluation in accordance with the acceptance criteria using test block(s) specifically accepted by the Buyer. In addition, personnel who acquire and analyze AUT data shall be trained using the equipment in use, and participate in the demonstration. Personnel who acquire
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A5.2

A5.3

A5.4

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and/or analyse UT data shall be trained in the use of the AUT equipment and participate in the performance demonstration. Personnel who evaluate the data from, interpret the results of, and/or report the results of examinations shall be certified to Level II or III.

A6.0 EQUIPMENT
A.6.1 Ultrasonic Equipment
A6.1.1 Automated Ultrasonic Examination systems shall be capable of meeting applicable

examination requirements for the weld diameters, wall thickness, and joint configurations.
A6.1.2 The ultrasonic examination shall be performed using a device employing automatic

computer enhanced data acquisition. Acceptance of the use of semi-automated scanning techniques is subject to review and written acceptance by the Buyer. Manually displaced probes with an integral encoding device are not acceptable for use, other than for supplemental scans.
A6.1.3 The ultrasonic examination shall be performed using a system capable of recording

the ultrasonic examination data, concurrent with scanning positions, to facilitate the analysis of the scan data by a third party and to ensure the repeatability of subsequent examinations, should they be required.
A6.1.4 Data location encoding devices shall be capable of locating the position of weld

indications within the accuracy required for application of the evaluation, recording, and acceptance criteria.
A6.1.5 For ToFD data, a method of monitoring the required acoustic coupling shall be

included in the examination procedure and demonstrated to perform satisfactorily.

A6.1.6 Automated UT examination system components shall be sufficiently shielded to

prevent data degradation due to non-integral electrical interference. A6.2 Data / Data Recording Equipment filtering, or scaling shall be included in the data record. A-scan presentation shall be available within the examination data.
A6.2.2 Final examination data shall be sufficient as to permit duplication of scan parameters,

A6.2.1 Data is to be recorded in unprocessed form. A complete data set with no gating,

location of discontinuities in the examination volume, weld ID, reference sensitivity, reference reflector, disposition of indications, and other information deemed pertinent to disposition of the weld. A6.3 Calibration indications for acceptance / rejection in accordance with the specified criteria. Preliminary calibration data shall be provided to the Buyer for review prior to commencement of production examinations.
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A6.3.1 Calibrations shall be adequate to examine the full weld volume and evaluate

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A6.3.2 Examination parameters including pulse length and repetition rate shall not vary from

those utilized for demonstration of dynamic calibration.

A6.3.3 Parameters necessary to consistently reproduce a calibration shall be included in the

report documentation.

A7.0 QUALIFICATION/DEMONSTRATION
A7.1 Procedure / AUT System Demonstration and Qualification: terms can be used interchangeably). AUT system demonstration / qualification specified by ASME B31.1 paragraph 136.4.6(A.1 & A.2), B31 Case 181, and B&PV Case 2235-9 shall be performed for all of the following applicable thickness ranges; 0.50 to 1.0 inch, 1.0 to 2.0 inch, 2.0 to 4.0 inch, and 4.0 to 6.0 inch. Needs for demonstration / qualification for welds greater than 6.0 inches in thickness shall be on a case-by-case basis.
A7.2.1 The effectiveness of proposed non-destructive procedures shall be demonstrated

A7.1.1 The terms "demonstration" and "qualification" shall imply the same result (e.g. these

and accepted prior to use. Work shall not commence where the applicable procedure has not been accepted for use by the Buyer. The procedure validation testing and demonstration shall be performed on welds made using Buyer accepted welding procedures, relative to the weld joint configuration being examined. A specific procedure, with instruction detail for each thickness and weld bevel preparation, shall be prepared.
A7.1.3 The automated UT examination system shall be considered qualified by successful

performance of dynamic calibration on the calibration / reference standard and successful dynamic demonstration on flawed samples.

A8.0 EXAMINATION
A8.1 A8.2 The definitions of 3.3.1, 3.3.2, and 3.3.3 apply to the allowable scan types detailed in the following paragraphs. Encoded manual scans will only be permitted for scans of partial coverage areas, supplemental scans, or other interrogatory scan, and must be accepted in writing by the Buyer, prior to examination. Non-encoded scan data may be allowed for use on a case-by-case basis. Linear scan types may employ automated or semi-automated scan apparatus. Scans employing raster-type displacement shall be performed using a fully automated AUT system capable of X-Y displacement. Procedures and scan plans shall be accepted (by the Buyer) prior to the commencement of production examination. Procedures, equipment, and technicians shall be satisfactorily demonstrated/qualified/calibrated prior to commencement of production examinations.

A8.3 A8.4 A8.5

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A8.6 A8.7 A8.8

Encoded manual scans are permitted for the performance of transverse defect scans, with prior written acceptance by the Buyer. Non-encoded manual scans are permitted for the performance of straight beam base material scans. Where ECA-type acceptance criteria are to be applied, it shall be demonstrated that indication sizing accuracy and tolerances can be maintained.

A9.0 EXAMINATION REPORT

Examination report content shall be in accordance with ASME Section V, Article 4, T-492 (and applicable Code case(s) if used). Examination report content shall include scanner manufacturer, model, data analysis software and version, calibration data file name, examination data file name, and focal law parameters. The examination report shall also include, as applicable, angular range, focal depth, element numbers used, angular incremental change, data acquisition increment, and details of restricted access areas or inaccessible welds and the resolution for those areas or welds.

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