PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

SHOP AND FIELD FABRICATION OF

STEEL PIPING

PTS 20.112
NOVEMBER 1995
 PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, the Principal will expect them to follow
those design and engineering practices which will achieve the same level of integrity as reflected
in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his
own responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
or death) suffered by any company or person whomsoever as a result of or in connection with the
use, application or implementation of any PTS, combination of PTS or any part thereof. The
benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated
to PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in order
to ascertain how users implement this requirement.
REVISION REGISTER

Issue Date. DETAIL OF REVISION

11/95 SSB/SSPC Revision 4

TABLE OF CONTENTS

1. SCOPE
2. DEFINITIONS
3 ABBREVIATIONS
4. UNITS/METRICATION

5. MATERIAL SPECIFICATION
5.1 MATERIAL
5.2 CERTIFICATION OF MATERIALS

6. WELDING CONSUMABLES
6.1 ELECTRODES, WIRES AND FLUXES
6.2 CONDITION AND STORAGE
6.3 HEATING AND BAKING REQUIREMENTS

7 QUALIFICATION OF WELDING PROCEDURES

7.1 GENERAL
7.2 PARAMETERS
7.3 ESSENTIAL VARIABLES
7.4 WELDING PROCEDURE QUALIFICATION TEST
7.5 PROCEDURE QUALIFICATION RECORDS
7.6 NON PERMITTED WELDING PROCESSES
7.7 TYPES OF TEST WELD

8. QUALIFICATION OF WELDERS AND WELDING OPERATORS

8.1 GENERAL
8.2 WELDER QUALIFICATION TEST FOR SMAW, GTAW AND GMAW
8.3 WELDING OPERATORS QUALIFICATION TEST FOR SAW
9 PRODUCTION WELDING.
9.1 GENERAL
9.2 WEATHER PROTECTION
9.3 ISSUE AND USAGE OF ELECTRODES, WIRES AND FLUXES
9.4 EDGE PREPARATION
9.5 BACKING STRIP
9.6 GROOVE WELDS
9.7 WELD EXECUTION
9.8 TACK WELDS
9.9 SIZE OF WELDS
9.10 PREHEATING AND INTERPASS TEMPERATURES
9.11 WELL INTERRUPTION
9.12 CLEANING
9.13 WELL FINISH
9.14 PEENING
9.15 DISTANCE BETWEEN WELDS
9.16 POST WELD HEAT TREATMENT

10 FABRICATION
10.1 GENERAL
10.2 ALIGNMENT AND FIT-UPS
10.3 FINISHING OF SURFACES
10.4 PROTECTION OF PIPE ENDS
10.5 REPAIR AND REMEDIAL PROCEDURES

11 QUALITY ASSURANCE

12. INSPECTION AND TESTING

12.1 GENERAL
12.2 INSPECTION PERSONNEL
12.3 TESTING OF WELDS
12.4 N.D.T. REPORTING REQUIREMENTS

13. DOCUMENTATION
14 REFERENCES
15. APPENDIX I - Table I - Non Destructive Testing
APPENDIX II - Table II - Preheat and PWHT Temperatures
1. SCOPE
This specification governs requirements of welding, fabrication and inspection of process and
utility piping systems fabricated in the shop or in the field.
For non or less critical applications, e.g. low pressure service, some of the requirements of
this specification may be waived or reduced. This will, in individual cases, be subjected to
review and approval by THE COMPANY

2. DEFINITIONS
Throughout this specification, the following definitions apply :
• 'THE COMPANY' means PETRONAS who has placed the contract for construction.
• 'The CONTRACTOR' means the fabricator to whom the contract has been awarded.
• 'The SUBCONTRACTOR' means a fabricator to whom the CONTRACTOR awards any
part of the work.
• 'SHALL' is used to indicate a requirement.
• 'SHOULD' is used to indicate a recommendation.
• 'MAY' is used to indicate one acceptable course of action subject to COMPANY approval.
• "APPROVAL" is a written response from THE COMPANY confirming agreement to the
proposal by the CONTRACTOR.

3. ABBREVIATIONS
AISI American Iron and Steel Institute
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
API American Petroleum Institute
ASTM American Society For Testing and Materials
ASNT American Society For Non-Destructive Testing
ASNT SNT-TC-1 A Personnel Qualification and Certification in Non-destructive Testing.
AWS American Welding Society
BS British Standard
CEV Carbon Equivalent Value
CSR Company Site Representative
CSWIP Certification Scheme For Welding Inspection Personnel
DAC Distance Amplitude Curve
PTS PETRONAS Technical standard
DIN Deutsches Institute For Normung
DPI Dye Penetrant Inspection
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
IQI Image Quality Indicator
ISO International Organisation For Standardization
 MPI Magnetic Particle Inspection
NACE National Association of Corrosion Engineers
NDT Non Destructive Testing
PCN Personnel Certification in NDT
PQR Procedure Qualification Record
PWHT Post Weld Heat Treatment

RT Radiographic Testing
SAW Submerged Arc Welding
SES Standard Engineering Specification
SMAW Shielded Metal Arc Welding
UT Ultrasonic Testing
WPQT Welding Procedure Qualification Test
WPS Welding Procedure Specification

4. UNITS/METRICATION
The Sl system and units of measurement shall be used. Imperial units may be indicated
where necessary e.g. where referenced standards are available only in Imperial units.

5. MATERIAL SPECIFICATION

5.1 MATERIAL
All steel pipes, flanges and fittings, etc. that shall be welded shall comply with the
requirements of PTS 20.081.

5.2 CERTIFICATION OF MATERIALS

5.2.1 General
The Certification is used for the purpose of confirming the specified mechanical, chemical and
physical properties of materials.
The following types of certificates are distinguished:
• Type A (Equivalent to DIN 50049.2.2)
Certificates on material based on testing carried out by the manufacturing or processing
works. It shall confirm that on the basis of test results from in-production testing the
material supplied corresponds to what was agreed in the order.
• Type B (Equivalent to DIN 50049.3.1B)
Certificates in which the manufacturers inspectors confirm, on the basis of tests carried
out on the delivery itself or on test specimens in accordance with the applicable
specifications and related to the delivery, that the product supplied corresponds with what
was agreed in the order. The necessary testing must have been carried out by a testing
centre which is independent of the production section in the manufacturing works and
which has the necessary facilities. When the independence of the testing centre is not
warranted, COMPANY approval of the testing centre shall be obtained.
 • Type C (Equivalent to DIN 50049.3.1C)
Certificates as described under Type B. however the mechanical and physical tests are
witnessed by an independent third party inspector approved by THE COMPANY. These
certificates shall be signed and stamped by this inspector for acceptance or alternatively
this inspector issues a separate certificate which refers to the mill certificates.

5.2.2 Contents of Certificates

• All material certificates shall state the Glowing:
- Name of manufacturer and factory symbol
- Purchaser order number and date of revision
- Certificate number and date of issue
- Material specification in full
- Dimensions
- Quantity and/or weight
- Charge number, batch number or heat number
- Actual chemical, mechanical and physical properties
- When applicable, NDT methods applied and results thereof
- When applicable, heat treatment procedure, furnace charge number of heat treatment
records
- Supplementary or additional requirements
• In addition, DIN 50049.3.1C type shall state:
- That identification of the material has been verified by the independent third party
inspector
- That all tests were witnessed by the independent third party inspector
- Independent third party inspectors identification symbol
- Certificate number and date of issue

6. WELDING CONSUMABLES

6.1 ELECTRODES, WIRES AND FLUXES

6.1.1 General
Consumables shall be approved by THE COMPANY and one of the following organisations:
• Controlas
• Lloyds Register of Shipping
• American Bureau of Shipping (ABS)
• Det Norske Veritas (DNV)
• Bureau Veritas (unified rules)
Electrodes, filler wires and wire/flux combinations shall produce weld metal that has a tensile
strength at least equal to the minimum specified for the parent metal.
All welding consumables shall be selected to produce welds with a tensile strength and
Charpy impact properties at least equivalent to those specified for the base material.
6.1.2 Covered Electrodes
Welding electrodes shall be of the low hydrogen type as described in ANSI/AWS A5.1 or
ANSI/AWS A5.5. The diffusible hydrogen content shall not exceed 10 ml/100g in the resulting
deposited weld metal.
All electrodes shall be suitable for the position and conditions of their intended use. The
parameters specified by the welding procedure shall be maintained throughout the welding
process.

6.1.3 Wires and Fluxes for Submerged Arc Welding

Wires and fluxes shall be in accordance with ANSI/AWS A5.17. Flux shall be of the fully basic
type. The flux supplier shall define the range or chemical composition of wire to be used for
his particular flux. Low-alloy wires shall not be used.

6.1.4 Gas Metal Arc Welding

Wires shall be in accordance with ANSI/AWS A5.18.
The gas metal arc and flux-cored arc welding process may only be used in fabrication areas
where the arc is protected against any draught and provided that the filler wire produces
welds with mechanical properties at least equal to those of the base metal. Special care shall
be taken to select filler metals for welding stainless steels and other alloys in order to ensure
that the corrosion resistance of the base metal and the weld will be maintained.

6.1.5 Gas Tungsten Arc Welding

Wires shall be in accordance with ANSI/AWS A5.18.
The gas tungsten arc welding process may only be used in fabrication areas where the arc is
protected against draught.

6.2 CONDITION AND STORAGE

Electrodes, wires and fluxes shall be supplied in fully sealed packages and stored in a dry
storage room where a minimum temperature of 20°C is maintained. All manual type
electrodes shall be properly identified up to the time of usage. Batch numbers shall be
recorded.
Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other
types.
Rutile or cellulosic electrodes shall not be kept in heated cabinets.
Wire spools for automatic and semi automatic processes shall be stored in cabinets with the
suppliers wrapping not removed and remain clearly identified up to the time of usage. All
non-identified wires shall not be used.
Each type of GTAW wire shall be properly identified and segregated up to time of usage.
Fluxes shall be supplied and stored in accordance with the manufacturers instructions.
Each batch of flux and wire shall be labelled with the information from the supply container.
The batch numbers shall be recorded for reference.
All non-identified, damaged, wet, rusty or otherwise contaminated consumables shall be
scrapped.
All bottles containing shielding gas shall have clear identification labels.
6.3 HEATING AND BAKING REQUIREMENTS
All low hydrogen electrodes shall be baked at 270°C to 330°C for one hour prior to use.
On completion of baking, the electrodes shall be transferred to a holding oven at 150°C.
When removed from the holding oven for use, the electrodes shall be transferred to heated
quivers or containers capable of maintaining a temperature of at least 75°C and used within 8
hours.
Electrodes not used within 8 hours or for some reason exposed to adverse atmospheric
conditions shall be rebaked for one hour and then transferred to the holding oven for later
use. Electrodes shall be rebaked only once.
Flux for submerged arc welding shall be held in a heated silo at 70°C and issue as required
for immediate use.
Fluxes may be recycled provided that it is free from contaminants (e.g. mill scales, rust, paint
flakes) and slag.

7. QUALIFICATION OF WELDING PROCEDURES

7.1 GENERAL
Detailed welding procedures shall be established and qualified in accordance with ASME IX,
Article II and as further required by this Specification. All procedures shall be submitted to
THE COMPANY for review and approval before any welding procedure qualification is
commenced. The procedure test shall be witnessed by THE COMPANY or nominated
representative. All costs connected with the establishment of any welding procedures shall be
borne by the CONTRACTOR.
No fabrication welding shall commence until the appropriate procedure tests have been
completed and approved by THE COMPANY.
Copies of the approved Welding Procedure Specification (WPS) shall be readily available for
reference at any time by the welder or welding operator and THE COMPANY.
Procedures shall be established and qualified for repair welding. Special care shall be taken
when repairing areas suffering from cracking or lack of fusion.
NDT for qualification test pieces shall be delayed for at least 48 hours following the
completion of welding.

7.2 PARAMETERS
• Welding Procedure Specifications (WPS) shall contain the following applicable
parameters with all the explanatory details necessary.
• Material specification of base metals (including P number).
• Welding process, manual, semi-automatic or automatic.
• Wall thickness and diameter range for which the procedure is valid.
• Geometry of welding groove showing allowable tolerances.
• Root gap showing allowable tolerances.
• Welding position and direction.
• Filler metal specification, brand and diameter.
• Filler metal classification.
• Flux specification and brand.
• Gas shielding, flow, mixture and composition (to include back purging).
 • Number and sequence of all passes, (indicate stringer or weave beads).
• Welding current range, voltage range and polarity. If pulse welding is used, the pulse
range.
• Travel speed or electrode run out length for each pass and range.
• Heat input range (KJ/mm)
• Preheat and interpass temperatures.
• Postweld heat treatment (PWHT).
• Method of gouging and cleaning.

7.3 ESSENTIAL VARIABLES

When any changes in the essential variables listed in ASME IX and the following are made,
the welding procedure shall be set up as a new WPS, and shall be completely requalified.
• A change in the type of groove (V-groove, U-groove, single bevel, double bevel etc).
• An increase in electrode diameter by more than 1.0 mm.
• A change from vertical-up to vertical-down welding or vice-versa.
• A change in the type of current or polarity.
• A change from manual or semi-automatic to machine or automatic welding and
vice-versa.
• The omission of back gouging.
• A change in back gouging technique from grinding to arc air gouging but not vice-versa.

7.4 WELDING PROCEDURE QUALIFICATION TESTS

Welding Procedure Qualification Tests (WPQT) shall be conducted to verify the WPS and
shall simulate, as far as practical the conditions and materials to be used for production
welding. Qualification tests on plates shall not qualify pipe welding. Limitations imposed by
the essential variables of the procedure qualification shall be adhered to in production
welding.
POR tests shall be witnessed by THE COMPANY or nominated representative.
Changes in the non essential variable(s) do not require a new procedure qualification test, but
a new WPS shall be written.
A qualified welding procedure is valid for materials, thicknesses, diameters and positions in
accordance with ASME IX Article V and the following additional requirements:
• A separate Welding Procedure Qualification Test shall be required for welding pipes of
nominal diameter DN75 and below.
• Butt welding of carbon steel and stainless steel pipes of nominal diameter DN75 and
below shall be done using the GTAW (TIG) process. The welding machine shall be
equipped with a high-frequency circuit to assist arc initiation.
• For stainless steels of all other diameters, the root and hot pass shall be done using the
GTAW (TIG) process.
• Butt welding of copper-nickel materials shall be done using the GTAW (TIG) process only.
7.5 PROCEDURE QUALIFICATION RECORDS
The specific facts from the WPS and the test results from the WPQT shall be recorded in the
Procedure Qualification Record (PQR).

7.6 NON PERMITTED WELDING PROCESSES

The use of high heat input welding process (greater than 4 KJ/mm) or the use of extremely
low heat inputs (smaller than 0.8 KJ/mm) is not permitted.

7.7 TYPES OF TEST WELD

7.7.1 Mandatory Tests
Three types of weld require full qualification:
• Butt welds in pipes DN75 diameter and below.
• Butt welds in pipes of over DN75 in diameter.
• Single pass fillet welds.

7.7.2 Optional Tests

The following types of weld do not require separate qualification.
• Multi-pass fillet welds made with qualified full penetration butt weld parameters.
• Tack welds made with qualified root pass parameters.
• Weld metal buttering deposited with qualified full penetration butt weld parameters.

7.7.3 NDT and Inspection Acceptance Criteria

Each completed test weld shall be visually inspected and shown to comply with the relevant
clauses of Section 12 of this specification. If inspection of the root of a single-sided weld
reveals an unacceptable profile, THE COMPANY may require the CONTRACTOR to repeat
the test using a different root gap.
Each test weld shall be non-destructively tested for soundness using the following methods:
• Radiography (for butt welds)
• Ultrasonic Inspection (for branch connections).
• Magnetic Particle Inspection (for fillet welds).
• Dye Penetrant Inspection for non-magnetic Materials.

7.7.4 Mechanical Test Requirements and Acceptance Criteria

All testing shall conform to the requirements of ANSI/ASME IX. The numbers and types of
tests required for any test weld are given in ANSI/ASME IX. THE COMPANY shall be notified
of all test failures, even where retests are permitted, before additional testing is undertaken.
• Transverse Tensile Tests
The test shall take the form of the 'reduced transverse test' piece in accordance with
ANSI/ASME IX. For acceptance, the tensile strength shall not be less than the minimum
value specified for the parent material (In the case of welds between materials of different
specified minimum tensile strengths, the acceptance level is the lower of the two).
 • Bend Tests
The type and number of specimens shall be in accordance with ANSI/ASME IX.
• Macro-Examination
The macro-examination test piece shall be prepared to a 600 grit finish or better, and then
etched to show the weld fusion boundary clearly.
The test sample shall show a sound weld and shall give full penetration to (but not
necessarily beyond) the limits of the weld preparation. Fillet weld leg lengths shall be at
least equal to the value specified. If only isolated inclusions are found outside the limits of
the acceptance criteria two further macro sections shall be taken from the same weld and
shall be shown to be free of defects.
If cracks or lack of fusion are found, the test piece shall be rejected. A new one shall be
made to identical parameters if an explanation acceptable to THE COMPANY is
forthcoming. If this also shows cracks or lack of fusion, the procedure shall be deemed to
have failed. The parameters shall be amended appropriately before a further test is
undertaken.
• Hardness Survey
Vickers hardness indents shall be made on the macro-section. A photo-macrograph shall
be produced showing the whole weld at a magnification of 1 to 3 times, illustrating the
location of the hardness indentations. Individual hardness values in the weld, or in the
HAZ of normalised carbon steels, shall not exceed 300 HV10. HAZ hardness limits for
other steel types will be specified by THE COMPANY. If any individual hardness value
exceeds the limit specified, two further section shall be taken, both of which shall meet
the specified requirement. For weld in carbon steel components or pipe designated for
sour service, (NACE MR-01-75) the hardness shall not exceed 248 HV10.
The minimum distance between the indentations should be two and one half times the
width of the previous indentation.
• Chargy Tests
This shall be required for low temperature service in accordance with PTS 30.10.02.31.

7.7.5 Failed Welding Procedures

If, after any permitted retests any procedures fails to meet the specified requirements, then it
shall be rejected.

8. QUALIFICATION OF WELDERS AND WELDING OPERATORS

8.1 GENERAL
8.1.1 Qualifications Required
Welders and welding operators shall be qualified in accordance with the requirements of
ANSI/ASME IX Article II and this Specification. Only qualified welders shall be employed
during fabrication including tack welding and repair welding. The CONTRACTOR shall ensure
that the welders/welding operators of any SUB-CONTRACTOR are qualified in accordance
with this Specification.

8.1.2 Witness and Approval of Test Before Welding

All welder and welding operator tests shall be witnessed and approved by THE COMPANY
before the welder or welding operator is permitted to work on the fabrication. The decision
taken by THE COMPANY regarding the qualification of any welder or welding operator shall
be final. Evidence of previous qualification tests shall be accepted solely at the discretion of
THE COMPANY.
8.1.3 Welder Identification System
An identification system shall be implemented for welders and welding operators. The system
shall provide each welder and welding operator with an identification card and shall be
established and agreed with THE COMPANY. Whilst on the works, the welder/welding
operator shall always be in possession of his card bearing his name, his photograph and his
identification number. Welders and welding operators not in possession of their card will be
dismissed from the works by THE COMPANY. In the event that a welder leaves the work, his
mark shall not be assigned to another welder employed on the work.

8.1.4 Marking of Welds

Each qualified welder and welding operator shall be supplied with an identifying marker. The
welder or welding operator shall clearly mark the pipe adjacent to his weld with the
identification mark assigned to his qualification certificate prior to starting the root run.
Marking shall include the date of weld completion. The identification marks may not be
removed until after the welds have been inspected both visually and non-destructively.

8.1.5 Applicability of Welder and Welding Operator Qualifications

The CONTRACTOR shall ensure that the qualified welders and welding operators are
employed during fabrication only on welding the type, process and position of weld for which
their qualification test so qualifies them.
A welder or welding operator shall be required to requalify if the accumulative length of repair
weld over a period of one month exceeds 5% of the total weld length deposited i.e. linear
repair rate.
A welder or welding operator may not be required to requalify if :
• The welder's competence certificate is more than six months old but the CONTRACTOR
can show that the welder's performance has been monitored and proven satisfactory
since the qualification test.
• The welder's competence certificate is more than six months old but the certificate has
been endorsed by a recognized certifying authority such as Lloyds, DNV, Bureau Veritas,
etc. at a date less than six months before the construction starts.
The CONTRACTOR shall maintain an accurate record of the performance of each welder
which should show the repair rate.

8.1.6 Parent Metals

As far as is practicable, welders and welding operators shall be qualified on the same material
as that to be used during fabrication. Similar types of materials may be substituted at the
discretion of THE COMPANY provided that it can be clearly demonstrated that the weldability
is equivalent to the material intended for use in the fabrication.

8.1.7 Retest
If the test joint does not meet the specified requirements, the welder or welding operator may,
at the discretion of THE COMPANY, carry out a new test joint of the same type as the one
rejected and provided the cause of failure is determined and is not attributed to inadequate
training. Failing of both these tests shall result in the disqualification of the welder or welding
operator for a period of one month employed on the work.
8.1.8 Welder Qualification Record
A record of each welder or welding operator qualification test, including a reference to the
corresponding WPS number, the essential variables according to ANSI/ASME IX and the test
results, shall be issued by the CONTRACTOR for each qualification test successfully
completed.

8.2 WELDER QUALIFICATION TEST FOR SMAW, GTAW AND GMAW

8.2.1 Welding Test and Welding Position
Welders shall be qualified in the 6G position. This shall qualify the welder to perform fillet or
groove welds in all positions. Other types of tests may be allowed at the discretion of THE
COMPANY.

8.2.2 Dimension of Test Piece

• For the 6G test, the dimensions shall be to ANSI/ASME IX.
• When other positions are allowed by THE COMPANY, the dimensions shall be to
ANSI/ASME IX.

8.2.3 Inspection and Test

Each test weld shall be subjected to the following inspection and tests:
• Visual Inspection.
• 100% Radiography.
• 100% Ultrasonic Test for carbon steel of thickness greater than 26 mm.
• Bend Tests: The position and numbers of specimens shall be to ANSI/ASME IX.

8.2.4 Quality Requirements

Acceptance criteria shall be as defined by ANSI/ASME IX.

8.3 WELDING OPERATORS QUALIFICATION TEST FOR SAW

8.3.1 General
Welding operators shall be qualified in the flat position with the pipe rotated.

8.3.2 Welding Procedure

A multipass technique shall be used with the root and hot pass deposited by GTAW, SMAW
and GMAW.

8.3.3 Dimension of Test Piece

The test piece shall have a diameter of not less than DN500 O.D. with a wall thickness of
19mm minimum.
8.3.4 Inspection and Test
Each test weld shall be subjected to the following inspection and tests:
• Visual Inspection
• 100% Radiography
• 100% Ultrasonic Test for carbon steel of thickness greater than 26 mm.
• Bend Tests: The position and numbers of test specimens shall be to ANSI/ASME IX.

8.3.5 Quality Requirements

Acceptance criteria shall be as defined by ANSI/ASME IX.

9. PRODUCTION WELDING

9.1 GENERAL
All production welding shall be in accordance with the requirements of ANSI/ASME B31.3 and
this Specification.
No welding shall be carried out before the welding procedure specifications and the
procedure qualification records are completed and approved and the welders have been
qualified.
Preparation and welding of pipe and pipe components shall be in accordance with the
appropriate qualified WPSs. No welding shall be done until as much of the piping system as
will be stiffened thereby has been properly aligned.
Attention shall be given to the necessity of achieving adequate firm support of the pipe
components in both the vertical and horizontal plane.
When alignment is required for two pipe components of an unequal thickness which will be
joined by a butt weld, this shall be done by tapering the thicker component to a 1:4 taper. This
shall be prepared as much as possible by machining in a shop rather than grinding in the
field.
Current return cables of welding equipment shall be connected directly to the pipe on which
the welding work is to be done.
No production welding shall be carried out before, where applicable, a hot-work permit has
been obtained.

9.2 WEATHER PROTECTION

Shelters giving adequate protection to the weld areas from wind, rain and moisture shall at all
times be provided.
Weld surfaces shall be thoroughly dried by heating before welding.
Provisions shall be made to reduce distortion that could occur due to differences in
temperature between the various components.
Provision shall be made for maintaining a satisfactory surrounding temperature and freedom
from the effects of wind.
9.3 ISSUE AND USAGE OF ELECTRODES, WIRES AND FLUXES
The CONTRACTOR shall have separate baking and holding ovens with temperature gauges
and automatic temperature control, to properly bake and keep the welding electrodes and
welding fluxes at required temperatures as specified in 6.3.
Each welder shall keep all electrodes in heated containers or quivers after removal from
baking or holding ovens. No electrode shall be left lying about or otherwise unnecessarily
exposed to the atmosphere.
Issuance of low-hydrogen electrodes from the baking ovens shall be controlled so that all
electrodes are used within 8 hours after issue. This time may be reduced under particularly
humid conditions at the discretion of THE COMPANY.
Issuing and recycling of electrodes shall be recorded on a log book.

9.4 EDGE PREPARATION

Cutting of pipes may be done either by mechanical means or by flame cutting or plasma
cutting when the following is taken into account:
• For carbon steel, name (or arc) cutting and bevelling is acceptable only if the cut is
reasonably smooth and all oxides are removed from the surface by grinding to bright
metal.
• For low-and intermediate-alloy steel, flame cut bevels are acceptable only where
machining or water cutting are not feasible. After flame cutting approximately 2 mm of
material shall be removed from the surface of the bevel by grinding.
• For stainless steel, flame cutting is not allowed but plasma or water cutting may be
applied.
Preparation of weld edges by flame cutting, wherever practicable, shall be done with a
mechanically guided torch. Edges shall be left free of slag spatter, scale, dirt, grease, salt,
protective coating or other foreign matter which might affect the quality of the weld. The cut
surface shall be ground to a smooth bright uniform surface by removing approximately
0.5 mm of metal. After grinding the edges shall be visually examined to ensure freedom from
defects.
Any bevelled edge that has been damaged shall be restored within the tolerances required by
the welding procedure to be applied. Where restoration involves welding, an approved
welding procedure shall be used.
End profiles of pipes and fittings to be butt-welded shall be in accordance with ANSI/ASME
B16.25.

9.5 BACKING STRIPS

The use of backing strips is not permitted.

9.6 GROOVE WELDS

Design of groove and performance of welding shall be in accordance with the approved WPS.
However, in general, the groove should be bevelled to give an included angle of not less than
60 degrees and shall be of the V-type.
9.7 WELD EXECUTION
9.7.1 SMAW Welding
Electrodes shall only be used in the position recommended by the manufacturer. Weld
progression in the vertical joints shall utilise the uphill method. The maximum size of electrode
to be used shall be 4.0mm.

9.7.2 SAW Welding

This shall be done in the flat position and the pipe shall be mechanically rotated.
9.7.3 GTAW and GMAW Welding
Weld progression in vertical joints shall utilise the uphill method. GTAW or GMAW will
normally be permitted in a workshop and special care shall be exercised to protect the weld
area from any draught both externally and internally. When automatic GTAW or GMAW is
employed on groove welds in stainless steel or non ferrous metals, argon back purge is
required for a minimum of two passes. For manual GTAW or GMAW, the argon back purge is
required until at least 6.0mm depth of metal has been deposited.

9.8 TACK WELDS

Where possible, bridge tacks shall be used. Tack welding shall be performed by qualified
welders using the same qualified welding procedures and electrodes as will be used for the
main weld.
All tack weld which will form part of the main weld shall be cleaned ground down to a feather
edge at both ends and visually inspected prior to welding the root pass.
Tack welds shall be approximately 50 mm long and spaced so that shrinkage forces cannot
cause cracking.

9.9 SIZE OF WELDS

To obtain optimum toughness, a small bead multiple pass technique shall be used for
welding. The weave width for SMAW shall not exceed two and a half times the electrode
diameter or 12 mm whichever is less.
For GTAW, GMAW and SAW, width of the beads shall not exceed six times the electrode
diameter.
THE COMPANY reserves the right to limit the thickness of each weld bead or pass when this
exceeds those given in the WPQT.

9.10 PREHEATING AND INTERPASS TEMPERATURES

9.1 0.1 General
• Preheating shall be carried out by electrical resistance or induction equipment or with gas
burners specifically made and shaped for this type of operation. Torches for flame cutting
or gouging shall not be used.
• The preheating temperature shall be established to a distance of at least 75 mm on either
side of the weld line and throughout the wall thickness prior to welding and be maintained
over the full length of the weld joint until the weld is completed unless specifically agreed
by THE COMPANY.
• The weld area must be protected from draughts and lagging shall be provided on
adjacent areas, if necessary, to maintain the required temperature of preheating during
welding.
 • The temperature measurement for preheating may be by thermocouple or temperature
sensitive crayons, or a combination of both as appropriate for the type of joint being
heated and the method of heating.
• For all welding where preheating is required, the joint may be submitted to temperature
checks by THE COMPANY before welding commences.
• In no event shall interpass temperatures exceed 300°C for carbon steel or 150°C for
stainless steel. The interpass temperature shall be monitored by means of thermosticks
or thermocouples.

9.10.2 Temperature Requirements

Minimum preheat temperature shall be as indicated in Appendix II. Where preheating is not
required, the actual minimum ambient temperature expected shall be indicated on the WPS.

9.10.3 Tack Welding

• Preheating for tack welding may be done with oxy-acetylene or propane-butane torches,
provided special shape nozzles are used. The material over 75 mm around the position of
the intended tack and throughout its full thickness shall be heated to the required
temperature.
• For tack welding, the minimum preheat temperature shall be 50°C above any preheat
temperature specified in the WPS for actual welding, with a maximum temperature of
150°C.

9.11 WELD INTERRUPTION

Welding of each weld shall be a continuous operation, with the exception of manually welded
root runs for submerged arc welding. In the case that welding must be discontinued, this shall
not take place before the hot pass is completed. The maximum time that a production weld
will remain part welded is 48 hours. The maximum number of heat cycles that will be used in
a production weld shall be two (2). Slow cooling of the weld area shall be ensured. Before
continuation of welding, the weld shall be inspected for cracks visually and by MPI.
Line-up clamps shall not be removed nor shall the pipe be moved until the root and the
second pass have been completed.

9.12 CLEANING
Upon completion of each welding pass, the weld shall be cleaned of spatter, slag and flux
deposits. After welding is completed, adjacent surfaces shall be thoroughly cleaned of all
spatter and deposits.
Only stainless steel wire brushes and grinding disc that have not been used on carbon, low
alloy materials or galvanised steels shall be used for stainless steels.

9.13 WELD FINISH

Welds shall be left as welded and not be treated with a torch or by any mechanical means,
outside the allowances of the welding procedure specification to change their appearance.

9.14 PEENING
Peening may be used on intermediate weld layers for control of shrinkage stresses in thick
welds to prevent cracking. Any such operation shall be carefully controlled. No peening shall
be done to the root or surface layer of the weld.
9.15 DISTANCE BETWEEN WELDS
Minimum distance between girth welds shall be the greater of either 50 mm, 4 times the wall
thickness or one half the nominal diameter.

9.16 POST WELD HEAT TREATMENT

A minimum interval of 48 hours shall elapse between the completion of welding and the
commencement of PWHT.
Temperature limitations, holding time, heating and cooling rates shall be as required by
Appendix II.
Care shall be taken to cover open ends of pipes to avoid draughts inside pipes.
Threads and gaskets surfaces shall be protected from oxidation during heat treatment if there
is no subsequent machining operation to be performed.
Post weld heat treatment shall be carried out using either a furnace or an electrical resistance
coil method. The temperature shall be measured by thermocouples in sufficient numbers and
position to give reliable temperature measurement. The thermocouples shall be connected to
a temperature recorder so that a record of the complete heat cycle is obtained. The
temperature chart shall be marked with an appropriate identification number.
PWHT procedures shall be submitted to THE COMPANY for approval.
PWHT shall be performed as required by Appendix II.

10.0 FABRICATION

10.1 GENERAL
All measures shall be taken to ensure correct positioning and swing of the components to be
welded.
Work shall not be performed when the weather and/or lack of sufficient protection does not
permit satisfactory workmanship or when conditions prevent adequate inspection.
If any fabrication is to be carried out in the vicinity of equipment already installed then, before
such fabrication work commences, adequate protection shall be provided to prevent any
damage from weld spatter, flame cutting droplets etc.
Care shall be taken to avoid overloading, damage or undue deformation in any of the pipe
components at all stages of the work.
The full pipe joint shall not be used, if laminations or split ends were discovered in any pipe.

10.2 ALIGNMENT AND FIT-UPS

Clamps, holding devices etc. shall be used to avoid tack welding in the groove. If the type of
holding device used for fit-up requires welding onto structural steel, such temporary
attachments shall be made with the same welding procedure specification as for a permanent
weld in the structural member. Alignment equipment shall remain in use until both the root
pass and hot pass are complete. Attachment welding onto pipe, flanges or fittings is not
allowed.
The misalignment at the inside of the piping shall be maximum 1.5 mm (1/16"). However, both
sides of the weld shall be completely fused by weld metal.
For butt welding of all piping components, pipe ends, fittings and welding neck flanges, a
uniform root opening, as speckled below, shall be required.
 Nominal pipe diameter Root opening
Smaller than DN50 1.5 mm
DN50 - DN250 1.5 – 2.5 mm
over DN250 2.5 – 3.5 mm

Alignment shall be in accordance with ANSI/ASME B31.3.

Branch connection cut-outs shall be carefully bevelled and accurately matched to form a
suitable groove for welding and to permit complete penetration of the welds at all points.
Reference is made to the relevant section of ANSUASME B31.3.

10.3 FINISHING OF SURFACES

When fabrication is completed, all welds shall be ground as indicated in the welding
procedures or on the drawings to allow proper radiographic or ultrasonic inspection, and to
remove all detrimental spatters, burrs, tack welds and other marks. Where so required the
damage shall be rectified in accordance with an agreed written procedure.

10.4 PROTECTION OF PIPE ENDS

All open pipe ends shall be capped off and sealed once installation is completed.

10.5 REPAIR AND REMEDIAL PROCEDURES

All repairs shall be executed by qualified welders according to approved welding procedures
and all requirements of this specification shall be met.
The removal of weld metal or portions of the base metal may be done by machining, grinding,
chipping, oxygen gouging or air carbon-arc gouging. The unacceptable portions of the weld
shall be removed without substantial removal of the base metal and shall be done in such a
manner that the remaining weld metal or base metal is not nicked or undercut. Where carbon
arc gouging is used, the edges shall always be ground to remove the hardened surface. The
grooves shall be free from scale, and shall have acceptable contours and shall be visually
and MPI/DPI inspected prior to rewelding, to ensure the defect has been completely removed.
Additional weld metal to compensate for any deficiency in size shall be deposited using
procedures as required in the making of the original weld. The surfaces shall be thoroughly
cleaned before depositing the additional weld metal.
Local repairs shall normally be inspected 100% by the method prescribed for the original weld
with due regard to confirming that the original defect has been removed.
Every possible care shall be taken with repairs to minimize welding stresses.
If planar defects (cracks, lamellar tears, etc.) have to be repaired, every effort shall be made
to prevent propagation of the defect during its removal. During the final stages of removal,
grinding (not gouging) shall be used. MPI/DPI shall be carried out to check for the complete
removal of the defect.
A weld with unacceptable defects may only be repaired twice. If the second repair is not
acceptable the complete weld shall be removed.
11. QUALITY ASSURANCE
The CONTRACTOR shall have an established and documented quality assurance system in
accordance with the applicable ISO 9000 series standards as defined elsewhere in the order.
The CONTRACTOR shall maintain this Quality Assurance system throughout the Contract
period.
Where the CONTRACTOR sub-contracts the whole or main parts of the work, then these
requirements shall be applied in full to the SUB-CONTRACTOR.
THE COMPANY or its nominated representative shall have the right to undertake QA audits
as he deems necessary to verify compliance with the stated requirements and/or to assess
the effectiveness of the CONTRACTOR's quality system.
THE COMPANY or its nominated representative shall have the right to undertake inspection
or testing of the goods or services, during any stage of manufacture at which the quality of the
finished goods may be affected, and to undertake inspection or testing of raw materials or
purchased components.
The CONTRACTOR shall notify THE COMPANY immediately when a non-conforming
product/work is identified which requires repair or a concession. THE COMPANY will review
the non-conformance and either agree with CONTRACTOR's proposed repair procedure or
agree with a concession or reject the product/work. Non confirmities and proposed corrective
actions shall be properly and systematically documented for COMPANY's appraisal/approval.

12. INSPECTION AND TESTING

12.1 GENERAL
The CONTRACTOR shall be responsible for undertaking all the inspection and
non-destructive testing (NDT) required by this specification, and any such activity carried out
by THE COMPANY shall not absolve the CONTRACTOR of this responsibility.
The CONTRACTOR shall maintain a quality control function, responsible for undertaking all of
the inspection and NDT requirements of this specification, which is independent of other
fabrication functions.
The CONTRACTOR shall as part of the Quality Assurance requirements of Section 11 of this
specification, formulate a Quality Control Plan which shall be submitted to THE COMPANY
for approval. The QC Plan shall include detailed procedures for all inspection and NDT
techniques, including proposed report formats and the names and qualifications of inspection
and NDT personnel.
THE COMPANY shall have the right to inspect the fabrication erection of all items covered by
this Specification. Any weld defects, damage due to fit up, arc strikes or other weld features
which THE COMPANY specified as deficient or detrimental to the integrity of the structure
shall not be acceptable.
COMPANY's inspection personnel shall have free access at all times to any part of the
CONTRACTORS' or his SUB-CONTRACTORS' yard and facilities that are concerned with
the Works. They shall be given full co-operation and allowed sufficient time for all inspection
and testing procedures to be properly executed. The CONTRACTOR shall carry out all
necessary cleaning of the area necessary to facilitate inspection and testing.
No testing shall be carried out within 48 hours of completion of welding without COMPANY's
approval.
The CONTRACTOR shall furnish, install and maintain in safe operating condition all
scaffolding, ladders, walkways, adequate lighting, etc. necessary for safe and thorough
inspection. These must conform with local industrial and safety codes.
THE COMPANY shall have the right to inspect the work and any tools or equipment to be
used on the work, at any time and shall have the right to condemn any equipment or work
which does not conform with the Contract documents.
 The CONTRACTOR shall inform THE COMPANY at least 48 hours prior to commencing any
work so as to enable THE COMPANY to adequately arrange any inspection and testing
deemed necessary.
When required by the Contract documents, the CONTRACTOR shall provide complete on site
facilities for radiography, ultrasonic, magnetic particle and dye penetrant inspection of welds
including equipment for developing and viewing films and the full time services of qualified
technicians conversant with radiographic and ultrasonic inspection techniques.
Any inspection by THE COMPANY shall not absolve the CONTRACTOR from his
responsibility to exercise such quality assurance procedures as will ensure that the
requirements and intent of this Specification are satisfied.
Final acceptance of Post Weld Heat Treated (PWHT) joints shall be done after PWHT.

12.1.1 Quality Control Plan

The Quality Control Plan shall identify all mandatory and surveillance inspection requirements
for welded joints together with the stages at which each is to be performed, and shall provide
the following information:
• Activity to be inspected.
• Inspection Activity to be performed
• Reference to governing Control Procedure
• Reference to applicable specification acceptance criteria
• Types of inspection verifying document provided
• CONTRACTOR's mandatory and surveillance inspection points
• COMPANY's required Hold, Witness and Review points.
This document shall be produced by the CONTRACTOR and supplied to THE COMPANY for
approval and for the inclusion of THE COMPANY's Hold, Witness and Review points.
A 'Hold' point is a stage in production beyond which CONTRACTOR shall not proceed without
THE COMPANY's approval.
A 'Witness' point identifies an activity which THE COMPANY may wish to witness and
therefore shall not be commenced until an agreed period of notice has elapsed.
A 'Review' point identifies a stage where THE COMPANY's review and approval of
documentation is required.

12.2 INSPECTION PERSONNEL

12.2.1 Qualification of Inspection and NDT Personnel
The qualifications and/or competence of all inspection and NDT personnel shall be
demonstrated to COMPANY's satisfaction by the CONTRACTOR. If the qualification or
competence of any personnel is in doubt, THE COMPANY may withhold its approval of such
personnel until such time their competence has been satisfactorily demonstrated.
12.2.2 Welding Inspectors
Welding inspectors shall be qualified in accordance with:
• PCN/CSWIP 3.1 Welding Inspector
• PCN/CSWIP 3.2 Senior Welding Inspector
• AWS Certified Welding Inspectors
All welding inspectors shall be approved at the discretion of THE COMPANY taking into
consideration the nature of work involved.

12.2.3 Ultrasonic Operators

Ultrasonic operators shall be qualified as per the requirements of SES 40.1.

12.2.4 Radiographic Technicians

Radiography technicians shall be qualified as per the requirements of SES 39.1.

12.2.5 MPI And DPI Personnel

MPI and DPI technicians shall be qualified to PCN/CSWIP level II or ASNT NDT level II or
equivalent.

12.2.6 Employer Based Qualifications

The CONTRACTOR shall submit his Written Practice for Personnel Qualification and
Certification in NDT to THE COMPANY for review and approval.

12.3 TESTING OF WELDS

12.3.1 Non-destructive Testing Procedures

The CONTRACTOR shall prepare procedures for each of the non-destructive testing
techniques which he proposes to use in the execution of the contract, and submit these to
THE COMPANY for its approval prior to the commencement of any testing. THE COMPANY
may require qualification of some or all of the procedures, by demonstration of their ability to
detect known defects.

12.3.2 Timing of Final Inspection and NDT

All visual inspection of completed welds shall be carried out as soon as practical after the item
has cooled down to ambient temperature.
NDT shall be carried out no sooner than 48 hours following completion of welding.
For welds/items which are subject to a PWHT requirement, the specified inspection and NDT
shall be performed and reported following completion of the PWHT process, but not before
the welds/items have cooled to ambient temperature.
Inspection and NDT prior to PWHT, performed in addition to mandatory inspection following
PWHT, shall be at the discretion of the CONTRACTOR. However, where defects requiring
repair are located by this inspection a detailed report shall be submitted to THE COMPANY.
12.3.3 Reporting
Inspection shall be recorded in a form which clearly identifies the work and the area of
inspection, method(s) and procedure(s), and the acceptability of the item inspected.
Datums used for reporting weld inspections shall be clearly marked on the work in paint, such
that it is possible to exactly relocate any weld defects reported.
The CONTRACTOR shall establish a system to provide traceability between documentation
and weld testing before fabrication starts.

12.3.4 Mandatory Stages Of Inspection

As a minimum, the inspection stages employed by the CONTRACTOR for welded joints shall
be as follows:
• All incoming materials are subject to visual inspection for surface defects, laminations etc,
• Fit-up prior to first pass.
• Following root pass.
• Following any back gouging operation (if any).
• Following completion of weld.
Inspection at stage a) will be visual and dimensional. Inspection at stages b), c) and d) will
nominally be visual/MPI/DPI inspection. Stage e) will be visual inspection and as instructed by
this Specification.
For joint repairs, visual /MPI/DPI inspection shall be carried out following grinding and/or
gouging operations to ensure that all unacceptable defects have been removed. After
welding, the weld shall be subjected to the same NDT methods prescribed for the original
weld.

12.3.5 Visual Inspection

All welds which are examined by visual inspection shall be judged in accordance with
ANSI/ASME B31.3.

12.3.6 Radiographic Inspection

All welds which are examined by radiography shall be judged in accordance with ANSI/ASME
B31.3 but this may be subjected to change at the discretion of THE COMPANY.
Where possible radiography shall be supplemented by ultrasonic testing accompanied by
magneto particle testing when there is reason to suspect planar defects such as cracks or
lack of fusion. This shall also apply to all butt welds where the root pass or the whole weld is
made by GMAW welding.
If, in the opinion of THE COMPANY, additional radiography of butt welds is required, the
CONTRACTOR shall radiograph all additional welds designated and shall perform the work at
unit price. If, in the opinion of THE COMPANY, less butt welds require radiographic
inspection, the CONTRACTOR shall credit THE COMPANY for all radiographs deleted, at the
unit price.
Inspection shall be carried out no sooner than 48 hours after completing welding.
12.3.7 Ultrasonic Inspection
All welds which are examined by means of ultrasonic shall be judged in accordance with
ANSI/ASME B31 .3.
Laminations found during cutting or welding shall be inspected to determine the extent and
reported to THE COMPANY.
Inspection shall be carried out no sooner than 48 hours after completing welding.

12.3.8 Magnetic Particle Inspection

All welds which are examined by means of MPI shall be judged in accordance with
ANSI/ASME B31.3 but this may be subjected to change at the discretion of THE COMPANY.
The wet continuous method shall be used, employing a yoke type or coil wrap equipment.
White background paint and black magnetic ink shall be used. The white background paint
shall be applied to a thickness not exceeding 20 microns using a spray can.
Inspection shall be carried out no sooner than 48 hours after completing welding. After
removal of temporary attachments and grinding flush the remaining weld, the ground area
shall be inspected 100%. This includes the grinding of spatters and arc strikes.

12.3.9 Dye Penetrant Inspection

Dye penetrant inspection shall only be used when magnetic particle testing is not practice.
Welds subjected to this inspection method shall be evaluated on the basis of the
requirements for visual inspection.
Inspection shall be carried out no sooner than 48 hours after completing welding.

12.3.10 Increased Inspection

For welds subject to less than 100% N.D.T. and found to contain unacceptable weld defects,
the entire weld length(s) shall be inspected using the method specified for the spot
examination. At the discretion of THE COMPANY, other NDT methods mentioned in this
Specification may also be required. In addition and at the discretion of THE COMPANY other
welds made by the same welder/welding operator shall be subjected to a higher level of
inspection (up to 100%) at those locations previously not subject to NDT.

12.3.11 Extent of Inspection

The extent of inspection shall be as per Appendix I - Table 1. Where Appendix I - Table 1
does not give a clear indication of the extent of inspection, advice shall be sought from THE
COMPANY.

12.4 N.D.T. REPORTING REQUIREMENTS

For each N.D.T. process applied to a weld an individual report shall be produced.
Each N.D.T. report shall include the following details as a minimum.
• Weld Identification Number(s)
• Welding Procedure Specification Number
• N.D.T. Procedure Number
• Percentage N.D.T. required
• Date and Time of N.D.T.
• Weld or Weld Repair
• Member Thickness(es) and Dimensions of Weld
• “As Welded" or Heat Treated Condition
• Defect Location(s)
• Conclusions

Magnetic Particle Inspection (M.P.I.) reports shall also include:

• Method of Magnetisation
• Field Strength

Ultrasonic testing (U.T.) reports shall also include:

• Probe Angles and Frequencies
• Equipment Identification
• Basic Sensitivity
• Primary Reference Level Sensitivity
• Surface Correction Factor for Calibration and Examination
• Joint configuration sketch
• Scan direction(s)
• Location(s) and Depth(s) of all Defects exceeding the 50% DAC Reference
• Curve and Signal Amplitude.

Radiographic testing (R.T.) reports shall also include as appropriate:

• Source Type
• Source to Film Distance
• Exposure Time
• Source Strength
• X-Ray Focal Spot Size
• Kilovolts, Milliamps, and Voltage
• Image Quality Indicator Details

Each radiograph shall contain the following details :

• Location of the Radiograph
• Weld Fusion Line Markers (for ground flush weld)
• The Character "R” to identify a repair weld
• The Character "F” to identify filmside l.Q.I Iocations
• Date
1 3. DOCUMENTATION
Prior to commencement of any part of the fabrication, the CONTRACTOR shall submit the
following documentation for approval by THE COMPANY.
• Original or certified true copy of mill certificate for CONTRACTOR supplied materials.
• Fabrication procedures, welding sequence and erection sequence. This is to include the
welding procedure specifications to be applied.
• List of proposed welding consumables and their areas of application including detailed
control procedures for consumable handling, baking, storage and issue.
• Welding procedures, repair welding procedures and their supporting procedures
qualification records including weld maps.
• Certificates of welders, welding operators and tackers qualified in accordance with this
Specification complete with list of welder identification numbers and photographs.
• Key plan showing an unambiguous member identification and weld marking scheme.
• Procedures and detailed test report forms for non-destructive testing and inspection. This
shall include separate forms for Visual, Radiography, Ultrasonic, Dye Penetrant, Magnetic
Particle, Painting and Coating inspections.
• Identification and control procedures for materials.
• Detail procedures for welding equipment maintenance and calibration.
• Qualification certificates for all inspection personnel.

As the work progresses, the following shall be required:

• Summary sheets for NDT reports for each joint which are to be kept up to date as the
work progresses.
• Where traceability is required, plans marked to relate certificate references for all
materials to its final position.
• NDT test reports (original only) including radiographs and key plans marked showing final
identification numbering, test report numbers and the results.
• Production mechanical test reports, post weld heat treatment charts, pressure test reports
and associated charts for all item tested.
• As-built drawings and Specifications which shall show in detail the manner in which the
facility was constructed and shall reflect all changes, additions, corrections or revisions
made during the course of construction. The objective being to build up a full documented
history of the Construction Work.
1 4. REFERENCES
The latest issue of the following documents governs the fabrication. Where the requirements
of this Specification conflict with the requirements of these documents, this Specification shall
take precedence.
(a) PETRONAS Technical Standards
SES 38.1 : The Design and Fabrication of Pipework
SES 38.3 : Pressure Testing of Process Piping Systems
SES 39.1 : Radiographic Inspection
SES 40.1 : Ultrasonic Examination
PTS 30.10.02.31- Metallic Materials: Requirements for Prevention of Brittle
Fracture of Equipment in Low Temperature Service (45°C or
below) and Equipment containing liquefied gas or lethal
substances.

(b) Extemal Standards

ASME/ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
ANSI/ASME V Nondestructive Examination
ANSI/ASME IX Welding and Brazing Qualifications.
ANSI/AWS A5.1 Specification for Carbon Steel Covered Arc-Welding
Electrodes.
ANSI/AWS A5.4 Specification for Corrosion - Resisting Chromium and
Chromium-Nickel Steel Welding Electrodes.
ANSI/AWS A5.5 Specification for Low-Alloy Steel Covered Arc-Welding
Electrodes
ANSI/AWS A5.7 Specification for Copper and Copper-Alloy Bare Welding
Rods and Electrodes.
ANSI/AWSA5.9 Specification for Corrosion - Resisting Chromium and
Chromium-Nickel Steel Bare and Composite Metal Cored
and Stranded Welding Electrodes and Welding Rods.
ANSI/AWSA5.14 Specification for Nickel and Nickel-Alloy Bare Welding Rods
and Electrodes.
ANSI/AWS A5.17 Specification for Carbon Steel Electrodes and Fluxes for
Submerged Arc Welding.
ANSI/AWS A5.18 Specification for Carbon Steel Filler Metal for Gas
Shielded-Arc Welding.
ANSI/ASME B16.25 Butt-Welding Ends
ASNT SNT-TC-1A Recommended Practice for Personnel Qualification and
Certification in Non Destructive Testing.
DIN 50049 Bescheinigungen uber Werkstoffprufungen
(Certificates on Material Testing)
ISO 9000-series Quality Management and Quality Assurance standards -
Guidelines for selection and use.
NACE MR-01-75 Sulfide Stress Cracking Resistant Metallic Material for Oil
Field Materials.
APPENDIX I

Table 1 - NON-DESTRUCTIVE TESTING

NOTES:
1. Partial hydrogen pressure > 7 bar.
2. Ultrasonic examination may be applied if the configuration precludes radiography
3. The indicated percentage of welds to be radiographed shall apply to all welders involved.
4. Small bore nipples to be included.
5. The following film qualities shall be applied:
- For X-ray fine grain may be used, e.g. Agfa D7, Kodak, Industriex AX.
- For J-ray ultra-fine grain film shall be used, e.g. Agfa D4, Kodak Industriex MX.
6. N.A. = Not Applicable.
7. MPI = Magnetic Particle Inspection.
APPENDIX II

Table II - PREHEAT AND PWHT TEMPERATURES

NOTES:
1. PWHT is required for CEV > 0.45 or C > 0.23%.
2. Temperature for optimum high-temperature properties.
3. Temperature range in the case of service for H2 or general refinery services.
4. Temperature range for maximum softening.
5. For hydrogen service PWHT is required irrespective of the wall thickness.
6. If ambient temperature is below 5°C, preheat to 40°C is recommended.
7. Low-hydrogen consumables shall be applied.
8. Minimum holding time one hour.
The post-weld heat treatment furnace temperature shall not exceed 300°C at the time of
insertion of the workpiece.
NOTE: NDT for acceptance purposes shall be carried out after final post-weld heat treatment.