Header
About this publication
Preface
1 Scope and general
1.1 Scope
1.2 Normative references
1.3 Terms and definitions
1.4 Approval
1.5 Qualification
1.6 Retrospectivity
1.7 Carbon equivalent (CE)
1.8 Heat input (arc energy)
2 Safety
2.1 Production welding
2.1.1 General
2.1.2 Electrical safety during welding
2.1.3 Welding environment
2.1.4 Equipment and compressed gases
2.1.5 Electric and magnetic fields (EMF)
2.2 Welding or cutting on a pipeline after commissioning
2.2.1 General
2.2.2 Risk assessment
2.3 Safety and protection from ionizing radiation
3 Qualifications
3.1 General
3.2 Welding engineering
3.3 Welding supervision
3.4 Welding inspection
3.5 Welders and welding operators
4 Materials
4.1 Scope of section
4.2 Consumables
4.2.1 General
4.2.2 Storage and handling of consumables
5 Design of a welded joint
5.1 General
5.2 Butt welds between components of equal nominal thickness
5.3 Butt welds between components of unequal nominal thickness
5.4 Reinforcement of a butt weld
5.5 Longitudinal butt welds
5.6 Fillet weld
5.6.1 Dimensions of a fillet weld
5.6.2 Fillet welding a lug, boss, pig bar or pad
5.6.3 Sleeve fillet welds
5.6.4 Flanges and forged socket components
5.7 Welding of threaded joints
5.8 Reinforcement of a welded branch connection
5.9 Reinforcement of multiple openings
5.10 Forged branch component
5.11 Effect of components on PIG passage
5.12 Offset of longitudinal welds
5.13 Distance between welds
5.14 Location of aluminothermic welds and brazing connections
5.15 Attachment of electrical conductors
5.16 Golden welds
6 Qualification of a welding procedure specification
6.1 Welding procedure specification (WPS)
6.2 Purpose of qualifying a welding procedure
6.3 Types of welds requiring qualification
6.4 Methods of qualification
6.4.1 General
6.4.2 Qualification by testing
6.4.3 Qualification to an alternate approved welding standard
6.4.4 Qualification by prequalification without testing
6.4.5 Qualification by the use of engineering
6.5 Changes in a welding procedure
6.5.1 Change in an essential variable
6.5.2 Change in other than an essential variable
6.6 Conduct of the qualification welds
6.6.1 Planning a procedure qualification weld
6.6.2 Test piece size
6.6.3 Test piece material
6.6.4 Preparation and assembly of test pieces
6.6.5 Test conditions
6.6.6 Identification of the test weld
6.6.7 Recording a test weld
6.6.8 Supervision of the test weld
6.7 Provisions for specific welding methods
6.7.1 Cellulosic welding
6.7.2 Provisions for waveform power sources
6.7.3 Aluminothermic welding
6.7.3.1 General
6.7.3.2 Aluminothermic welding without qualification
6.7.3.3 Aluminothermic welding with qualification
6.7.4 Brazing
7 Assessment of the test weld to qualify a welding procedure
7.1 Method of assessment
7.2 Visual examination
7.3 Non-destructive testing
7.4 Destructive tests
7.4.1 Types of test and number of test specimens
7.4.2 Transverse butt tensile strength test
7.4.3 All-weld-metal tensile test (AWMT)
7.4.4 Transverse guided side bend test
7.4.5 Macro test — Cross-section examination
7.4.6 Hardness test
7.4.7 Fracture toughness tests
7.4.7.1 Charpy V-notch impact test
7.4.7.2 Toughness test
7.5 Retesting and further testing
7.5.1 General
7.5.2 Visual examination and non-destructive testing
7.5.3 Destructive testing
7.5.4 Cause of failure
7.6 Record of results
7.7 Period of validity
7.8 Disqualification of a qualified welding procedure
7.9 Aluminothermic welds and brazing connections
8 Welding positions
8.1 Designation
8.2 Limits of qualified positions
9 Qualification of a welder or welding operator
9.1 Purpose of qualifying a welder or welding operator
9.2 Scope of welder or welding operator qualification
9.3 Methods of qualification
9.4 Qualification by testing
9.5 Essential variables for welders and welding operators
9.6 Test piece
9.7 Assembly of test pieces
9.8 Automatic welding equipment
9.9 Making a test weld
9.10 Supervision of a test weld
9.11 Identification of a test weld
9.12 Qualification of aluminothermic welding and brazing operators
10 Assessment of test welds for welder or welding operator qualification
10.1 Method of assessment
10.2 Visual examination
10.3 Non-destructive testing
10.4 Repeated test
10.4.1 General
10.4.2 Repeated failure
10.5 Record of results
10.6 Portability of a welder’s or welding operator’s qualification
11 Welder or welding operator qualification and disqualification
11.1 Reciprocity of a welder’s or welding operator’s qualification
11.2 Period of validity
11.3 Qualification record
11.4 Disqualification of a welder’s or welding operator’s qualification
12 Production welds
12.1 Welding process
12.2 Welding equipment
12.3 Welder and welding procedure
12.4 Supervision of welding
12.5 Safety in welding
12.6 Storage and handling of electrodes, filler rods and fluxes
12.7 Welding in adverse climatic conditions
12.8 Preparation for welding
12.8.1 Edge preparation
12.8.2 Internal cleaning
12.9 Method of making the weld preparation
12.10 Accuracy of alignment
12.11 Line-up clamp
12.12 Tack welds
12.13 Working clearance
12.14 Placement of weld passes
12.15 Arc strike and arc burn
12.16 Cleaning
12.17 Peening
12.18 Insert patching
12.19 Preheat and interpass temperature
12.19.1 General
12.19.2 Application of preheat and interpass temperature
12.19.3 Extent of heating
12.19.4 Monitoring of preheat and interpass temperature
12.19.5 Condensation
12.20 Post-weld heat treatment (PWHT)
12.21 Identification of a production weld
13 Post-weld heat treatment (PWHT) and post-weld cooling
13.1 Post-weld heat treatment
13.2 Post-weld cooling
14 Assessment of production welds and repair welds
14.1 General
14.2 Methods of examination
14.3 Production cut-out welds
15 Welding and cutting on a pipeline after commissioning or after hydrostatic testing
15.1 General
15.2 Safety
15.3 Hot repair of leaking gas-filled pipelines
15.4 Where gas is not escaping
15.5 Pipelines containing petroleum fluids other than lean natural gas
15.6 Qualification of welder(s)
15.7 Qualification of welding supervisors and welding inspectors
15.8 Fit-up before welding and cutting
15.9 Examination and testing
15.10 Criteria of acceptance
16 Welding onto an in-service pipeline
16.1 Pipeline containing flammable or pressurized fluid
16.2 Precautions to be undertaken before in-service welding
16.2.1 Avoidance of hydrogen assisted cold cracking (HACC) and burn-through
16.2.2 Items to be considered before in-service welding
16.2.3 Risk assessment and risk management plan
16.3 Lining
16.4 Safety
16.5 Inspection before welding
16.6 Ultrasonic testing before welding
16.6.1 Purpose of testing
16.6.2 Method
16.6.3 Criteria of acceptance
16.7 Welding consumables
16.8 Preheat
16.9 Qualification of welding procedures
16.10 Welding sequence
16.11 Qualification of welder(s)
16.12 Qualification of welding supervisors and welding inspectors
16.13 Fit-up before welding
16.14 Examination and testing
16.15 Criteria of acceptance
16.16 Welding of test assembly
17 Criteria of acceptance for girth weld discontinuities
17.1 General
17.1.1 Acceptance criteria
17.1.2 Fatigue
17.2 Tier 1 criteria RT — Workmanship standard
17.2.1 General
17.2.2 Inadequate penetration
17.2.3 Inadequate penetration due to high/low
17.2.4 Incomplete fusion due to cold lap
17.2.5 Root concavity
17.2.6 Incomplete fusion
17.2.7 Porosity
17.2.8 Slag inclusions
17.2.9 Burn-through
17.2.10 Cracks
17.2.11 Undercutting
17.2.12 Root slag intrusion
17.2.13 Accumulation of discontinuities
17.2.14 Coincident discontinuities
17.2.15 Pipe or component discontinuities
17.3 Ultrasonic testing acceptance criteria (AUT, MUT, PAUT AND TOFD where applicable)
17.3.1 General
17.3.2 Planar indications
17.3.3 Non-planar volumetric indications
17.3.4 Transverse indications
17.3.5 Tier 1 UT acceptance criteria — Planar surface indications
17.3.6 Planar embedded indications
17.3.7 Transverse (t) indications
17.3.8 Volumetric cluster indications
17.3.9 Volumetric embedded individual indications
17.3.10 Volumetric root indications
17.3.11 Cracking
17.3.12 Parent material discontinuities
17.3.13 Copper contamination/cracking
17.4 Tier 2 acceptance criteria — Generalized fitness for purpose standard
17.4.1 General
17.4.2 Tier 2 acceptance criteria
17.5 Tier 3 criteria — Engineering critical assessment
17.5.1 General
17.5.2 ECA input assumptions
17.5.3 Coincident load conditions
17.5.4 Locations to be tested
17.5.5 Defect positions to be analysed
18 Visual examination
18.1 Purpose
18.2 Method of examination
18.3 Extent of visual examination
18.4 Criteria of acceptance
18.4.1 All-welds
18.4.2 Butt welds
18.4.3 Alignment (high/low)
18.5 Undercut depth measurement
19 Non-destructive testing (NDT)
19.1 General
19.2 Organizations undertaking non-destructive testing (NDT)
19.3 Qualifications of personnel
19.4 Methods
19.5 Amount of non-destructive testing (NDT)
19.6 Non-destructive testing of golden welds
19.7 Exemption from radiographic or ultrasonic testing
19.8 Timing of non-destructive testing
20 Radiographic testing
20.1 General
20.2 Safety and protection from ionizing radiation
20.3 Film density
20.4 Image quality
20.5 Undercut depth measurement
20.6 Gas pore depth measurement
20.7 Interpretation and assessment of radiographs
20.8 Criteria of acceptance
20.9 Report of radiographic testing
20.10 Retention of radiographs and digital images
21 Qualifying a radiographic procedure
21.1 Radiographic procedure
21.1.1 General
21.1.2 Film density range to be achieved — Additional requirements for computerized and digital radiography
21.2 Method of qualifying the radiographic procedure
21.3 Test conditions
21.4 Radiographic procedure specification documentation
21.5 Period of validity
22 Ultrasonic testing
22.1 General
22.2 Surface preparation
22.3 Manual ultrasonic testing
22.4 Phased array ultrasonic testing (PAUT)
22.5 Sensitivity
22.6 Assessment
22.7 Criteria of acceptance
22.8 Report
22.9 Procedure qualification
22.10 Automated ultrasonic testing (AUT)
22.10.1 General
22.10.2 AUT system qualification
22.10.3 AUT procedure
22.10.4 Project-specific validation
22.10.4.1 General
22.10.4.2 Tier 1 and 2 acceptance criteria
22.10.4.3 Tier 3 acceptance criteria
22.10.5 AUT operators qualification
22.10.6 Test on the repairs
23 Magnetic particle testing
23.1 Purpose
23.2 Method
23.3 Qualification of personnel
23.4 Criteria of acceptance
24 Dye-penetrant testing
24.1 Purpose
24.2 Method
24.3 Qualification of personnel
24.4 Criteria of acceptance
25 Repair of an unacceptable weld
25.1 General
25.2 Repair methods
25.3 Qualification of the repair welding procedure
25.4 Inspection
25.5 Criteria of acceptance
26 Removal of an arc burn
26.1 General
26.2 Repair by grinding
26.3 Method of inspection
26.4 Criteria of acceptance
26.5 Cleaning after testing
27 Cutting out an unacceptable weld or an arc burn
28 Records
Appendix A
Appendix B
B.1 Scope
B.2 Background
B.3 HACC in pipeline welding
B.4 Weld metal hydrogen assisted cold cracking (WMHACC)
B.5 Detection of HACC with NDT
B.6 The effect of delay time
B.7 The effect of strength
B.8 Welding procedure qualification
B.9 Methods for “designing-out” HACC from welding procedures
B.9.1 Restrictions
B.9.2 Welding of pipe
B.9.2.1 Normal lifts
B.9.2.2 Extreme lifts
B.9.3 Welding of components
B.9.4 Repair welding
Appendix C
C.1 Scope
C.2 Background
C.3 Strength matching
C.4 Electrode quality
C.5 Supplementary recommendations
Appendix D
D.1 General
D.2 System changes
D.2.1 Strength
D.2.2 Impact resistance
D.2.3 Flux designations — MMAW
D.2.4 Usability designations — FCAW
D.2.5 Positional designations
D.2.6 Weld metal hydrogen
D.3 Extension of weld procedure qualification
D.4 Other processes
Appendix E
E.1 Scope
E.2 Automatic/mechanized welding systems
E.3 Items for consideration when automatic GMAW welding is considered
E.3.1 Equipment
E.3.1.1 Welding equipment
E.3.1.2 Auxiliary equipment
E.3.2 Pipeline welding spread
E.3.2.1 General
E.3.2.2 Line-up clamp
E.3.2.3 Consumables
E.4 Weld parameter monitoring
E.5 Weld procedure qualification
E.5.1 General
E.5.2 Weld bevels
E.6 Inspection
E.7 Operators
E.8 Consistency welds
E.9 Components
E.10 Repair welds
Appendix F
Bibliography
