015-ih-1008 (pipeline field welding non-sour service)

8/15/2019 015-IH-1008 (Pipeline Field Welding Non-Sour Service)

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KU W AIT OIL COM PANY K.S.C.)

Engineering Group

Specification Number

Pipeline Field Welding Non Sour Service

1 17 JUN 94 ISSUED AS KOC ENG. GROUP SPEC.

6 FEB 94 ISSUED FOR INVITATION TO BID

Rev Date Revision BY Chkd Section PE Client


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CONTENTS

Eng/ ng 0

.0 SCOPE 3

.0 STAN DAR D SPECIFICATIONS 3


01 5 IH 1008

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 SERVICE CONDITIONS 4

0 CONTRACTOR S OBLIGATIONS 5

Rev

1

.0 MATERIAL 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..0 QUALITY SYSTEMS 5

Date

17 6 94

. 0 WELDING PROCEDURE APPROVAL 6 . . .

Sheet

2 0 f 17

8 0 QUALIFICATION OF WELDING PROCEDUREANDWELDERS

0 WELDING CONSUMABLES 8

0.0 PRODUCTION WELDING 8

0 1 Fit Up 80 2 Welding 90 3 Repairs 1 0

1 . 0 H E AT T R E AT M E N T- 11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 0 INSPECTION 112 1 General 1 1

12 2 NDE Operator Qualifications 1 112 3 Non Destructive Testing 2

2 4Radiography

1 212 5 Magnetic Particle Inspection 1 61 2 6 Liquid Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . 1 7


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1 0 SCOPE

1.1 This specifications covers the design and manufacture of pipeline fieldwelding for installation at the Facility in Kuwait.

1.2 The field welding shall fully comply wi th all relevant contractualrequirements specified in the Scope of Work and Technical Specificationof the Contract.

2 0 ST ND RD SPECIFIC TIONS

2.1 The pipeline field welding shall conform in design material and

performance except where otherwise specified with the current issueand amendments of the following prevailing on the effective date of theContract:

2.1.1 International Standards

In addition to the text of this specification the following codesand standards are applicable:

API 1 10 4 Welding of Pipelines and Related Facilities

ASME Vlll Div 1 Unfired Pressure Vessels

ASME IX Welding and Brazing Qualification

ASME B31.4 Liqu id Tra nsmi ssio n System s forHydrocarbons Liquid Petroleum GasAnhydrous Ammonia and Alcohols

ASME 831.8 Gas Transmission and Distribution Piping

Systems

ASNT-SNT-TC-1 A American Society for Nondestructive Testing

ASTM E747-87 Test Method for Controlling Quality ofRadiographic Tes t ing Using WirePenetrameters

2.1.2 British Standard

BS 5750 Quality SystemsPart Specification for Production and Installation

2.1.3 Engineering Group Specifications

01 5-AH-1 001 Basic Design Criteria

nwpSpecification Number

01 5-IH-1008

ev

1

Date

17-6-94

Sheet

30 f 17


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Specification Number Rev Date Sheet...- ng rwp

01 5 IH 1008 1 17 6 94 4 0 f 17

International Codes and Standards

Pipeline Co nstruction

Pipeline Design

Pipeline Pigging and Hy drostatic T est

Pipeline Dew atering and Dry ing

Pig LauncherIReceiver

Field W elding

External Coating of Pipeline

Induction Bends

Pipeline Field Jo int Co ating

Line Pipe Ma terials

Shop and Field PaintingCathodic Protec tion Design Requirements

2.2 Compliance w ith this spec ification shall n ot relieve the C ontractor of i tsresponsibility t o supply equ ipment suited to meet th e specified servicecond itions an d applicable regulations.

2.3 Where conflicts exist between this specification and other Drawing,standards, c odes or specifications, the m ost strin ge nt shall be applied,and the Com pany decision shall be final.

3 0 SERVI E OND ITIONS

3.1 The welded pipeline shall be suitable for continuous operation at a desertlocation under high ambient temperatures and hum idity the atmosphe rea t the fac ility is generally dusty and corrosive and may con tain traces o fhydrog en sulphide.

3.2 The welded pipeline shall in all respects be suitable for continuousoperation in service conditions stated in the Engineering GroupSpe cification entitled Basic Design Criteria (Num ber 0 15-AH-10 0 1 .


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4 0 CONTRAC TOR S OBLIGATIONS

4.1 The Contractor shall submit descriptions of all welding equipment,welding materials to be used, tools, etc. t o the Company for approvalprior to starting work.

4.2 This equipment shall consist of at least:

Welding machines, welding generators and gas weldingequipment.

Equipment and machinery for cutting, bevelling, preheating and

postheating.

External and internal line-up clamps.

Welding electrodes, welding wire, fluxes, etc.

Welder's tools.

Tests and asbestos blankets for weather protection of thewelds to be made.

Portable or permanent meters to calibrate machines andregulate voltage and amperes.

4.3 Sufficient equipment for each welding method to be applied shall bepresent to ensure a replacement in the event of failure so that operationscan be continued normally.

5 0 MATERIAL

5.1 The Contractor shall supply the line pipe in accordance wi th theEngineering Group Specification entitled Pipeline Pigging andHydrostatic Test (Number 01 5-IH-1004).

5.2 The line pipe supplied by the Contractor wi th a limitation on the carbonequivalent as follows:

6 0 QUALITY SYSTEMS

6.1 The Contractor shall maintain a Quality System to BS 5750, Part 2.

6.2 The Contractor shall submit to the Company a copy of i ts QualityManual for approval.

E@ ng Grwp@edf n

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01 5-IH-1008

Rev Date

17 6 94

Sheet

5 0 f 17


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oSpecification Number Rev ate Sheet

E@ ng m pv a t i o n 01 ~ I H I O O ~ 1 17-6-94 6 o f 17

6.3 The Contractor shall submit a Quality Plan for the entire work forCompany approval prior to commencement of fabrication.

7 0 WELDING PROCEDURE APPROVAL

The Contractor shall submit to the Company for approval written weldProcedure Proposals (WPPs) to cover the range of materials, thicknessesand diameters in the work. This shall include a welding repair procedure(WRP). Upon Company approval, each WRP shall be qualified inaccordance wi th API 1104. All weld procedure qualification (WPQ)tests shall be witnessed by the Company s Representative. Followingqualification, the supplier shall prepare a weld procedure specification

(WPS) for use on site.

When testing is completed, the Contractor shall submit the completepackage of WPSs and weld procedure qualification records (WPQRs) orCompany approval.

All welding details required by API 1104, Sec. 2, shall be included ineach WPS and qualified by the corresponding WPQR.

In addition to the requirements of API 1104, the WPSs and WPQRs shall

specify string or weave bead.

The following shall be considered as essential variables in addition to API1 104:

7.5.1 For filler materiallelectrode and any change in AWSclassification.

7.5.2 A change in welding equipment for automatic processes.

7.5.3 Any change in wall thickness or outside diameter (OD) outsidethe wall thickness or OD group qualified. Wall thickness andOD groups are defined in paragraph 3.2.2 of API 1104.

7.5.4 A change in current or voltage range beyond that of the WPQR.

7.5.5 A change in polarity of the electrode.

7.5.6 A change in electrode diameter.

7.5.7 Post-weld heat treatment (PWHT).

7.5.8 Any change in root pass welders.

7.5.9 Any significant change in heat input.

7.5.10 Any change in shield flux manufacturer or brand.


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In addition to the testing requirements of API 1 104, the test welds shallbe visually inspected and radiographed. The acceptance criteria shall be

as per of API 1104, Sec. 6. In addition, a macro etching specimen shallbe produced for both the WPQ and repair. Hardness testing shall alsobe made on the etched specimen; hardness impression shall be made atthe weld, heat-affected zone, and base metal hardness value shall notexceed HVlO 248 BHN 237.

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Welding procedures shall be approved by the Company prior to thecommencement of production welding.

Specification Number Sheet

01 5 IH 1008 17 6 94 7 0 f 17

Previously qualified procedures may be acceptable provided they comply

fully wi th the requirements of this specification and API 1 104, and havebeen witnessed by a third party.

8 0 QU LIFIC TION OF WELDING PROCEDURE ND WELDERS

8.1 The Contractor shall comply wi th the conditions described in allapplicable specifications. If the Contractor wishes to depart fromspecification requirements, this shall be submitted in writing forCompany approval.

8 2The qualification of the welding procedure and welders/operators shallbe established, inspected and tested as laid down in thesespecifications.

8.2.1 Quality of the Welding Work

a. The Contractor shall at all times be responsible for the goodquality of the welding work.

b. A Quality Plan describing the systematic control of theconstruction, inspection and testing required by thisspecification, other relevant specifications, codes andstandards and the Contract conditions shall be submitted t othe Company for approval.

c. The Contractor shall compile a log identifying by numbereach pipe and fitting and indicating the weld numbersjoining them to other items. Each circumferential weld

whether a field joint or a shop-made weld) shall beallocated a unique number which shall be used forreference to the weld in all reports, radiographs and non-destructive testing NDT) documents.

8.2.2 Performance of Welding Work


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Welded joints in lines of 2 in. and up may be produced bymanual electric are shield welding with a minimum of four

beads.

Eng/ ng GnwpSped tbWn

8.2.3 Welders Qualification

Welders shall be qualified to API 1104, wi th testing at the jobsite and on Project-specific material. Previously qualifiedwelders with current certificates may be acceptable to theCompany provided all the requirements of this specification andAPI 1104 are met and the qualification tests have beenwitnessed by a third party.


01 5 IH 1008

9 0 WELDING CONSUMABLES

9.1 The Contractor shall submit a procedure for the storage and handling ofwelding consumables for approval by the Company.

Rev

1

9.2 Welding consumables shall be stored in accordance wit h the ApprovedManufacturer s recommendations in a covered, clean, dry location.

9.3 Heated quivers shall be used for low-hydrogen electrodes.

Date

17 6 94

9.3.1 The welds shall be made with electrodes or welding wiresuitable for the purpose and approved by the Company. Toobtain this approval, the welds shall be subjected to the testsdescribed in the section on welding procedure qualification.

Sheet

8 o f 1 7

9.3.2 Each coil of filler wire, bag of flux and packet of electrodesshall be clearly marked with its batch number. Batch testingshall be completed before the start of field welding. Batchtesting may be undertaken by the Approved consumablesManufacturer, and the test results shall be submitted to theCompany for approval.

9.3.3 The values found in the mechanical tests of the weld metalshall at least comply with the specified minimum mechanicalrequirements of the steel that has been welded.

9.4 Welding consumables showing signs of damage or deterioration shall notbe used.

10 0 PRODUCTION WELDING

10.1.1 Internal line-up clamps shall be used for 16-in. pipe and largerand shall not be removed prior to the completion of the rootpass.


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Specification Number Rev ate SheetngfMng rwp

SpedhhWn 01 5 IH 1008 17 6 94 90f 17

10.2 Welding

Where it is not practicable to use internal line-up clamps,external clamps shall be used. These shall not be removed until

70 minimum of the root pass has been completed and isevenly distributed around the pipe circumference. Cleats andbrackets shall not be attached to the pipe for alignment.

The pipe on both sides of the joint shall not be raised, loweredor otherwise moved until both root pass and the hot pass havebeen completed.

Where field bevelling is necessary, t shall be effected usingeither mechanical or automatic flame- or plasma-cutting

equipment, followed by grinding to remove all oxide, andpreparing the joint surfaces to a clean, bright finish. Bevels shallcomply with the approved welding procedure.

Tack welds shall be made using qualified welders andprocedures qualified in accordance wi th this specification. Atleast four evenly spaced tack welds a minimum of 25 mm longshall be used. Tack welds to be incorporated into the final weldshall be ground to a suitable taper at either end to ensureadequate fusion with the root run. Where heat is required for

the root run, this shall also be applied to the tack welds.

The tolerance on misalignment at butt joints shall be inaccordance with API 1 104. Additionally, any misalignmentshall be reduced to minimum by rotating the pipes to theoptimum position.

Where longitudinally welding pipe is used, the pipe shall bepositioned such that the weld is located in the upper half of thepipe circumference. The longitudinal or spiral welds of adjacentpipes shall be offset by the lesser of 90° or a circumferentialdistance of 25 0 mm or on neutral axis of bent sections of pipe.No welds shall be made on pipe other than the circumferentialwelds between the pipe and appurtenances.

Earthing connectors shall not be weld t o the pipe, and onlysuitable clamps which do not cause arcs shall be used.

Under no circumstances may the arc be struck on the surfaceof the pipe outside the weld bevels. If this inadvertentlyoccurs, the entire weld and the drainage part of the pipe shallbe subject to removal.

10.2.1 Welding shall not be carried out on wet steel. Wet steelsurfaces shall be thoroughly dried by the application of heat to


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Specification Number Rev Date Sheet

0 1 5 iH 1008 1 17 6 94 10 of 17

the entire joint prior to welding commencing. Preheat shall bebased on weldability tests chemical analysis and welding in

procedure and shall be in accordance with ASME Vlll Div. 1The minimum preheat temperature shall be 50° C

The maximum interpass temperature shall be 25 0° C.

As far as possible welds shall not be left in a partiallycompleted state. However if this is unavoidable a minimumof three passes shall be made prior to cooling. The joint shallbe entirely wrapped in dry insulating material withwaterproofed exterior and cooled in a slow uniform manner.

Prior to the recommencement of welding the joint shall bedried in accordance wi th paragraph 9 2

Joints shall not be welded by blocking out individual segments.

The stringer bead technique shall be used when welding withlow hydrogen electrodes.

Adequate weather shielding shall be in place for all welding.The Company reserves the right to discontinue all welding in

the event of non-fulfillment of welding requirements.

Where the vertical down process is used for welding the rootpass the time delay before welding the hot-pass shall bestrictly in accordance with the qualified WPS and not in excessof five minutes.

Only earthing clamps shall be used on the pipes. Arc strikes onbase metal are forbidden. Only arc striking on fusion face shallbe allowed.

A WPS for weld repairs shall be submitted together with acorresponding WPQR for Company approval prior to thecommencement of the work.

Weld repairs shall be effected in accordance with therequirements of API 1 104

Defects shall be removed by arc air gouging followed bygrinding or by grinding alone. Metal surfaces shall be dried inaccordance wi th paragraph 9 2 prior to any gouging operation.

The Contractor shall maintain a full record of all repairs. Suchrecord shall show the weld number type and size of defectcircumferential location estimated depth of the defect number


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or repair, welding procedure, name of repair welder, date ofrepair, etc.

All repairs shall be witnessed by the Com pany Inspector. Rootsealing or single-pass repair deposit shall n ot be done; on ly t w oattem pts on the repair are permitted.

Repair length shall be limited t o 30 of the we ld if the repairdoes no t require opening the root. If a repair opens the root,only 20 o f the weld length shall be repaired. If the repaircan not be implemented within these limitations, the w eld shallbe cut out .

The c ut end o f the pipe shall be re-bevelled, and about1 0 0 m m on either side o f the joint shall be examined b yultrasonic for laminations. The n e w bevels shall be magneticexamined.

1 1 0 HEAT TREATMENT

1 1 I The requirement for post-w eld stress relief shall be in accordance w ithASME B31.4, paragraph 434.8.9.

11.2 If PWH T is necessary, the Con tractor shall subm it a detailed procedurefor p os t-w eld stress relief for Com pany approval. This shall include alldetails required by ASME Vlll Div. 1, paragraph UCS56.

1 1.3 A cha rt recording o f each PWHT shall be produced.

12 0 INSPECTION

12 1 General

Inspection and witnessing by the Company shall not release theContractor from its sole responsibility for carrying out the necessaryinspection, testin g and non-de structive examination (NDE) required bythe c ode and by this specification. The Com pany shall have the right t oorder the removal of any weld for the purpose of carrying outdestructive tests.

12 2 NDE O ~ e r a to r uali fications

12.2 .1 NDE operators shall be qualified by a third party to ASNT-SNT-TC-1A Level II or Ill and of API 1104, sections 5.3 and 5.4.

12.2.2 NDE operators shall have current certification for the wo rkundertaken, and their qualification certificates shall be subjectto approval by the Company.

QKOCnginesting G t w pSpecification Number

01 5 IH 1008

Rev

1

ate

17 6 94

Sheet

11 of 17


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12.3 Non-Destructive Testing

All NDT work shall be the full responsibility of the Contractor.The Contractor shall submit procedures for all NDT to theCompany for approval prior to work commencing.

NDT radiograph, wire-type image quality indicators shall be inaccordance with ASTM E747. The sensitivity shall be betterthan 2.0 .

High-pressure HP) gas and condensate lines welds shall be100 radiographed. Nozzles or attachment welds that cannot

be radiographed shall be examined by the wet magnetic crackdetection method.

Low-pressure LP) gas and crude oil lines shall be 10radiographed except at the road crossings, populated areas, tie-in points and repair welds, where 100 radiography on weldsshall be made. All fillet welds, nozzle or branch welds andother attachment welds shall be examined by the wet magneticcrack detection method.

The first five production welds of each welder or welding groupshall be 100 radiographed.

Tw o additional welds shall be radiographed for a welder if thesewelds do not meet the acceptance criteria as per API 1104should any or both of the additional radiograph showunacceptable welds. The entire welds made by that welder orwelding group shall be radiographed at the expense of theContractor.

12.4 Radioara~hy

The following defines the minimum requirements for radiography workto be carried out by the Contractor or the Approved Subcontractor:

12.4.1 Procedure

A detailed procedure and production of images shall beprepared by the Contractor for Company approval:

a. Radiation source machine identification.

b. Film Manufacturer and relevant ASTM Class.

c. Intensifying screen.


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d. Exposure geometry (double wall, double imageldouble wall,single imagelor single wall, single image).


0 1 5-IH-1008

e. Source film distance of focal film distance.

f. Number of exposures required for radiography of acomplete weld.

Rev

1

g. Exposure conditions and exposure time.

h. Processing (manual or automatic).

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17-6-94

i. Material thickness range.

Sheet

13 of 17

j Penetrameters 101): ype, material and related standard.

k. Density and sensitivity.

I. Collimator or field limitation device.

m. Safety precautions and aids.

12 4 2Minimum Requirements for Radiographic Examination

X-radiography shall be used for site inspection unless priorapproval is obtained for the use of the isotope iridium 192

12 4 3 Film Density

The density through the weld metal shall not be less than 1 8and not more than 3 The Company has the right to check theContractor's unexposed films at any time and from any lot offilms intended to be used by the Contractor.

12 4 5 Film Type

a. The following types of industrial radiographic films shall beused for X-ray and for iridium 192 radiography:

Class 1

Class 2

Class 3

Low Speed Film o r M a t e r i a IThickness < 0.50

Med. Speed Film

High Speed Film

For MaterialThickness 0.50but not exceeding 1

F o r M a t e r i a IThickness 1


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Specification Number Rev Date Sheetnginoettng Grwp

S p W a W n 0 1 5-IH-1008 1 17-6-94 1 4 0 f 17

b. For X-Ray Radiography:

Mat l Thickness (inch) V Range Film Class

U pto 114 inclusive 120- 1 5 0 2

U pto 114 inclusive 150-250 1

> I 1 4 - 112 1 20- 1 5 0 2

12.4.6 Penetrameters 101)

a. Qu ality indicator (penetrameter) shall co nfo rm t o ASTM-E7 47 for w ire penetrameter or any alternative standard forwire penetrameter subject t o Com pany approval.

b. A t least one penetrameter per radiograph exposedsimultaneously wi th the specimen shall be used.

1 2.4.7 Sensitivity

2 or better sensitivity is required.

12.4.8 Exposure Geom etry

The dou ble wall, doub le image technique shall be used forpiping of less than 3 112 in. inclusive. A t least t w oexposures separated by 90 degrees shall be made for the

radiographic inspection of a complete weld. Onepenetrameter on the source side with its lengthperpendicular t o th e we ld shall be used.

For single wall, single image, at least four penetrametersspaced approximately equally around the circumference o fthe pipe shall be used at source side.

Dou ble wall, single image shall be used for pipe diameter >3 112 in. The penetram eter shall be placed o n sou rce side,if applicable; otherwise, it shall be placed on film side atthe mid length of the film: an overlap of at least 2 in. isrequired betw een shots.

In radiography of tankage annular plates b ut t weld, wh enbacking strip is used or we ld reinforcement is high, a shimplate of the same type o f m etal as the parent metal shall be


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placed under the penetrameter to provide the samethickness of material under the penetrameter as the

average thickness through the weld.

12 4 9 Identification of Location Markers on Radiographs

Each radiograph shall be identified so that there is apermanent correlation between the part radiographed andthe film.

The types of identification and method of identificationshall be as per the Contractor procedure unless otherwise

specified by the Company.

The letter R should be used to designate a radiograph ofrepaired area.

The exact location of location markers should be clearlymarked on the surface being radiographed so that the areaof interest can be identified accurately.

When more than one image is used to inspect a weld,

identification markers shall overlap at a minimum of2

in.The last reference marker on each end of the image shallappear on the appropriate adjacent images in a way that nopart of the weld images could be omitted.

Radiographic Report

The format of radiography results shall be based on thisspecification and shall be agreed upon with the Company priorto implementation of the work.

12 4 1 1 Interpretation

a. Prior to any weld repairs, the radiographs shall besubmitted to the radiography report and any relevantDrawings.

b. The designated length for interpretation shall not containany discontinuities whose severity exceeds that allowed inthe related code, standard, specification or Companylimitations.

c. When two or more types of weld defects are present in thesame radiograph whose extent equals the maximumacceptable limit for both, the weld shall be judgedunacceptable.


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12.5 Maanetic Particle lns~ection

12.5.1 Equipment for magnetization of parts shall be capable ofinducting flux density of sufficient intensity and direction toperform the required job.

Sheet

1 6 of 1 7

12.5.2 Either AC or DC (full-wave or half-wave rectified) equipment orpermanent magnets shall be used as specified in the Contractorprocedure to produce the required magnetization. Flexiblemovable legs of the yoke should be available for workrequirements.

ngimng Grwpn

12.5.3 Magnetic particle may be applied wet or dry. Dry particlesshould be applied uniformly with a dusting or light blowingaction. Wet particles should be applied by aerosol cans or byhosing. Provisions should be made available to ensure that therequired amount of particles are in the suspension when thespray is applied and to periodically check the concentration ofthe solution. When fluorescent dyed particles are used,ultraviolet light (3200 3800 A O must be available.

Rev

1

Specification Nu mber

0 1 5-IH-1008

12.5.4 Equipment for demagnetization should be available fordemagnetizing parts to the minimum residual field.

ate

17-6-94

Radiographs showing processing defects, improper densityor sensitivity, or any image that masks the weld or adjacent

base metal shall not be submitted for interpretation.

Record of Radiographic Examination

The Contractor shall produce a record for all films wi th theiridentification marks on a developed shell plate diagram (fortanks), on isometrics or plans (for piping) and on thewelding key plan (for other equipment).

Upon completion and acceptance of the relevant equipment

or piping and all other related works by the Company, allradiographic films shall be handed over to the Company ingood condition when they wil l become the sole property ofthe Company and shall be retained for a minimum period offive years.

Radiography work shall be at the expense of theContractor. Should the Company request additionalradiography, it will be at Company expense unless t doesnot meet the Engineering Group specification. The cost ofthe rework of these non-conforming conditions, includingthat of radiography, shall be to the Contractor s account.


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Specification umber

12.6 Liauid Penetrant lns ~e ct io n

12.6.1 The Contractor should prepare the necessary apparatus to applythe penetrant wash the surface of the part dry the part andapply a developer and a properly lighted area in which the partcan be inspected by the Company. The inspection materialsshould not adversely affect the parts to be tested. Whenfluorescent dyed particles are used ultraviolet light

3200 3800 A O must be available.

12.6.2 Only aerosol cans for cleaner penetrant and developers shall beused in order to allow for the smooth flow of parts.

015-ih-1008 (pipeline field welding non-sour service)

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