Transcript

SPEC : DP-W-3

REV : 16 DATE : 03/08

BY : FE APP : RD

TITLE : WELDING - STRUCTURAL



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DUBAI PETROLEUM
STANDARD SPECIFICATIONS






WELDING - STRUCTURAL







REV. DATE BY REMARKS

16 03/08 Fac Engr Dropped the C from DPC only

15 08/06 BM Periodic Review- No change in the Specification

14 11/02 J GN/SBB Drawings Updated & URL Created

13 10/90 RCR/ABM Major revision to include PRD/ESD comments

12 09/89 RR/NF Moved fabrication topics to the
new S-8 specification

11 06/88 RR/NF Minor revisions by ESD and DP.

10 05/87 CJ W Minor revisions throughout

09 03/87 STM Minor revisions, significant change in
Section 12.







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TABLE OF CONTENTS




1.0 INTRODUCTION
2.0 REFERENCES
3.O DOCUMENTATION
4.0 WELDING PROCEDURE AND QUALIFICATION TESTS
5.0 QUALIFICATION OF WELDERS AND WELDING OPERATORS
6.0 GENERAL WELDING REQUIREMENTS
7.0 PRODUCTION WELDING
8.0 PRODUCTION WELD TESTS
9.0 INSPECTION AND NON-DESTRUCTIVE EXAMINATION (NDE)

TABLE 1 Test Specimen and NDE Requirements for Weld Procedure Tests

TABLE 2 HAZ Hardness Limits

TABLE 3 Charpy Impact Requirements

TABLE 4 Weld Flaw Acceptance Levels

TABLE 5 Extend of NDE


FIGURE W-5 Test J oint for Welding Procedure Qualification Test

FIGURE W-6 Test Specimen Locations in Welded J oints

FIGURE W-7 Location of Charpy Impact Specimen Notches - Single Sided Butt Welds

FIGURE W-8 Location of Charpy Impact Specimen Notches - Double Sided Butt Welds

FIGURE W-9 Vickers Hardness Testing
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1.0 INTRODUCTION

1.1 Scope

This specification defines minimum Dubai Petroleum (DP) requirements for welding,
inspection, non-destructive examination and testing of structural steel for offshore
structures. Minimum requirements for fabrication and erection of structural steel are
covered in DP-S-8, "Fabrication of Offshore Structures", which shall be read in
conjunction with and be considered complementary to this specification.

1.2 Definition of Terms

1.2.1 Dubai Petroleum is referred to herein as COMPANY and/or DP.

1.2.2 The fabrication contractor is referred to herein as CONTRACTOR.

1.2.3 Corporations or firms engaged by the CONTRACTOR for the performance of
work are referred to herein as SUB-CONTRACTOR.

1.3 Quality Control and Quality Assurance Responsibilities

The CONTRACTOR shall be responsible for all Quality Control and for compliance with
all Quality Assurance requirements throughout fabrication and production welding as
stated in this specification and the contract documents.


2.0 REFERENCES
2.1 General
2.1.1 The CONTRACTOR is responsible for ensuring that quality of the work complies
with requirements of this specification and the applicable Codes and Standards
listed below.

2.1.2 The welding of offshore structures shall meet requirements of the American
Welding Society's Structural Welding Code D1.1 and API RP 2A as augmented by
this specification.

2.1.3 In the event of conflict between this specification and any Code, Standard, or
Regulation, the CONTRACTOR shall inform the COMPANY in writing and receive
written clarification from the COMPANY. The CONTRACTOR shall have readily
available for COMPANY use at the work site; current copies of all Codes,
Specifications and Standards necessary for the execution of the work.
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Copies shall be in the language of the country appropriate to the work site and in
the English language.

2.2 Applicable Codes and Standards

Unless specifically noted in this specification, the latest edition of the following standards
shall apply:-

American Petroleum Institute

API RP 2A 18th Edition, April 1989
Recommended Practice for Planning Designing and Constructing
Fixed Offshore Platforms

API 2B 3rd Edition, November 1977
Specification for Fabricated Structural Steel Pipe

API 2H 5th Edition, J uly 1988
Specification for Carbon Manganese Steel Plate for Offshore Platform
Tubular J oints

API 5L 37th Edition, May 1988
Specification for Line Pipe

API RP 2X 2nd Edition, 1988
Ultrasonic Examination of Offshore Structural Fabrication and
Guidelines for Qualification of Ultrasonic Technicians

API 2Y 2nd Edition, 1 1990
Specification for Steel Plates, Quenched and Tempered, for Offshore
Structures

API 2Z 1st Edition, May 1, 1987
Recommended Practice for Preproduction Qualification for Steel Plates
for Offshore Structures

American Society of Mechanical Engineers

ASME Boiler and Pressure Vessel Codes 1988 Section V Non-Destructive
Examination 1989 Section VIII Division 1 Pressure Vessels


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American Society of Non-Destructive Testing

ASNT Recommended Practice No. SNT-TC-1A Personnel Qualification

American Society of Testing and Materials

ASTM A370-87c Methods and definitions of Mechanical Testing of Steel Products

ASTM E23-86 Notched Bar Impact Testing of Metallic Materials (Charpy)

ASTM E92-82 Standard Test Method for Vickers Hardness of Metallic Materials

ASTM E94-88 Standard Guide for Radiographic Testing

ASTM E142-86 Standard Method for Controlling Quality of Radiographic Testing

ASTM E709-80 Standard Practice for Magnetic Particle Examination

ASTM E747-87 Standard Method for Controlling Quality of Radiographic Testing
Using Wire Penetrameters

Dubai Petroleum Company Specifications

DP-S-1 Steel Structures Design
DP-S-8 Fabrication of Offshore Structures DP-W-5 General Welding
Requirements

British Standards Institute

BS 427-81 Pt 1, Method for Vickers Hardness Test

BS 638-84 Arc Welding Plant, Equipment and Accessories

BS 709-83 Methods of Testing Fusion Welded J oints and Weld Metal in Steel

BS 4165-84 Electrodes, Wires and Flux for the Submerged Arc Welding of
Carbon and Medium Tensile Steel

BS 5135-84 Processes for Metal Arc Welding Carbon and Carbon Manganese
Steels


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American Welding Society

AWS D1.1-90 American Welding Society, Structural Welding Code

AWS A2.4-79 Symbols for Welding and Non-Destructive Testing

AWS A3.0-89 Terms and Definitions

AWS A5.1-81 Carbon Steel Covered Arc Welding Electrodes

AWS A5.5-81 Low-Alloy Steel Covered Electrodes

AWS A5.17-80 Carbon Steel Bare Electrodes and Fluxes for Submerged Arc
Welding

AWS A5.20-79 Carbon Steel Flux Cored Arc Welding Electrodes

AWS A5.29-80 Specification for Low-Alloy Steel Electrodes for Flux Cored Arc
Welding


3.0 DOCUMENTATION

3.1 Documentation Required with Bid

The CONTRACTOR shall submit the following procedures and documentation as a
minimum for COMPANY review at the time of bid submission. This information shall be
accompanied by that required by DP-S-8, "Fabrication of Offshore Structures", as defined
therein.

Procedures

a. Detailed procedures for Non-Destructive Examination (NDE) including visual,
ultrasonic, magnetic particle and radiographic examination procedures. Radiation
safety procedures shall be submitted by the CONTRACTOR for COMPANY approval.

b. Procedures for storage, drying, handling and distribution of welding consumables.

c. Mechanical testing procedures.

d. Qualified welding procedures and repair procedures for both permanent and
temporary welded attachments.
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e. Details of welder training schemes.

f. Procedure for monitoring welding procedure qualification and testing.

g. Resumes of all NDE Supervisors.

Subsequent to Contract award and prior to the commencement of fabrication, all above
procedures must be approved by the COMPANY and any other procedures requested by
the COMPANY shall be submitted to the COMPANY for review and approval.

3.2 Commencement Documentation

3.2.1 Prior to the commencement of each part of the fabrication, the CONTRACTOR
shall submit as a minimum the following procedures and documentation for review
and approval by the COMPANY.

a. List of proposed qualified welding procedures, including repair procedures, in
accordance with this specification for both permanent and temporary welded
attachments. The CONTRACTOR shall indicate the proposed area of
application for each procedure proposed.

b. Detailed procedures for non-destructive examination and inspection if not
otherwise approved.

c. Certificates of welders and welding operators qualified in accordance with this
specification.

d. NDE personnel and qualifications.

e. Welder and welding operator identification system for production welds.

f. Production Test Program, where applicable.

3.2.2 Following completion of any part of the fabrication or upon completion of each
sub-assembly, CONTRACTOR shall submit copies of the following documentation
to the COMPANY for review and approval.

a. Identification system for production welds including NDE drawings showing an
unambiguous member identification and weld identification scheme, NDE and
inspection requirements and welding procedure identification. Such NDE
drawings and weld plans shall include as a minimum:

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- Weld Line Number,
- Weld Procedure Number and Welding Processes,
- NDE Requirements,
- NDE Reports referenced to NDE Drawings showing all Welds Tested and
their locations,
- PWHT Records,
- Repair Details and Statistics
- Welder Identification.

b. Production mechanical test results and records for each weld tested.

c. Other documentation as required by specification DP-S-8.

3.3 Contractor Drawings and Documentation

3.3.1 The review and/or approval by the COMPANY of the documentation detailed in
Section 3.1 and 3.2 shall only indicate that the general methods of fabrication are
satisfactory and shall not relieve the CONTRACTOR of his responsibilities for any
errors or for any resultant remedial work.

3.3.2 The CONTRACTOR shall ensure that only documents which have been reviewed
and approved by the COMPANY are made available at the work site.


4.0 WELDING PROCEDURE AND QUALIFICATION TESTS

4.1 General

4.1.1 Only welding procedures approved by the COMPANY and CONTRACTOR shall
be used for production welding. Pre-qualified welding procedures under AWS
D1.1 shall not be permitted. See Section 4.3.2.

4.1.2 Weld test plates shall be of sufficient size to include all the test pieces required by
this specification including any re-tests that may be required. All test plates shall
be adequately restrained in order to minimize distortion during welding, such
restraint being representative of that in production welding, unless prefabrication
of girders allows for rotation of the flange and web.
4.1.3 The COMPANY shall approve the material used for the welding procedure
qualification.

4.1.4 Each test plate shall have the appropriate heat and cast numbers together with
any plate identification number transferred from the parent plate. The Mill Test
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Certificate(s) shall be appended to the welding procedure proposal and
qualification test documentation.

4.1.5 A complete set of mechanical tests as defined in Table 1 shall be required for
each welding procedure qualification test.

4.1.6 The approval of welding procedure qualification test welds shall be based on
satisfactory non-destructive examination (NDE) and mechanical testing of the test
assemblies in accordance with the attached Table 1. The level of inspection and
NDE shall be 100%, to include visual, magnetic particle, ultrasonics and/or
radiography (radiography applicable only to butt welds), all of which shall satisfy
the requirements of Table 4.

4.1.7 Welding procedure qualification approval shall be subject to Section 4.1.6 and the
submission of appropriate documentation. The documentation required as a
minimum shall be:

a. Welding Procedure Proposal.
b. Material Test Certificate.
c. Procedure Qualification Welding Records.
d. NDE Records.
e. Mechanical Test Reports (including original photo-macrographs).

4.2 Welding Procedure Proposal

4.2.1 The CONTRACTOR shall submit to the COMPANY for review detailed welding
procedure proposals prior to conducting qualification tests.

4.2.2 Each welding procedure proposal shall include, but not be limited to, the following
information:

a. Welding processes.

b. Procedure plate carbon equivalent(s) (with mill sheets appended).
CE =C +Mn +Ni +Cu +Cr +Mo +V
6 15 5

c. Sketch of joint showing plate edge preparation, orientation and joint fit-up
(indicating bevel, included angle, root gap and root face).

d. Material type, qualification material thickness and thickness range qualified.

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e. Welding position(s).

f. Welding direction(s).

g. Welding consumables; manufacturer, AWS classification, trade name, size of
electrodes.

h. Weld pass sequence diagram indicating the depth of back gouging or back
grooving.

i. Welding parameters for each welding pass to include the following as a
minimum:
- Arc current and voltage ranges,
- Welding speed range,
- Minimum and maximum permitted electrode run-out lengths based upon a
50mm (2 inch) stub length and welding time (this must be verified on
subsequent qualification and related to travel speed),
- Current type and polarity,
- Electrode diameter,
- Calculated heat input, HI such that:
HI =Amps x Volts x 60 =kJ /mm,
S x 1000
where S =travel speed in mm/min.
For multiple wires, HI is the summation of each wire.
- Inter-pass temperature.

j. Welding technique per pass, i.e. stringer or weave and degree of weave.

k. Method of back gouging.

l. Proposed preheat temperature and the range of preheat temperatures
applicable to the welding procedure, and the method of heating.

m. Maximum inter-pass temperature.

n. Method of test panel restraint.

4.3 Welding Procedure Qualification Tests

4.3.1 The CONTRACTOR shall establish and qualify all welding procedures in
accordance with this specification. Weld procedure qualification test results shall
be submitted for COMPANY review.
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4.3.2 Previously qualified procedures meeting all the requirements of this specification
may be submitted, but acceptance and application limitations shall be at the sole
discretion of the COMPANY. Where previously qualified procedures have been
reviewed and approved by the COMPANY, such procedures will be used to
develop welding procedure operating sheets which shall be used in production
welding. The CONTRACTOR shall provide any additional documentation required
by the COMPANY to fully develop the welding procedure operating sheets. Final
acceptance of previously qualified procedures may be dependent upon the
demonstration of satisfactory results from production weld tests (Section 8.0)
carried out on the first day of fabrication.

4.3.3 The CONTRACTOR shall inform the COMPANY, giving 2 days notice of intended
time and location of where each welding procedure qualification test weld is to be
performed and tested. All procedure qualification testing shall be recorded in
detail and witnessed by CONTRACTOR, and the COMPANY.

4.3.4 Welding procedure qualification test welds shall be performed in the simulated
production welding environment i.e. under temporary covers in an outside location
with identical equipment to that proposed for production welding.

4.3.5 Unless approved otherwise by the COMPANY, no interpass grinding shall be
utilized during welding of the procedure qualification test welds. If approved, it
shall be duly recorded on the welding procedure operating sheet and applied for
all production welds using that procedure.

4.3.6 Weld passes with heat inputs which exceed 3.5 kJ /mm shall be qualified at the
highest heat input. Weld passes with heat inputs which are below 1.0 kJ /mm shall
be qualified at the lowest heat input. The welding parameters listed in the welding
procedure specification shall include an appropriate tolerance to insure that the
heat input extremes are not exceeded in production. These limits on heat input
and parameters are applicable to all passes used to complete the weld procedure
qualification test joint. Temper beads shall not be used for qualification tests and
capping passes shall be deposited with a workpiece temperature equivalent to the
minimum preheat temperature.

4.3.7 The allowable variation in preheat temperature along the length of the test plate
shall be +10°C ( +18°F) of the minimum specified preheat temperature for the cap
passes.

4.3.8 Essential variables for welding procedure qualification of ASTM A-36 and API 5L
Grades A and B shall be as specified in the latest revision of AWS D1.1.

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Essential variables for the welding of or making weld attachments to all other
materials, unless specifically agreed otherwise in writing by the COMPANY, shall
be as given in the following sections (a) through (n):

a. Carbon Equivalent

An increase of more than 0.05% in carbon equivalent.

b. Type of J oint

A change in weld preparation, unless approved by the COMPANY, outside
the following limits:-

- A change of included angle by +10°/-5°,
- For butt joints less that 45°, +10° - 0°,
- A change in root face by +1.6mm,
- A change of root gap of +1.6mm.

Single sided welds shall require separate qualification.

For double sided where back gouging is employed, changes in root face and
gap by up to 3.0mm shall not necessitate re-approval.

c. Back Gouging/Back Grooving

The omission or any decrease in the depth of back gouging or grinding.

d. Material Grade

The qualification of a higher yield strength grade will qualify all lower grades.

e. Welding Position

Any change to a welding position which has not been previously qualified
per AWS D1.1 Table 5.10.5 or otherwise approved by the COMPANY.

f. Thicknesses Range Qualified
For materials listed in API RP 2A Table 8.1.4-1 and 8.2.1-1 Group 1 or 2: Any
change of thickness outside the range of 0.5t through 1.5t where t is the
thickness of the qualification test piece.


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Materials not listed in API RP 2A shall be separately tested and are qualified
for the range 0.5t through 1.5t unless otherwise approved by the COMPANY.
Appropriate plate, or pipe joints are to be tested depending on the intended
application.

g. Weld Progression
A change in weld progression from upward to downward direction or vice
versa.

h. Weld Consumables
A change of classification, type or brand name of welding consumables
(electrodes, flux or wire).

For SMAW welding any increase of more than 1mm in the size of
consumables qualified.

A change of more than 10% in gas flow rates, or any change in composition
of the gas mixture.
Any change in the size of consumable from that qualified for automatic and
semi-automatic welding.

A change of +10% in the feed rate of iron powder additions for submerged
arc welding.

i. Diameter

Qualification test diameters shall be in accordance with Table 5.10.1 of the
AWS D1.1 code unless otherwise approved by the COMPANY in writing.

j. Welding Parameters Submerged Arc Welding (SAW):

Any change greater than 10% from the current range qualified for any
specific portion of the weld, i.e. root, fill and cap.

Any change greater than ±2V from the voltage qualified for a given current.
Voltage shall be measured as close to the arc as practical.
Any change greater than 10% on travel speed qualified for any specific
portion of the weld, i.e. root, fill, cap.


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The combined effect of changes to current, voltage and travel speed shall
also be considered in the following manner. The heat input for each weld
within any specific portion of the weld, i.e. root, fill or cap shall not vary by
more than 15% from that qualified provided this is within the range 1.0-
3.5kJ /mm.

Any change in the number or any change in the position of consumables.

Any change in the angle of electrodes of more than:-

+3° in the direction of travel,
+5° normal to the direction of travel.

Any change of more than 10% in the longitudinal spacing of arcs.
Any change in the type of current used for welding from AC to DC or vice
versa or any change in polarity for DC.

Any change of more than 5mm in electrode stick out length.

Shielded Metal Arc Welding (SMAW):

Any change in the current, outside of ±15° of the qualified welding procedure.

Any change greater than 10% in the travel speed or electrode run out length
qualified for the specific portion of the weld, i.e. root, fill or cap.
The combined effect of changes to current, voltage and travel speed shall
also be considered in the following manner. The heat input for each weld
within any specific portion of the weld, i.e. root, fill or cap shall not vary by
more than 15% from that qualified provided this is within the range 1.0-
3.5KJ /mm.

Any change in the type of current from AC to DC or vice versa or any change
in polarity for DC.

Self Shielded or Gas Shielded Flux Cored Arc Welding (FCAW):

The combined effect of changes to current, voltage and travel speed shall be
considered in the following manner: The heat input for each weld within any
specific portion of the weld, i.e. root, fill or cap shall not vary by more than
15% from that qualified provided this is within the range 1.0-3.5kJ /mm.

Voltage control for gas shielded flux cored arc welding shall be within +2V of
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the value qualified. Voltage for self shielded flux cored welding shall be
within ±1V.

k. Preheat and Inter-pass Temperature
Any decrease below the minimum qualified preheat temperature.
The weld inter-pass temperature shall not exceed 260°C.

l. Weld Passes

Any change of more than +20% and -10% in the number of passes from that
qualified for the same thickness of material. For thinner or thicker sections
the maximum and minimum number of weld passes shall be proportional to
the change in cross sectional groove area. The welders operating sheet
shall detail the allowable number of passes.

m. Backing Strips
The deletion of a backing strip.

n. Post-Weld Heat Treatment
The addition or deletion of post-weld heat treatment.

4.4 Test Categories

The principle welding procedure test categories that require qualification are listed below.
The CONTRACTOR shall also qualify other procedure categories necessary to satisfy
AWS D1.1 and this specification.

4.4.1 Plate and Tubular Butt Weld

The weld test specimens required shall be in accordance with AWS D1.1
paragraphs 5.10 and 10.12.

4.4.2 Plate and Tubular T-, Y- and K- Connections

The weld test specimens required shall be in accordance with AWS D1.1
paragraphs 5.10 and 10.12 except that the 6GR test assembly shall be as shown
in Figure 1 of this specification.



4.4.3 Fillet Weld Qualification
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Fillet welding procedures shall be qualified in the 2F and 4F positions as defined
in AWS D1.1. 2F shall qualify 1F and 4F shall qualify 3F positions. Both single
and multi-pass fillet welds shall be qualified. SMAW and FCAW fillet welds with a
leg length greater than 8mm shall be multi-pass. Single pass fillet welds shall be
qualified at the minimum leg length specified for fabrication. Qualifications
conducted on a continuous member plate thickness of 40mm and above shall
qualify all thickness ranges.

4.4.4 Repair Weld Qualification

Repair welding procedure proposals shall be presented for all anticipated repair
situations in test categories outlined in 4.4.1, 4.4.2 and 4.4.3 above.

Subject to the requirements of Table 1, qualification testing shall be to clauses
4.5.1, 4.5.2, 4.5.5 and 4.5.6.

4.4.5 Weld Metal Buttering Procedure Qualification

In the event that the joint fit up tolerances of production welds exceed those
permitted, a weld buttering procedure specification shall be developed by the
CONTRACTOR for COMPANY review and approval. Buttering procedures shall
employ qualified welding procedures approved by the Company and shall be
within the essential variables or the welding parameters. Combinations of existing
procedures are permitted except where self-shielded FCAW is employed in
combination with other processes. In such cases, full qualification of a separate
groove welding procedure using the same combination of processes and pass
sequence used in production is required.

4.5 Mechanical Test Requirements

4.5.1 General

4.5.1.1 Mechanical testing shall be carried out to verify that the test weldment
meets the requirements of this specification.

All mechanical testing shall be performed by a test house or laboratory
recognized and approved by the COMPANY. All qualification testing
shall be witnessed by the CONTRACTOR and the COMPANY.


4.5.1.2 Should a welding procedure qualification test weld fail to pass any of the
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required tests, the COMPANY shall be informed of the reasons for failure
and of the subsequent proposed modification to the welding procedure
essential variables as appropriate before re-qualification of the procedure
(See Section 4.3.8).

4.5.1.3 The locations of the various test samples are shown in Figure 2 and the
type and number of tests required, are detailed in Table 1.

4.5.2 All Weld Metal Tensile Test

4.5.2.1 In addition to AWS D1.1 requirements, all weld metal test specimens are
required from structural plate and tubular butt procedure test plates.
Specimens shall be removed in accordance with Figure 2 of this
specification and as detailed in Table 1. The specimens shall have the
form of and be tested to the requirements of AWS D1.1. Standard size
specimens are preferred; however, sub-size specimens are acceptable
where test piece thickness limitations exist.

4.5.2.2 The 0.2% offset yield strength recorded during the all weld metal tensile
test shall be equal to or greater than the specified yield strength of the
base material. The ultimate tensile should not be lower than the base
material.

4.5.2.3 Where the welding procedure material thickness qualification range
overlaps into a higher minimum yield strength material, the yield strength
of the all weld metal tensile test shall be equal to or greater than that
specified for the thinner and higher yield material.

4.5.2.4 The all weld metal tensile test specimen after testing shall record
elongation equal to or greater than 20% in a 50mm gage length.

4.5.3 Transverse Tensile Tests

4.5.3.1 Specimens shall be removed from the locations specified in Figure W-6.
Specimens shall have the form and dimensions of and shall be tested in
accordance with AWS D1.1.

4.5.3.2 The test specimen shall fail in the base metal or have a tensile strength
of 80 ksi minimum.


4.5.4 Bend Tests
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4.5.4.1 Specimens shall be taken from the locations specified in Figure W-6.

4.5.4.2 Each bend specimen shall be etched to identify the weld region. The
weld and heat affected zone of the bend specimen shall be completely
within the bent portion of the specimen after testing.

4.5.4.3 Specimens shall be prepared and tested in accordance with AWS D1.1
except that for side bend specimens over 38mm (1 1/2 inches) thick, the
cutting of specimens into strips is not mandatory.

4.5.4.4 For acceptance, the maximum crack length shall not exceed 3.2mm.
Cracks occurring on the corners of the specimen shall not be considered
significant unless they are associated with a weld defect.

4.5.5 Macro-sections and Hardness Tests

4.5.5.1 Macro-section(s) shall be cut from the test assembly in accordance with
Table 1, polished and suitably etched to reveal the weld structure and
number of weld passes. Groove and fillet weld macro-sections shall be
removed as detailed in Figure W-6.

4.5.5.2 The welded joint section shall show a regular profile with a smooth
transition to the base material. There shall be no unacceptable flaws as
defined by NDE listed in Table 1. The weld profile requirements shall be
in accordance with AWS D1.1 Section 3.6.

4.5.5.3 Hardness surveys shall be carried out in accordance with BS 427 or
ASTM E92 with Vickers hardness testing equipment, using a 5kg load.
Test location shall be as shown in Figure W-9.

4.5.5.4 The maximum allowable hardness value at any location shall be in
accordance with Table 2.

4.5.5.5 A photo-macrograph of 1X-3X magnification shall be required of all
macro specimens. The magnification factor shall be noted under the
photo-macrograph in the welding procedure qualification test certificates.
Hardness impressions must be clearly visible in the photo-macrograph.
Identification of the specimen must also be included in the photo-
macrograph.

4.5.6 Charpy V Notch Impact Tests
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4.5.6.1 Charpy V notch test specimens shall be removed and tested in
accordance with ASTM A370 and E23 or BS 131 part 2, & BS 709.

4.5.6.2 Each Charpy V notch test set shall consist of 3 test specimens.

4.5.6.3 Test specimens for Charpy V notch testing shall be performed as
required in Tables 1 and 3.

4.6 Welding Procedure Operating Sheets

4.6.1 After review of the welding procedure and qualification test results by the
COMPANY, the CONTRACTOR shall produce welding procedure operating
sheets. These operating sheets shall specify all welding parameters to be used
for production welding. The acceptable welding parameter ranges shall be those
specified which satisfactorily passed qualification testing for production welding.
All weld procedure operating sheets shall be approved by the COMPANY prior to
commencing production welding.

4.6.2 Welding procedure operating sheets shall be given to the welders and welding
operators by the welding foreman for each relevant joint to be welded. They shall
contain all the information necessary for the joint to be properly welded in
accordance with the qualified and COMPANY approved welding procedure.

4.6.3 Operating sheet requirements conflicting with the approved and qualified welding
procedure shall be rejected by the COMPANY.


5.0 QUALIFICATION OF WELDERS AND WELDING OPERATORS

5.1 General

5.1.1 All structural welding, including tack and repair welding, shall only be performed
by qualified welders and welding operators approved by the COMPANY.

5.1.2 All welders and welding operator tests shall be witnessed and approved by the
COMPANY and the CONTRACTOR before the welder or welding operator is
permitted to weld on any part of the structure. Any decisions regarding
acceptance of previously qualified welders or welding operators shall be at the
sole discretion of the COMPANY.

5.1.3 The CONTRACTOR shall establish, in agreement with the COMPANY, an
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identification system for each welder and welding operator.

5.1.4 All materials required for the testing of welders and welding operators shall be
approved by the COMPANY.

5.1.5 Welders and welding operators shall not be qualified on production welds.

5.1.6 The CONTRACTOR shall ensure that welders and welding operators are only
employed on those parts of the work for which they are qualified.

5.1.7 Welders and welding operators shall execute their qualification tests using
approved welding procedures agreed with the COMPANY. Inability of a welder
or welding operator to follow the welding procedure shall be cause for rejection.
5.1.8 The CONTRACTOR shall institute a formal system of instruction to ensure that all
welding personnel are familiar with relevant sections of this specification.
As a minimum all welders and welding operators shall be instructed in the
significance of heat input levels, determination of and significance of preheat,
welding operating sheets and essential variables of the welding procedures.

5.1.9 All welders and welding operators shall be qualified using the same consumables
and welding process(es) as intended for production welding.

5.1.10 The CONTRACTOR shall maintain and issue on COMPANY request, a current
record for all welders employed giving the following information:-

a. Welder's name and identifying number or symbol.
b. Welding processes, thickness, diameters, procedures and positions for which
each welder and welding operator is qualified.
c. Dates of qualification.

5.2 Previous Qualification

5.2.1 The CONTRACTOR may submit evidence of previous qualifications to the
COMPANY in accordance with minimum requirements of this specification.

5.2.2 In addition to the above, all previously qualified welders and welding operators
shall:-
a. Have been tested within the preceding 90 days.
b. Have been employed by the CONTRACTOR on offshore fabrication work, or
work of a similar nature, during the preceding 90 days.
c. Have a satisfactory production welding performance record.
5.2.3 The COMPANY'S decision regarding the acceptability or otherwise of any
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previously qualified welder or welding operator shall be final.

5.3 Re-Testing

5.3.1 Any welder or welding operator who for any reason produces a test weld which
does not meet the requirements of this specification may, at the discretion of the
COMPANY, be immediately re-tested. The re-test shall consist of 2 tests,
identical to the test that the welder or operator failed, both of which shall meet the
requirements of this specification. In the event that one or both re-tests are
unacceptable, no further re-testing shall be permitted until the welder or welding
operator has completed a COMPANY approved period of re-training.

5.4 Welder Performance Qualification Testing

5.4.1 Welder performance qualification testing shall be conducted and assessed in
accordance with AWS D1.1 except as modified by this specification.

5.5 Welding Operator Qualification Testing

5.5.1 Welding operator performance qualification testing shall be conducted and
assessed in accordance with AWS D1.1 Section 5, Part D, except as modified by
this specification.

5.6 Documentation

5.6.1 A certificate shall be prepared for each test successfully completed by a welder
or welding operator. Each certificate shall be endorsed by the COMPANY. The
COMPANY shall be provided with a copy of each endorsed certificate.
Certificates of welders approved by the COMPANY as detailed in Section 5.2
shall also be supplied.

5.6.2 In addition to the above, the CONTRACTOR shall maintain a complete list of
qualifications for all welders or welding operators employed on COMPANY work
and shall provide the COMPANY with an updated copy of this on a regular basis.

6.0 GENERAL WELDING REQUIREMENTS

6.1 General

6.1.1 Welding and NDE shall be in accordance with the requirements of this
specification and AWS D1.1 where appropriate.
6.1.2 Only welding procedures approved by the COMPANY and the CONTRACTOR
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shall be used for any production welding.

6.1.3 Prior to fabrication, the CONTRACTOR shall submit the following information on
welders to the COMPANY. This information shall be current at time of submission
and shall be continuously updated as required throughout the fabrication
program.
- Welders names, and identification numbers.
- Welder Performance Qualification Records.

6.1.4 Each qualified welder shall be supplied with a heat resistant indelible marker
which shall be used to apply his identification number to all production welds to
which that welder or welding operator has been assigned. The location of such
identification numbers shall be in the vicinity of the weld toe and at approximately
1 meter intervals. Welds not clearly identified may be rejected by the COMPANY.

A group numbering system for small pieces may be proposed by the
CONTRACTOR for review and approval by the COMPANY.

6.1.5 CONTRACTOR tools for grinding and profiling of all welds shall be subject to
specific COMPANY review. Tool(s) may be rejected at COMPANY's discretion.

6.1.6 Each welder and welding operator shall possess a copy of the approved welding
procedure operating sheets applicable to the work assigned, together with
appropriate temperature measuring devices.

Weld procedure operating sheets shall also be displayed at each welding
location. Welders shall not produce welds without being familiar with the
requirements of the appropriate approved welding procedure operating sheet.
Any welder found not to be complying with the full requirements of the approved
welding procedure, during production welding, shall be removed from the work
and the non-conforming weld(s) may be completely rejected, at the discretion of
the COMPANY.

6.1.7 Work shall not be performed when lack of protection precludes satisfactory
workmanship or conditions prevent adequate inspection and NDE at the
COMPANY'S discretion.

6.2 Welding Equipment

6.2.1 All welding equipment shall be of sufficient capacity and be maintained in such a
condition as to ensure welds of the specified quality throughout the Work, and
shall conform to appropriate sections of BS 638 or equivalent standards.
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Welding equipment which, in the opinion of the COMPANY, does not comply with
these requirements for the service in which it is being used, shall be replaced by
the CONTRACTOR. The COMPANY may request recalibration of gauges and
meters, etc. to ensure compliance with welding procedure operating sheets at
any time.

6.2.2 All electrical equipment shall be adequately grounded and welding machine
ground leads shall be affixed firmly to the work piece by clamps or other
approved means. All return currents shall travel via the insulated grounding
cable. Particular care shall be exercised if a welding machine is placed on
reinforced concrete. In this case the machine shall be on rubber tyres or wooden
supports. Welding cables shall be maintained in first class condition at all times.
Loose connections or damaged cables as evidenced by localized heating shall
be replaced or repaired immediately.

6.3 Welding Processes

6.3.1 Shielded metal arc welding (SMAW), submerged arc (single and tandem wire)
welding (SAW), and flux cored arc welding (FCAW) are acceptable welding
processes. However, acceptance of the flux cored arc welding process (FCAW)
for any part of the structure shall be at the COMPANY'S discretion and be subject
to the requirements of Section 6.3.4 and 4.3.8 j.
6.3.2 Iron powder additions during submerged arc welding are permissible subject to
written prior approval of the COMPANY who reserve the right to limit the scope of
application and to request additional testing.

6.3.3 Where the use of self shielded FCAW is proposed, the CONTRACTOR shall
submit, for COMPANY review and approval, details of specific weld locations and
the consumables proposed. Such details shall be presented to the COMPANY at
the bid stage. All details pertinent to the achievement of HAZ hardness and weld
metal toughness shall be included in the CONTRACTOR'S submission.

6.3.4 The COMPANY reserves the right to refuse the use or limit the use of the
intended process(es) and to specify additional testing and inspection
requirements.

6.3.5 If alternative processes are intended to be used, a proposal shall be made stating
items and areas of intended use together with full details of the process and all
consumables.


6.4 Welding Consumables
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6.4.1 Electrodes shall conform to AWS or to an equivalent standard approved by the
COMPANY.

6.4.2 Only basic low hydrogen electrodes shall be used for shielded metal arc welding.

6.4.3 Welding electrodes, including covered types and bare spooled electrode (wire
form) shall be handled with such care as may be necessary to prevent
damage. Where containers show evidence of damage, their contents should be
examined and electrodes with cracked or flaked-off coatings, or damaged spools
of filler metal should not be used on production welding. Unopened covered
electrodes and bare electrodes (wire form) and rods shall be stored under clean
dry conditions to prevent damage from contamination, moisture or water.

6.4.4 Handling, storage and baking of low hydrogen electrodes shall conform to the
requirements of AWS D1.1 paragraph 4.5.

6.4.5 A welding consumable control and identification procedure shall be approved by
the COMPANY prior to implementation. This procedure when approved shall be
strictly controlled by the CONTRACTOR throughout all phases of production
welding. Electrodes shall be kept clean and free from grease, oil, dirt, rust,
moisture and other contaminants. All unidentified, damaged or rusty electrodes,
as defined by the COMPANY shall be removed from the working area and
rejected. Any electrodes not contained in heated quivers shall be removed from
the site and rejected. Electrodes shall not be exposed to wet conditions.

6.4.6 Submerged arc consumables shall be withdrawn from store as required for
immediate use. Unused consumables shall be returned to store on completion of
the welding operation. After issue from storage, flux shall be held in a heated
oven or silo at a 70°C minimum temperature and 60% maximum relative
humidity.

6.4.7 Unused flux may be re-cycled at a mix rate of 2 parts new flux to 1 part used flux
according to a procedure which has been approved by the COMPANY. Such a
procedure shall be based on the flux manufacturer's recommendations. Flux
recovery systems which immediately reintroduce unused flux into the flux hopper
are acceptable.

Flux shall be removed from individual welding machine hoppers and returned to
the heated flux holding ovens whenever there is a break in welding of 1 working
shift or more.
6.5 Weld J oint Quality
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6.5.1 All surfaces or cut edges to be welded shall be visually inspected prior to any
welding and shall be free from fins, laminations, tears, cracks or any discontinuity
which would adversely effect weld quality. Surfaces to be welded and adjacent
surfaces shall be free from mill scale, rust, grease or other foreign materials
which could adversely affect weld quality and shall be ground to a bright steel
surface for a distance of at least 12mm from the welding edge. Aluminized paint
may also be used on weld preparations to act as a weldable primer; areas of
usage will be at the COMPANY'S sole discretion.

6.5.2 Finished weld preparations shall be smooth and free from gouges or other
deformities which could affect weld quality. Notches up to a depth of 3mm
resulting from flame cutting shall be locally ground to give an even profile prior to
welding. Notches greater than 3mm shall be ground out and the bevel face weld
repaired with a COMPANY approved and qualified welding procedure, in
accordance with Section 7.10. Welding procedure root opening tolerances are to
be maintained.

6.6 Welding Sequence

6.6.1 Insofar as practical, all welds shall be deposited in a sequence that will balance
the applied heat of welding while the welding progresses.

6.6.2 The CONTRACTOR shall prepare a welding sequence for a member or structure
which, in conjunction with the joint welding procedures and overall fabrication
methods, will minimize distortion and produce members or structures meeting the
dimensional requirements specified.

6.6.3 The direction of the general progression in welding on a member shall be from
points where the parts are relatively fixed in position with respect to each other
toward points where they have a greater relative freedom of movement.
6.6.4 J oints expected to have significant shrinkage should in general be welded before
joints expected to have less shrinkage

6.6.5 Long girders or girder sections may be made by splicing sub-sections.

6.6.6 In making welds under conditions of severe external shrinkage restraint, welding
shall be carried out continuously to completion or to a point that will ensure
freedom from cracking before the joint is allowed to cool below the minimum
specified preheat and inter-pass temperature. Reference should be made to
Section 7.6 regarding interruption of welding.
7.0 PRODUCTION WELDING
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7.1 General

7.1.1 The CONTRACTOR shall make no substitution of materials or modifications to
details without prior written COMPANY approval.

7.1.2 The CONTRACTOR shall demonstrate to the COMPANY that any SUB-
CONTRACTOR not pre-qualified at the time of contract is capable of producing
work to this specification. This may be achieved by producing documented
records of past and current types of work on which the CONTRACTOR and SUB-
CONTRACTOR has been engaged. COMPANY approval of all SUB-
CONTRACTORS is required prior to the placement of sub-orders.

7.1.3 Preparation and welding of structural members shall be in accordance with the
approved, qualified welding procedures.

7.1.4 Wherever possible all butt welds shall be made from both sides of the joint.

7.1.5 Ends of finished girders shall be left un-welded for a length of 300mm to allow
matching of mating girders during fabrication unless agreed otherwise by the
COMPANY.

7.2 Weld Preparation

7.2.1 Butt Welds

For single sided full penetration welds, the root opening dimension shall be in
accordance with the approved welding procedure.

Butt welds between materials of different wall thickness shall be tapered by
scarfing the parent material at a taper of 15° (1 in 4) and shall not be tapered by
the use of additional weld metal outside the width of the weld joint.

7.2.2 Plate and Tubular T, Y, or K J oints

a. Tubular J oints:
T, Y, or K joint welds onto any member shall be full penetration double sided
butt welds where access permits, unless the attachment diameter is 800mm
(tubulars) or less and 30mm thickness or less. Single sided butt welds shall
be permitted only under this condition and shall have a root face and root gap
in accordance with the COMPANY approved welding procedures.
b. Plate J oints:
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Where access permits, all welds shall be full penetration double sided butt
welds. Single sided butt welds shall have a root face and root gap in
accordance with the COMPANY approved welding procedures.

7.3 Execution of Welding
7.3.1 The use of permanent backing strips shall not be permitted without prior approval
of the COMPANY.

7.3.2 Weld stops and starts shall be staggered so that adjacent weld passes do not
contain stops/starts within 50mm of each other.

7.3.3 The width of weave during production welding shall be within the acceptable limit
of the COMPANY approved and qualified welding procedure, qualification
certificates, and production welding operating sheets.

7.3.4 Double sided welds shall be back-gouged and ground, or ground to sound metal
before the second side is welded. The resulting excavation shall have a profile
suitable for welding in accordance with the COMPANY approved and qualified
welding procedure.

7.3.5 Each run of weld metal shall be thoroughly cleaned of flux, spatter and slag
before depositing the next weld run. Any cavities which could result in lack of
fusion, or slag entrapment shall be removed by grinding.

7.4 Arc Strikes
Arc strikes outside the weld groove should be avoided. Should they occur, they shall be
removed and inspected as for temporary attachment welds in accordance with
specification DP-S-8.

7.5 Tack Welds
7.5.1 Wherever possible the use of tack welds should be minimized by the use of
temporary attachments, such as "strong backs" or other suitable fabrication aids.
Where tack welds are to be used, the area shall be pre-heated prior to welding to
a temperature 50°C above that shown for the root run specified on the
COMPANY approved welding procedure.

7.5.2 Where tack welds are used they shall be a minimum length of 100mm and shall
be of sufficient throat thickness and frequency to avoid any movement and
cracking of the tack weld or adjacent areas. All tack welds shall be 100% visually
inspected.

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7.5.3 Tack welding shall be carried out by welders qualified in accordance with the
requirements of this specification.

7.5.4 Where tack welds are to be incorporated into the welded joint, the tack welds
shall be deposited in accordance with the root pass parameters of the
COMPANY approved welding procedure operating sheets. Such tack welds shall
be ground to a feather edge on both ends and visually inspected prior to
incorporation into the weld.
7.5.5 Where visual examination indicates a tack weld to be defective, it shall be
completely removed and the entire area examined by MT for rejectable flaws.
Defective tack welds shall not be incorporated into the finished work.

7.5.6 Where tack welds are removed, the bevel preparation shall be correctly
maintained for the subsequent root pass. Removal of defective tack welds by
arc/air gouging in single sided welds shall not be permitted. Removal of defective
tack welds by arc/air gouging in double sided welds to be back-gouged shall be
subject to COMPANY approval.

7.6 Interruption of Welding
7.6.1 Welding of joints shall be completed in one continuous operation. Where
interruption is unavoidable at least one third of the joint thickness over the full
weld length shall have been completed before welding is discontinued.

7.7 Weather Protection
7.7.1 All welding shall be adequately protected in order to limit wind speed to 5mph.

7.8 Weld Profile Requirements
7.8.1 Weld profile requirements shall be in accordance with AWS D1.1, Section 3.6
except as indicated on COMPANY approved construction drawings. Where
fatigue behavior improvement is required, then AWS Section 10.7.5 shall be met
as well as the improved weld profile of AWS D1.1, Figure C 10.7.5.

7.8.2 Surfaces of plate butt weld joints required to be flush shall be finished so as not to
reduce the thickness of the thinner base metal or weld metal by more than 1mm
or 5% of the thickness, whichever is smaller, nor leave reinforcement that exceeds
1mm.
7.8.3 The CONTRACTOR shall remove any weld spatter which will interfere with NDE
interpretation or proper coating.


7.9 Preheat and Inter-pass Temperature
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7.9.1 Pre-heating shall be conducted by electrical resistance methods, gas burners or
radiant heaters. Deposition of carbon by incorrectly set burners shall be avoided.
Preheat shall apply to all welded joints including tacking and repair welding of
existing welds.

7.9.2 Measurement of preheat and inter-pass temperature shall be by thermocouples,
contact digital pyrometers and/or temperature indicating crayons. It shall be the
responsibility of the CONTRACTOR to ensure that the minimum preheat
temperature is within the range specified on the applicable welding procedure
operating sheets. The minimum preheat shall be established for at least 75mm
on each side of the weld centerline and shall be established through the plate
thickness prior to production welding. Whenever possible preheat and inter-pass
temperature shall be measured on the plate surface on the opposite side to that
of preheat application. Where access to only one joint face is possible, the heat
source shall be either removed or power switched off to allow for temperature
equalization of one minute for each 25mm of combined joint thickness, prior to
measurements of the preheat temperature. Temperature measurement on the
weld shall not be permitted and inter-pass temperature shall be measured within
25mm from the weld fusion face.

7.9.3 In all cases until notified otherwise by the COMPANY the minimum preheat
temperature shall be 20°C. The determination of minimum preheat temperatures
for production welds shall be based upon BS 5135 (except as modified by this
section) after consideration of specific heat input, joint thickness and consumable
combinations.

7.9.4 The maximum inter-pass temperature shall be 260°C (500°F).

7.9.5 Welding shall not be carried out when the ambient temperature is -10°C or lower,
unless specific precautions to maintain the required preheat levels are applied
and have been approved by the COMPANY. In such cases or when
condensation is forming on metal surfaces, a minimum work piece temperature of
20°C or a temperature above the dew point shall be established for sufficient time
to give dryness for a distance of not less than 75mm either side of the weld.

7.9.6 Unless agreed otherwise by the COMPANY, the minimum preheat temperature
shall be applied to the whole joint lengths to be welded and shall be maintained
without interruption until the welds have been completed. Where interruption is
unavoidable, reference should be made to Section 7.6.

7.9.7 Insulation shall be provided on adjacent areas where necessary to maintain the
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required degree of preheat during welding.

7.10 Repair Welding

7.10.1 No rectification, repair or modification shall be made without the approval of the
COMPANY.

7.10.2 Prior to the use in production of an approved qualified welding procedure the
CONTRACTOR shall qualify and obtain approval from the COMPANY for repair
procedures to cover anticipated repair situations for that welding procedure.

7.10.3 If the CONTRACTOR intends to apply a repair procedure to more than one
welding procedure then a list shall be submitted for COMPANY approval
identifying the relevant repair procedure and the applicable welding procedures.
The COMPANY reserves the right to require further qualified repair procedures to
be submitted.

7.10.4 The removal of defective areas shall be by machining, grinding, chipping or
arc/air gouging followed by grinding to bright metal. The resulting excavation
shall be clean, free from scale and have a contour to permit ease in repair
welding. Oxy acetylene gouging shall not be permitted. Defect removal shall be
confirmed by magnetic particle inspection.

7.10.5 Unless otherwise approved by the COMPANY, repair welding qualifications shall
include NDE and mechanical testing in accordance with Sec. 4.4.4.

7.10.6 All defects deemed unacceptable to this specification shall be repaired at no cost
to the COMPANY.

7.10.7 Any defect requiring rectification shall be reported to the COMPANY. Any
cracking shall be reported immediately to the COMPANY and its cause is to be
established and approved steps taken to prevent the reoccurrence of such
cracking.

7.10.8 All repair welding shall be performed by welders fully qualified in accordance with
Section 5.0 of this specification.


7.10.9 Any repair welding carried out after post-weld heat treatment shall necessitate a
second post-weld heat treatment of the complete item or weld joint as directed by
the COMPANY.
7.10.10 CONTRACTOR shall establish and maintain a detailed log of all weld repairs.
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The log shall include details of all defects together with welders and welding
procedures employed during the production of the defective welds.

The COMPANY reserves the right to require re-qualification of welders, welding
operators or welding procedures should the frequency of defects become
unacceptable to the COMPANY. Detailed repair statistics based on weld length
and number of welds etc. shall be reported to the COMPANY on a weekly basis.

7.10.11 Repair welding shall be performed strictly in accordance with the following:-
a. Welding shall be in accordance with a qualified welding repair procedure.
b. Preheat shall be applied to 50°C above that specified in the relevant original
welding procedure, or a minimum of 50°C, whichever is higher.

7.10.12 The weld repaired area shall be subject to 100% visual inspection and NDE by
the same techniques used for original examination.
7.10.13 Rectifications, repairs and modifications shall be fully identified and documented.

7.10.14 The CONTRACTOR shall advise the COMPANY of all first time repairs which
fail to remove the initial defect or re-introduce defects that require further repair.


8.0 PRODUCTION WELD TESTS

8.1 General

8.1.1 Production weld tests may be requested by the COMPANY at any time. When
requested, the CONTRACTOR shall ensure that production coupons represent
the production welds as far as practically possible.

8.1.2 Wherever possible, test welds shall be welded as extensions to production
welds. Care shall be taken to insure that the extension plates represent the
preheat and inter-pass temperature of production welds. Where this is not
possible they shall be welded in the same location, at the same time, by the
same personnel using the same equipment and consumables as production
welds. They shall be welded in accordance with the welding procedure
operating sheets used for the welds being evaluated.

8.1.3 Where separate test plates have to be used, particular attention shall be paid to
achieving the necessary restraint on the test coupon.

8.1.4 Production test welds shall be non-destructively examined in accordance with
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the requirements for the production welds represented. Any unacceptable
defects shall be reported.

8.1.5 CONTRACTOR shall inform the COMPANY of the results of production weld
tests immediately upon completion of all testing, which shall be not more than 7
working days from the completion of welding. All original documentation relating
to production tests shall be retained by CONTRACTOR for incorporation into the
final documentation.

8.1.6 Production test welds shall be subject to mechanical testing in accordance with
Section 4.5 except that tests shall be limited to the following:-

a. All weld metal tensile.
b. Macro-section and hardness.
c. Charpy impact tests are the same as for the procedure qualification
requirements.

8.1.7 In the event that mechanical tests fail to meet the minimum requirement of
Section 4.5, CONTRACTOR shall establish the cause of failure and shall detail
his proposals for establishing the acceptability of the respective production
welds. All production welding using the affected welding procedure shall stop
until such time as the cause of the unacceptable mechanical test results has
been established.

8.1.8 All production test welding, NDE and mechanical testing shall be witnessed by
the CONTRACTOR and the COMPANY.

8.1.9 In the event of a failed production test, the COMPANY reserves the right to specify
further mechanical tests, at the CONTRACTOR'S expense.

8.1.10 In the event of a failed production weld test, the CONTRACTOR shall establish a
new welding procedure proposal with sufficient modification of the welding
variables to avoid repetition of the cause of failure. Upon preliminary approval by
the COMPANY, the procedure shall be qualified in accordance with the
requirements of this specification.





9.0 INSPECTION AND NON-DESTRUCTIVE EXAMINATION (NDE)

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9.1 General

9.1.1 The CONTRACTOR shall co-operate fully with the COMPANY in all aspects of
inspection and NDE and shall give adequate notice of any required fabrication
inspection stages, together with sufficient time for thorough inspection by the
COMPANY.

9.1.2 CONTRACTOR shall be responsible for supplying all NDE equipment, tools and
materials for his use in conducting any inspection required by Company.
9.1.3 Any examination and inspection by the COMPANY shall not absolve the
CONTRACTOR from his responsibility to exercise such quality control which will
ensure that the requirements of this specification and related Codes, Standards
and Specifications are satisfied.

9.1.4 After completion, all NDE reports shall be furnished to the COMPANY within 2
working days. These reports shall detail a complete history of the fabrication
and inspection sequences. The reports will form the basis of final inspection and
acceptance by the COMPANY.

9.1.5 The CONTRACTOR shall demonstrate that all NDE procedures are able to
consistently identify allowable flaws defined in Table 4. Each NDE procedure
shall be demonstrated to be suitable for its intended purpose. If satisfactory,
these procedures shall be approved by the COMPANY and all NDE shall be
performed in accordance with these COMPANY approved procedures.

9.1.6 The COMPANY reserves the right to test, monitor and record all NDE operators
and equipment and to reject any NDE operator or equipment if deemed
unsuitable.

The equipment used by the CONTRACTOR during NDE shall be capable of
performing the required tasks. The CONTRACTOR shall calibrate, test, monitor,
and record all equipment and shall remove from production use any equipment
which in the opinion of the COMPANY is not satisfactory for the
intended purpose.

The COMPANY reserve the right to re-examine any production welds submitted
for approval and to employ independent NDE personnel and whatever
equipment the COMPANY considers necessary to enable evaluation of the
production welds. The COMPANY reserves the right to undertake independent
NDE at any stage of fabrication.
9.2 Extent of Inspection and NDE

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9.2.1 The extent of inspection and NDE shall be in accordance with the minimum
requirements laid down in attached Table 5 along with this Section.

9.2.2 COMPANY reserves the right to increase or decrease the levels of percentage
inspection subject to known rejection rates and joint locations. The COMPANY
reserves the right to increase the level of inspection and NDE specified in Table
5 if at the sole option of the COMPANY the CONTRACTOR'S quality
performance record is deemed to be unsatisfactory. The inspection and NDE
requirements may be subsequently reduced at the COMPANY'S discretion on
reversion to an acceptable quality performance record.

9.2.3 If severe defects (e.g. cracks and other linear type defects) occur repeatedly, all
welds deposited using the same welding procedure during the period in question
may be inspected and non-destructively examined in full.

9.2.4 Where less that 100% of the weld length is required to be tested the COMPANY
shall approve the lengths of weld to be tested.

9.2.5 Lengths of weld which are found to be defective shall be 100% retested to the
original requirements after repair welding.

9.2.6 All full penetration welds in which any part of the welding is by the gas
shielded metal arc process shall be 100% examined by ultrasonics.

9.2.7 As a minimum, on all primary structural steelwork the CONTRACTOR shall
submit to the COMPANY documentary evidence of the following inspection
stages:-

Inspection Stage Type of Examination Required

a. T, Y, and K joints UT lamination check
continuous member
(prior to fit-up)
b. Edge preparation and Visual, dimensional and NDE
fit-up (UT lamination check) including
materials identification
c. Fit-up prior to welding Visual and dimensional
(after tacking or strong
backing)
d. After back-gouging Visual, dimensional, MT
(if required)
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e. On completion of welding Visual, dimensional and
NDE as required.
f. After defect removal prior Visual and MT, UT where
to repair welding required. See 7.10.
g. On completion of repair Visual
welding
h. After removal of temporary Visual and NDE as
attachments required

Note: Dimensional inspection referred to above relates to localized dimensional
checks on weld preparation, depth of back-gouge etc. and not global
dimensions of weldments. The acceptance criteria for all NDE shall be in
accordance with Table 4 of this specification.

9.3 Visual Inspection

9.3.1. All weld joints shall as a minimum be visually inspected at the relevant stages
listed in Section 9.2.7.

9.3.2 Visual inspection shall be carried out after the removal of all slag, mill scale, dirt,
grit, weld spatter, paint, oil or other foreign matter from the weld(s) and adjacent
area. All welded items shall be presented in a suitable condition to the
COMPANY to perform a visual inspection.

9.3.3 Visual inspection shall be completed prior to final NDE and shall be done after any
weld grinding has been completed. This shall also apply to any weld repair.

a. All welds meet the profile requirements and weld reinforcement
requirements as detailed in AWS D1.1 or as specified in contract drawings.

b. All arc strikes wherever located shall be removed in accordance with the
requirements of this specification.
9.4 Ultrasonic Examination (UT)

9.4.1 Ultrasonic examination (UT) shall be carried out in accordance with COMPANY
approved procedures. These procedures shall be in accordance with API RP 2X,
except as modified by this specification. The CONTRACTOR shall submit
procedures to the COMPANY for approval prior to their implementation.
9.4.2 A compression probe scan shall be conducted on the continuous member of T, Y,
and K joints prior to fit-up. Reflectors within 150mm (6 inches) of the intended
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weld location shall be evaluated in accordance with API RP 2X Level C
acceptance criteria. Cylindrical can sections shall be rotated to avoid
unacceptable reflectors within 150mm (6 inches) of the attachment weld.

9.4.3 Each weld joint shall be examined with sufficient probe angles to guarantee full
coverage of the joint. Scanning shall be done from both sides of the weld and
from both inside and outside surfaces where access permits if the member
thickness exceeds 25mm (1 inch). Refer to API RP 2X, Paragraph 3.4.2 for UT
equipment requirements. Where problems exist in coverage of a weld joint due to
material, configuration, surface condition, etc; probes of a different frequency will
be used in addition to the basic API RP 2X probe requirements.

9.4.4 Prior to shear wave examination, a compression probe search shall be conducted
to confirm that no lamination type defects exist within the scanning surface of
members at T, Y and K joint weld locations, which will mask the shear wave
examination.

9.4.5 Prior to conducting ultrasonic examination, the operator shall ensure that both
weld deposits and surrounding areas are sufficiently smooth to avoid spurious
indications. The maximum surface correction factor shall be +6dB. If this
correction factor is exceeded, additional surface grinding shall be performed prior
to final ultrasonic examination. All flaw indications which exceed 50% of the
reference level shall be investigated and detailed in the operators report.

9.4.6 All ultrasonic operators shall be qualified in accordance with a Certification
Scheme approved by the COMPANY.

9.4.7 During production examinations, the CONTRACTOR shall produce a test report
for each weld joint or weld repair examined.

9.4.8 Each ultrasonic examination report shall detail the following information as a
minimum (using joint diagrams to indicate scans).
a. J oint identification number.
b. Welder(s) and welding operator(s) identification(s).
c. Welding procedure number.
d. Ultrasonic procedure identification number.
e. Operator identification and signature.
f. Sketch showing location(s) face width or amplitude above the reference
level, length and location of all indications exceeding 50% of the ref. level.
g. Date and time of welding completion and NDE.
h. Original weld or repair.
i. Heat treated condition or "as welded".
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j. Plate thicknesses.
k. Probe angles and frequencies.
l. Equipment identification serial numbers.
m. The primary reference level sensitivity, and transfer value.
n. Couplant.
o. State if "hot" or ambient temperature examination. Surface correction factor
adopted during examination and calibration.
p. Conclusions; accept or reject with respect to this specification.

9.4.9 All UT reports shall be submitted for COMPANY review and approval.

9.4.10 The CONTRACTOR shall make an initial assessment of defects against
acceptance criteria and all ultrasonic reports including recommendations shallbe
reviewed for approval by the COMPANY.

9.5 Magnetic Particle Examination (MT)

9.5.1 Magnetic particle inspection (MT) procedures shall be written in accordance with
ASME Section V, Article 7 using wet or dry particles in accordance with Clause T-
726 and the prod method Clause T-743 or yoke method T-746. Acceptable levels
shall be in accordance Table 4 of this specification. The CONTRACTOR shall
submit procedures to the COMPANY for approval prior to their implementation.

9.5.2 MT shall be conducted after passing visual inspection and after any weld profile
grinding.

9.5.3 All weld areas examined by MT shall be sufficiently smooth to avoid false
indications.

9.5.4 MT shall be used to detect both longitudinal and transverse defects. The applied
magnetic field strength and sensitivity shall at all times meet the ASME Section V
requirements.

9.5.5 MT operators shall be qualified to Level II in accordance with SNT-TC-1A, to the
standard of CSWIP 3.1 tester (MT), or to an alternative standard approved by the
COMPANY.

9.5.6 Spurious indications may be removed by grinding to a maximum depth of 1.0mm
at weld toe locations. Weld metal indications may be removed by grinding
provided the weld profile requirements are maintained.
9.5.7 Light surface grinding may be carried out before or during MT examination to
provide a satisfactory surface finish on which to carry out the test, or to assist the
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operator in the interpretation of any indication.

9.5.8 If surface indications cannot be removed by light dressing to a maximum depth of
approximately 1.0mm, the COMPANY shall be informed and shall witness any
further grinding required to remove the indication. The repair by welding of any
location where grinding is carried out to a depth greater than 1.0mm shall be at
the discretion of the COMPANY.

9.5.9 Each report shall outline the following information as a minimum:-
a. J oint identification number.
b. Type of joint or areas, i.e. full penetration butt joint, T, Y and K joint, fillet
weld, area of arc strike, scar area, etc.
c. Welder(s) and welding operator(s) identification(s).
d. Welding procedures(s) identification(s).
e. Operator identification and signature.
f. Magnetic particle procedure number.
g. Method of magnetization and consumables (yoke, prod, ink, powder, etc.)
used.
h. Date
i. Original weld or repair.
j. Flaw types and sizes discovered and location(s).
k. Conclusions; accept or reject with respect to this Specification.
l. Flaw excavation profile (mimic).
m. Ink strength.

9.5.10 All MT reports shall be submitted to the COMPANY for review and approval.

9.6 Radiographic Examination (RT)

9.6.1 Radiographic examination shall be carried out in accordance with COMPANY
approved procedures. These procedures shall be written by the CONTRACTOR
and be in accordance with AWS D1.1 and referenced ASTM specifications E94
and E142 except as modified in this Section. The CONTRACTOR shall submit
radiographic examination procedures to the COMPANY for review and
subsequent approval with details of any practical limitations prior to fabrication. In
the event of such limitations the COMPANY reserves the right to modify
accordingly the NDE requirements of this specification in order to maintain the
optimum level of quality assurance considered necessary by the COMPANY.


9.6.2 The COMPANY reserves the right to test CONTRACTOR'S radiographic
examination procedures to ensure that they meet the requirements of this
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specification.

9.6.3 Should a procedure prove inadequate at any time, the COMPANY reserves the
right to require the CONTRACTOR to modify and re-submit the procedure to the
COMPANY for review and subsequent approval.

9.6.4 Radiographic film density shall be between 2.0 and 3.5. Densitometers shall be
used to ensure compliance with film density requirements. Only ASTM Type 1 or
Type 2 film and lead intensifier screens shall be used.

9.6.5 Radiographic operators will be qualified in accordance with the Certification
Scheme for Weldment Inspection Personnel (CSWIP) to the level of Industrial
Radiographer Grade I (welds) or Industrial Radiologist (welded construction),
ASNT Level II to the requirements of SNT-TC-1A, or COMPANY approved
equivalent.

9.6.6 Radiographs will have a film sensitivity of at least 2% in the weld area when using
DIN wire-type Image Quality Indicators or shall meet 2-4T requirements when
using ASTM penetrameters. Placement/quantity of IQIs' shall be in accordance
with AWS D1.1. Where geometry restricts compliance to AWS D1.1, alternative
methods may be employed with Company approval.

9.6.7 Each radiograph shall contain sufficient information via lead characters to identify
the following:-
a. J ob number.
b. The individual weld identification.
c. Reference arrow along weld.
d. Weld fusion line markers (where required).
e. Repair weld shall contain the character R, for second time repairs, R2, etc.
f. Date of radiograph.

9.6.8 Radiographs presented for interpretation will be free from film defects or film
processing marks which might mask or be confused with flaws in the welds being
examined.

9.6.9 Where less than 100% radiography is specified, the welds and weld locations to
be radiographed shall be approved by the COMPANY unless the locations are
detailed in this specification or contract documents.


9.6.10 All radiographs shall be accompanied by a test report for each weld seam when
presented for interpretation and approval by the COMPANY. Each report shall
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detail the following information as a minimum:-

a. J oint identification number.
b. Radiographers identity.
c. Location of film and type.
d. Original weld or repair.
e. Wall thickness(es).
f. All flaws discovered and locations.
g. Details of Image Quality Indicator(s) (IQI).
h. Date of examination.
i. Conclusions; accept or reject with respect to this specification.
j. Welder(s) identification(s).
k. Welding procedure(s) identification number(s).

9.6.11 All radiographic reports and radiographs shall be assessed by the
CONTRACTOR and reviewed/approved by the COMPANY. All rejectable flaws
shall be repaired and re-examined in accordance with this Section.

9.6.12 At the discretion of the COMPANY rejectable flaws detected by radiography may
be evaluated by ultrasonic methods prior to repair.


TABLE 1

TEST SPECIMEN AND NDE REQUIREMENTS
for Weld Procedure Tests

Procedure J oint Transverse Weld Charpy V-Notch Sets
Test Thickness NDE Weld Metal Bend Hardness/
Type (mm) (100%) Tensile Tensile Tests Macro Weld FL FL +2mm

Tubular butt t <12 VT MT RT 2 - 2 face 2 1 1 1
and plate butt 2 root

12 <t <20 VT MT UT/RT 2 1 4 side 2 1 1 1

20 <t <40 VT MT UT/RT 2 1 4 side 2 See Note 1

t >40 VT MT UT/RT 2 1 4 side 2 See Note 2
See Note 4

Fillet Weld See Section VT MT - - - 2 - - - 4.4.3

Repairs All VT MT UT/RT - See Note 4 - See Note 4 See Note 4


NDE =non-destructive examination FL =fusion line
UT =ultrasonic tested FL +2mm =2mm from fusion line
MT =magnetic particle tested
RT =radiographic tested
VT =visual inspection
UT/RT =either UT or RT

_____________________________________________________________________________________________________

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NOTES ON TABLE 1




1. For single sided butt welds 21 to 40mm in thickness, 5 charpy sets are required (reference
Figure 3).

For double sided butt welds 21 to 40mm in thickness, a minimum of 4 charpy sets are required
with a further 3 being required should welding procedures on the first and second side differ
(reference Figure 4).

2. For single sided butt welds greater than 40mm in thickness, a minimum of 6 charpy sets are
required including the mid-thickness fusion line (reference Figure 3).

Double sided butt welds greater than 40mm in thickness will require a minimum of 4 charpy sets,
with a further 3 sets being required should welding procedures on the first and second side differ
(reference Figure 4).

3. For transverse tensile test on weldments greater than 38mm (1 1/2 inches) thick, the tensile test
specimens shall be cut into equal sized strips in order to test the full thickness of the plate
material at the weld joint. Each strip shall meet the minimum requirements.

4. Charpy impact, macro, hardness and NDE requirements shall be as required by the original
procedure and as per sections 4.4.4 and 7.10. The all weld metal test is not required if the
consumable has been qualified on a previous procedure and the parameters are within the
essential variables of that procedure.














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TABLE 2



Maximum Acceptable HAZ hardness for C.E. =0.30 - 0.50%



C.E. HV1 HV5 HV10
0.30 240 250 260
0.31 242 252 262
0.32 245 255 265
0.33 250 260 270
0.34 255 265 275
0.35 265 275 285
0.36 270 280 290
0.37 280 290 300
0.38 290 300 310
0.39 300 310 320
0.40 310 320 330
0.41 320 330 340
0.42 330 340 350
0.43 and over 340 350 360




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TABLE 3

CHARPY ENERGY REQUIREMENTS



GROUP CLASS TEMPERATURE MINIMUM ABSORBED ENERGY

I C Not Required Not Required

I B -10°C (14°F) 20 ft. lbs.

I C -18°C (0°F) 20 ft. lbs.

II C O°C (32°F) 25 ft. lbs.

II B -10°C (14°F) 25 ft. lbs.

II A -18°C (0°F) 25 ft. lbs.

III C 0°C (32°F) 30 ft. lbs.

III B -10°C (14°F) 30 ft. lbs.

III A -18° (0°F) 30 ft. lbs.


Notes

1. Material Groups and Classes refer to API RP 2A, Table 10.2.2.

2. When welds are made joining materials from different test categories, the weld metal shall
meet the requirement of the material with the lower test temperature, or where the test
temperature is the same, the material with the higher impact requirement.

3. The absorbed energy specified is the minimum for any individual test bar.

4. See 4.5.2.2 of this specification for effect of strength ratio on toughness requirements.
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TABLE 4

WELD FLAW ACCEPTANCE LEVEL




Visual Inspection - AWS D1.1 paragraph 9.25.1 considered as
welds subject to tensile stress.

Radiographic Inspection -

- for butt welds in tubulars - AWS D1.1 paragraph 10.17.3

- for butt welds in plate - AWS D1.1 paragraph 9.25.2,
considered as welds subject
to tensile stress.

Magnetic Particle Examination - AWS D1.1 paragraph 9.25.2,
considered as welds subject to tensile
stress.

Ultrasonic Examination - API RP 2X, Level C.



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TABLE 5

CASE EXTENT, PERCENT VISUAL METHOD
Structural Tubulars
Longitudinal Weld Seam (L) 10
*
100 % UT or RT
Circumferential Weld Seam (C) 100 100 % UT or RT
Intersection of L & C 100 100 % UT or RT

Tubular J oints
Major brace-to-chord welds 100 100 % UT
Major brace-t0-brace welds 100 100 % UT

Misc. Bracing
Conductor Guides 10
*
100 % UT or MT
**

Secondary bracing and 10
*
100 % UT or MT
**

Sub-assemblies, i.e. splash
zone, and/or mud line secondary
bracing, boat landings, etc.
Attachment weld connecting 100 100 % UT or MT
secondary bracing/subassemblies
to main members

Deck Members
All primary full penetration 100 100 % UT or MT
welds
All partial penetration welds 100 100 % Visual
***

All fillet welds 100 100 % Visual
***


* Partial inspection should be conducted as 10 percent of each piece, not 100 percent
of 10 percent of the number of pieces. Partial inspection should include a minimum
of three segments randomly selected unless specific problems are known or
suspected to exist. All suspect areas (e.g. areas of tack welds) shall be included in
the areas to be inspected. If rejectable flaws are found from such 10% inspection,
additional inspection should be performed until the extent of rejects has been
determined and the cause corrected.
** Depending upon design requirements and if specified in the plans and specifications
MT may be an acceptable inspection method.
*** May include MT and/or PT.
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FIGURE 2

TEST SPECIMEN LOCATIONS IN WELDED J OINTS




FIGURE 2A

PLATE BUTT WELD


Discard Min. 50mm
Bend
Transverse tensile test
Bend
Macro section and hardness survey
Impact test specimens
All weld metal tensile test
Bend
Transverse tensile test
Macro section and hardness survey
Bend
Material available for re-test purposes
Discard min. 50mm

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