SPECIFICATION FOR Doc. No.

BK91-1324-EPL-999-
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Provision of EPCC for Export Pipelines of

Dry Gas and LPG

SPECIFICATION FOR PIPELINE WELDING AND

NDT

Document No: BK91-1324-EPL-999-PPL-SPC-0002

Issued for
0 10-08-2023 Gamler Li Ming He Zuxiang Wang Guoxing
Construction

REV. DESCRIPTION DATE PREP’D CHK’D REV’D APP’D

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REV DATE REVISION DETAILS

0 10/08/23 Issued for Construction

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Contents
1.0 General ................................................................................................................................. 5

1.1 Scope .................................................................................................................................... 5

1.2 Definitions ............................................................................................................................. 5
1.3 Document Precedence.......................................................................................................... 5
1.4 Reference Documents .......................................................................................................... 5
1.5 Abbreviations ........................................................................................................................ 6
1.6 Codes and Standards ........................................................................................................... 7
2.0 Specifications General Requirements .............................................................................. 8

2.1 Standards .............................................................................................................................. 8

2.2 Welding Process ................................................................................................................... 8
2.3 Welding Consumables .......................................................................................................... 9
2.4 Shielding Gases .................................................................................................................. 10
2.5 Welding Equipment ............................................................................................................. 10
3.0 Welding Procedure Specification .................................................................................... 10

3.1 General ............................................................................................................................... 10

3.2 Welding Procedure Specification Information ..................................................................... 11
4.0 Welding Procedure Qualification ..................................................................................... 12

4.1 General ............................................................................................................................... 12

4.2 Essential Variables.............................................................................................................. 13
4.3 Testing of Weld Joints – Butt Welds ................................................................................... 14
4.4 Records ............................................................................................................................... 14
5.0 Qualification Of Welders .................................................................................................. 15

6.0 Production Welding .......................................................................................................... 15

6.1 Cleaning, Bevelling and Pipe End Preparation ................................................................... 15

6.2 Alignment of Pipes .............................................................................................................. 15
6.3 Preheating and Interpass Temperature .............................................................................. 15
6.4 Tack Welds ......................................................................................................................... 16
6.5 Type and Removal of Line-Up Clamps ............................................................................... 16
6.6 Golden Welds...................................................................................................................... 16
6.7 InterPass Cleaning / Grinding of Welds .............................................................................. 16
6.8 Partially Completed Joints................................................................................................... 16
6.9 Marking of Welds ................................................................................................................ 17
6.10 Weather Conditions............................................................................................................. 17
6.11 End Protection..................................................................................................................... 17
6.12 Supports, Attachments, Lifting Devices .............................................................................. 17
6.13 Proximity Of Welds.............................................................................................................. 17

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7.0 Inspection And Testing Of Production Welds ................................................................ 17

7.1 General ............................................................................................................................... 18

7.2 Radiographic Examination .................................................................................................. 18
7.3 Ultrasonic Examination ....................................................................................................... 18
7.4 Magnetic Particle Inspection ............................................................................................... 19
7.5 Inspection Records ............................................................................................................. 19
8.0 Standard Of Acceptance .................................................................................................. 19

8.1 General ............................................................................................................................... 19

8.2 Reinforcement ..................................................................................................................... 20
8.3 Flaw Type and Size............................................................................................................. 20
8.4 Porosity (Other Than Elongated Porosity in Root Run) ...................................................... 20
8.5 Cracks ................................................................................................................................. 21
8.6 Arc Strikes ........................................................................................................................... 21
9.0 Repair And Removal Of Defects ...................................................................................... 21

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1.0 General
1.1 Scope
This Specification is supplementary to API 1104 (22nd Edition), and shall be read in conjunction
with the codes, standards and documents as defined in Clause 1.6 of this document. It defines
the minimum technical requirements that shall be applied to the butt welding of carbon steel
pipelines and associated carbon steel components on the project. Only the butt welding of
carbon steel line pipes/fittings is included in this specification.
1.2 Definitions
Definitions Description

PROJECT EPCC of Export Pipelines for Dry Gas and LPG project
COMPANY Kuwait Energy Basra Limited (KEBL)
PMC China Huanqiu Contracting & Engineering Co., Ltd. (HQC)
EPC
China Petroleum Pipeline Engineering Co., Ltd. (CPP)
CONTRACTOR
MANUFACTURER Any person or company engaged by the Contractor to
/SUPPLIER manufacture and/or supply Installation Equipment or other
/VENDOR equipment and material for the PROJECT.
SHALL Indicates a mandatory requirement.
Indicates a strong recommendation to comply with the
SHOULD
requirements of this document.
1.3 Document Precedence
In general, the project shall be designed, constructed and operated in accordance with the
following:
1) Iraqi national, regional and local legislation (including regulations, official letters)
2) Project documents/drawings/specifications and standards.
3) Relevant international codes and standards such as API, ASME, ISO and etc.
4) Best engineering practices in Iraq.
5) COMPANY/PMC’s procedures and working standards.
The Contractor shall comply with all the Iraq legislation and practices that apply to this Project.
1.4 Reference Documents
Document Numbers Document Titles
BK91-1324-EPL-999-PPL-BOD-0001 Pipeline Design Basis
BK91-1324-EPL-999-PPL-SPC-0001 Specification for Pipeline Construction

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Document Numbers Document Titles

BK91-1101-EPL-999-MAW-SPC-0003 Specification for X60M SAWL Pipeline
BK91-1101-EPL-999-MAW-SPC-0004 Specification for X60M SAWL Induction Bend
Specification for X60Q Seamless Pipeline (API 5L
BK91-1101-EPL-999-MAW-SPC-0006
X60 Sour Service)
Specification for X60Q Seamless Induction Bend
BK91-1101-EPL-999-MAW-SPC-0007
(API 5L X60 Sour Service)
1.5 Abbreviations
List of the used Abbreviations is given below.
Table 1.5-1 Abbreviations and Definitions

Item Description

API American Petroleum Institute

ASME American Society of Mechanical Engineers
ASNT American Society for Nondectructive Testing
ASTM American Society for Testing Materials
AWS American Welding Society
CE Carbon Equivalent
CVN Charphy V-notch Test
FCAW Flux Cored Arc Welding
GMAW Gas Metal Arc-Welding
GTAW Gas Tungsten Arc-Welding
HAZ Heat Affected Zone
HIC Hydrogen Induced Crack
ISO International Organization for Standardization
MT Magnetic Test
NACE National Association of Corrosion Engineers
NDT Non-Destructive Test
OD Outside Diameter
PWHT Post Weld Heat Treatment

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Item Description

PQR Procedure Qualification Records

PT Penetrant Test
QA Qualifty Assurance
QC Quality Control
RT Radiographic Testing
SMAW Shielded Metal Arc-Welding
SSC Sulfied Stress Cracking
UT Ultrasonic Testing
WPQ Welding Procedure Qualification
WPS Welding Procedure Specification
WT Wall Thickness

1.6 Codes and Standards

Design should be complying with world widely used petroleum industry practices.
Table 1.6-1 Codes and Standards
Title Description
API Spec. 5L Line Pipes
API STD 1104 Welding of Pipelines and Related Facilities
ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries
ASME B31.8 Gas Transmission and Distribution Piping Systems
Standard Test Methods and Definitions for Mechanical Testing of Steel
ASTM A370
Products
Standard Test Methods, Practices, and Terminology for Chemical
ASTM A751
Analysis of Steel Products
Standard Test Methods for Notched Bar Impact Testing of Metallic
ASTM E23
Materials
ASTM E92 Standard Test Method for Vickers Hardness of Metallic Materials

ASTM E112 Standard Test Method for Determining Average Grain Size
ASTM E164 Standard Practice for Contact Ultrasonic Testing of Weldments
Standard Test Method for Knoop and Vickers Hardness
ASTM E384
of Metallic Materials

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Title Description
ASME Section V Nondestructive Examination
ASME Section IX Welding, Brazing, and Fusing Qualifications
ISO 9001 Quality management system requirements
ASNT RP SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing

2.0 Specifications General Requirements

2.1 Standards
Welding requirements shall be in accordance with the requirements of API Std 1104, 22nd
Edition, as modified by the present specification.
The requirements of this specification shall prevail over those of API Std 1104 and where this
specification states no overriding requirements, those of API Std 1104 apply in full.
2.2 Welding Process
Acceptable welding processes, subject to the conditions below are:
• Shielded metal arc welding;
• Semi-automatic flux cored arc welding;
• Gas tungsten arc welding;
• Automatic gas metal-arc welding.
Welding may only start when qualified welding procedures and welders have been approved by
the Company and the Inspection agency. Do not generate the arc or test current on surface of
weldment. Internal line-up clamps shall remain in place at least until the root pass is completed
around the full circumference. External line-up clamps shall not be removed until a minimum of
50% of the root pass, uniformly spaced around the circumference, has been completed, or
according to the WPS. Quality of arc starting and arc stopping shall be guaranteed. Arc crater
shall be filled up when stopping arc. Interlayer joints of multilayer welding shall be stagger. Two
beads shall not be started at the same location, and the distance shall be larger than 30mm.
Scale and slag shall be removed from each bead and bevel, and after welding, slag and splash
nearby shall be cleaned off. Power tools shall be used when called for in the procedure
specification; otherwise, cleaning may be performed with either hand or power tools. The
number of filler and finish beads shall allow the completed weld a substantially uniform cross
section around the entire circumference of the pipe. The face of the completed weld should be
approximately 3 mm wider than the width of the original groove. The completed weld shall be
thoroughly brushed and cleaned. When semiautomatic or mechanized welding is used, surface
porosity clusters, bead starts, and high points shall be removed by grinding before weld metal
is deposited over them. The deposition of each weld shall generally be a continuous operation.
However, in the case that welding must be discontinued, this shall not take place before at least
the root and hot passes are completed. Before resumption of welding, the joint shall be reheated
to a temperature within the inter pass temperature of the WPS. All surfaces to be welded shall

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be visually inspected, such that they shall contain no laminations or other injurious defects.
Peening of welds shall be restricted.
2.3 Welding Consumables
Welding consumables shall have certificate of qualification. Certificates shall be according to BS
EN 10204 type 3.1 or type 3.2. Log number on material package shall conform to the certificate.
Electrode covering shall not be affected by damp, fall off or have clear crack. No electrodes,
filler wires or fluxes that are damaged, damp, greasy or oxidized may be used.
Control of Welding Consumables: All different welding rods shall be stored in separate locations
in welding rod control room. After removal from an oven, all low-hydrogen electrodes shall be
kept in a storage cabinet or quiver. No electrodes shall be directly exposed to the atmosphere.
Issue of low-hydrogen electrodes from the storage cabinet shall be controlled so that all
electrodes are used within 4 hours of issue. To maintain the low hydrogen content below,
electrodes shall be baked immediately before use at 350-400°C for 1 hour or in accordance with
Vendor's recommendations. This requirement may be waived when the electrodes are removed
from a hermetically sealed package immediately before use. Plastic wrapped cartons are not
considered to be hermetically sealed. If the cellulose electrodes shall be packaged very well and
not be affected with damp, which may be not baked. The damp cellulose electrodes shall be
baked according to the manufacture recommendation or at 80-100°C for 0.5-1 h. After drying as
described above, low-hydrogen electrodes may be transferred to an intermediate storage
cabinet maintained at approximately 150°C. Upon removal from such drying or storage the
electrodes shall be transferred in small numbers to be heated - quivers with a minimum
temperature of 70°C and used within 4 hours. Low-hydrogen electrodes not used within 4 hours,
or for some reason exposed to adverse atmospheric conditions, shall be baked again in
accordance with the above conditions. Electrodes may be baked twice only. If these electrodes
are not used within four hours after the second baking treatment, they shall be discarded. In
case of differences between above described conditions and manufacturer's instructions,
manufacturer's instruction shall be applied.
The electrodes shall have type approval by a certifying authority. Each electrode shall have the
AWS or other appropriate classification marked on the flux near the grip end. Electrodes which
do not have this marking shall be removed from the job site to the satisfaction of the COMPANY.
All welding consumables used during production shall be the same manufacturer, brand and
AWS type as those used and approved during welding procedure qualifications.
All welding consumables shall be selected to produce welds seam with yield strength at least
equal to the minimum specified for the parent material.
For sour service (H 2 S), low-hydrogen welding consumables shall be used, and the maximum
sulphur content shall be less than 0.005%, the diffusible hydrogen content shall not exceed
5ml/100g. The Ni content of carbon steel and low alloy carbon steel welding consumables shall
be less than 1 %.
For sour service, the cellulosic electrodes shall not be used for root pass and repair welding.

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2.4 Shielding Gases

For GTAW/GMAW used for carbon steel, the shielding gas shall be follow the recommendation
from Manufacturer of welding consumable. In addition, shielding gas and backing gas shall meet
the purity requirements of AWS A5.32/A5.32M and not less than 99.9%, whichever is higher.
The WPS shall indicate the shielding gas and backing gas (if used), percent composition and
flow rate. Gas purity shall be recorded on PQR and WPS when a single gas is used.
2.5 Welding Equipment
All welding machines, line up clamps, bevelling machines, cutting torches and other equipment,
tools and supplies used in connection with the welding work shall be kept in good mechanical
condition. Sufficient meters, portable or permanent, shall be provided to calibrate machines and
to regulate voltage and amperages as may be needed.
3.0 Welding Procedure Specification
3.1 General
The Welding Procedure Specification (WPS) for the pipeline welding and weld repair shall be
submitted one month minimum before the start of qualification tests. The WPS shall be
accompanied by a summary table showing: process, consumables, direction of welding, type of
weld, WPS No., WT, OD and scope of specification. The welding procedure qualification tests
shall not be undertaken until the COMPANY has given his approval of the principle on the WPS.
The WPS shall include, as a minimum, all items listed in Clause 5.3.2 of API Std 1104 and the
additional details noted hereafter:
• Manufacturer and trade name of consumables;
• Minimum and maximum preheating temperature;
• Minimum and maximum interpass temperature;
• Number of welders;
• Time at which removal of line-up clamp is allowed;
• Fit-up tolerances and bevel dimensional tolerances;
• Scope of qualification in terms of material sourcing, steel grade, OD and WT groups;
• CE, Pcm and C%.
The maximum time lapse between the root and hot pass (the second pass) shall be recorded
on the welding procedure specification and shall be qualified during weld procedure qualification.
The time shall be kept to a minimum. No partial completion of a joint shall be left incomplete for
more than 24 hours.
For these welds the root bead shall be deposited in the uphill progression.
Preheat shall be specified on the Welding Procedure Specification when it is required and shall
be qualified during weld procedure qualification testing. The following methods of preheat are
acceptable:

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• Electric induction
• Electric resistance
• Oxy-fuel gas
The use of oxyacetylene gas for preheating is not permitted.
All tie-in welds, fillet welds, pipe to bends include pipe to cold bend, cold bend to cold bend or
hot bend, and fitting-to-pipe welds shall be preheated to 50°C minimum above that required for
similar pipe-to-pipe butt welds. The actual preheat shall be qualified during weld procedure
qualification. The interpass temperature shall not exceed 250°C.
If post weld heat treatment (PWHT) is required, it shall be specified on the WPS and shall be
qualified during weld procedure qualification. A separate PWHT procedure shall be submitted
for approval, and shall include thermocouple placement and PWHT cycle. Acceptable methods
are:
• Electrical induction
• Electrical resistance
Where pipes and fittings having unequal wall thickness, the welding ends shall meet the
preparation as defined in ASME B31.4 Clause 434.8.6, and ASME B31.8 Appendix I as
applicable.
3.2 Welding Procedure Specification Information

3.2.1 Pipe and Fitting Materials

Pipe made from material from different sources, or in different pipe grade shall be treated
separately and shall require separate procedure qualification. Identical welding procedures
qualified on pipes from different sources will also qualify joints between pipes from the two
sources.

3.2.2 Diameters and Wall Thickness

Different wall thicknesses and outside diameters shall be qualified separately as shown in API
Std 1104, Clause 6.2.2.

3.2.3 Weld Beads

The number and position of weld beads shall be chosen to give the completed weld a
substantially uniform cross-section. No two weld beads shall start at the same point, unless the
area is dressed clean and sound before the second bead is started.

3.2.4 Joint Design

The specification shall indicate the allowable tolerances on each of the joint design details.

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Permanent backing rings or consumables inserts shall not be permitted.

3.2.5 Electrical Characteristics

The target voltage and amperage for each bead shall be stated. The ranges of voltage and
amperage shall not vary from these target values by more than ±10 percent.

3.2.6 Speed of Travel

Alternatively, for SMAW the range of electrode run-out length for each pass in each electrode
size shall be clearly specified. Speed of travel or electrode run-out length shall be within a range
of 10% of the nominal value for the specified electrode type and size as stipulated by the
Manufacturer.

3.2.7 Heat Input Range

The allowable range of energy input per unit length to be applied by the welding processes for
each weld bead shall be clearly specified. The units to be used shall be kilo joules per millimetre
(kJ/mm) based on the following formula:
U ⋅I
E =
1000 ⋅ v

Where: E energy input per unit length [kJ/mm];

U voltage [V];
I amperage [A];
v welding speed [mm/sec].

4.0 Welding Procedure Qualification

4.1 General
Welding procedures shall be qualified under simulated conditions similar to the planned
installation, using the same welding, alignment and preheat equipment that will be used in
production. Sufficient test welds shall be made to include repair procedure qualification and all
required mechanical testing.
CONTRACTOR shall notify COMPANY of the date and location of the Welding Procedure
Qualification Test welding as that specified in Contract. COMPANY reserves the right to witness
all Welding Procedure Qualification and Welder Qualification welding and testing.
Any revision to welding procedure specification shall be given a new number in sequential order
and revisions marked in order to identify changes.
Welders and welding operators shall be qualified in accordance with the applicable code prior
to fabrication for PQR. Records shall be submitted to the inspection agency for approval.
Alternative qualifications may be accepted subject to the inspection agency approval.
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4.2 Essential Variables

Welding procedure must be qualified as new WPS when any of the essential variables listed in
API Std 1104 Clause 5.4 and the follows are changed.

4.2.1 Filler Metal and Number of Beads

The following changes in filler metal over the qualified and approved WPS constitute essential
variables:
• A change from one filler metal group to another;
• A change of bead numbers.

4.2.2 Electrical Characteristics

A change from direct current (DC) electrode positive to DC electrode negative, or vice versa, or
a change in current from DC to alternating current (AC), or vice versa, constitutes an essential
variable.

4.2.3 Direction of Welding

A change in the direction of welding from vertical downhill to vertical uphill, or vice versa,
constitutes an essential Variable.

4.2.4 Speed of Travel

A change in the range for speed of travel constitutes an essential variable.

4.2.5 Time between Passes

An increase in the maximum time between completion of the root bead and the start of the
second bead constitutes an essential variable.

4.2.6 Preheat and Interpass Temperature

A decrease in the specified minimum preheat temperature constitutes an essential variable.

4.2.7 Removal of Line-up Clamp

Removal of the line-up clamp at a stage earlier than the approval procedure shall constitute an
essential variable.

4.2.8 Energy Input Variation

Change in welding parameters to result in energy input variation greater than 10%.

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4.2.9 Joint Design

A change in joint design (for example, from V groove to U groove) constitutes an essential
variable. Minor changes in the angle of bevel or the land of the welding groove are not essential
variables.

4.2.10 Direction of Welding

A change in the direction of welding from vertical downhill to vertical uphill, or vice versa,
constitutes an essential variable.

4.2.11 Post-weld Heat Treatment (PWHT)

The addition of PWHT or a change from the ranges or values specified in the procedure shall
each constitute an essential variable.
4.3 Testing of Weld Joints – Butt Welds
To test the butt-welded joint, test specimens shall be cut from the joint at the locations shown in
API Std 1104 Figure 3.
The minimum number of test specimens and the tests to which they shall be subjected are given
in API Std 1104 Table 2. The specimens shall be prepared as shown in API Std 1104 Figures
4, 5, 6, or 7. The following tests shall be carried out on test joints of pipes manufactured as API
Spec 5L as per API Std 1104, Clause 5.6.
• Tensile-strength test;
• Hardness test;
• Nick-break test;
• Bending test;
• Charpy impact test.
In addition, the PQR of pipe in sour service shall also include hardness test, HIC test and SSC
test. All above tests shall be employed after PWHT, only when all the test results are acceptable.
The welding procedure specifications are qualified. The location for extraction of samples for
testing shall be from the welded seam and HAZ.
4.4 Records
A form based that in API Std 1104 or similar shall be used for recording all test performance
conditions of the welding procedure qualification test.
Records shall be established and Inspector who intended the test. Records shall be available
on site when the production welding is performed.
Each revision of the documents shall be given a new identification number in sequential order
and revision shall be marked in order to identify the changes.

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5.0 Qualification Of Welders

A welder who satisfactorily completes the procedure qualification test is a qualified welder,
provided the number of test specimens required by API Std 1104 Clause 6.5 has been removed,
tested, and meet the acceptance criteria of API Std 1104 Clause 5.6, for each welder. The
objective of this test is to demonstrate the ability of the welder in producing welds with suitable
mechanical properties and soundness.
The destructive test will be carried out only if required by COMPANY.
A welder who has successfully completed the two weld qualification tests (butt weld test and full
size branch connection test) shall be qualified to weld in all positions, on all wall thicknesses,
joint design, fittings and on all pipe diameters. In this context requirements outlined in API Std
1104 shall be strictly adhered to.
Each welder or welding operator shall be assigned a unique identification number which shall
be marked in paint against all welds. A list of qualified personnel with photographs shall be kept
up to date and made available to Inspector.
6.0 Production Welding
6.1 Cleaning, Bevelling and Pipe End Preparation
Pipeline shall be welded by qualified welders using qualified procedures. The surfaces to be
welded shall be smooth, uniform, and free from laminations, tears, scale, slag, grease, paint,
and other deleterious material that might adversely affect the welding. The joint design and
spacing between abutting ends shall be in accordance with the welding procedure specification
used.
6.2 Alignment of Pipes
For the alignment of abutting ends shall minimize the offset between surfaces. For pipe ends of
the same specified thickness, the offset should not exceed 1/8 in. (3 mm). Larger variations are
permissible provided the variation is caused by variations of the pipe end dimensions within the
pipe purchase specification tolerances, and such variations have been distributed essentially
uniformly around the circumference of the pipe. Hammering of the pipe to obtain proper line-up
should be kept to a minimum.
6.3 Preheating and Interpass Temperature
The need for an appropriate level of welding preheats shall be determined at weld procedure
qualification stage, taking into account any weld ability results that may be available from the
line pipe supplier.
In any event, prior to commencement of welding, sufficient heat shall be applied to remove all
traces of moisture. The preheat temperature required by the qualified WPS shall be maintained
throughout the entire welding of the joint.
Preheat or warm up shall be applied in a uniform manner using gas burner or electrical means
except that hand held torch heating shall not be permitted other than where external line-up
clamps are used. The method shall be subject to approval by the Inspector.

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Temperature shall be measured using contact pyrometer or indicating crayons of the melting
type. Color changing type shall not be permitted.
The minimum preheat temperature shall be maintained and measured over a distance of at least
50 mm or 5 times wall thickness whichever is greater on each side of the joint.
The interpass temperature shall not be permitted to drop below the minimum preheat
temperature (if required). The interpass temperature shall not be allowed to exceed 250°C.
6.4 Tack Welds
Tack welds shall be a minimum of 50 mm long, performed with the same weld procedure
specification as the root run and by a welder qualified for that run. Where preheat is required for
the root run, this shall be applied prior to tack welding and maintained until the joint is completed.
Tack welds incorporated into the final weld shall be ground to a feather edge at each end to
ensure adequate fusion on the root pass.
Tack welds shall not be permitted when a clamp is used.
6.5 Type and Removal of Line-Up Clamps
For mainline pipe to pipe welds, an internal line-up clamp shall be used, unless impracticable
(e.g. tie-in welds).
Power operated internal clamps shall be demonstrated as capable of reducing the maximum
permitted manufacturing out-of-roundness sufficiently to meet the alignment requirements of
Section 6.2 in this specification.
Internal line-up clamps may be removed only after the root pass is 100% completed and when
the pipes are to remain at rest (i.e. when no subsequent movement is anticipated for the pipes).
External line-up clamps can be removed when the root pass is at least 50% complete and
equally spaced around the pipe circumference.
6.6 Golden Welds
Golden welds (i.e. non-hydro tested welds) shall be minimized. Any golden weld shall be subject
to the following NDT: 100% visual testing, 100% RT, 100% UT and, if necessary, 100% magnetic
particle testing.
6.7 InterPass Cleaning / Grinding of Welds
Each weld pass shall be cleaned by experienced helper/welder using power tools to remove all
welding slag and foreign matter prior to welding the successive pass in according to WPS.
Where accessible, all welds to valves, flanges and fittings shall be ground back smooth internally
prior to proceeding with radiography or ultrasonic examination.
6.8 Partially Completed Joints
Welds shall not be left partially completed overnight.
When production conditions are such that pipe joints have to be left partially completed, the
following conditions shall apply:

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• At least half of the wall thickness shall be completed;

• Upon discontinuation of welding, the joint shall be wrapped in dry, insulating, heat
resisting material with a waterproof backing, and shall be allowed to cool in a slow and
uniform manner;
• Prior to welding restarting, the joint shall be examined using magnetic particle
inspection;
• Prior to welding restarting, the joint shall be preheated within the specified inter-pass
temperature range.
6.9 Marking of Welds
All welds shall be marked with paint stick by the welders according to numbers assigned to them.
Should any welder leave the job, his number shall be voided and not duplicated on the project.
No punch or steel stamping shall be permitted.
Prior to radiography of the circumferential weld, the CONTRACTOR shall paint the weld location
number on the covering of the pipe adjacent to the weld at a point where it shall remain visible
after field coating. These numbers shall be used by the surveyors to locate and record the welds
and for the radiographers for identification of the welds. The numbers shall be applied with a
spray can or a brush and water-proof paint of a contrasting colour to pipe outside coating.
6.10 Weather Conditions
Welding shall not be carried on when the weather conditions are unsatisfactory and likely to
impair the quality of the welds. CONTRACTOR shall provide wind breaks and welder's platforms
when conditions, in opinion of Inspector, warrant their use.
6.11 End Protection
The open end of pipe strings shall be securely closed at the end of each day’s or shift’s work
and lunch breaks break. They shall be placed over the pipe ends to prevent the entrance of
water, trash, small animals or other objects. These covers shall not be removed until the work
is to be resumed. Where the line is left apart at the intervals to be later tied-in, the ends shall
likewise be fully closed. Metal covers shall not be tack welded to the pipe.
6.12 Supports, Attachments, Lifting Devices
The CONTRACTOR shall take measures to support the pipe for safe welding. If the pipe is to
be supported over the ditch, the skids shall be of sufficient length so as to prevent the ditch from
collapsing.
6.13 Proximity Of Welds
Adjacent circumferential welds in mainlines shall be separated by a minimum of 2.0 m.
The distance can be reduced in the above ground pipe at valve stations and pipe on the plant
side of anchor blocks or expansion loops at end stations.
7.0 Inspection And Testing Of Production Welds

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7.1 General
Welding operation instruction shall be compiled according to WPS report before welding. The
welder shall operate according to the instruction. Any welding performed prior to review and
acceptance of welding documents is subject to rejection at Company's sole option. The surfaces
to be welded shall be smooth, uniform and free from laminations, tears, scale, slag, grease,
paint and other deleterious material that might adversely affect the welding. The weld joint
surfaces shall be examined for the presence of moisture before welding. If moisture is present,
the joint shall be dried with the use of approved solvents, flame torch or other engineering
approved methods. If the pipe size exceeds DN400 at least two welders should weld
simultaneously around the pipe circumference based on the site condition. If following situations
happen in construction site for welding of pipe and no protective measure are taken, welding
operation shall be stopped.
1). Environment temperature is lower than 0°C;
2). Environment humidity is more than 90% relative humidity;
3). Environment wind velocity is more than 8m/s (SMAW) and 2m/s (GMAW/GTAW);
4).The rest is rain, blowing sand (with high wind) Cerium tungsten rod may be used for argon
tungsten-arc welding. If preheating is specified in relevant WPS, it shall be performed.
All welds shall be 100% visually inspected after completion and before any NOT technique is
applied. The completed weld shall be thoroughly brushed and cleaned. Surface of weld joints
shall be treated according to the requirement before inspection of weld joints. Appearance of
weld joints shall be satisfactory. The face of weld should be approximately 3 mm wider than the
width of the original bevel, width of cap shall be at least 1 mm wider than bevel at each side.
Surface of seam cannot be lower than outside surface of the pipe, and the height of weld shall
not be raised above the base metal by more than 1.6 mm. Height of leg shall meet the design
document. The offset shall not exceed 12.5% of wall thickness and no larger than 3mm.
7.2 Radiographic Examination
Materials necessary to perform 100% radiography on all circular welds. Radiography shall be
by means of X-rays only.
All radiographic techniques and procedures as well as quality of films shall comply with ISO
17636, ISO 2504 and ISO 5579 and this specification. Standards of acceptance shall comply
with the requirements of API Std 1104, 22nd edition and this specification. Any weld which in
Inspector’s opinion is not satisfactory as indicated by the radiography shall be repaired or cut-
out and re-welded.
7.3 Ultrasonic Examination
Equipment and material shall conform to the requirements of ASTM E317.
At the commencement of welding with an approved automatic process (other than SAW) all
welds shall be tested 100% by ultrasonic examination until COMPANY is satisfied that the
process is under complete control (minimum of 50 welds). The level of UT examination may
then be reduced with COMPANY’s approval, when a satisfactory level of confidence in the

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automatic process and quality of the welding has been reached. A detailed UT procedure is
required which includes a test block with known defects for calibration purposes.
7.4 Magnetic Particle Inspection
Where magnetic particle inspection (MPI) is applied on parent material (e.g. following pipe re-
bevelling) no cracks or crack like defects are permitted. Any indications revealed by MPI shall
be investigated and removed by grinding or pipe re-cutting, as necessary.
Magnetic particle inspection is required for the following:
• Re-bevelling due to pipe damage and/or cut outs;
• Repair excavations;
• On removal of arc strikes.
Electromagnetic yoke and/or adjacent cable techniques shall be used.
CONTRACTOR shall supply an MPI procedure based on ASTM E709 or equivalent for review
and approval by COMPANY. Calibration blocks and approved magnetic flux indicators shall be
available on Site at all times.
Inspector reserves the right to test the proposed MPI procedure prior to acceptance.
MPI operators will be qualified level II or III in accordance with SNT-TC-1A or COMPANY
approved equivalent standard.
7.5 Inspection Records
The system for reporting the defects shall be such that they can be quickly identified and
accurately located in welds.
All radiographic and ultrasonic examination records shall be suitably stored in fire proof cabinets
by CONTRACTOR for a period of construction and shall be handed over to COMPANY at its
request.
8.0 Standard Of Acceptance
8.1 General
The following acceptance standards shall apply to visual and non-destructive inspections
(radiography, etc.) of welding procedure qualification tests, welder qualification tests and
production welds, as applicable.
In case of dispute, the Inspector’s interpretation of the NDT results shall prevail or COMPANY’s
approval after level III technician consulted for final decision.
The standards of acceptance shall be as per API Std 1104 and the amendments stated here
after in the present section.
In areas of weld preparation such as pipe ends, bevel faces and branches, planar defects shall
not be acceptable whatever their sizes.

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8.2 Reinforcement
Weld reinforcement shall be uniform and not less than 1.0mm no more than 3.0mm in height.
Excessive reinforcement shall be grinded smoothly to meet the requirements.
It shall merge smoothly with the parent metal and shall extend beyond the original weld
preparation by not more than 2.5mm.
8.3 Flaw Type and Size
The standards of acceptance applicable to the type and size of defects detected shall be as
defined in Section 9 of API Std 1104.

8.3.1 Cap Undercut

Undercut adjacent to the cover pass (EU) or undercutting adjacent to the root bead (IU) shall be
considered a defect when either of the following conditions exists:
• The aggregate length of indications of EU and IU, in any combination, in any continuous
12-in. (300-mm) length of weld exceeds 2 in. (50 mm);
• The aggregate length of indications of EU and IU, in any combination, exceeds one-sixth
of the weld length.

8.3.2 Internal Concavity

Internal concavity shall not exceed that of the thinnest adjacent parent material. For any areas
that exceed the density of the thinnest adjacent parent material, the internal concavity shall be
considered a defect. If there is no lack of root fusion and if the thickness of the weld (including
cap reinforcement) is not less than the specified wall pipe thickness.
8.4 Porosity (Other Than Elongated Porosity in Root Run)
Porosity is generally spherical but may be elongated or irregular in shape, such as wormhole
porosity, and when the size of the indication produced by a pore is measured, the maximum
dimension of the indication shall apply to the criteria:
• The size of an individual pore exceeds 1/8 in. (3 mm) in diameter or 25 % of the specified
wall thickness, whichever is less;
• The size of an individual pore exceeds 25 % of the thinner of the two specified wall
thicknesses joined, but no more than 1/8 in. (3 mm) in diameter;
• The distribution of scattered porosity exceeds the concentration permitted by API Std
1104 Figure 20 or Figure 21;
• The length of an individual indication of Hollow Bead exceeds 1 in. (25 mm);
• The aggregate length of indications of Hollow Bead in any continuous 12-in. (300-mm)
length of weld exceeds 2 in.(50 mm);
• The aggregate length of all indications of Hollow Bead exceeds 8 % of the weld length.

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8.5 Cracks
Any form of crack or suspected crack shall not be acceptable.
Welds found with cracks (other than crater cracks) shall be cut out.
8.6 Arc Strikes
Arc strikes shall not be permitted.
9.0 Repair And Removal Of Defects
The CONTRACTOR shall not repair or cut-out any weld without instruction and inspector’s
presence and shall cut non-repairable defects from the pipeline as cylinders and replace with
good pipe. The length of cylinder to be cut shall be a minimum of 1.5 time diameter of the line.
In no case the length of cutting shall be less than 15 cm.
Cracks shall be removed as non-repairable defects. Defects in the root, hot and filler beads
consisting of slag inclusion, porosity and gas pockets may be repaired with the approval and in
accordance with API Std 1104 if the following apply (correction of an individual bead prior to the
laying of a succeeding bead is not considered repair of a defect).
The CONTRACTOR shall submit to Inspector’s approval full details of the proposed repair
procedures to be used. This shall include:
• the method of removing defects;
• the preparation and inspection of the area to be repaired;
• the welding procedure
The repair procedure to be used is fully qualified in accordance with API Std 1104.
Qualification of weld repair procedures shall be carried out at the same time as the qualification
tests of main procedures. Repair procedure qualification tests shall include the following, unless
a different repair scheme is proposed and approved by COMPANY:
• Execution of a full thickness repair centred on the initial weld axis (through thickness
repair);
• Execution of a repair of repair (outside weld root), when such repairs are proposed.
Grouping of materials and pipe sizes for qualification of welding repairs may be
considered.
An area covering a minimum of 50 mm (or 5 times wall thickness of pipe whichever is greater)
on each side of the weld at the repair area shall be uniformly preheated to a minimum
temperature of 100℃ and maintained during repair welding. The temperature shall be checked
by the use of temperature indicating crayons approved by Inspector.
All repair cavities shall not be less than 50 mm in length. The start and stop of additional repair
passes shall not be superimposed over the start and stop of the proceeding repair passes. Ends
of the completed repair shall be ground to a smooth contour blending into the surface.
A given repair area may consist of one or more defects.

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Any notches resulting from back welding shall be removed by grinding, including those occurring
along the edge of the bead. The completed back weld shall be cleaned.
Repaired areas shall be re-radiographed or inspected by the same means previously used.
A full record of all repairs shall be maintained. The record shall include the following:
• Weld number;
• Type and size of defect;
• Circumferential location (defined to an approved system);
• Estimate of the depth (assessed by ultrasonic test where possible);
• Where possible, the name of the welder who produced the defect;
• Repair welding procedure number;
• Name of repair welder;
• Copy of the inspection report for the repair;
• Date of repair.
Only once root repair attempt shall be made, and for others that shall not exceed 2 times on one
location. The repair weld which fail to meet the acceptance requirements the weld shall be cut-
out, edges re-bevelled and re-welded.
Weld repairs to the pipe body or to the body of fittings or bevels are not permitted.
Repair to the weld root by welding from the inside of the pipe shall not be permitted.

Template No.:BK91-1000-000-GEN-TMP-0011
Revision:2
Date: 06.07.2021