Explorer Pipeline-SP 870801 (2)SECTION 6 - CONSTRUCTION WELDING SPECIFICATION
6.1 SCOPE
6.2
6.3
This specification applies to the welding o4 pipe, valves,
flanges, fittings and other equipment for t~e installation of
or modification to Company's facilities. S~ecifically
excluded is welding of full-encirclement sp~it repair sleeves,
~connections, permanent branch connections and weld +
end couplings to pressurized operating liquid filled i
pipelines. The standards of acceptability to be applied to
welds tested destructively or non-destructi~ely are also
defined. The purpose of this specification is to define the
minimum standards required for the productic~n of high quality
weldments.
CODES AND STANDARDS
As a minimum, all welding performed under t]is specification
shall meet the requirements of the following codes and this
specification. In the event of a conflict Detween D.O.T. Part
195 and any referenced material in this spec
requirements of D.O.T. Part 195 shall preva~
requirements of the referenced material are
which case the requirements of the reference
govern.
~ Department of Tra~sP°rtation, Title 49, ~
Transportation of Hazardous Liquids by Pi
ASME/ANSI 31.4, Liquid Transportation Sys
Hydrocarbons, Liquid Petroleum Gas, Anhyd
Alcohols, Most Recent Edition.
API Standard 1104, Standard for Welding
Related Facilities 15th Edition, 1980.
MATERIALS
This specification shall apply to the weldin
valve and flange material listed in Exhibit
to:
~ API Specification 5L, API Specification
ASTM A105, Standard Specification For Ste
Flanged Fittings
ASTM A105(F42), Standard Specification Fc
Flanges & Flanged Fittings
ASTM A106 (Gr. B),, Standard Specification
Carbon Steel Pip~'For High Temperature Se
ification, the
1 unless the
more stringent, in
d material shall
art 195,
peline.
rems for
rous Ammonia, and
ipelines and
g of pipe, fitting
E and conforming
or Line Pipe
el Pipe Flanges &
r Steel Pipe
For Seamless
rvice.
6.4
6.5
6.6
ASTM A234-WPB (Y42)(Y52), Standard Specifl
Fittings of Wrought Carbon Steel & Alloy
& Elevated Temperatures
ASTM A694 (F52)(F60)(F65), Standard Speci
Forgings, Carbon & Alloy Steel, For Pipe
Valves, & Parts For High-Pressure Transmi
Materials with chemical and mechanical pr~
comply with the above, even though they a~
manufactured in conformance with them.
PROCESS
Process shall be manual shielded metal arc wl
metal arc welding (GMAW), a combination of ti
submerged arc welding (SAW). Automatic and
processes may be used only upon specific pri
Company.
WELDING EQUIPMENT
Contractor shall furnish all welding equipmel
Page 2
Lcation For Piping
~teel For Moderate
~ication For
?langes, Fittings,
~sion Service
)perties which
~e not:
~lding (SMAW), gas
~ese processes, or
~emi-automatic
)r approval by the
~t and supplies
required for the work. Ail equipment shall ~e in good working
order and subject to approval by Company RepSesentative.
Equipment shall be maintained in good operatSng condition to
ensure acceptable welds, avoid breakdowns, a~d protect the
safety of personnel. Any equipment which do~s not meet the
approval of the Company Representative or is~incapable of
producing satisfactory welds shall be remove([ from the job and
replaced with acceptable equipment at Contra¢:tor!s expense.
WELDING MATERIALS AND SUPPLIES
All welding materials and supplies shall be
that will prevent damage from moisture orC
oil, grease or other deleterious elements.
Coated electrodes, filler metals, shielding
shall be stored and handled in accordance wi
manufacturer's recommended practice. Coated
be stored in sealed original metal container~
use. Those in opened containers shall be pr(
deterioration and excessive moisture changes.
which show surface oxidation or fractured co~
removed from the work site.
Low hydrogen electrodes EXXl8 and EXXl8~-i wh(
sealed containers shall be stored in rod over
between 250 - 300 degrees Fahrenheit. ~ny e]
~tored in a manner
~tamination from
[ases and fluxes
:h the
electrodes shall
until ready for
~tected from
Electrodes
~tings. shall be
~n removed from
~s at temperatures
.ectrode of
6.7
low-hydrogen classification which has been
atmosphere for more than one hour shall be
recommended by the manufacturer.
Argon and carbon dioxide shielding gases sha
containers in which they are supplied, firml
storage and away from temperature extremes.
Any welding materials or supplies which in t
Company Representative.~are damaged, contamin
for use shall be replaced with acceptable ma
supplies at the Contractor's expense.
WELDING PROCEDURES
Ail welding performed under this specificati
performed in accordance with a Qualified Wel
Specification. Contractor shall use Company
Welding Procedures (Attachment XXX) except t
its option, may elect to qualify Alternate ~
Alternate Welding Procedure qualification sk
accordance with API 1104 and the requirement
specification, including preparation of a wi
Procedure Specification, welding of the test
destructive testing of the test weld(s). A]
preparation and qualification of Alternate ~
shall be born by Contractor.
6.7.1 ALTERNATE WELDING PROCEDURE QUALIFI£
Alternate Welding Procedure Specific
established by Contractor then submi
for approval at least two weeks pric
testing. Contractor shall request f
Company's "Welding Procedure Specif~
this purpose~
An approved Alternate Welding Proced
shall be qualified by joining two j¢
nipples following all details of th~
Specification as they will be appliE
welding. Company may require more t
for Alternate Welding. Procedure Spec
wide variable ranges. It is suggest
make several test welds to establisk
variable rangeS before submitting f~
Welding Procedure Specification to f
approval. All,procedure weld tests
in the presence of a Company Repres~
Page 3
xposed to the
ried again as
11 be kept in the
¥ anchored during
he opinion of the
ated or unsuitable
terials or
on shall be
ding Procedure
's Qualified
hat Contractor, at
elding Procedures.
all be in
s of this
itten Welding
weld(s), and
1 costs for
'elding Procedures
ATION
ations shall be
tted to Company
r to qualification
rom and use
cation" forms for
ure Specification
b sized pipe
Procedure
d to construction
han one test weld
ifications with
ed that Contractor
~ practical welding
nal Alternate
ompany for
shall be conducted
ntative.
6.8
6.9
6.10
Welding procedures which have been e:
approved, and qualified shall not be
way without approval of Company. Re.
be required for any change.
MATERIAL DEFECTS AND DAMAGE
Contracto~ shall take precautions during all
operations to prevent damage to pipeline com
pipe, fittings, flanges, valves, and other i
Page 4
~tablished,
changed in any
-qualification may
material handling
)onents including
~ems. '
Material containing surface defects or damag.~ that may affect
its strength or serviceability shall not be welded into the
pipeline. These include, gouges, dents, buckles,
laminations, split ends, hard spots, roll-in~, blisters,
cracks, or other defects. The material cont$ining the surface
defect or damage shall be set aside for inspection and
disposition by the Company Representative. ~f it is
determined the defect or damage was not caused by Contractor's
action then Contractor will be reimbursed fo~
correcting the defect or damage as directed
Representative.
WEATHER CONDITIONS
Welding shall not be done whenever the quali
weld would be impaired by weather conditions
snow, dew point, high winds, blowing sand or
cold weather the interior of the pipe shall ]
slush. The effects of cold weather can be m~
use of preheat and controlled cooling in acc¢
specification. The use of shelters, windshi~
may make conditions acceptable for welding.
devices, if used, should not be removedunti]
cooled enough to be touched by a bare hand.
the welding groove and vicinity shall remain
weld is completed and has cooled to ambient l
Company Representative shall decide if weath~
suitable for welding.
WELDER QUALIFICATION
6.10.1 TESTING
Each welder, and each welding unit al
automatic welding, shall pass a weld~
test. Welders assigned to work in O]
a valid state certificate. All aspe¢
qualification shall meet the requirer
Standard 1104, Sections 3.0 and 9.6
removing or
)y Company
:y of a completed
such as rain,
dust. During
)e free of snow or
.nimized by the
~rdance with this
~lds or umbrellas
These protective
. the weldment has
Pipe surfaces in
dry until the
~emperature. The
~r conditions are
~d operator on
~r qualification
:lahoma shall have
~ts of ~
~ents of API
~xcept the -
6.10.2
6.10.3
6.10.4
requirements of Section 6.10.7 of th
shall be considered in addition to t
Judgement as to failing or passing r
the Company Representative who will
His decision will be final and irrev
welder shall use the same welding te
proceed with the same speed he will
the test and is permitted to do prod
Upon successful qualification the we
issued a "Welder Qualification" docu
Company which will identify those pr
is permitted to use. Unless otherwi
Company, this qualification will rem
months from date of test provided th
provisions of API 1104 are met and s
Company are satisfactory. At the op
Company Representative, the welder m
radiographic inspection in lieu of t
tests.
RETEST
If, in the mutual opinion of the Com
Representative and Contractor Repres
of a welder to pass the test was a r
unavoidable conditions or conditions
control, such a welder may be given
opportunity to qualify. No further
permitted.
EQUIPMENT AND SUPPLIES
The Contractor shall furnish all equ
supplies required for the test, incl
testing machine capable of measuring
a tensile specimen fails. The machi
equipped with a 1-3/4 inch plunger f
tests. The Company shall furnish th
joints of pipe for the purpose of ma
Contractor shall furnish certificati
of the tensile test machine. Certif
by an independent testing company an
nine months of the contract award da
WELDING OF TEST JOINT - BUTT JOINT
Two job size pipe nipples shall be j
the details listed in the Qualified
Specification(s). The Company Repre
Page 5
.s specification
hose of API 1104.
ests entirely with
conduct the tests.
ocable. The
chnique and
use if he passes
uction welding.
lder will bel
ment by the'~
ocesses the welder
se excepted .by
ain valid fdr 6
e necessary
pot checks by the
tion of the '
ay be qualified by
he destructive
pany
entatives, failure
esult of
-beyond wel~ers'
a second
retest shall be
ipment and
uding a tensile
the load at which
ne should 'be
or guided bend
e Contractor
king test nipples.
on of the accuracy
ication shall be
conducted within
te.
~ined by f01~owing
Welding Procedure
sentativg'will
6.10.5
6.10.6
6.10.7
decide whether the butt joint will b
horizontal or vertical plane or incl
angle. Normally the test will be in
horizontal position or inclined at s
than 30 degrees. The test weld for
automatic welding shall be in a fixe
position. The welder should be give
adjust the current on the weldingma
beads on scrap steel.
VISUAL INSPECTION OF TEST WELDS - BU
The Company Representative shall ins
of a welder or welding operator duri
test weld. The speed of welding sho
the speed of a construction weld. T
all the visual examination requireme
criteria prescribed by kPI 1104. Th
contour of the root and cover beads
workmanship. Failure~to meet the ab
cause to disqualify the welder. No
is necessary.
TEST SPECIMENS
Ail specimens may be oxygen-cut or m
Specimens in the field will be oxyge
coupon-cutting machine. Specimens r
to a laboratory shall be cut slightl
for irregularities in the torch drag
Company Representative shall careful
specimen as soon as it is removed.
allowed to air cool to ambient tempe
testing. Dunking specimens in water
Contractor shall furnish coupon-cutt.
DESTRUCTIVE TESTING
6.10.7.1 TENSILE TEST RESULTS
In addition to the requirel
Paragraph 2.623, if a spec.
weld or at the junction of
parent metal, and also fai
minimum specified tensile~
parent metal, the welder sl
disqualified.
Page 6
e in a fixed
ined at some
the fixed
ome angle less
an operator of
d horizontal
n enough time to
chine by weldin~
~T JOINT
pect the progress
ng welding of the
uld approximate
he weld shall meet
~ts for acceptance
~ size, shape and
~hall show good
~ve-noted shall be
~dditional testing
achine-cut.
~ cut with a
.~moved to be sent
~ larger to allow
line. The
~y mark each
Specimens shall be
'ature before
is not permitted.
.~r.
nents of API 1104,
Lmen breaks in the
the weld and the
Ls to develop the
strength of the
~all be
6.11
6.10.7.2
6.10.7.3
ARC BURNS
NICK-BREAK TESTS
In addition to the require!
a welder shall be disquali:
specimen shows defects exc~
limitations of API 1104, Pi
ROOT AND-FACE BEND TESTS
Page 7
Rents of API 1104
~ied if any
~eding the
~ragraph 2.633.
Welds in high test line pipe (API Spec. 5LX)
may not bend the full U shape. These shall
be considered acceptable i~~ the specimens
which crack are broken apa~'t and their
exposed surfaces meet the l.equirements of
the nick-break test.
Should one of the bend.tes: specimens fail
~to meet'these requirements and in the
opinion of the Company Rep::esentative the
lack of penetration occurrlLng is not
'representative of the weld. the test
specimen may be replaced b~ an additional
specimen adjacent to the one that failed.
rifled if the
The welder shall be disqual
additional specimen also si
exceeding the specified lil
The preferred remedy for an arc burn shall b~
cutting out a cylindrical portion of the pip~
arc burn and replacing it with another cylin(
suitably qualified by inspection'or testing.
an arc burn on the cap of a weld which is not
be repaired.
On a case by case basis, Company Representat~
Contractor to repair an arc burn by grinding
Contractor shall be made in advance of any w~
contractor shall have all necessary equipment
perform the repair. The arc burn and associl
notch if removed by grinding shall not reduc~
wall thickness to less than that permitted b~
specification. The ground area shall be smo~
blending into the adjacent pipe surface. Af~
evidence of the arc burn has been removed by
complete removal of the metallurgical notch ~
by swabbing the ground area with a 20 percen~
ammonium persulfate. A blackened spot is ew
metallurgical 9otch and indicates that additl
%ows defects
mits.
removal by
containing the
er of pipe
An exception is
serious and may
ye may permit
. Request by
)rk and the
on site to
ted metallurgical
the remaining
the material
th with edges
:er visible
grinding,
:an be determined
: solution of
~dence of a
Lonal grinding is
6.12
6.13
6.14
necessary. If after grinding the remaining
less than that permitted by the material sp(
portion of pipe containing the arc burn sha]
cylinder. Wall thickness in the ground are~
with a Contractor furnished ultrasonic thic}
other suitable method is approved by Compan5
All areas exposed to the ammonium persulfatE
thoroughly swabbed with fresh water, rinsed
An arc burn is defined as a discontinuity c¢
localized remelted metal, heat-affected met~
the surface profile of any part of a weld o2
resulting from an arc. "Trail" where a per(
indentation is present from arc impingement
considered as an arc burn under these speci~
burns are caused by an energized electrode,
broken insulation in the welding leads, or
clamp.
Removal or repair of arc burns caused by Co
at Contractor's expense.
GROUND CONNECTION AND ELECTRODE HOLDER
Ail ground connections shall be securely att
burns on the pipe. Whenever possible, connE
placed in the V-groove joint. To further a%
electrode holders and electrode leads shall
when used for repairing welds on the inside
manifold or pump station construction, the ¢
shall be located as close to the work as pr~
arcing on pump shafts, flange facings and ot
surfaces. Ground connections shall not be n
shaft, motor shaft or coupling nor shall a ~
be tacked or welded to the work piece being
LONGITUDINAL WELD SEAM OFFSET
Longitudinal seams in adjoining lengths of
arc-welded pipe shall be located-in the top
line and within 30 degrees from the top cent
otherwise required under the bending require
contract specification. Successive joints s
right or left to avoid aligning the seams ir
TRANSITION JOINTS
Prefabricated'transition nipples, designed
ASME/ANSI B31.'4 code, shall be installed at
locations where the adjoining nominal pipe
Page 8
wall thickness is
~cification, the
.1 be removed as a
~ shall be verified
~ness gage unless
Representative.
solution shall be
and dried.
~nsisting of any
~1, or change in
· base metal
~eptible
shall be
!ications. Arc
by a connection or
~ a grounding
~tractor shall be
~ached to avoid arc
~ctions shall be
~id arc burns,
be fully insulated
of the pipe. On
iround connection
.cticable to avoid
.her machined
~ade to any pump
'round connection
welded.
.ongitudinally
quadrant of the
er, unless
ments of this
hall be rotated to
..adjoining joints.
n accordance with.
designated '-
'all thicknesses
6.15
vary more than 3/32-inch. The'nipples shall
one-half pipe diameter in length. Tie-in we
made at a transition joint, the addition of
pipe is recommended.
Internal tapering may also be accomplished i
the use of a mechanical pipe-end-prep machin
purpose.
PIPE ENDS
6.15.1
6.15.2
MILL BEVELS
Pipe joints will be furnished with e
degrees plus 5 degrees minus 0 degrc
face or land of 1/16-inch plus or mi
FIELD BEVELS
Pipe ends shall be field beveled by
machine oxygen cutting to conform to
shown in the Approved Welding Proced
Bevels or cuts shall be made in apl
to the longitudinal pipe axis. The
shall be borne by the Contractor exc
pipe manufacturing defects or other
by the Contractor. Field beveling s
accomplished by one of the following
below in order of preference.
1. POWERRn PORTABLE MECHANICAL PIPE
The machine should be accurately
aligned for out-of-roundness of
cutting tool is essential and th
chatter-free, non-scalloped and
2. STRAP-ON PORTABLE OXYACETYLENE
The band or saddle should be of
and configuration to align the c
desired angle tO pipe allowing n
than circumferentially. Torch c
high quality smooth surface free
slag. Torch flame adjustment is
carburizing flame, produced by a
acetylene, introduces carbon int
contributes to cracked welds. ¢
cuts shall be rejected.
Page 9
not be less than
Ids should not be
a short length of
n the field with
e suited for this
nds beveled to 30
cs with a root
nus 1/32-inch.
machine tool or
the dimensions
ure Specification.
ane perpendicular
cost of beveling
ept to eliminate
defects not caused
hall be
methods listed
END PREP MACHINE
positioned and
the pipe. A sharp
e cut should be
~urr-free.
~VELING MACHINE
the proper size
utting head at
o movement other
ut shall produce a
of tenacious
critical. A
n excess of
o the steel which
arburizing flame
6.16
6.17
6.18
6.19
3. HAND HELD OXYACETYLENE CUTTING T
In some instances (with Company
prior approval) manual torch cut
acceptable provided that the sur
cut is ground by power grinder/s
filed to the quality of finish a
cut made by machine.
JOINT PREPARATION
The area to be cleaned should extend at leas
the end of the bevel on both the inside and
The surfaces to be welded shall be smooth, u
fins, burrs, laminations, tears, scale, slag
and completely dry. Cleaning shall be done'
operated brushes, grinders, sanders or by ha
brushes shall be of stainless steel and powe
shall not contact the pipe beyond the weld a
-CLEARANCE
The working clearance around the pipe for ab
should not be less than 16-inches. When the
the trench and especially at tie-ins, the be
sized generously to provide the welder or we
to the joint so that their skill is not hamp
be pumped out of the bell hole to aid the co:
welder and to avoid water splashing onto the
LINE-UP CLAMPS
Internal expanding type line-up clamps shall
practical for pipe sizes 10-3/4-inches O.D.
External clamps may be used for pipe diamete
10-3/4-inches O.D. or where the use of an in
clamp is impractical.
Internal line-up clamps shall be retained in
pipe shall be supported firmly and not moved
root bead has been deposited. External line
not be removed until segments of the root be
uniformly along the circumference of the pip.
accumulative length of 50% of the circumfere
ALIGNMENT - OFFSET
Line-up clamps shall be used to fit, &lign a
joint in position during root bead welding.
remove out-of-roundness and provide a ~nifor]
Page 10
DRCH
Representative's
ting maybe
!ace finish of the
Lnder, or hand
nd dimensions of a
one-inch from
~utsi~e surfaces.
~iform, free of
rust or grease
~ith power
md filing. Power
grinding discs
:ea.
)ve ground welding
pipe is welded in
.1-hole shall be
.ders ready access
~red.~ Water shall
nfort of the
weld.
be used wherever
~nd larger.
rs less than
ternal line-up
position, the
until 100% of the
-up clamps shall
~d are deposited
~ with a minimum
.%ce.
nd re~ain the
The clamps shall
n joint fit-up
6.20
(high-low) which, for pipe of the same nomin
does not exceed 1/16-inch. The root opening
in the Qualified Welding Procedure specifica
complete root penetration, free of burn-thro
circumference of the join%. Once welding of
started, hammering on the pipe at that joint
Hammer blows to all pipe should be held to a
used to yield pipe ends to fit. Improper an
strikes produce stress concentrators (defect
evaluated under the "Material Defects and Da
this specification.
In some cases for pipe of dif'ferent nominal '
whe~he offset between internal edges of al
exceeds the 3/32-inch maximum permissible of
access to the inside of the pipe for welding
may be made with a tapered weld. The slope .
not be less than 1:4 or more than 1:2 in acc.
ASME/ANSI 31.4. Electrode holders and leads
insulated when used for welding inside the p
above-noted treatment shall be approved by C
Representative on a case by case basis prior
work.
PREHEATING
Preheating of the~pipe and fittings shall be
the satisfaction of the Company Representati
"Preheat" is used in this specification, it
both "Preheat Before Welding" and "Concurren
Welding". Preheating may be accomplished by
as listed, provided that it is uniform and tl
temperaturedoes not fall below the prescrib
Page 11
al wall thickness,
shall be as shown
tion to ensure
~gh along the
the root bead is
is prohibited.
minimum and never
~le of hammer
s) and will be
nage" section of
~all thicknesses
Outting pipe ends
fset and there is
, the transition
~f the weld should
~rdance with
shall be fully
[pe. The
~mpany
to the start of
carried out to
;e. When the term
[s meant to cover
~ Heat During
suitable methods
hat the
~d minimum during
the actual welding operatiOn. Preheat does ~ot necessarily
mean~the addition of heat from external sources. An effective
form of preheat is using the residual heat from previous
welding passes.
When heat from external sources is required :he following
methods are preferred in this order:
1. PROPANE OR BUTANE HEATING
Torch heating with a single burne~ or ri%g burners
employing "softer" flames such as propan~ or butane.
2. OXYACETYLENE HEATING
Oxyacetylene ~orches outfitted with "ros,-bud" heating
tips utilizing a "neutral" flame shall b~sUSed.~ A
"carburizing" flame, produced by an exce~ of acetylene
imparts carbon into the weld and shall n~)t be used.
Heating with cutting torch tips is proh~ted.
6.21
6.22
6.23
6.24
6.25
RESISTANCE HEATING
Finger elements or blankets heated by e]
resistance in nickel chromium wires ins]
and powered by a welding machine. Thes~
"Cooperheat".
4. INDUCTION HEATING
This method must be approved by the Com~
TEMPERATURE CONTROL
The temperature shall be carefully controlle
with pyrometric crayons such as "Tempilstiks
lead-free type), "Tempilabels", direct readi
attached surface thermometers or thermocoupl
Care shall be taken not to exceed 400"F when
or 4, previously mentioned, are used.
coNTRoLLED COOLING
During extremely cold weather, especially in
during the winter, precautions shall be take
weld cooling rate through the use of insular
Excessive cooling rates during.inclement wea
significantly impair weld quality and contri
formation of cracks.
DISSIMILAR MATERIALS
When welding dissimilar materials having dif
requirements, the material requiring the hig
govern.
STRESS RELIEVING
Not required. (This is only for wall thickn,
1-1/4-inches.)
AREA TO BE PREHEATED
Uniform heat.shall cover a band 6-inches wid~
the proposed weld.
Page 12
ectrical
de ceramic sleeves
are made by
any before using.
d by monitoring
"(sulfur and
ng magnetically
e pyrometers.
methods 1, 2, 3,
northern states
n to lower the
lng covers.
ther will
bute to the
!erent preheating
~er preheat shall
~sses above
on each side of
6.26
CONDITIONS FOR PREHEATING PIPE AND FITTINGS
,
' Pipe
'Classification
API Std. 5L
'Grade B
ASTM Al06
Grade B
API Std. 5L
X-42, X-46,
X-52, X-56
X-60, X-65
6.27
6.28
Material '
& Welded I Wall
Fittings ,'Thickness
ASTMA105
ASTMA106
Grade B
ASTMA234
WPB(Y42)(Y52)
ASTMA694
(F52)(F60)
(F65)
0.344
Inches &
Under
Over
0.344
Inches
0.344
Inches &
Under
Over
0.344
Inches
Minimum
Preheat
Temp.
250°F
250°F
250"F
WELDING SAFETY
300°F
Pipeline construction paralleling high volta
transmission lines may produce dangerous ele
capacitative effects. To avoid shock.hazard
be grounded. One method of grounding is to
diameter copperweld rod into the ground and
pipe with insulated #8 stranded copper wire
All grounding methods shall be approved by t
Representative in advance.
MINIMUM NUMBER OF WELDERS
Page 13
400"F
400"F
400OF
ge electric
=trical
s the pipe should
install a 1/2-inch
=onnected to the
~ith a C-clamp.
~e Company
qualified
ormed in
)ipeline
construction practices.
The minimum number of welders that shall wor]
on a weld is as follows:
Production Welds
4" Thru 8" 10" Thru 18" 20" Thru
Root Bead 1 2 - 3
Hot Pass 1 2 2
Filler & Cap 1 2 2
28" .301" Thru 36"
simultaneously
4
2
2
Contractor shall assign an adequate number ol
welders to the job to ensure all work is per:
accordance with this specification and good
400OF
%;hen
Temp.
is below
40"F
When
Temp.
is below
50°F
When
Tempo
is below
50OF
When
Temp.
is below
50"F
Maximum '
Preheat 13aml::}ient ,
Temp. I Temp.
6.29
6.30
6.31
6.32
Tie-In Welds
The minimum number of welders for tie-ins f!
36-inch pipe is two.
Tie-in welds, once started shall be complete
interruption.
MAXIMUM TIME 'LAPSE BETWEEN BEADS
When preheating is required - start the hot
after completion and cleaning of stringer be
3 minutes. The filler beads and cap shall a
before the weld area temperature drops below
minimum or additional preheating shall be re
When preheating is not required - time lapse
and hot pass shall be 5 minutes maximum. Ti
hot pass and first filler bead to completion
up to 14 hours maximum, unless Otherwise aut
Company Representative.
CLEANING BETWEEN BEADS
Ail scale, slag and weld splatter shall be r
bead and groove. Cleaning shall be done wit
rotating grinding discs and 'wire brushes. P.
be stainless steel. Grinding shall not cont
beyond the weld area. Metal removed during.
so change the geometry of the joint as to ad'
strength. Disc grinding shall be used to im
bead contour.
PIPE SUPPORT
Ail position welds shall be made over or at
ditch with the pipe resting on skids, earth
Page 14
'om 6-inch thru
~d without
pass immediately
ad. Always within
lways be completed
the prescribed
quired.
between root bead
me lapse between
of the cap maybe
horized by the
~moved from each
~ power operated
~wer brushes shall
~ct the pipe
:leaning shall not
~ersely affect its
)rove the root
~he side of the
)erms or suitable
supports to prevent movement. These support~ shall be
arranged to prevent toppling resulting from ~ongitudinal pipe
expansion and shall be padded to protect the pipe coating from
damage.
ROOT (STRINGER) BEAD WELDING
6.32.1 SHIELDED METAL ARC WELDING (SMAW)
The entire .root bead shall, be deposit:ed with the pipe
in a stationary position during roll or position
welding. The movement of pipes duri~Lg root bead
deposition is forbidden. Welders sh~Lll commence
6.33
6.34
welding simultaneously with the wor~
along the pipe circumference. Tack
permitted. The practice of "skating
with high current to fuse the gap is
pass travel speed on most pipes shou
inches per minute. Root beads shoul
internal bead about 1/16-inch high a
Two beads shall neither be started n
same location. Skimpy beads may be
6.32.2 GAS METAL ARC WELDING (GMAW)
To preserve weld integrity with this
welding arc shall be protected again
that disperse the shielding gas. Tr
be about 15-inches per minute using
and 100% carbon dioxide at 35 CFH.
"stick-through" or "whiskers" protru
interior of the root bead may be cau
rejects. The practice of ejecting t
~hrouqh the gap of the joint with th
the arc is struck may be cause for w
HOT PASS (SECOND BEAD) WELDING
The root bead joint shall not be subjected t
until the hot pass has been completed. High
by the cantilever load effect of a pipe join
other lifting operations shall be limited.
shall be cleaned rapidly and thoroughly with
disc grinder. A 5/32-inch thick disc grinde
improve the bead contour. The hot pass shal
immediately, always within five minutes afte
the root bead to take advantage of the resid
delay is encountered between root and hot pa
joint shall be preheated to a minimum of 250
of 400"F before the hot pass is started.
FILLER BEAD(S) WELDING
Ail filler beads shall be made in rapid sequ
allowing the joint to cool. Two beads shall
-stopped at the same location. Each bead sha
joint before another bead is started. Inter
shall be with powered stainless steel wire b
deposition faults, such as may be found at s
'shall be removed by grinding.
Page 15
evenly spaced'
welding is not
"the electrode
prohibited. Root
ld be about 15-18
d have a smooth
nd 3/16-inch wide.
or stopped at the
rejected.
process, the
st strong drafts
avel speed should
0.035 inch wire
Excessive wire
ding along the
se for weld
he filler wire
hand gun before
~lder dismissal.
high stresses
stresses induced
t/double-joint or
the root bead
power-brush and
r may be used to
1 follow
r completion of
ual heat. When a
ss beads, the
°F and a maximum
~nce without
not be started or
ll circle the
pass cleaning
rushes. Any bead
tarts and stops,
6.35
6.36
6.37
Page 16
FINISH BEAD (COVER PASS OR CAP) WELDING
The cover pass shall not be started until allL of the filler
beads are completed. The weld surface shall merge smoothly
into the pipe surface with complete fusion. The surface.
finish of the cover pass shall have closely ~paced uniform
ripples with a continuous convex cross section. The weld
reinforcement shall not be less than 1/32-in¢:h and not more
than 1/16-inch above the pipe surface. The %
pass is determined by the width of, the V-gro¢
pass shall overlap the groove by 1/16-inch ox
top buttons shall be ground off to blend wit!
contour, surface pinholes shall not be spot
localized arc impingement. A pinhole may be
stripper bead at least 2-inches long. The fJ
be thoroughly cleaned of slag and weld spattE
IDENTIFICATION OF WELDERS 'AND WELDING OPERA~X~RS
The Company Representative will assign an idE~ntifying number
or letter to each qualified welder and weldi~g operator to
mark the section of a weld which he has made The number or
letter and the name of the welder or welding operator will be
recorded by the Company Representative. Whel a welder or
welding operator is terminated from the work, .his identifying
symbol shall be voided and not duplicated. '~arking of welds
shall be with weather proof crayons. Steel lie stamping of
the pipe for this purpose is prohibited.
WELD QUALITY INSPECTION
The quality of welding will be monitored by ne or more of the
following methods: visual, radiographic or ther
non-destructive methods, or destructive testing. Other
non-destructive methods including magnetic pgrticle and liquid
penetrant may be used for maintenance and rg~air welding.
.nd any or all
The Company will inspect all welds visually a
welds radiographically. 100 percent of fabr]
tie-in welds shall be radiographed for the cc
circumference and up to 100 percent of produ¢
radiographed. The Company shall determine tk
radiographic inspection. At intervals, comp]
removed from the line for destructive examina
paragraph "Test Welds". Welds which do not ~
requirements of the method by which they are
rejected. Radiographic inspection shall prod
of defects which can be accurately~interpret~
Welds subjected to non-destructive testing sk
on the basis of the following: -
~idth of the cover
)ye. The cover
each side. High
the bead
~elded by
repaired with a
.nishedbead shall
~r.
cation welds and
~mplete weld
tion welds may be
.e frequency of
.eted welds may be
.tion. See
~et the
tested shall be
uce indications
~ and evaluated.
all be evaluated
6.38
6.37.1
sTANDARDS OF ACCEPTABILITY - NON-DES:
API 1104 Section 6 shall be used as
acceptable welds with the following
provisions:
Excessive Wire "Stick-Through" wi
Welding
Excessive wire "stick-through'' or
protruding along the interior of
be cause for a weld rejection and
The codes are silent regarding th
when loosened by scrapers creates
valves and equipment. It is caus
0.035 inch wire through the joint
gun before the arc is struck. Th
Representative'will determine the
of "stick-through".
Cracks
No weld containing cracks either
the heat-affected zone of the par
regardless of size or location, s
acceptable.
Undercutting
Undercut adjacent to the cover be.
of the pipe shall be eliminated b
Undercut adjacent to the root beal
2-inches in a continuous weld len
or 1/6 the length of the weld, wh
smaller. When both mechanical a~
measurements are available, the m
measurements shall govern.
RRPAIR OR REMOVAL OF DEFECTIVE BUTT WELDS
Authorization shall be obtained from the Com
Representative prior to any work to repair d
.surface of the cover pass or internal defect
bead.
6.38.1
PROCEDURE TO DETERMINE REPAIRS
The radiographer shall immediately n.
Representative of any welds which ha'
by radiography. .If'the weld cannot
Page 17
~UCTIVE TESTING
the standard of
~dditional
th Gas Metal Arc
"whiskers"
the root bead may
welder dismissal.
is. This wire
havoc with block
~d by ejecting the
gap with the hand
~ Company
acceptable extent
Ln the weld or in
mt metal,
hall be
~d on. the outside
repair.
shall not exceed
~th of 12-inches
[chever is
radiographic
~chanical
)any
~fects beneath the
along the root
,tify the Company
;e been rejected
~e repaired, the
6.38.2
Page 18
weld shall be removed. If in the opinion of the
Company representative the defect c~n be repaired he
shall notify the Contractor who maylchoose to either
Cut out such weld or mak? repairs. ~If the Contractor
chooses to make the repair, the Com])any Representative
shall be notified so he may observe
and/or radiographer accurately mark
limits of-the defect on the weld.
REPAIR OF DEFECTS BENEATH THE SURFA(
PASS
Cracks - No weld containing a crack
or in the heat-affected zone of the
regardless of size or location shall
such welds shall be cut-out.
Defects beneath the surface of the ¢
specifically defined as slag inclusJ
gas pockets may be repaired provide~
following conditions are met:
The defects can be removed withou
completely through the weld.
No single area of defect shall
pipe circumference length. A gi~
consist of one or more defects.
Before such repairs are made, suc
entirely removed to clean metal b
slag and scale shall be removed.
Oxyacetylene torch gouging or air
gouging shall not be used.
Before welding, an area 6-inches
the repair shall be preheated to
and a maximum of 400°F and the mi
maintained during repair welding.
shall be monitored with "Tempilst
indicating crayons or "Tempilabe]
.direct reading temperature indic~
approved by the Company Represent.
The repair weld shall be made by]
metal-arc electrodes using dry
electrodes AWS E-7018. The minim
repair weld shall be 2-inches in
starts and stops of welding passe
the Contractor
the location and
;E OF THE COVER
either in the weld
parent metal,
be repaired, all
over pass
.ons, porosity or
that the
t grinding
ceed 7% of the
en single area may
defects shall be
grinding. Ail
carbon arc
Dn each side of
· minimum of 300"F
~imum temperature
Temperature
[ks" temperature
labels or other
lng method_
~tive.
Danual shielded
~-hydrogen
am length of
length. The
shall not
coincide. All repairs shall have
passes. Each pass shall be grou~
cover pass shall conform to the c
original cover pass.
Repairs shall be witnessed by the
Representative.
Repairs shall be radiographed and
the "STANDARDS OF ACCEPTABILITY
TESTING" of this specification.
shall be made in these areas.
6,38.3 RRPAIRS TO INTERNAL DEFECTS ALONG T~
WELDS
Internal repairs shall be limited
24-inches O.D.'and larger.
Internal defects such as burn-thr
incomplete fusion or penetration
be repaired by back-welding with
requirements or limitations:
High-low resulting in incompl
may be repaired'byback-weldi
an accumulative length of 25%
circumference.
b. Other internal defects may be
back-welding not to exceed 8-
c. For any repair area 4-inches
rod shall be used for each be
shall begin and end outside t
The cleaning, preheating, wel
inspection methods are the sa
under "Repair of Defects Bene
the Cover Pass".
ee
Electrode holders and cables
which are fully insulated too
arc burns.
6.39 TEST WELDS
Company shall reserve the privilege of cutti
the pipeline and then have the weld tested b
destructive methods. Destructive testing sh
Page 19
at least two
d smooth and the
ontour of the
Company
shall comply with
NON-DESTRUCTIVE.
o further repairs
ROOT BEAD - BUTT
to pipes
)ugh, craters,
and high-low may
the following
ere penetration
ng not to exceed
of the pipe
repaired by
inches in length.
or longer, a new
ad. Each bead
he repair area.
~ing and
me as outlined
ath the Surface of
shall be' the type
prevent internal
~g any weld from~
~ visual and
all consist of -
6.40
sectioning the weld into specimens and testil
outlined in "Welder Qualification, Destructi~
paragraph 6.10.7. If the weld is tested and ~
Company requirements, the company will reimb~
Contractor the cost of replacing the weld, e;
Company shall be permitted to cut one (1) te~
each welder from the line at no_cost to the
test weld shall fail in any of the standard
welder may not be permitted to continue weld
pipeline~. If two or more welders participat~
weld which failed, the Contractor and Compa~
shall determine which welder or welders were
the defebtive work.
Ail welds which fail shall be replaced at no
Company. Company Representatives shall whent
test welds from the pipeline in such a manne~
time so as to result in a minimum replacement
not possible to pull the pipe back into posit
has been removed, a nipple with a minimum lei
seventy-two (72) inches (unless required oth~
Representative) shall be set in and two (2) ~
required to close the line. Company Represel
the right to cut any of these replacement we]
if there is evidence of defective workmanshi'
A recor~ of results of each weld test shall
the Company Representative and the Contracto
Representative. When a weld that has met Com
specification has been cut out, except for t!
described weld per welder, the Contractor sh~
for the weld in accordance with the price qu¢
"B". The record made jointly by the Company
and Contractor shall indicate the location o~
stake number, the welder's identification an~
the test. This record shall be signed by Ret
both the Company'and Contractor and must be n
the test is performed. No reimbursement will
weld not covered by a Contract Work Order.
RADIOGRAPHY
The Contractor Shall Furnish Radiographic Se~
Radiography will be used to maintain weld qua
The frequency of inspection will be specified
All aspects of the radiographic procedure, e~
penetram~ter selection and placement, radiat~
and film.process shall comply with API Stands
of cqntractor's radiographic procedures shall
Company Representative for approval on Compa~
"Radiographic Procedure Specification".
Page 20
~g these as
;e Testing"
:onforms to all
~rse the
(cept that the
~t weld made by
~ompany. If the
~ompany tests, the
Lng on the
~d in making the
Representative
responsible for
expense to the
~ver possible cut
or at such a
cost. If it is
ion after a weld
~gth of
~rwise by Company
~elds shall be
~tative reserves
.ds from the pipe
~e made jointly by
~S
~pany's
~e one (1)
~11 be reimbursed
~ted in Exhibit
Representative
the weld by
the results of
resentative of
~ade on the day
be made for any
vices
lity control.
· by the Company.
posure geometry,
on protection,
rd 1104. Details
be presented to
y forms entitled
The Contractor shall demonstrate that his ra,
procedures will produce acceptable results bI
production radiography is started.
6.40.1 RADIOGRAPHERS
Shall be qualified in accordance wit
recommendations of the American Soc~
Non-Destructive Testing Recommended
SNT-TC-iA. Only Level II or Level ~
interpret radiographs. Company shal
copies of technicians certification
start of work.
6.40.2 RADIOGRAPHIC SOURCES
X-ray machines or radioisotopes. I~
shall be used for pipes 12-inch and
tie-ins and station fabrication.
6.40.3 RADIOGRAPHIC FILM
Films of high contrast and relative2
which will produce high resolution
6.40.4 PROCESSING DEFECTS
Radiographs shall be free from mech
processing defects. Any films cont~
interfering with the interpretation
discarded and the welds shall again
6.40.5 FILM PROCESSING
Radiographs shall be processed to a]
film without discoloration for at 1E
6.40.6 FILM IDENTIFICATION
Production radiography shall not st~
Company Representative has specifie¢
identification procedure. The markE
placed on the pipe on the downstre~
so that the numbers will be read c1¢
viewed from the upstream side. WheI
one film is used to inspect a weld,
appear on each film and adjacent fi]
Page 21
~iographic
~fore any
:h the
Lety for
Practice
iii shall
L1 be furnished
prior to the
~ternal machines
larger except at
~y fine grain
~hall be used.
Lnical and
Lining artifacts
shall be
be radiograPhed.
.low storage of
~ast 3 years.
~rt until the
the
.rs shall be
~ side of the weld
,ckwise when
~ever more than
the markers shall
.ms shall overlap..
6.40.7
6.40.8
6.40.9
6.40.10
RADIATION PROTECTION
The radiographer shall be held resp
safety of all people and domesticat.
vicinity. Each radiation area shal
delineated and shall be conspicuous
signs bearing the radiationsymbol.
REJECTED WELDS
The radiographer shall immediately l
Representative of any welds which h~
by radiography.
REPAIRED WELDS
Welds which have.been rejected by r~
inspection for defects other than cl
subsequently repaired, shall be re-i
order to verify repair was made to~
the repair radiograph(s) shall be o~
length to provide correlation to th~
radiograph for'that weld. No furth~
be allowed in these areas.
RECORDS
The radiographer shall maintain dail
for each weld radiographed, the x-ri
location of the weld, the size and
fitting, the material specification
thickness, the location and type of
whether the weld is accepted or rej~
The Company will keep a record of ~
radiographers.
A copy of the daily records and fi~
welds shall be handed to the Compaq
each working day. Films shall remaJ
the Company.
Page 22
~nsible for the'
~d animals in the
l be clearly
[y posted with
%otify the Company
~ve been rejected
~diographic
:acks and
:adiographed. In
:he defect area,
sufficient
original
r repairs shall
Ly records to show
~y number and
:ype of pipe or
the wall
any defect and
~cted.
Lalified
of accepted
Representative
~ the property of